JOGNI-II MINI HYDRO POWER PROJECT SECTION-M

VOLUME-III

M. ELECTRIC OVERHEAD TRAVELLING (EOT) CRANE 1. SCOPE OF WORK This specification covers the provisions for the design, manufacture, shop testing, delivery, testing and commissioning (not erection), Purchaser and guarantee for one year of 1 x 25 T EOT crane (Assumed capacity, the bidder has to finally decide the as per the design if higher weight of assembled generator works out) for power house complete with all accessories for making the system complete and for warranting a trouble free and safe operation. It is not the intention of this specification to specify in complete, the details of practices of manufacturers, who shall furnish the equipment, which shall meet in all respects the specified requirements in regard to performance durability and satisfactory operation. 2. GENERAL The EOT Cranes shall be electrically driven, single trolley, double girder, overhead traveling type. The Cranes shall operate on rails in the scope of supply. The bridge of the Crane shall be carried on sufficient number of wheels, mounted on trucks, designed to distribute the load equally on the truck beams & wheels and to allow the wheels to adjust themselves to the irregularities of the rail. Suitable platforms shall be provided for access to bridge trucks. Suitable walkways of sufficient width shall be attached to the outside of each bridge girder. Power shall be supplied from the feed rail power supply system mounted on convenient height along the length of powerhouse. 3. SPECIFICATION OF EOT CRANE FOR JOGNI-II HEP. Capacity Span 25 Tonne (assumed) to be increased suitably if 9.3m (assumed) (to be suggested by the bidder as 37m (assumed) 15m (assumed) do bidder do Page 1 of 13 to suggest as per

higher weight to handled shall work out) per designed layout) Long travel Lift equipment size). Elevation of Crane beam Particular Technical Specifications -

JOGNI-II MINI HYDRO POWER PROJECT Elevation of floor -

VOLUME-III

centre line of turbine runner is at 1350 do

M elevation bidder to suggest the exact elevation Hook reach from rails Not more than 1.2 metres from up

stream side, not more then 900 mm from down steam side. Note: the data given above is tentative the bidder to check from the layout suggested and the material to be handled. Speed a) b) c) Hoisting Cross Long travel Main 1.5 m/min 8.0 m/min 10 m/min 0.15m/min 0.8m/min 1.0m/min Creep

Specification: the crane should conform to relevant IS3177-1999& IS807. The bidder to give the complete specification of the equipment offered along with prices. The specification should include the type of motors with capacity and starter used, the type of brakes used and complete note on control system. The control shall be pendent type The bidder shall give the maximum possible hook reach with sketch in the offer. The supply available shall be 415V three phase + 10%AC and 110V + 10% DC control supply. The crane shall confirm to category M-3 as per IS:13834. 4. PERFORMANCE CRITERIA AND GUARANTEE The cranes shall be capable of performing all intended duties and it is the responsibility of the Contractor to supply the equipment as per Guaranteed Technical Particulars. The cranes shall be capable of raising, lowering holding and transporting their rated loads without any damage to or excessive deflection of any component. The vertical deflection of crane girders caused by the rated load plus all dead load should not exceed 1/1000 of the crane span. Minimum factor of safety of crane shall be five (5).

Particular Technical Specifications

Page 2 of 13

JOGNI-II MINI HYDRO POWER PROJECT 5. SAFETY REQUIREMENTS

VOLUME-III

In the design of Crane, all safety regulations as applicable with factory Acts, Indian Electricity rules etc. as prevailing in the country and the site of installation shall be taken into consideration and provided for. 6. Construction requirement RUNWAY RAILS The runway rails along with sole plates, fixing clamps etc. for bridge travel, shall be designed and supplied by Contractor as per relevant Indian and International Standards. The trolley rails shall be of the same quality and material as that of main runway rails. The rails shall also be supported side way to withstand the starting and stopping of trolley with load. The Contractor shall supply all the materials required for fixing the bridge and trolley rails. At the end of the travel suitable stopper to provided. 7. PENDANT CONTROLLER The EOT cranes shall be pendant controlled. The pendant switches shall be capable of withstanding rough handling and harsh environmental conditions without being damaged and the cover shall be effectively secured. Means shall be provided to prevent inadvertent operation from the floor while maintenance work is being carried out on the crane. Push buttons or switches shall be used in pendant control, which shall automatically return to the Off position immediately after they are released. One lockable type push button shall be provided to switch off control power when the crane is not in use and if other means of switching off is not available. The weight of the pendant shall be supported independently of the electric cables by means of chain or wire rope. 8. WALKWAYS & LADDERS Ladders, platforms, walkways, hand hold, foot hold etc. necessary to give safe access to and movement in the bridge drive and trolley drive mechanism, and all other components of the crane needing inspection maintenance, lubrication and repair shall be provided for. Walkways shall be provided along the entire length of the bridge. All walkways and stair ways shall be of rigid construction, with non-skid checker plate treads or grating, toe-boards not less than 0.1 m high. Walkways shall be continuous and permanently secured. Walkways shall have a clear passageway.

