Military Engineer Services Tender

Lump Sum price worked out by the contractor for "SEWAGE DISPOSAL" as listed in Schedule ‘A’ Part-IV representing percentage ( + or - denomination) derived under last column of this schedule above/below the lump sum price prepriced by the MES B/F from Sl page No. 37

Lump Sum price worked out by the contractor for "AREA DRAINAGE" as listed in Schedule ‘A’ Part-V representing percentage ( + or - denomination) derived under last column of this schedule above/below the lump sum price prepriced by the MES B/F from Sl page No. 38

Lump Sum price worked out by the contractor for "GREEN BUILDING NORMS" as listed in Schedule ‘A’ Part-VI representing percentage ( + or - denomination) derived under last column of this schedule above/below the lump sum price prepriced by the MES B/F from Sl page No. 39

Lump Sum price worked out by the contractor for "INTERNAL WATER SUPPLY" as listed in Schedule ‘A’ Part-VII representing percentage ( + or - denomination) derived under last column of this schedule above/below the lump sum price of prepriced by the MES B/F from Sl page No. 40

Lump Sum price worked out by the contractor for "EXTERNAL WATER SUPPLY" as listed in Schedule ‘A’ Part-VIII representing percentage ( + or - denomination) derived under last column of this schedule above/below the lump sum price of prepriced by the MES B/F from Sl page No. 41

Lump Sum price worked out by the contractor for "INTERNAL ELECTRIFICATION" as listed in Schedule ‘A’ Part-IX representing percentage ( + or - denomination) derived under last column of this schedule above/below the lump sum price prepriced by the MES B/F from Sl page No. 46

Lump Sum price worked out by the contractor for "EXTERNAL ELECTRIC SUPPLY" as listed in Schedule ‘A’ Part-X representing percentage ( + or - denomination) derived under last column of this schedule above/below the lump sum price prepriced by the MES B/F from Sl page No. 54

Lump Sum price worked out by the contractor for "LIGHTNING PROTECTION" as listed in Schedule ‘A’ Part-XI representing percentage ( + or - denomination) derived under last column of this schedule above/below the lump sum price prepriced by the MES B/F from Sl page No. 55

Lump Sum price worked out by the contractor for "REFRIGERATOR, AC, WATER COOLER, COOLING APPLIANCES, AIR CURTAIN" as listed in Schedule ‘A’ Part-XII representing percentage ( + or - denomination) derived under last column of this schedule above/below the lump sum price prepriced by the MES B/F from Sl page No. 56

Lump Sum price worked out by the contractor for "STAND BY DG SET" as listed in Schedule ‘A’ Part-XIII representing percentage ( + or - denomination) derived under last column of this schedule above/below the lump sum price prepriced by the MES B/F from Sl page No. 57

Lump Sum price worked out by the contractor for "DEMOLITION & DISMANTLING OF BUILDING" as listed in Schedule ‘A’ Part-XIV representing percentage ( + or - denomination) derived under last column of this schedule above/below the lump sum price prepriced by the MES B/F from Sl page No. 58

Sch 'A' PART-XV (MISCELLANEOUS B&R AND E&M WORKS) Notes: (i) This schedule is not pre-priced by MES and the pre-priced rate indicated as "Rs 0.00" under column 5 signifies this fact only. (ii) Excavation and earth work except for the items which categorically includes for same shall be measured and paid separately under respective schedule.

INTERNAL WATER SUPPLY S & F 15mm bore, fancy type, CP brass bib cock with wall flange, screwed for iron pipe or CPVC pipes or for brass ferrule and fixed complete all as specified and directed. Make - Jaquar Essco SERIES or techno commercial equivalent of any make specified in Appx 'B'.

S & F 15mm bore, two way, fancy type, CP brass bib cock with wall flange, screwed for iron pipe or CPVC pipes or for brass ferrule and fixed complete all as specified and directed. Make - Jaquar Essco SERIES or techno commercial equivalent of any make specified in Appx 'B'.

S & F 15mm bore, fancy type, CP brass angular stop cock screwed for iron pipe or CPVC pipes or for brass ferrule and fixed complete all as specified and directed. Make - Jaquar ESSCO SERIES QQT-7053 or techno commercial equivalent makes as per Appx 'B'.

S& F health foucet with 1200mm long flexible mild steel tube 80mm dia with wall hook complete all as specified and directed. Make - Jaquar QUEEN SERIES Cat No ALD-573 or techno commercial equivalent of any make specified in Appx 'B'.

