TECHNICAL SPECIFICATION

FOR
2 TON GANTRY GIRDER CRANE
Goliath Crane (With Cantilevered Extension)

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 TECHNICAL SPECIFICATION
1. Scope:
This specification is intended to cover design, manufacture, inspection, assembly shop
testing and delivery at site of complete Goliath Gantry crane as specified herein, for the
Centralised Waste Management Facility at Kalpakkam. This shall also include complete
erection, final check up, testing and commissioning at site of entire equipment supplied
under this specification.

1.1. The gantry Crane of Class M5 outdoors type as per IS: 3177-1999 shall include but not
limited to the following equipment and accessories.
1.1.1 Crane structure including bridge, crab trolley, end carriage, wheels, platforms and hand
rails, complete with driving gears for the Long travel, cross travel and hoisting.
1.1.2 Load blocks complete with sleeves and fittings
1.1.3 Hook
1.1.4 Cable drum and wire rope
1.1.5 Trolley rails complete with all fixtures i.e. clamps, plates, anchor bolts
1.1.6 End stoppers and spring-loaded buffers for the bridge and trolley travel on both ends.
Anti- topple lugs shall be provided.
1.1.7 Motors for the LT and CT motions and Hoists, creep speed through VVFD.
1.1.8 Brakes for hoist motion, long travel and cross travel
1.1.9 Limit switches for limiting upper and lower travel of hook
1.1.10 Limit switches for long travel and cross travel
1.1.11 Torque regulated Motorised Cable drum with flexible cables shall be provided
1.1.12 Mounted pushbutton control with emergency push buttons to interrupt power incase
of emergency. These controls can be placed on one leg of the crane as shown in
schematic sketch so that operator can see the operations along with the crane.
1.1.13 Suitable clamping arrangements to be provided to hold the crane in position when not
in operation to avoid derailing due to wind pressure. The wind catch should be capable
of anchoring the crane to the rails when not in motion.
1.1.14 Necessary cable wiring
1.1.15 Necessary bolts, screws and other fixtures.
1.1.16 Guarding and covers for all rotating components.
1.1.17 Supply of first charge of oil, lubricants, grease etc.
1.2. One set of special erection and maintenance tools.
1.3. One set of recommended spares like hoist pinion, fuses, hoist brake liners, hoist
contactor. Separate list for electrical spares shall also be provided.
1.4. The scope of work shall also include transportation to site including insurance
arrangements, unloading, handling at site before erection, erection complete with
supervision, final testing at site and commissioning of entire crane with all accessories
and application of painting as per this tender.

Signature of the Indenting Officer

2. Work not Covered:
All civil works, supply and installation of LT rails are not under Supplier scope.

3. Terminal Point Schedule: The runway conductor shall terminate in triple pole
isolation switch as per clause 43.

4. Applicable Standards and Codes:

The relevant standards should confirm to the following as applicable:
4.1. IS: 3177; Code of practice for design of overhead traveling cranes and Gantry cranes
other than steel work cranes.
4.2. IS: 807-1976; Code of practice for design, manufacture, erection, testing (structural
portion) of cranes and hoists.
4.3. IS: 2266; Steel wire suspension ropes for lifts and hoists
4.4. IS: 816; Code of practice for use of Metal arc welding for General construction in mild
steel.
4.5. AWS A 5.1:Electrode designations & qualifications
4.6. ASME section IX: Qualifications of welding procedures and welders
4.7. ASME Sec. VIII Div. I; Radiographic inspection of metallic products and Liquid die
penetration for inspection of metallic surfaces.
4.8. USA standards institute code No 8302 Safety code for Derricks and hoists.
4.9. IS: 3443-1980 Specification for crane rail sections.
4.10. Standard referred in IS-3177 for material and code of practice shall be followed where
applicable.
4.11. IS: 3815 Point hook with shanks for General Engg. Purposes.
4.12. IS: 1875 for material of construction of hooks.
4.13. IS: 5749 Forged Rams horn hooks.
4.14. IS: 8610: Wrought iron and mild steel hooks for cranes, slings, blocks and general
engineering purposes.
4.15. IS: 1477: Code of practice for painting of ferrous metal in building and allied finish
4.16. IS: 1030: Steel casting for general engineering purposes
4.17. IS: 1852: Rolling and cutting tolerance for hot rolled steel product
4.18. IS: 970: Wrought steel in the form of bar and for up to 6 inch rolling section and general
engineering purposes.
4.19. IS: 4460 for gears/ pinions for gearboxes.
4.20. IS: 325; Three phase induction motors.
4.21. IS: 4029 Code for testing three phase induction motors
The weldability test required for steel shape, plate and bars for welding over 20mm
thickness shall be carried out as per clause 9.2 of IS : 2062. All the butt welds in the
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Signature of the Indenting Officer

 crane girder subject to the tensile loading shall be 100% radio-graphically inspected in
accordance with ASME Sec. VIII, Div I. All other welds shall be subject to Dye penetrant
inspection as per ASME, Sec VIII, Div I on each weld pass.

5. General Description:
5.1. Drawings: The following drawing enclosed with this tender document forms a part of
this specification:
a) Drg. no. CWMF/0&M/62.04/729 shows the layout of area where the crane is to be
installed
b) Drg No. CWMF/0&M/62.04/730 shows the schematic layout of the crane, the
provision of pockets for foundation bots and overall height span and other details. No
additional embedded parts/ pockets will be provided other than that indicated in
drawing.
5.2. Electric power supply available at site is as follows:
a) 400 Volts ± 10%, 50 Hz ± 3%, 3 phase AC and
b) 230 Volts ± 10%, 50 Hz ± 3%, Single phase AC
If the equipment is designed for voltage other than the specified, necessary equipment
and accessories for conversion, rectification and / or step down/ up shall also be
included in the scope of supply.