Particular Technical Specifications

Page 3 of 13

JOGNI-II MINI HYDRO POWER PROJECT 9. BUMPERS

VOLUME-III

Bumpers shall be attached to the bridge trucks and the trolley. The bridge shall have four bumpers one at each corner arranged to meet the crane stops. The trolley shall have two bumpers on each side placed to meet the trolley stops. The bumpers shall be fastened to the trucks and the trolley and shall be capable of bringing the crane and the trolley to a gradual stop when traveling at rated speed in either direction. All bumpers shall be designed so that there is no direct shear on bolts and shall be equipped with safety cables to prevent falling of parts from crane in case of breakage. These stops shall be designed and fastened to resist the forces applied when contacted. Stops engaging the tread of the wheel will not be acceptable. 10. HOLDING CLAMPS As a safeguard against movement of crane off the rail during an earthquake, suitable provision to contain the movement of crane shall be made. Clamps to keep the crane in a locked condition while not in operation shall be supplied and arranged. 11. BRAKES Mechanical or hydraulic operated brake shall be provided for long travel, in addition to automatic electro-mechanical DC brakes and electro hydraulic thrusters brake for each motor of LT travel. An automatic electro-mechanical DC brakes capable of bringing the motion of fully loaded trolley safely to rest shall be provided. In addition, a thruster brake shall also be provided for each motor of CT motion. All brakes provided on each bridge and trolley drive motor shall have a capacity not less than 100% of the full load torque of the bridge or trolley drive motor and shall be of sufficient size to stop the bridge or trolley within a distance equal to that traveled in 6 seconds at full speed with full load. Two brakes working on different principles shall be provided for all hoists. Hoisting motion shall be fitted with an electro-mechanical DC brake and electro hydraulic thruster brakes. The hoisting brakes shall be fail safe and shall have adequate capacity to bring the fully loaded crane to rest in shortest possible time and to arrest the motion and sustain any load up to and including test load at any position while hoisting and lowering. Each brake shall be capable of meeting the complete hoisting requirements independently.

Particular Technical Specifications

Page 4 of 13

JOGNI-II MINI HYDRO POWER PROJECT 12. GUARDING

VOLUME-III

All gears, wheels, pinions and chain drives shall be totally encased unless such parts are so situated in relation to the structure of crane as to be as safe as if complete encasement were provided. 13. LUBRICATION Provision shall be made for lubricating all bearings, gears and other moving parts, which shall be easily accessible from working platform of the crane. Electrical Apparatus and controls 13.1 General All electrical equipment associated with the crane including motors push buttons, switches, control panels, starters, control transformers, relays, shall be in accordance with relevant Indian and International Standards. A 3-phase, 4 wire power supply at 415V + 10%, 50 Hz shall be provided by the Employer at the runway conductors through suitable L.T. Panel arranged at suitable location in the power house. The contractor shall supply all equipment and devices required thereafter. Allowable temperature rise of the equipment shall be as prescribed in the relevant Indian Standards or the corresponding International Standards and shall be based on ambient temperature of 400 C. The crane shall be equipped with motors of ample capacity for performing the duties specified without exceeding the rated full load torque and shall conform to latest version of relevant International and Indian Standards. All the motors should be totally enclosed type and shall be strong and sturdy to withstand shock and vibrations transmitted to them. All motors shall be suitable for reversing, frequent acceleration and mechanical braking. Motor shall be so located that terminals are accessible for inspection and maintenance and normal ventilation is not restricted. All motors shall at least be of 60 minutes (40% CDF) rating Electrical equipment mounted on bridge platform shall be enclosed type in sheet metal enclosure, with a provision for easy access to parts inside. The control panel shall be so spaced that efficient maintenance is possible and shall withstand the mechanical forces imposed by the crane under service condition.