EXTERNAL WATER SUPPLY M & L for Construction of PCC Block Masonary valve chamber of size 450 x 450 x 900mm (Internal dimenssions) with PCC foundation 1:4:8 type D-2 using 40mm graded stone aggregate 10mm thick, 150mm wide off sets alround over 100mm thick hard core , one brick thick walls built in CM 1:6, 50mm thick PCC 1:2:4 Type B-1 coping finished even and smooth, rendering 10mm thick in CM (1:6) finished even and smooth, with out using extra cement internally including top of floor including excavation earth work in hard/Dense soil 3mm thick MS sheet cover fixed on 50mm x 50mm x 6 mm thick angle iron frame with hold fasts embedded in PCC coping with locking arrangement, mild steel handle and painting to steel surfaces with two coats of synthetic enamel paint over one coat of primer including disposal of surplus soil to a distance not exceeding 50 m etc complete all as specified and directed.

S & F modular type MCB SP 20 Amps with socket, conforming to IS 60898- 1: 2002 complete all as specified and directed.

S & F modular type MCB TPN / FP 32 Amps with socket, conforming to IS 60898- 1: 2002 complete all as specified and directed.

Supply and fixing Modular type, 1 module RJ-11 Gang with shutter (Telephone socket) complete with all accessories complete all as specified and as directed.

Supply and fixing Modular type, 1 module RJ-45 Lan socket with shutter complete with all accessories complete all as specified and as directed.

Supply, installation , testing and commissioning load line distribution board TPN vertical, 4 way double door type, fixed on wall semi flush with incoming MCCB 4 poles , busbars , neutral link, blanking plates complete with all accessories all as specified and as directed. Note: Outgoing MCBs shall be measured and paid separately.

S & F of moulded case circuit breaker (MCCB) 40 Amps, 4 pole with thermal magnetic trip unit (TMD), compression lug connectors, protection against overloads (Ir adjustable from 0.7- 1 x In), protection against short circuits (Isd adjustable from 5- 10 x Ir), inbuilt encapsulated double break roto active type instanteneous protection, earth fault leakage protection etc having Ics = 100% = Icu = 16 KA as per IEC 60947-2 and suitable for 3 Phase, 415 Volt, 50 Hz electric supply complete all as specified and directed

S & F LED batten light fitting 20 Watt, surface / wall mounted capable of delivering 2100 lumen, having PC diffuser, luminous efficacy of 90 lumen/Watt, CRI 80, PF 0.9, CCT 6500 K, independent isolated SMPS based constant current electronic LED driver with THD 20%, surge voltage protection and other safety tests as per IS-15885 (Part-2/Sec-13): 2012, polycarbonate diffuser, housed in powder coated white extruded aluminium channel housing. white coloured ABS end caps, IP-20 protection, input voltage range 140- 270 Volt, input frequency 50- 60 Hz, including electrical connection with 3 core flexible Copper conductor cable of appropriate size from ceiling rose to the fixture complete all as specified and directed.

S & F LED batten light fitting 10 Watt, 2 Feet capable delivering 1000 lumen having luminous efficacy of 100 lm/Watt, starting time 0.5 s, CRI 80, CCT 6500 K, PF 0.9, input voltage range 140- 270 Volt, input frequency 50- 60 Hz and B-22 socket complete all as specified and directed rose to the fixture complete all as specified and directed.

Supply and fixing LED highbay light 120 Watt, 230 Volt, AC outdoor type with thermal management in multiple optics and equipped with IP-66 protection with impact and corrosion resistant with driver and lamp complete all as specified and directed.

Supply & fix 15 Watt LED Downlight having luminous efficacy of 100, input voltage range 140-270 Volt, input frequency 50-60 Hz complete all as specified and as directed.

Supply & fix 36 Watt LED panel light 2 x 2 having luminous efficacy of 100, input voltage range 140-270 Volt, input frequency 50-60 Hz complete all as specified and as directed.