6. Operating Conditions:
The Goliath Gantry Crane shall be designed to operate at ambient temperature not
exceeding 50 C under the following conditions.
6.1. Mode of operation : From fixed panel and Radio Control System
6.2. Hoist capacity : 2 Ton
6.3. Span centre-centre runway : 15,100 mm rails
6.4. Crane runway length : (90 lb/yd rails existing) As indicated in layout drawing
The supplier should take exact dimensions of span at the site before starting fabrication .
6.5. Maximum lift of main hook:
Above top of rail- level : 6.5 Meters
Below top of rail- level : 3.0 Meters
6.6. The motions of crane shall be as follows:
a) Long travel : 20 Mtrs/min
b) Cross travel : 10 Mtrs/min
c) Hoist : 10 Mtrs/ min
d) Creep speed for LT : 04 Mtrs/ min
e) Creep speed for CT : 02 Mtrs/ min
f) Creep speed for Hoist : 01 Mtrs/ min

Signature of the Indenting Officer

6.7. Type of crane : Class M5 as per IS: 3177-1999
6.8. Duty : Outdoor
The crane is meant for installation in open yard where high wind velocity up to 160
km/hr is expected and the atmosphere is corrosive. However the IS recommended
value of 180 km/hr (basic wind speed as per IS 875) for this region should be followed
for design purpose.
6.9. Overhang: 04.00 meter with maximum 1.2 meter hook approach from the cantilevered
end

7. Design Requirements:
7.1 The supplier shall provide detailed design calculations for components of mechanism such
as motor KW, brake calculations, Gear box HP rating and ratio, gear design, rope drum,
sheaves, ropes, shafts etc and structural design of crane and get approval of the
purchaser before fabrication of the crane. The supplier shall also furnish design
calculations of all major electrical components like motor and switchgear etc. The
supplier has to submit stage wise quality assurance plan vide raw material inspection,
bought out components, fabrication and inspection prior to dispatch and testing after
erection.
7.2 Three sets of necessary installation, maintenance and operational manuals shall be
provided.
7.3 Drawings: The supplier shall furnish following two sets of drawings to get the approval of
the purchaser prior to fabrication.
a) General arrangement of crane.
b) Assembly and detailed drawings of bridge
c) Assembly and detailed drawings of trolley
d) Detailed drawing showing hoist drive arrangement
e) Detailed drawing showing bridge and trolley drives.
f) Detailed drawing of trolley structure.
g) Bridge and end truck and wheel assembly drawing.
h) Assembly and detailed drawings of lower hook and pulley block.
i) All gear boxes assembly drawings.
j) Drawing showing constructional features and constructional details of brakes and
limit switches.
k) Rails and their fixing arrangement for C.T along with L.T and C.T end stopper
details.
l) Electrical schematic and wiring diagram of power and control system.
m) GA and internal component layout of electric panels.
n) G.A of all panels of crane.
o) Layout and wiring diagram of push pendent.
7.4 In the design of components on the basis of strength, a factor of safety not less than 5,
based on ultimate strength may be used. Impact load fatigue, wear and stress
concentration factors shall be taken into account for shaft etc.
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Signature of the Indenting Officer

7.5 Drive shall be designed with adequate margin to give the best performance and efficiency.
Safety arrangement shall be incorporated to prevent damage to motors, gears and
shafts.
7.6 All materials shall be tested for quality and shall conform to the specification requirement
& standards mentioned and shall be new and first class in all respects. Relevant test
certificates for the materials used shall be furnished.
7.7 Castings and forgings shall be of tested quality and shall conform to their respective
material specification and shall be free from flaws and objectionable imperfections,
machined true in a workman like manner.
7.8 Proposals for repair or any other similar operations involving plugging, welding, boring or
addition of metal to the original castings or forging shall be submitted to the purchaser
and his approval shall be received before any such work is carried out. Drawing
showing details and location of such repairs shall be submitted to the purchaser for his
records. However G.I castings shall not be weld repaired.
7.9 All welding shall be carried out by certified welders.
7.10 Temperature Effects:
Where any portion of the structure is not free to expand or contract under variations of
temperature, allowance shall be made for the stresses resulting from these conditions.
The maximum variation of temperature may be taken as 30° C. Clause 8 of Section II of
IS: 800-1984; code of practice for use of structural steel in General Building
construction shall also apply.

7.11 Breathing holes shall be provided in completely enclosed welded box type girders. Drain
holes shall be provided in all places where water or oil is likely to collect. Where
practicable, means of access shall be provided for inside inspection of completed
enclosed box girders.

8. Bridge Girder:
8.1 Bridge girder shall be of standard manufacturing design but of box type welded
construction. The material of construction to be M.S plates conforming to IS: 2062
Grade B. The minimum thickness of load bearing plates shall not be less than 10mm
and that of non-load bearing plates not to be less than 6mm. The ratio of the length of
girder to depth at any place shall not be greater than 18.
8.2 The ratio of the effective length of the compression flange of the girder (l) to the breadth of
flange of the girder shall not exceed 60.
8.3 Limiting Deflection: The deflection of member or the structure as a whole (without taking
into consideration impact factor) should not be such as would impair the strength or
efficiency of structure of lead to damage to finishing. Girder shall be designed so that
the vertical deflection caused by the 125 % of safe working load and the weight of crab
in central position shall not exceed 1/1200 of the span.
8.4 Lifting points: To enable handling of crane girder without any damage during erection, due
care should be given to provide handling points and mark the same clearly on girders.

Signature of the Indenting Officer

8.5 Quality Assurance: Plates must be tested for chemical, mechanical properties and shall
meet that required grade and valid test certificate from approved laboratories shall be
submitted.

9. Supports:
9.1 Supports shall be of ample strength to resist all the stresses likely to be imposed on them
under service conditions including collision with stops. Gantry Legs shall be of
fabricated box type.
9.2 The supports shall be fitted with safety stops to prevent crane from falling more than
one inch in event of breakage of a track wheel, bogie or axle.
9.3 Supports shall be designed so as to enable the track wheels to be withdrawn readily.
9.4 Supports shall be provided with spring-loaded buffers and end stoppers at each end to
enable smooth stopping of the crane at the end of runway.
9.5 Quality Assurance: Plates must be tested for chemical, mechanical properties and shall
meet that required grade and valid test certificate from approved laboratory shall be
submitted.

10. Platforms and Ladders:

10.1 Safe means of access shall be provided to every place where any person engaged in
examination or maintenance of the crane has to work. Adequate hand holds and
footholds shall be provided wherever necessary.
10.2 Platforms: All platforms shall be securely fenced with double tired guard rail and toe
boards, unless parts of the crane structure provide equal safety and platforms shall be
of sufficient width to enable normal maintenance work to be undertaken safely. On
bridge platforms, which shall not be less, than 762 mm, facing shall extend along the
full length of the outer edge.
10.3 All the platforms should be connected to main girder by a bolted joint to enable easy
transport of girders and platforms as separate parts.
10.4 Platforms should be of chequered / non slip surface steel plates of suitable thickness.
10.5 Side rails to ladder shall extend to a reasonable distance beyond platforms, or some
other reliable handhold shall be provided.
10.6 Ladders shall if possible slope forwards.
10.7 Quality Assurance: Plates must be tested for chemical, mechanical properties and shall
meet that required grade and valid test certificate from approved laboratory shall be
submitted.