Particular Technical Specifications

Page 5 of 13

JOGNI-II MINI HYDRO POWER PROJECT 13.2 Controllers

VOLUME-III

All electrical equipment shall be suitably enclosed so that live parts will not be exposed to accidental contact under normal operating conditions. All master control switches, manually operated switches, circuit breakers, starters, contactors, limit switches and relays shall be clearly and permanently identified by attached nameplates. All master control switches, manually operated switches, circuit breakers, starters, contactors, limit switches and relays shall be clearly and permanently identified by attached nameplates. All hoist controls and brakes shall provide for limiting the vertical movement of the hooks, with rated load and when starting from standstill, within increments of 1.5mm. The controls and brakes shall limit the movement of the bridge and trolley, under the above operating conditions, within increments of 3mm and 6 mm respectively. 13.3 Control System Details For Travelling Movements: Each travel motion shall have a separate control lever or set of push buttons. General: Separate controls shall be provided for the hoist. Smooth acceleration shall be provided for all loads in both directions. Lowering: The lowering speeds for all loads within the rated capacity shall be gradually increased. The lowering speed shall not exceed 125% of the rated speed. Hoisting: The hoisting speeds for all loads within the rated capacity shall be smoothly increased. In no case shall any load up to 125% of rated capacity cause a hoist to lower. 13.4 Limit Switches Necessary limit switches shall be provided for crane hoists to prevent over winding, over traversing and over travelling. At least the following limit switches shall be provided for each crane. Hoist driven limit switches for the upper and lower hook position; A back-up over travel limit switch for the extreme upper position of each hoist; Lever-operated limit switches for both end positions of all travel motions.

Particular Technical Specifications

Page 6 of 13

JOGNI-II MINI HYDRO POWER PROJECT

VOLUME-III

The manufacturer shall fit one or more devices to the crane to give warning of the approach to the danger zone. Limit switches shall be so arranged that they can be readily tested. 13.5 Protective Panels The power supply from main shall be protected by a three pole main line contactor and totally enclosed MCCB with a minimum interrupting capacity of 35 kA at 415 V to switch off power supply to the Crane with provision to lock in open position. The following protection shall be provided for all motors: Single phase protection Instantaneous over current protection Thermal overload relays Under voltage protection The contacts of protective relays shall be so worked that the operation of any relay shall trip the main contactor, thus making it necessary to bring all the controls to OFF position before restarting the motor. All switches, contactors shall be enclosed in suitable cabinet placed in accessible location. 13.6 Long Travel Current Collection System The crane shall be provided with an approved feed rail power supply system. The feed rail system shall be of the metal enclosed, collector bus way type with internally supported conductors and collector trolley and shall have no live parts outside of the enclosure. The full current-carrying capacity of the system shall be maintained throughout. The feed rail system shall consist of an assembly of standardized, fully interchangeable units and shall include expansion sections at each building contractions joint, feed box, door track sections or other means of removing the collector trolley, coupling sets, dead-end caps track hangers and power take off collector trolleys as required for the complete system. The feed rail system, when assembled in place shall permit independent longitudinal movement of the housings and conductors to allow for unequal thermal expansion and contractions. All conductors shall be housed in a common enclosure made of sheet steel not less than 16 gauges thick. Conductors shall be of harddrawn Copper capable of carrying the rated current per pole continuously without overheating. Pickup trolleys shall have wheels equipped with sealed ball bearings and contacts of sufficient size to maintain full current carrying capacity without overheating. Particular Technical Specifications Page 7 of 13