Supply, installation, testing and commissioning of factory made, indoor cubical compartmental type MLTP (TTA) of suitable size for short circuit, temperature rise, protective earth short circuit test and dielectric tests of required ratings, conforming to IEC 61439-1 & 2 and IEC 61641 having both sides openable with hinged double doors and locking arrangement, IP-42 protection made out of 2.0mm thick mild steel CRCA sheet, supported and fixed on structural frame of angle iron of suitable size, including earthing stud, labelling, painting to all internal & external exposed steel surfaces with powder coating paint (7 tank process), duly fixed in ground with PCC foundation (1:2:4) type B-1, with danger notice plate of 1.6mm thick mild steel vitreous enameled (white) with letters, figures and conventional skull and bones in signal red colour suitable for 3 Phase, 4 Wire system, 500 Volt grade with necessary wiring with PVC sheathed stranded copper conductor of appropriate length and size including fixing lugs, bolts, screws etc comprise of the following components complete as specified and directed. Make : Schneider, Siemens, ABB

[A] BUSBAR CHAMBER [i] Copper busbar (3L + N) of rated capacity 250 Amps, covered with PVC insulated sleeves including insulator, nuts, bolts etc with complete connection. - 01 Set [B] INCOMING [i] MCCB, 4 Pole 200 Amps, 415 Volt, 50 H, Ics = 100% Icu = 25 KA, conforming to IEC 60947-2, having microprocessor based trip unit, adjustable overload setting (0.7-1 x In), adjustable short circuit setting (5-10 x Ir), adjustable neutral protection (N, N/2, OFF), front indication LEDs (ready, overload and pre-alarm & overload) - 01 No. [ii] Cl, 1.0 multi function meter capable of measuring V, A, F, PF, W / VA, Wh / VAh, Runhrs, Onhrs & interupts- 01 No. [iii] LED phase indicators (Red, Yellow, Blue) - 01 Set

[C] OUTGOING [i] MCCB, 4 Pole 63 Amps, 415 Volt, 50 H, Ics = 100% Icu = 16 KA, conforming to IEC 60947-2, having microprocessor based trip unit, adjustable overload setting (0.7-1 x In), adjustable short circuit setting (5-10 x Ir), adjustable neutral protection (N, N/2, OFF), front indication LEDs (ready, overload and pre-alarm & overload) - 02 Nos. (For SPARE, MDB - FF) [ii] MCCB, 4 Pole 40 Amps, 415 Volt, 50 H, Ics = 100% Icu = 16 KA, conforming to IEC 60947-2, having microprocessor based trip unit, adjustable overload setting (0.7-1 x In), adjustable short circuit setting (5-10 x Ir), adjustable neutral protection (N, N/2, OFF), front indication LEDs (ready, overload and pre-alarm & overload) - 03 Nos. (For MDB GF, DB GF) [iii] MCCB, 4 Pole 4032 Amps, 415 Volt, 50 H, Ics = 100% Icu = 16 KA, conforming to IEC 60947-2, having microprocessor based trip unit, adjustable overload setting (0.7-1 x In), adjustable short circuit setting (5-10 x Ir), adjustable neutral protection (N, N/2, OFF), front indication LEDs (ready, overload and pre-alarm & overload) - 01 No. (For 2.5 TON EOT CRANE) [iv] Cl, 1.0 multi function meter capable of measuring V, A, F, PF, W / VA, Wh / VAh, Runhrs, Onhrs & interupts- 01 No. [v] LED phase indicators (Red, Yellow, Blue) - 01 Set.

EXTERNAL ELECTRIC SUPPLY Supply, installation, testing and commissioning weather and vermin proof LT feeder pillar box conforming to IP-54, CPRI approved factory fabricated outdoor type, double door cubicle/KIOSK type made out of 3.00mm thick sheet metal with partician and switch enclosure door of 1.60mm thick sheet metal and canopy made out of 3.00mm thick MS sheet all as per IS & shall be available inside for easy access and working condition mounted on angle iron frame of MS angle 40 x 40 x 6mm with clearance of at least 0.45 Mtr above GL and an appron of 2.00mm MS sheet suitable for operation on 3 phase, 4 wire, 440 Volts, 50 HZ system, with hinged panel doors (covers) on two sides with handles, bottom gland plate and locking arrangement consisting of sufficient Nos of circular cable entry holes at bottom only with suitable PVC/rubber /wooden bushes to prevent ingress of water/vermin etc, inside the enclosure, the required nos of holes to be fixed with chromium plated brass cable glands for cable entry and exit complete with necessary internal wiring with stranded copper conductor PVC insulated cables of adequate size, duly painted with two coat of synthetic enamel paint over a coat of red oxide primer internally/externally of approved colour with PCC foundation including following components:- .