11. Guarding:
11.1 All gear wheels, pinions and chain drives shall be completely encased unless such parts
are so situated in relation to structure of the crane to be as safe as in case, when
complete encasement were provided.
11.2 Effective guards shall be provided for revolving shafts and couplings unless every
setscrew, bolt or key on any revolving shaft is sunk shrouded or otherwise effectively
guarded.

Signature of the Indenting Officer

11.3 Long travel cross shaft shall be guarded throughout the length.
11.4 The sheaves of hook blocks shall be guarded to prevent the trapping of a hand between a
sheave and the running rope.
11.5 Quality Assurance: Plates must be tested for chemical, mechanical properties and shall
meet that required grade and valid test certificate from approved laboratory shall be
submitted.

12. Runway Rails:

12.1 The rails existing at site for the LT are of 90 lb/ yd section. However supplier should take
the exact measurement of span etc at site.
12.2 The rails for cross travel shall also be as per IS: 3443, the supplier shall provide adequate
length of these rails and submit the fixing details of same on the bridge girder.
12.3 Adequate provision for end stoppers shall be made on cross travel rail ends. These should
be preferably a spring-loaded type.

13. Crane Wheels:

Wheels for bridge and trolley shall be preferably of double flange type with thread and
proved with radius. 8 Nos. of wheels are recommended for the LT motion.
13.1 The wheels shall be mounted in such a manner as to facilitate removal and replacement
easily.
13.2 Materials for wheels shall be forged EN-9 steel with a hardness of minimum 300 BHN.
13.3 The dimension of flanges of track wheels shall be as per IS: 3177-1999
13.4 Wheel material shall be tested chemically, mechanically. Wheels shall be tested
ultrasonically and test certificates shall be submitted.

14. Wire Ropes:

The wire ropes shall be of suitable diameter as per supplier’s design of crane. The rope
shall conform to IS: 2266. The factor of safety based on nominal breaking strength and
safe working load of rope shall not be less than 6. The rope must be 6 x 37 type
construction with fiber core. The wire rope shall be of “Usha Martin” make.

15. Rope Drum:

The drum shall be fabricated from structural steel plate to IS: 2062 Gr B. All butt welds
shall be subjected to 100% radiography. The plate shall be physical, chemical, and
ultrasonic tested by approved laboratory and test certificates shall be submitted. The
drum shall be preferably machined from seamless pipe (ASTM 106 Gr B) to the extent
possible.
15.1 It should be sufficiently wide to accommodate in one layer, the entire length of rope
required for the specified lift and in addition not fewer than two dead turns at each
anchored end and one spare grove at opposite end.
15.2 The drum shall be flanged at both ends and flanges shall project to a distance not less
than two rope diameters above rope. A spur or other wheel secured to the drum may
be regarded as forming one of the flanges.
15.3 Rope anchorage shall be readily accessible.
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Signature of the Indenting Officer

15.4 Strength of the drum: Drums shall be designed to withstand the compressive stress
caused by wound on rope and the local bending stress caused in the drum at the groove
when rope is wound on. The bending stress due to the beam action of the drum shall
also be taken into consideration.
15.5 Diameter: The drum diameter measured at the bottom of the groove shall not be less
than the appropriate value specified in the IS: 3177
15.6 Drum grooves:
15.6.1 The lead angle of rope shall not exceed 5° (1 in 12) on either side of the helix angle of
groove in the drum.
15.6.2 Rope drums shall be machine grooved and the contour at the bottom of groove shall be
circular over an angle of 120°. The radius of the groove shall be larger than the radius
of rope as per IS: 3177.
15.6.3 The depth of groove shall not be less than 0.35 times diameter of rope.
15.6.4 The clearance between the adjacent turns of ropes shall be as per clause 5.11 of
IS:3177.

16. Sheaves:
16.1 Material: The sheaves shall be of carbon steel casting/ forged steel having chemical
and mechanical properties as per grade I of IS:2707-1996.
16.2 Grooves: Sheaves shall be machine grooved to a depth not less than 1.5 times the
diameter of rope. The grooves shall be finished smoothly and free from surface defects
liable to injure the rope. The contour at bottom of the groove shall be circular over an
angle of approximately 130° ±5°. The radius of this part of grooves shall be larger than
the radius of rope by an appropriate amount as per table 2 of IS: 3177.
16.3 Diameter of Sheaves: The diameter of the sheaves at the bottom of the groove shall
not be less than that of the drums as specified in clause 5.4 of IS: 3177.
16.4 Sheave Guards: Sheaves shall be provided with guards to retain the rope in the
grooves if necessary.

17. Bearings:
17.1 The type of bearings for various parts shall be as per IS: 3177 and of SKF/ FAG make.
17.2 Provision shall be made for service lubrication of all bearings. Bearing enclosures shall
be designed as far as practicable to exclude dirt and prevent leakage of oil or grease.
17.3 Suitable drip pans shall be provided as required to collect oil and grease, which may
drop, from operating parts. All drip pans shall be accessible for draining and cleaning.
17.4 All bearings of gearing shall be antifriction type. Angular contact ball or taper & roller
bearings shall be used wherever necessary. The bearings shall correctly locate the
shafts while allowing for internal expansion of the shafts. Bearings shall be enclosed in
suitable housing with proper plugs to provide grease and holes to permit easy
lubrication.

18. Couplings:

Signature of the Indenting Officer

18.1 All couplings shall be of steel and designed to suit the maximum torque that may be
developed.
18.2 Alignment of all solid couplings shall be made accurately. Flexible coupling shall be
initially aligned with the same accuracy as solid couplings.
18.3 Flexible couplings shall be fitted between motor shafts and extension shafts.