JOGNI-II MINI HYDRO POWER PROJECT

VOLUME-III

Contacts shall maintain constant contact pressure and alignment with the conductors. 13.7 Power Conductors for the Crane Trolley and Monorail Hoist (Cross Travel Current Collection System) Trolley power conductors shall be of the festooned insulated wire type. Each motor on the trolley shall have separate conductors for the power and in no case shall a power conductor be used as a common conductor for more than one circuit. The power conductors shall be insulated, jacketed, 900 C conductor temperature extra flexible cables. All conductors insulators and brackets shall be supplied with the crane. 13.8 Cable Wiring and Other Conductors All wiring shall be laid on perforated cable trays or clipped on the crane structure by suitable device. All the cables shall have sufficient current carrying capacity as per relevant Standard specification. Cables used for crane wiring shall comply with relevant Indian and International Standards specifications. Unless otherwise agreed, only Copper cables shall be used for power wiring and only Copper cables shall be used for control wiring. 13.9 Lighting & Convenience Outlets The permanent 250 volts lighting system of the crane shall consist of adequate number lighting units to illuminate uniformly the area under the crane and in operator's cabin. The ladders, platforms and walkways shall be equipped with vapour-tight incandescent industrial lighting fixtures with clamp or screw guards. The lighting fixtures shall be such that it must be able to withstand the shock and vibrations of the crane. Fixture units shall be furnished and mounted for general illumination under the crane. They shall be metal halide or high-pressure sodium type, as specified in these specifications. Metal-halide lamps shall be coated. Fixtures shall be mounted in a position that will provide a uniform pattern of light for the length of the crane on the floor beneath it. They shall be mounted so that they produce no major shadows and are readily accessible for safe servicing. Ballasts shall be of the constant wattage, high power factor, and weatherproof 2winding type suitable for operating on the voltage specified. Fixtures shall be of Aluminum shock-resistant construction, specifically designed for use on overhead cranes. Convenience outlets at each end of the bridge shall be provided.

Particular Technical Specifications

Page 8 of 13

JOGNI-II MINI HYDRO POWER PROJECT 13.10 Earthing

VOLUME-III

The crane structure, motor frames and metal cases of all electrical equipment including metal conduit or, cable guards shall be effectively connected to earth complying Indian Electricity rules 1956 and IS 3043. 13.11 Emergency Push Button

Emergency push button shall be provided in the pendant controller for emergency tripping. The push button shall be so arranged as to immediately put off the main supply and apply all the brakes simultaneously irrespective of controller position. Other Construction Detail 13.12 General

All fastening shall be adequate to hold the parts in place under all condition of service. All steel castings, steel forgings and wrought steel wheels and sheaves shall be annealed properly. Steel used in crane shall be of tested quality. The unit stresses values and slenderness ratio assumed in designing various members, shall be furnished by the contractor 13.13 Bolts, Nuts Screws & Washers

Bolts & Nuts for mechanical equipment shall be semi-finished and shall have hexagonal heads. All bolts and setscrews in rotating parts shall be locked. Bolts in tension shall be avoided wherever possible. Tapered washers and tapered pads shall be provided on the underside of steel sections with tapered flanges and shall be tack-welded in place. All bolts and nuts shall preferably be in accordance with relevant Indian Standards. Black bolts and nuts shall not be used generally. Washers shall conform to relevant Indian Standards. 13.14 Keyways

Connections subject to torsion such as couplings, driving wheels, and drive gears shall be keyed to the shafts with rectangular keys. The keys shall be sized to be within safe bearing and shearing limits of the materials in contact. 13.15 Name Plates

All motors, starters, disconnect switches, circuit breakers, panels, push buttons, controls, relays and instruments shall have name plates

Particular Technical Specifications

Page 9 of 13

JOGNI-II MINI HYDRO POWER PROJECT

VOLUME-III

indicating the equipment characteristics and identification or function number. The hoisting capacity of hook on crane shall be indicated on a sign plate fastened to the bridge. The sign shall show the hoisting capacity in tons, clearly visible from the generator floor. The details of components like trolley, wheels and axles, winding drums, rope, hook, gears bearings, lubrication, bumpers, girders brakes, motors and their protection, control gear, wiring, earthing etc. shall conform to the modern practices and relevant standards. 13.16 Painting

Before delivery, all exposed, unfinished metal surfaces shall be cleaned and shop painted. Cleaning and Preparation of steel surfaces shall be in accordance with relevant standards and they shall be given at least one prime coat the same day. Paint shall be in accordance with applicable portions of relevant Indian and International standards. The colors of the paint will be selected at the Employers option. All interior surfaces of the crane those are accessible for maintenance inspections shall also be completely painted. All other interior surfaces shall be painted with only the 1 coat of primer. The inside of all gear housings shall be painted with 2 coats of oil resisting enamel as recommended by the gear-housing manufacturer. A quantity and type of paint equal to 15% of the paint used for the second and third coats shall be provided for field touch-up work. The colour of the paint will be subject to approval of the Employer. 13.17 Wrenches, Cradles, Tools etc.