(a) MCCB 4 POLE, 415 Volts, AC, 315 Amps, 36 KA repturing capacity - 01 No. (Incomer) (b) MCCB 4 POLE, 415 Volts, AC, 250 Amps, 36 KA repturing capacity - 02 Nos. (For Main bay bldg & spare) (c) MCB SPN, 16 Amps, 10 KA repturing capacity - 01 No (For Street light) (d) On load Change over switch 415 Volt in sheet metal enclosure 4 pole of capacity 250 Amps - 01 No (e) Digital Voltmater 0 - 500 Volt of size 96 x 96mm square with selector switch - 01 No. (f) Digital Ammeter 0 to 400 Amp with selector switch & suitable range of CTs - 01 No (g) LED Phase Indicator lamp (RYB) with holder (Set to three) - 01 Set (h) Aluminium bus bar 100 Amps Cap, 3 phase 4 wire - 01 Set (j) Time switches astro type (having longitude and latitude of indian cities in memory) 250 Volts, single phase of 100 Amps rating with contactor fitted inside the steel enclosure - 01 Set

Supply and fix highbay light fitting with pressure die cast housing integrated PC optics and 150 lm/m efficiency , 4 KV in built and 10 KV external surge protection , IP-66 ingress protection with additional chain of capacity 100 Watt complete all as specified and directed.

REFRIGERATOR, AC, WATER COOLER, COOLING APPLIANCES, AIR CURTAIN Supply and fix Voltage stabilizer for automatic operation, single phase naturally air cooled indoor type & designed for input variation between 170 Volt to 250 Volt with output voltage stabilized at 230 Volt with accuracy of ± 2.5% and of capacity 4 KVA complete all as specified and directed.

All as per item No 50 above but 1 KVA.

Supply & fixing 600mm sweep, Wall mounted air circulated fan, 230 Volt, single phase oscillating complete all as specified and directed.

Supply, installation commissioning and testing of air compressor reciprocating type two cylinder of storage capacity 200 Ltr with high and low pressure cut off valve electric driven of motor capacity 10 HP, 3 phase, 415 Volt, 50 Hz, copper wound assemble with air compressor connecting with DOI, starter 3 phase, 410-440 Volts, 25 Amps TPN industrial plug complete with all accessories and two Nos pressure guns with size ½” for operation of heavy nuts & bolts complete all as specified below and as directed.. (a) Pneumatic pipe 100 Meter length, 15mm dia connected with compressor. (b) 12 Nos take of points with wall. (c) Two filters to be provided reduces moisture. (d) Small air gun 12 Nos. (e) PU heavy duty flexible pipe which connect air gun to valve.

DG SET Supply, install, testing and commissioning of 200 KVA Diesel Engine driven generating set with acoustic enclosure made out of CRCA Sheet powder coated specially designed lifting arrangement/hooks, meet the latest CPCB norms of 75 dBA form 1 Meter distance and as per the testing guide line of CPCB DG set shall be conforming to IS : 10001/10002 and alternator as per IS : 13364 coolant type self starting system with 12 Volt, DC Supply, 3 phase, 4 wire, AC 415 Volt + 5% at 1500 RPM, 50 Hz, 0.8 PF self exiled self regulated Automatic voltage regulation class ‘H’ insulation type alternator installed on PCC foundation platform with and including following accessories complete all as specified and directed. Make : Kirloskar , Crompton Greves, Cummins

(a) Coupling arrangements . (b) Mounting arrangement with ISMC fabricated frame on anti vibrating pad. (c) Fuel tank with base frame suitable for not less 8 hrs Running capacity on full load Inlet & Outlet arrangement with air vent level indicator drain plug arrangement and provision for cleaning. (d) Battery maintenance free dry cell battery 12 Volt, 120 AH of approved make . (e) Water Pump. (f) Radiator with fan. (g) Silencer muffler as per approved of CPCB / MoEF. h) LT Panel electronic modular type for DG Set floor mounted cubical 2mm thick powder coated finish indoor type with the following arrangement. :- (j) Indicating lamp LED type for ‘’Load on’’ & Set Running’’ – 01 No. (k) Ammeter with selector switch digital type suitable to read current in each phase . (l) Voltmeter with selector switch digital type suitable to read phase voltage and line voltage (multi function) all as specified. (m) Hours Rung meter digital type to read cumulative and present running Hrs. (n) RPM indicator digital type - 01 No. (o) Frequency meter digital type – 01 No. (p) Earthing terminals – 2 Nos.