19. Shafts & Axles:

19.1 Shafts shall be made from solid rolled or forged steel bars as per relevant IS standards.
Shafts & axles shall be of EN8 and EN9 respectively.
19.2 Shafts and axles shall have ample strength and rigidity, adequate bearing surface for their
purposes. They shall wherever necessary, be finished smoothly and if shouldered, shall
be provided with fillets of as large a radius as possible and/ or tapered to suit.
19.3 Keys, keyways, splines and serrations shall conform to relevant Indian standards.
19.4 Shafts are required to be tested chemically and mechanically and test certificate from
approved laboratory shall be submitted.

20. Gearing:
20.1 Gears shall comply with relevant Indian standard and shall be machine cut.
20.2 The gears shall be of forged steel with teeth cut from the solid blanks, Pinions shall be of
Steel forging. All shafts and axles shall be turned from forged steel bars. Material of
construction of gears and pinions shall be EN 19 and EN 24 respectively or better. Shaft
and axles shall be of EN 8 and EN 9 respectively. The rating of gears shall be established
as per IS: 4460.
20.3 Gears and pinions teeth shall be treated for resistance to wear.
20.4 Gears shall have tooth form and modules as recommended in IS 3681 and they shall be
adequately designed to stand shock load and vibration. They shall not be excessively
noisy in operation.
20.5 Gear blanks are to be tested chemically and mechanically and test certificate from
approved laboratory shall be submitted. Ultrasonic Testing has to be in proof machined
condition.

21. Gear Boxes:

21.1 Gear boxes shall be so designed that the gears, which they enclose, will be automatically
lubricated. The gears shall be readily removable and boxes shall be oil tight. They
should be of rigid construction and fitted with inspection covers and lifting lugs
wherever necessary.
21.2 The HP rating of gearbox for individual motion shall be greater than mechanical HP rating
of the motor selected for that motion. The design calculation for HP rating of gearbox
shall be provided as per IS 4460. It is also desired that the design calculation of gearbox
shall consist of selection of gears, shafts and bearings.
21.3 Facilities for oil filling, adequate breathing, drainage and means of indicating clearly the
correct oil levels shall be provided.

Signature of the Indenting Officer

21.4 Gear box feet shall be machined and shall be seated and positively located on appropriate
level surface preferably machined except where integral or shaft mounted. All the
gearboxes must be stress relived to remove any residual stresses induced during
fabrication.
21.5 The housing shall be of sufficient design not to permit a temperature in excess of 90° of
the oil bath and shall be adequately supported and readily removable without
disturbing the gear assembly.
21.6 Internal of gearbox shall be sand blasted and painted with 2 coats of oil resisting enamel
paint.
21.7 Noise level of gearbox shall be within 80 db at 1 meter distance from gearbox.
21.8 Quality Assurance: Plates must be tested for chemical, mechanical properties and shall
meet that required grade and valid test certificate from approved laboratory shall be
submitted.

22. Hook Blocks and Hooks:

22.2 The hook block shall be designed to lift without twisting. The hooks shall be of high tensile
forged steel swiveling type and shall be mounted on thrust bearing with protective
skirt for bearing. The hooks shall be provided with locking device to prevent the
rotation of hook when desired.
22.3 The hook of the crane shall be of 2 Ton S.W.L point hook with shank as per IS: 3815.
22.4 The hook shall be of proof load tested marked and duly certified by competent authority.
Material of construction of hook shall be as per IS 1875 class 3A of IPSS.
22.5 Hook material shall be tested chemically and mechanically and test certificate shall be
submitted. Shank shall be ultrasonically tested after machining.

23. Drive Unit:

23.1 Equal driving efforts shall be applied at each drive wheel of the bridge and crab to
prevent one end traveling faster than the other.
23.2 All machineries for the drive unit shall be properly aligned. Self aligning type gear
couplings shall be used between connecting shafts to take care of transverse as well as
axial movement wherever necessary. Wherever components of considerable amount of
inertia are directly mounted on the high-speed shaft they shall be balanced statically as
well as dynamically to minimize vibration.

24. Power Connectors:

24.1 Cable reeling drum (CRD): The power supply shall be by cable reeling drum mounted
on one leg of the crane, which will be motorized. Power points are available in a span of
100 M each. The CRD shall be torque regulated motorised type with limit switches to
prevent over stress on the cables. The CRD shall have 4 + 1 terminal i.e. (3-phase
terminal, neutral + earth terminal)
24.2 Cross conductors on Bridge: For bridge conductors, flexible tailing cable systems
mounted on retracting supporting systems shall be preferred. The conductors shall
consist of insulated multi conductor cables with permanent termination on the bridge
and on the trolley. The flexible trailing cable shall have ample length and shall be
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Signature of the Indenting Officer

 supported by means of properly designed movable clamps. These clamps shall be fitted
with rollers and shall run freely on a guide rail allowing relative movement of bridge
and crab without un-due stress or wear on the suspended cables. Consideration shall
be given to the inclusion of spare conductors of provision for the later addition of
conductors.

25. Electric Motors:

25.1 Variable frequency drive along with encoders shall be provided. The make of drive shall
be ABB / Schneider / Siemens suitable for operating on 400 ± 10%, 3 phase, 50 Hz ±
3% supply at an ambient temperature of 50° C. Motors shall be of GEC/Bharath
bijli/ABB make and suitable for outdoor application. Creep speed shall be achieved by
VVFD.
25.2 The insulation of all motors (duty cycle S4) shall be designed for class F with
temperature rise limited to class B. The motors shall have thermisters embedded in
motor winding. The thermister trip relay shall be provided in control panel. The
enclosure shall be IP 55 as the crane is for out door application, separate canopy shall
also be provided for outdoor application. The motor shall be capable for producing
maximum torque required to produce motions in most unfavourable conditions. The
pullout torque at rated voltage and frequency shall not be less than 2 times of
computed rated torque. The motor shall be capable of withstanding 250 % rated speed
without damage. The CDF shall be 40% and capable of 150 starts/hour.
25.3 SS grid Resistance boxes wherever required should be reputed make such as BCH /
Speedo control.