All wrenches and special tools necessary for the proper operation and maintenance as required for assemblies, dismantling and for the efficient maintenance, operation and repair, the list of such tools shall be supplied by the contractor. The tools are not in the scope of supply For load and overload tests at site a suitable cradle, capable of accommodating test load, its design shall be supplied. The design of cradle should be got approved indicating its iron weight. The cradle shall not be supplied by contractors. 14. DRAWINGS AND DOCUMENTS The Contractor shall submit the all the drawings and documents. Which should at least include the following:

Particular Technical Specifications

Page 10 of 13

JOGNI-II MINI HYDRO POWER PROJECT 15. 16. General Assembly of the crane General Assembly drawing of crab/ trolley

VOLUME-III

General Assembly drawing of individual mechanisms Drawing of Bridge, end girder and their connection Sub-assembly drawing of wheels, hook blocks and hoist drums Wiring and Control diagram of the crane showing detailed rating of each motor, cable sizes etc. DESIGN CALCULATION Calculation for Ultimate Tensile Strength, yield point and factor of safety and other parameters for designing the EOT cranes Complete data about various stresses/loads etc. under various conditions including worst condition. Calculations for selection of motor, reducer, brake, couplings, etc. Calculation for bridge girder, end carriage and their connections GENERAL The purchaser or his authorized representative shall have access to the manufacturer's work at all reasonable times for the purpose of witnessing the manufacture, inspection of assembly, match marking etc. and testing of all the components, subassemblies and assemblies of complete crane.

17.

SHOP ASSEMBLY AND MATCH MARKING The crane shall be completely assembled, operated and load tested in the shop also and checked for adequacy of design and suitability for reliable, safe and proper operation. The parts of the crane shall be delivered assembled in as large units as practicable for field erection and handling. Field connection shall be fitted in the shop and match marked suitably for each field erection. All match marks shall be clearly visible and legible. Six copies of all match marks diagram shall be furnished with crane for field connection.

18.

TESTS AT MANUFACTURER'S WORK All material furnished shall be of tested quality and all work performed shall be subject to inspection as specified in relevant International or Indian Standard and no articles or material or supplies shall be despatched until the despatch instructions are

Particular Technical Specifications

Page 11 of 13

JOGNI-II MINI HYDRO POWER PROJECT

VOLUME-III

issued by Purchaser, which shall be issued only after all test's analysis and shop inspection have been completed or certified copies of reports or, results of tests and analysis have been accepted by Employer. Duplicate copies of manufacturer tests certificate shall be submitted to the engineer as soon as the tests are completed. In case test certificates are not available for any of materials, the same shall be tested if requested by the engineer and only those materials, which fulfill the requirements of the specifications, shall be used. All the required tests as per standard/specifications shall be carried out at Contractors expenses. If any component of the equipment fails in the specified test, the same shall be replaced/rectified and again offered for inspection. The Contractor shall submit the Type Test reports in respect of all the major components as per requirement of the latest standard for examination. The Employer may at his option, get any or all the type test or any other test of a reasonable nature carried out in presence of Employer's inspector for which payment shall be borne by the contractor. Full load and 25% overload test shall be done at manufacturers work on hoisting and cross travels motions. Full load and 25% overload test with trolley up to 1.5 meter on either side from center of the bridge shall be done. Tests to verify specified speeds under load conditions and tests about deflection bridge girders under safe working load at rest and with crab in a central position as per standard shall be done. Operation of brakes as per relevant Indian and International Standards 19. INSTALLATION AND COMMISSIONING All installation work shall be done by the purchaser The Contractor is required to do the commissioning and any rectification work if required at site. Supply of all types of consumables and other materials required shall be in the scope of the contractor. 20. FIELD TEST After installation at site, the contractor shall repeat all functional tests as specified in IS 3177:1999. The contractor shall furnish a complete outline of the proposed methods and procedures to be followed for the testing, including a list of equipment and instruments to be used, to the Employers Particular Technical Specifications Page 12 of 13

JOGNI-II MINI HYDRO POWER PROJECT

VOLUME-III

representative for review at least 60 days before the scheduled testing. All necessary materials for performing all the above tests shall be provided by the contractor, and shall take them back after functional tests. 21. DEFLECTION TEST The deflection test shall be carried out with test load at rest and with the crab in central position. The measurement shall not be taken on the first application of load. Datum line for measuring the deflection should be obtained by placing the crab on the extreme end of the crane span with smaller hook approach. 22. cost. SCHEDULE OF REQUIREMENT Sr. No. 1. Name of item EOT Crane 60 T Capacity Quantity 1 No. GENERAL SPARE PARTS The Contractor shall recommend the required spares, along with the

Note : the bidder is required to fill in above schedule the capacity of Crane as per his design.

Particular Technical Specifications

Page 13 of 13