(q) Digital Manual and AMF control panel : Digital Manual in equipped with 16 bit high speed RISC processor controller. It displays the following parameters Safety system with special sensors to safe sensors to safe guard the engine against faults like low lub oil pressure, high coolant temperature, battery over / under /weak volt, fail to crank/start, sensor failure, over speed, low fuel level etc with alarm. (r) AC Alternator protection over/under voltage over under frequency. (s) ‘Preset’ system with push button. (t) DC voltmeter – 01 No. (u) Mechanical Governor. (v) Reverse power relay & reverse power relays. (w) neutral switching facility. (x) SMPS suitable for charging, 12 Volt battery with trickle and boost facility – 01 No. (y) Independent earthing terminals for engine & alternator – 02 each. (z) battery charging alternator 12 volt. (aa) M & L for making PCC foundation (1:3:6) type C-1 including from work of size 4 x 2 x 0.50 Mtr height along with necessary earthwork and excavation in any type of soil, brick work in CM (1:4), 15mm thick rendering in CM (1:6)finishing the surface even and smooth, 100mm thick flooring PCC (1:3:6) type B-1 using 20mm graded stone aggregate over 150mm thick hard core over rammed earth for 200 KVA DG set complete all as specified and as directed.

The control panel consists of the following parts : [i] Control Panel: Manufactured with 14/16 gauge CRCA sheet and powder coated for weather-proof and long lasting finish. [ii] Controller: Aluminum bus bars with suitable capacity with incoming/outgoing terminals. [iii] Indicating lamps for ‘Load ON’ and ‘Set Running’. [iii] Instrument fuses duly wired and ferruled. [iv] MCCB of suitable rating with overload and short circuit protections

[v] Microprocessor based generator set monitoring and control system including an intuitive operator interface that allows for complete generator set control as well as system metering, fault annunciation, configuration and diagnostics, LED backlit LCD display with tactile feel soft-switches & generator set status LED lamps, remote START-STOP.

ƒ[vi] Engine Metering: Oil pressure, engine temperature, starting battery voltage, engine running hours. ƒ [vii] AC Alternator Metering: L-L voltage and L-N voltage, current (phase and total), KVA (phase and total) and frequency . [viii] ƒEngine Protection: Low lube oil pressure, high/low coolant temperature, battery over/under/weak volts, fail to crank/start, sensor failure, cranking lockout, low fuel level.

[ix] AC Alternator Protection: Over/under voltage, over/under frequency, loss of AC sensing. [x] Data Logging : Engine hours, control hours and upto 5 recent fault codes. ƒƒ[k] Configurable glow plug control. [xi] ƒƒ24 V DC operation. [xii] Mounting Arrangement : ƒƒEngine and alternator are mounted on a common MS fabricated base frame with AVM pads. [xiii] ƒƒBase frame with integral fuel tank is provided with drain plug, air vent, inlet and outlet connection, level indicator and provision for cleaning.

ELECTRICALLY OPERATED CRANE Design ,Manufacturing, Supply, Erection & Commissioning of indoor type, M-6, Class-IIII, Electrically operated travelling (EOT) overhead crane (Flame proof) as per IS : 3177 & 807 (latest version), IS : 2148 of 2004, capable of handling 20 Metric Tonnes (MT), main hoist with centre to centre clear span approximate 35 Metres, double box girder type with span required for cross , cross travel through pendant push button, floor operated moveable having hoisting height 6.60 Mtr approx including independent of crab trolley with frame, crab, buffer, gear with gear boxes, shaft, rope drum, rope shelves, wire rope, wheel, lifting hook, platform on the one side of crane, brakes, motor, limit switches, control panel, pendant push button station, micro speed arrangement, wiring etc complete with all accessories / equipments duly painted with two coat of synthetic enameled paint all as per OEM specifications and as approved by GE. The make of crane shall be as per approved list of make given in P.S or otherwise the manufacturer who installed the crane in MES department with following specification :

EOT cran shall be provided with the following electrically controlled movements type:- (a) Capacity of crane - 20 Tons (20000 Kgs) double box Girder. (b) Clear span - 35 Meters approx each. (c) Bay length - 62 Meters approx. (d) Lift - 4.50 to 6.00 Metres (Approx) (e) Longitudinal Travel speed - 15 mpm (f) Cross travel speed - 10 mpm (g) Hoisting speed (Faster) - 3 mpm (Approx) (h) Overlaod capacity - 25% (j) Operation Control - Pendant push button from floor (k) LT Motor - Twin drive, capacity As per OEM recommendations , each with gear box (l) CT Motor - Capacity As per OEM recommendations (m) Hoisting Motor - Capacity As per OEM recommendations (n) Wire rope - As per requirement & OEM recommendations (o) Main Girder - Double Box type for traverse movement (p) Electric Motor - All Motor shall be square cage type - Crane duty.