26.Brakes:
26.1 All the brakes shall be “fail safe type” and shall be applied automatically when power to
drive motor is cut off or fails. Double shoe type brakes shall be provided for each drive
of all motions of the crane suitable for operation at 415 V, 3 phase, 50 Hz power supply.
The brake shoe shall be self-aligning type and shall have large cooling surface for low
temperature rise.
26.2 Brakes shall be a combination of DC electromagnetic breaks (BCH make) and Electro
Hydro Thruster (EHT) of “Speed-O- Control” make. Both the brakes shall be applied
directly to the motor shaft and equally effective in both directions of rotation. Torque
rating of each brake shall be 150 % of rated torque of the motor.
26.3 The thruster motor shall be of 3 phase, totally enclosed class B insulated, continuously
rated motor. The thruster motor shall be designed for frequent switching operation in
the range of 700 switchings per hour. Thruster shall have reserve of at least 30% stroke
length available for necessary adjustment as well as provision for adjustment of time
for upward and downward travels of the piston.
26.4 Bridge and Trolley travel brakes: The brake for each motion shall have to retard in a
safe manner to avoid derailment even when applied at maximum speed.
26.5 Hoist Brake: The design shall be such that braking action in the “OFF” position and
release with current.
26.6 Emergency Braking: All brakes shall irrespective of controller position to be applied
immediately on operating of an emergency stop push button or switch.

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Signature of the Indenting Officer

27.Limit Switches:
27.1 Hoist shall be provided with two limit switches of “Speed-O-Control” make for over
hoisting and these shall be of following type:
a) The first limit switch to act in case of over hoisting shall be rotary type with self-
resetting feature and included in the respective motor control circuit.
b) The second shall be gravity operated hand reset type connected in the main
contactor control.
27.2 Bridge travel and trolley travel shall be provided with limit switches to prevent OVER
TRAVELLING and OVER-TRAVERSING respectively. The limit switches shall operate the
respective motor control circuits.
27.3 The heavy-duty limit switches with IP-55 enclosure with properly designed actuators
shall be provided and shall be readily accessible for adjustment and repair.

28.Crane Controls:
28.1 Hoist motions: For hoist control in hoisting and lowering directions, the supplier shall
offer suitable schemes and complete equipment to meet functional requirement as
specified below. The hoist control shall be designed to achieve ‘inching speed’ of
approximately 10% of rated speed in both hoisting and lowering directions with loads
(from no load to full load) on hooks.
28.2 The control system shall be designed for 110 V ± 10% single phase, 50 Hz power supply.
Necessary transformers and all other equipment shall be furnished by the supplier.

29.Emergency Push Button:

Mushroom type emergency push button to open the main contactor shall be provided,
one near the operator’s panel and two on bridge platform with in easy reach. The push
button shall be provided with suitable cover in order to prevent any undesired tripping.
Main isolating switch fitted in cabin shall be capable of cutting off power supply to all
equipment except lighting. Isolators fitted on Crane Bridge, which shall not be operated
from floor for preventing inadvertent operation is required for carrying out
maintenance activities.

30.PCC/MCC Control Panel & Contactors:

30.1 All the switchgears inclusive of the power contactors, motor controlling VFDs, SDFs, etc.
shall be housed in a PCC/MCC panel. The panel shall be fabricated in accordance to IEC-
61439/IEC-60439. The type of enclosure for the panel shall be IP-54 in accordance to
IS-2147. Bottom entry of the cables shall be sealed by rubber grommets.
30.2 Contactors shall be of heavy duty and suitable for frequent operation. The contactors
shall be silver-plated. The contactors shall be capable of making and breaking duty (AC-
3).
30.3 Contactor coil shall be of impregnated type and temperature rise of coil for repeated
operation should not exceed the permissible limit of class insulation.

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Signature of the Indenting Officer

30.4 Contactor’s current rating shall be at least 25% higher than the maximum current rating
of motors being controlled.
30.5 All the contactors, Motor Circuit breakers, OLR, MCB, time relays should be reputed make
such as Siemens/ABB/Schneider/L&T.

31.Illumination:
The lighting system shall be suitable for 230 volts ±10% single phase, 50 Hz supply fed
from the live side of the disconnect switch located in the protective panel. The
illumination system shall be controlled by separate isolating switches. Lighting fixtures
shall be suitable for outdoor applications.

32.Grounding:
32.1 The crane structure motor frame and metal cases of all electrical equipment including
metal conduits or cable guards shall be effectively connected to earth complying with
Indian Electricity Rules (IS-3043). Each motor shall be grounded at two points with
bare copper conductor wire of size not less than 14 SWG. However, all other non-
current carrying metal surfaces shall be earthed with one no. of 14 SWG bare copper
conductor wire.
32.2 When any equipment will be connected to the supply by flexible cables, the particular
equipment shall be connected to earth by means of an earthling conductor enclosed
with the current carrying conductors within the flexible cable.
32.3 The crane wheel, flexible conduits and other metal parts shall not be used for earthing
purpose.

33.Wiring:
33.1 The supplier shall furnish and install all power, control and auxiliary circuit wiring of the
equipment and panels located in the trolley, bridge.
33.2 The wiring shall be complete in all respects to ensure the proper functioning of the
equipment.
33.3 All wiring to any motor shall be done with 1100 V grade HR FRLS PVC, XLPE insulated
copper conductor cable for armored cables and HR FRLS PVC, XLPE insulated cables for
unarmored cables of suitable sizes. Minimum size of cable for power wiring shall not be
less than 6 mm2 sizes.
33.4 For selecting the rating of the cables for power wiring, consideration shall be given to the
duty of the motor, ambient temperature, grouting of disposition cables, voltage drop
etc.
33.5 All cables shall be adequately protected against mechanical damage, if unarmored cables
are used; the same shall be mechanically protected by running through heavy duty
electrical conduits. However, no conduits are required for wiring in case armored
cables are used.
33.6 Each motor shall be wired up independently. Power and control wiring shall be
effectively separated.
33.7 For control panel wiring, each wire shall be identified at both ends in accordance with
supplier’s wiring system diagram.

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33.8 All wiring termination to the panel shall be made with clamp type connection block.
Screw type terminals with screw directly impinging on conductor are not acceptable.
33.9 All electrical panels shall be chemically treated, thickness of component mounting plates
shall be 3 mm. All wiring shall be done with 1.5 / 2.5 sq.mm HFFR wires of RR /
Polycab/KEC/Unistar make.

34.Load Indication:
The crane bridge shall have permanent inscription on English on each side, readily
legible from the ground floor stating the safe working load.

35.Anchor Bolts, Sleeves, Inserts, Lifting Eye Bolts Etc:

35.1 The specification included the supply of all supports, insulators, brackets, fixtures,
anchoring materials for the runway conductors and bridge cross conductors.
35.2 The equipment shall be equipped with lifting lugs, eye bolts etc, at suitable location for
handling, assembling, lifting and placing into position crane parts.