NOTE :- (a) Unit rate quoted shall be deemed to include provision of copper wiring of suitable size in rigid metallic conduits with accessories fixed on surfaces from main switch upto electrical control panels and provision of ISMC channel welded alongwith ISMB (gantry girder) and longitudinal travelling rail welded alongwith ISMC. (b) Clear span and bay length specified and shown on building are only indicative. The tenderer shall visit the site and ascertain exact span and bay length before designing/execution. (c) Long travel gantry girder is in the scope of building work & LT wheel and CT wheel track Sqbar has to be provided by the tenderer and cost for the same is to be included in unit rate . (d) Cap channel and rail of both sides included quoted rate it deemed to be included such provision and accessories before execution of work. (e) Dimensions, capacities/sizes of equipments/accessories mentioned on drawing are minimum to be provided. Prior approval of accepting officer shall be obtained for the detailed construction drg and electrical wiring diagram of EOT crane and contractor shall incorporate components wherever required and the rates quoted above shall be deemed to be inclusive of such provisions and all accessories. (f) Longitudinal travel shall be limited to 1.5m away from the wall on both ends. (g) The cranes should be manufactured as per latest IS standards and safety factors.

EOT Crane shall comprise of the following :- (1) Major Technical Specification: Type, Capability and general requirements (a) Type : Double box type girder EOT Crane as per IS : 807 & IS : 3177.(latest version) (b) Crane Operation : Pendant control of reputed make with push button for ON, OFF, UP, DOWN, Forward, Reverse, Left, Right, Siren, Bridge Light & Emergency Stop with option for control selection. Operating voltage 110 Volts. (c) Duty Class : M-6 for Indoor Operations. (d) Lifting Capacity : 20 Metric TON (e) Span : 35 Metre (f) Height of Lift : 4.5 to 6.00 Metre

(2) Maximum Speed (Metre/Min) :- (a) Hoisting : 3 mpm (b) 15 mpm LT Speed (c) 10 mpm CT Speed (3) Hook Approach (Maximum possible): (a) Side Clearance: Side clearance to be fixed to suit the Blanking section clearances minimum 250/300mm. (4) Long Travel Motion : LT Motion shall be twin drive type. (5) STRUCTURAL FABRICATION Constructional Details) : (a) Bridge Girder: Shall be of double Girder Box Type construction having Minimum vibrations. (b) End Carriage Fabricated from rolled steel sections/plates as per IS : 2062 (c) Raw Material : Only tested quality steel Fe 410 WB as per IS-2062, IS : 1964 & IS : 808 and certified for quality by reputed inspection authorities, shall be used.

(d) BRIDGE STRUCTURE / CRANE GRIDER: Shall be made out of double box girder type construction having minimum flange width 500 mm and thickness 6.00mm , minimum Web height 1250mm, thickness 8.00mm. Beam should not have deflection more than 1/900 of span on full load as per BS : 466/1960, all as per OEM specifications. (e) Welded Joints (To be followed for Girder fabrication) (i) NO Number of Joints allowed: Max 2 Nos (ii) Welding Electrodes for all Horizontal Welding E-7018 Electrode only should be used. (iii) Welding Electrodes for all Vertical Welding E 7048 Electrode only should be used (f) Welded Joint Testing : All Butt Welded Joint (both compression/tension and flanges/web joints) shall be subjected to 100% X-Ray Testing and X-Ray Film to be produced for MES evaluation and form part of the documentation. (g) Mechnical Joints: Hexagonal Fit Bolts (as per IS 3640-1982) for all joints coming in Main members (h) Heat Treatment & NDT Examination : The Trolleys shall be stress relived, if necessary, by thermal heat-treatment process after welding & NDT. All welding shall be tested by NDT means [MPI, LPI & RT] after stress relieving operation (Govt. approved Test House & certificated). Contractor to furnish the details of facilities for Heart Treatment furnace & NDT Lab at their works. All the welded joints should be NDT tested by Govt. approved Test House & certificate/X-Ray films to be submitted at time of inspection. .