36.Special Tools and Tackles:

The supplier shall quote separately for a complete set of all special tools, wrenches etc
including tool boxes as required for erection, maintenance, overhaul or complete
replacement of the equipment under this specification. The tenderer shall enclose with
his proposal a list of these tools.
37.Spare Parts: The specification includes the supply of spare parts for two years operation.

38.Testing and Inspection At Manufacturers Works:

38.1 The supplier shall provide tests to establish and maintain quality of workmanship in his
works and that of his sub-contractors to ensure the mechanical accuracy of
components, material, parts and equipment. The supplier’s inspection shall include the
control of quality of manufacturing processes and shall include but not limited to the
following.
38.2 Weldments:
38.2.1 All welding shall be carried out as per relevant IS codes and according to approved
procedure, qualified operators certified by purchaser or his representative.
38.2.2 All butt-welds subjected to tensile loading will be tested 100% by radiography and all
other welding shall be checked with dye penetrant checks. Radiography shall be
arranged by supplier.
38.2.3 The faulty welds if any; shall be brought to notice of the purchaser and shall be
repaired at contactor’s cost by adopting approved procedure and permission from
purchaser or his representative.
38.3 Steel Castings:
38.3.1 Steel casting material shall be in accordance with relevant Indian standard. The
supplier shall provide purchaser with a copy of the ladle analysis and shall arrange for
test bars either cast with castings or separate. The test bars shall be identified by the
representative of purchaser at the time of pouring. The tensile test shall be carried in
accordance with IS: 1608-95. The test results shall comply with respective standard.

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38.3.2 All casting shall be subjected to magnetic particle test inspection in accordance with
ASTM E- 109 and basis of acceptance shall be judged by reference to ASTM E-125.
38.3.3 Heat treatment:
The steel castings shall be heated by proper heat treatment cycle to satisfy the finished
material conditions required by relevant Indian standard. The heat treatment
procedure shall be submitted to purchaser for prior approval.
38.3.4 Repairs:
Any casting if found defective during any time of fabrication/ machining process shall
be referred to Purchaser for his review to accept or reject the same not withstanding
any previous certification of satisfactory testing or Inspection or both. In case
Purchaser agrees to salvage the casting by repairs, the supplier shall submit detailed
repair procedure for approval. The repairs shall proceed only after getting approval
and as per approved procedure. The casting thus repaired shall be subjected to test to
ensure proper repairs.
38.4 Forgings:
38.4.1 All forgings shall conform to physical and chemical requirements laid down in relevant
Indian Standards. The supplier shall provide co-related test certificates or arrange for
physical and chemical testing after getting the forgings identified and sample pieces
made.
38.4.2 All the forgings shall be subjected to magnetic particle testing at the areas of fillets and
change of section. The testing shall be carried out after the rough machining operation.
38.4.3 Any defect, which will, not machined out during the final machining will be gauged out
fully, inspected by dye penetrant or magnetic particle inspection to ensure that the
defect is fully removed and repaired using an approved repair procedure. Any
indication which proves to penetrate deeper than 2.5 % of the finished thickness of the
forging shall be reported to the purchaser, giving location, length, width and depth.
However, weld repair of hook shall not be permitted.
38.5 Fabricated Components:
38.5.1 All components machined or fabricated from plate, sheet or bar shall be as per relevant
IS or material specification approved by purchaser.
38.5.2 All or a representative number of such components shall be subjected to one or more of
the following tests visual, dye penetrant, magnetic particle, ultrasonic or radiography.
These tests shall be in accordance with respective Indian standards.
38.6 The Purchaser’s representative shall be given full access to manufacturer’s works where
fabrication and testing are conducted. At adequate time, prior to major shop tests, the
manufacturer shall inform the purchaser so that if the purchaser so desired, his
representative can witness the tests.
38.7 The crane shall undergo at the manufacturer’s shop overload tests and full load tests and
deflection tests as specified in IS 3177 and IS 807. The test load, the lifting tackles,
slings, test gadgets, instruments shall be furnished by the supplier, The certified report
on these tests shall be submitted to Purchaser.

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Signature of the Indenting Officer

38.8 All crane wirings and equipments after energizing, shall be subjected to Insulation
resistance tests, as per IS 3177. Rectification shall be done until satisfactory results are
obtained in this test. Certificate on these tests shall be submitted to Purchaser.
38.9 The following tests shall be conducted at manufacturer’s works for the control panels.
a) Functional test of the control panel by simulating working conditions.
b) Functionality test of trip modules/panel interlocks/limit switches etc.
b) Insulation resistance test (before & after HV test)
c) High voltage test with the following test voltages:
 2.5 KV for one minute for the main power circuits.
 1.5 KV for one minute for all control circuits, with all the meters/control
elements in circuit.
d) Load test of bridge girder.
38.10 Following tests shall be carried out at manufacturer’s works at each of the resister unit:
i) Insulation resistance test.
ii) High voltage test at 2.5 KV for one minute
iii) Temperature rise test to be conducted on one resister unit of each type.

39.Tests at Site:
39.1 After assembling and erection at site, the crane shall be subjected to commissioning
tests as laid down in British standard BS: 466 / Indian standard IS 3177 and IS 807.
The supplier shall be fully responsible for carrying out all the tests required by these
standards including the overload testing of the crane.
39.2 The lifting tackles, slings, test gauges, instruments shall be furnished by supplier. The
purchaser shall however provide the test load.
39.3 The report on these tests shall be submitted to the Purchaser by the manufacturer’s
authorized representative at site.