(6) MECHANICAL ELEMENTS : (a) Wheels : Wheels shall be as per IS of forged and made of C-55 Mn 75 Carbon steel, Hardened to BHN 300-350 as per IS /OEM specifications. (b) Wheels Sizes : Outer diameter shall be as under :- (i) Cross Travel (CT) – Contractor to submit the size as per OEM specificaton. (ii) Long Travel (LT) – Contractor to submit the size as per OEM specificaton (c) Number of Wheels : For LT - 04 Nos & CT - 04 Nos. (d) Wheel Assembly : The wheel Assembly of Long Travel (LT) shall be of Live Axle System with L-Type Bearing only. (e) Brake Drum Sizes and minimum braking torques : (i) Main Hoist : As per OEM specifications & design calculation (ii) Cross Travel : As per OEM specifications & design calculation. (iii) Long Travel : AS per OEM specifications & design calculation.

(f) Gear & Gear Boxes Details : Gear Box should be of fabricated type duly stress relived. Pinions made of En-24 and gears of En-18. Gears in all the Stages shall be helical in design and to be of machined, lapped and hardened. Straight and helical spur gearing shall normally be used for all motions. Worm and bevel gears shall not be used. First and high speed reductions shall be through helical gears. All first reduction pinions and also the other pinions if feasible shall be integral with the shafts. All gears shall be of hardened and tempered alloy or carbon steel with machine cut teeth. Gear tooth shall be cut in metric module system. Surface hardering of teeth is not allowed. The Gear /pinion should be hardened to HRC 50-55 and ground. Reduction Gear box ratios in all motions shall be maintained as under : - (i) Main Hoist : As per OEM specifications. (ii) Cross Travel (CT) : As per OEM SPECIFICATIONS . (iii) Long Travel (LT) : As per OEM specifications.

(g) Lubrication : Suitable totally enclosed continuous oil/grease lubrication system shall be provided for gear box for its all rotating parts wherever applicable. (h) Rope Drum : Shall be fabricated type stress relived or seamless pipe. The circumferential weld joints shall be tested by 100% A-Ray quality size i.e. diameter and length shall be as under. :- (j) Main Hoist Rope Drum : As per OEM specificationsNS . (k) Type of Coupling : Coupling should beflexible geared Barrel type. No pin / bush / rubber type coupling to be used. (l) Machining Operation : All mechanical mating surfaces and wheel seating areas are to be machine to the required finish and protected. (m) Hoist Wire Rope Details : Fiber core confirming to IS : 2266. Maintion wire rope dia 16mm, 4 No. of fall & construction. Minimum factors of safety & tensile strength (1960N/Sqmm for wire rope) as per ISO : 4309 :1990 or as per OEM Specification & design. (n) Main Hoist : As per OEM specifications. (o) Buffers (End Stoppers) : Buffers of adequate size be provided. (p) Maintenance Platform : Maintenance / service platform made of 6.0mm thick chequered plate of 750mm width shall be provided & fixed through bolted joints only. A hand railing 1000mm height are to gaurd (Minimum 50mm) shall also be provided. Platform shall have anti-skid grating. (q) Guards : All the moving parts should be duly covered with guards as per safety norm. Proper guard cover / tray to prevent falling of bolts from coupling etc should also be provided, wherever required.

(7) Electricals : (a) Input Power Supply : Shall be 415 ± 10% Volts, 50 ± 3% Hz, 3 Phase, AC. (b) Control Voltage : Shall be 110 Volt AC. (c) Protection : All Panels, Limit-Switches and Motor shall be IP-54 protection. (d) Motor Details : Squirrel Cage Induction Crane duty motors, Totally enclosed, fan cooled, Insulation Class-F & confirming to relevant latest IS:325, and IS-123, S4 duty, 150 starts per hour and 40% CDF. All electric motors shall be provided VVVF drives in all motions, Noted No. of motors, capacity of motor as under. (i) Main Hoist : Min of 10 HP speed less than 1000 rpm or as per OEM specifications. (ii) Cross Travel (CT) : Min of 0.5 HP speed less than 1000 rpm or As per OEM specifications. (iii) Long Travel (LT) : 2 Nos of Min of 0.5 HP speed less than 1000 rpm or as per OEM specifications. (e) Type & Details of Brakes for all Motions : EHT type shall be provided to hold the mechanism in position instantaneously as soon as the power supply is ‘OFF’ either accidentally for all motions. (f) Electric Contactors : All Contactors shall have SIEMENS / L&T/ BCH contactors suitable for Crane operations. Crane duty AC-4 ratings.