40.Performance Guarantee and Tolerances:

40.1 The equipment shall be guaranteed to meet the performance requirement specified in
this specification.
40.2 The performance of the crane will be tested in manufacturer’s shop as specified in
clause 39 and rectification shall be done if necessary, until the performance
requirements are satisfactorily met.
40.3 The crane shall be subjected to further tests at tests at site as specified in clause 40 which
shall also be satisfactorily met.
40.4 The supplier shall give guarantee for satisfactory performance for a period of 18 months
from the date of delivery or 12 months from the date of installation, whichever is
earlier. The guarantee shall cover failure occurring to the units defective in
workmanship or material and will be limited to replacement of parts recognized as
being defective.
41.Special Cleaning, Protection and Painting:
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 All parts of the crane shall be thoroughly cleaned preferably sand blasted of all loose
scales, rust or foreign matter. All exposed metal surfaces shall be protected from
environmental effects. Control panels shall be painted by 7 tank process, and shall be
suitable for out door application.
All parts except motors, resistors, gears thruster etc shall be painted with two coats of
primer (red lead) and two coats of enamel as per applicable Indian standard. Interior of
all gearbox housing shall be give one coat of rust inhibitor. Final painting of all
equipment and structures shall be done by Supplier. Internal painting of all panels shall
be semi gloss white with external painting semi gloss golden yellow. Before the
equipment is closed they shall be carefully checked to be sure that all extraneous
matters such as rags, rubbish, foreign matter etc. have been removed. After the interior
is cleaned and dried opening shall be closed with cap to prevent entry of water, dirt or
any other foreign matter.
42.Shipment:
The supplier shall be responsible for ensuring that all equipments are carefully
prepared for shipment so that they will arrive at site in a satisfactory manner. Packing,
forwarding, transportation including transport insurance are in the scope of contractor.
Delivery must not take place until the receipt of proper shipping release from
Purchaser. Place of delivery is CWMF stores, BARC, Kalpakkam, Kancheepuram dist,
Tamilnadu.
43.Power Supply:
43.1 Power supply at 400 V ± 10%, 3 phase, 4 wire, 50 Hz will be made available to an
adequately rated triple pole isolation switch to be supplied by the contractor and
located at as convenient position for the operation from the floor.
43.2 The Contractor’s scope of work shall commence from this isolation switch and include
complete crane electrical items as elaborated here.
43.3 Main isolating switch shall be fitted in cabin capable of cutting of power supply to all
equipments except lighting.
43.4 An isolator fitted on Crane Bridge, which shall not be operated form floor for preventing
inadvertent operation is required for carrying out maintenance.
43.5 The firm shall furnish design calculations of all major electrical components i.e motor
and switchgear components.

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Signature of the Indenting Officer

 Erection Specification

1. Scope:
The contractor shall unload, handle, assemble, install and place in successfully operation
of the crane in accordance with the requirements of this specification. Mobile crane
required for unloading of crane components and erection of crane is in the scope of
contractor.
2. Inspection at Site:
The contractor or his representative is deemed to have inspected and examined the site
and surroundings before submitting his tender.
3. Superintendence of Labour:
The contactor shall provide supervision of erection, which shall include:
a. The employment of a competent erection superintendent engineer who shall be
constantly at the site and shall give his whole time to the superintendence of the erection
and commissioning of the works and whose duties shall include the supervision of the
unloading, assembly and installation, repair and replacement of any damaged
components, fabrication, and operating adjustments.
b. The employment of a sufficient number of competent assistants to the erection
superintendent to provide supervision of the number of working shifts per day and days
per week necessary to complete the work within the time specified.
The contractor shall employ only such person as careful, skilled and experienced in their
several trades.
4. Notices:
Any notice, order, direction or other communication to be given to the contractor under
any of the provisions of the purchase order shall without limitation be conclusively
deemed to have been received by the contractor if delivered or mailed to the contractor
if delivered or mailed to the contractor’s last known place of business or residence or to
his Superintendent or Foreman.
5. Sub-Contractor:
The contractor shall not sub-let the whole of the erection work. The contractor shall not
sub-let any part of the erection work without written consent of the Purchaser.
The contractor shall be responsible to the Purchaser for all the work of Sub- contractor.
Any sub-contractor shall be bound to the contractor by the terms of drawings and
specifications and shall assume towards the contractor the entire obligation and
responsibilities that the contractor assumes towards the Purchaser.
6. Co-Ordination of Work:
The contractor shall plan his operations so as to avoid interference with the operations
of the Purchaser, the general contractor or other contractor and/or sub-contractor at
site. The contractor shall organize his work to suit the timings shown on the
construction schedule or revised date, issued by Purchaser.

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7. Layout Measurements:
The purchaser will give basic building lines and establish datum but such layout shall
not relieve the contractor of his responsibility for the proper performance of the works.
The contractor shall provide equipment for and he shall carry out and check all precision
and detailed layout including setting and alignment of equipment and machinery. The
contractor shall protect all survey reference points established by the Purchaser and he
shall provide sufficient, safe and proper facilities at all times for layout and
measurement of the work.
8. Sanitation:
The contractor may have the use, free of charge, of the Purchaser’s First Aid facilities
(First aid room and attendant) and toilet facilities in the work area. All other medical
and sanitary arrangements shall be furnished by the contractor at his own expense.
9. Clean-Up and Observance of Safety Precautions:
The contractor shall at all times keep the site free from the accumulation of waste
materials and debris and upon completion of the works shall clean away and dispose of
all surplus materials, rubbish and temporary works of whatsoever nature and kind as
directed by the purchaser and shall leave the works and site clean and tidy.
The contractor shall be responsible for the taking of all safety precautions during the
construction and on completion of the works and for leaving the site safe at all times and
at the end of each working day and at all times when the work is temporarily suspended
he shall protect all construction materials, equipment and facilities from causing damage
to existing property or interfering with the operations of the facility when it goes into
service.
The contractor shall comply with all applicable provisions of the safety regulations,
clean-up programme and other precautionary measures which the purchaser has in
effect at site.
During erection of the various units, safety precautions such as providing ladders for
safe approach shall be provided by the contractor. A safety supervisor will be stationed
on the works and the contractor shall comply with any instruction given by the safety
supervisor regarding safety, pre-cautions, protective measures, clean up and any
practices with which in the opinion of the safety supervisor may present unavoidable
hazard.
10. Services Supplied by the Purchaser During Erection:
For the purpose of planning, the contractor shall furnish along with tender, the
estimated requirement of electric power for the execution of the work in terms of
maximum KW demand and also the maximum water requirement.
The purchaser will provide for the contractor the following services during the
performance of the works.
Temporarily electric power of 415 volts, 3 phase, 50Hz and 230 volts subject to the
following conditions:
a) The electric power will not be used for heating purposes.
b) The purchaser shall meter the supply of power to the contractor at the points at
which the supply is given. For this purpose, the contractor will be liable to pay the rent of
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Signature of the Indenting Officer

 meter at rates to be fixed by purchaser. If any dispute on accuracy of meter is raised by
contractor, the meter under dispute shall be checked in the Standards laboratory of the
State Government in Chennai and the meter replaced if required. No request for rebate
on past consumption will be entertained, nor will any recovery be made on account of
any excess consumption. The Fees levied by the Chief Electrical Inspector to the
Government of Tamilnadu for testing the meter shall be collected from the Contractor.
The purchaser may, at his discretion, replace any meter installed.
c) The purchaser will supply this power to the Contractor at a point, which will be within
130 meter of the locations of the works.
d) The contractor’s temporary distribution system shall be subjected in every respect to
the approval of the Purchaser and shall be so arranged as to avoid any interference with
the operations of the other contactor/work at site.
e) It shall be the responsibility of the Contractor to provide and maintain the complete
installation on the load side of the supply with due regard to the safety requirements at
site. All cabling and installations shall comply in all respects with the appropriate
statutory requirement given in the following:
i) Indian Electricity Act, 1910 (As amended)
ii) Electricity Supply Act, 1948 (As amended)
iii) Indian Electricity Rules, 1956 (As amended)
and shall be subject to approval of the Purchaser. Any expenses on the inspection
required by an authorized inspector under the above regulations shall be borne by the
Contractor.
f) The power supply will also be regulated as per terms and conditions of supply of
Tamilnadu Electricity Board.
g) The contractor shall maintain the power factor at not less than 0.8, by installing, if
necessary, at his own cost, suitable corrective devices, The contractor’s failure to take up
necessary action in this regard within a period stipulated by the purchaser may entail
installation of the corrective devices by the purchaser at the contractor’s risk and cost.
h) The purchaser will not be liable for any loss or damage to the Contractor’s equipment
as a result of variations in voltage of frequency of interruption/ stoppage resulting in
interruption/ stoppage of power supply for a continuous period not exceeding 24 hours,
the contractor shall have no claim whatsoever against the Purchaser. For any power
failure/ stoppage resulting in interruptions for continuous period exceeding 24hours,
the contractor will be eligible for only reasonable extension of time and not for any
compensation on this account.
i) Purchaser will not be liable for any loss to the contractor arising from interruption,
failure or stoppage of works and any attendant delays consequent upon such
interruptions, failure or stoppage of power supply or variations in voltage or frequency.
j) Electric energy drawn by the contractor for works will be charged at the current rate
plus fixed meter charges per month on the basis of actual consumption.
After completion of the works, the contractor shall promptly dismantle the distribution
and other facilities he may have erected, at his own cost.
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 The contractor shall make his own arrangements for all the necessary tools and
necessaries required for the work.
11. Site Handling & Stores of Material and Requirement to be Incorporated in Works:
The contractor shall deliver all materials and equipment to be incorporated in the works
at site, unload and place in storage at locations designated by the Purchaser at site. The
Contractor will be responsible for adequate arrangements for storage of these materials
and equipment until such time as required for site assembly and erection. The
contractor shall be responsible for loading and movement from the place of temporary
storage the point of installation of the works.
The contractor shall unload and handle all materials and equipment at the point of
installation of works.
Adequate lighting facilities such as floodlights, hand lights and area lighting shall be
provided by the Contractor at his own cost at the site of construction and storage of his
materials and equipment and temporary access roads within his working area. The
contractor shall obtain approval of the Purchaser to the lighting scheme prior to its
installation.
12.Equipment and Services provided by the Contractor:
The equipment and services provided by the contractor and his sub-contractor shall
include but not limited to the supply of compressed air if required, blocking, scaffolding,
indoor storage for perishable material, locked storage for tools, welding rods and
welding equipment, sand-blasting equipment, miscellaneous tools and adequate
materials and supplies.
13.Transportation of Erection/Equipment and Materials to Site:
The contractor shall be responsible for all transportation of all erection equipment and
materials to and from the site.

14.Access Roads and Temporary Building:

The contactor shall have reasonable use of existing roads at the site. The contractor may
use the main roads into the plant for vehicle storage provided that it does not interfere
with access by other contractors to the plant.
The purchaser will regulate the entry of vehicles into the plant.
All temporary buildings, tool sheds, offices etc. shall be provided by the Contractor.
15.Accommodation and Travel:
The contractor’s lump sum erection prices shall include all traveling, transportation and
accommodation costs of all his forces including supervisory personnel. The purchaser
will not provide any quarters for the accommodation of Contractor’s personnel.
However for Contractor’s erection engineers/ supervisors, temporary hostel
accommodation at prevailing rate for contractors shall be arranged by purchaser, subject
to availability.

16.Erection:
The contractor shall take over the concrete foundations for the equipment after checking
their perfectness. Any defect shall be rectified by Purchaser.
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17.Mode of measurement when not specified in the tender shall be in accordance with relevant
Indian Standard specifications and where not spelt out in IS, the engineer’s decision shall
be final and binding on the contractor.
The contractor shall furnish along with his tender the site organization proposals to
employ for execution of the works covered by this contract.
During the execution of the contract and until completion certificate is issued, the
contractor will be fully liable to compensate all concerned for any loss, damage or
destruction of ‘works’, structure, plant and machinery, persons, property etc. including
third party risk arising due to causes attributable to the contractor as may be decided by
the Purchaser whose decision in this regard will be final. No claim shall be made against
Purchaser on this account.
The contractor shall note that the work has to be carried out in a coastal area. The
contractor shall take necessary precautions to ensure safety of his crew, materials,
equipment and the works during the period of contract. No claim from the contractor for
loss of or damage to equipment, materials, crew or the works during the course of work
due to natural causes like cyclones, gales, floods, rains or other cause or combination of
causes will be entertained by Purchaser. The contractor shall be fully liable to
compensate Purchaser for any loss or damage to works till the time of taking over of the
work by the Purchaser.
Contractors shall submit along with the tender details of their past experience in
execution of large works, including value of each work and name of clients, place of
execution and other relevant information.
18.Commissioning And Testing:
All the units shall be commissioned by the Supplier and testing of each unit shall be
carried out by the supplier to the utmost satisfaction of the purchaser. It is envisaged
that other works not covered under this tender, works on installation of equipment,
piping etc may have to be carried out by other agencies in the completed/ partially
completed portion of the building, along with this work. The tenderer shall permit such
works along with this work. The tenderer shall permit such works to be carried out
without any hindrance and fully co-ordinate his activities with other agencies. No
compensation or claim for such contingencies shall be entertained.

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Signature of the Indenting Officer