(g) Contactor Rating : The rating of all contactor shall be at least 50% higher than the respective electric motor full load current, at the specified duty cycle. (h) Wiring: All the panel wiring should be done by using standard multi core Copper conductor highly flexible, FRLS cables. (j) Down Shop Lead (DSL) : XLPE/PVC insulated copper conductor festoon trailing cables fire resistant and retardant cables as per IS : 694. (k) Trailing Cables Erection : Trailing cables (Extra flexible having copper conductors only) for CT shall be supplied with ready chain type (E-chain) with tongue and groove type (Make - Igus / Gortrac) and erected by contractor. LT shall be tailing cables, Fastoon type, copper conductor. (l) IIlumination : 03 Nos totally enclosed 100 w LED Lamps and fitting shall be provided under the bridge. (m) Limits Switches : Hoist shall be provided with gravity type (Over Hoisting and Over lowering). Shunt adjustable type limit switches. Limit switches shall be provided for both CT and LT motions. Two way lever type for CT and LT for both directions. (n) Pendent control : Pendent should be MS Sheet fabricated having push buttons for each motion e.g. Bridge light, Siren/bell On and Off switches and stay put type emergency stop switch push button. Pendent shall be independent moveable type. (o) ANTI-COLLISION DEVICE: As per OEM specifications

(8) Painting Instructions:. (a) Surface Cleaning : Girder to be shot blasted or chemically treated for surface cleaning, after completion of all operations but prior to painting. (b) Painting : One coat of Red Oxide Primer and 48 hours of compulsory curing after painting.. (c) The crane should be thoroughly cleaned and final painting with two coat of synthetic enameled paints (Colour- Golden Yellow) and intermitted curing of 16 hours. Final touching will be done after erection and testing.

(9) MAKES OF BOUGHT OUT ITEMS (BOI) : Makes shall be as per the list given below. (a) Hoist Hooks : Herman Mohtta / Hercules / Silpa Udyog / Smriti Forgings / Karachiwala (b) Wire Ropes : Usha Martin / Fort William / GARWARE. (c) Electric Motors : GE/ Bharat Bijlee / Siemens / KEC / ABB / Crompton / Alstom /marathan. (d) Thruster Brake Unit : ElectroMag / Speed-O-Control / Omega. (e) Limit Switches (Gravity type) : Siemens / EMM/BCH / SOC / SKF. (f) Contactors : Siemens / L&T / GE / BCH (g) Over Load /Time Relay : Siemens / L&T /GE / BCH. (h) HRC Fuses : Siemens / L&T / GE

(j) Switch fuse unit : Siemens / L&T / GE / BCH . (k) MCB / MCCB : Siemens / L&T / GE. (l) PUSH Buttons : Siemens / L&T / BCH. (m) Couplings : As per OEM. (n) Bearings : SKF / FAG / NTN / Ina only. (o) Cables : LAPP / Schiess Kabel / CCl / Fort Gloster / Grandely / Finolex / KEI ISI marked /polycab / IGUS . (p) Bridge light fittings : Bajaj / Philips / Wipro / Sudhir / Balaji / Flexpro . (q) Transformer : Logistat / Pactil / Any reputed make. (r) Control Panel : As per OEM specification. (s) Documents / Details for submission : The following documents/ details shall be submitted to MES reference for approval of accepting officer / checking within 30 days from the date PO placement, prior to taking up the manufacturing of the crane.

(10) Drawing / Documents : For approval from accepting officer. (a) GA Drawing of the Crane (for approval) - Contractor to submit. (b) GA Drawing of Hoist /Trolley(for approval) - Contractor to submit . (c) Calculation of Bridge Girder- ISMB / ISMC - Contractor to submit. (d) Calculation for Selection of Electric Motors, Gears, Brakes, Couplings, Wheels, Wire Rope etc.: Contractor to submit. (e) Design calculation for Bridge Girder, Crab etc.: Contractor to submit. (f) Calculation of Bridge Girder- ISMB / ISMC - Contractor to submit. (g) Wiring Diagram with Logic Circuits and Bill of Material (for Approval) - Contractor to submit. (11) INSPECTION : (a) Verification of Test certificate for Raw materials used for Girders, end carriages, Hoist, Gear box casings etc - Contractor to comply. (b) Verification of X-Ray report of butt joints coming in the girders and Random testing on the welds by Physical examination - Contractor to comply. (c) Inspection of Bridges and End carriages with Wheel assembly and Alignment checking - Contractor to comply. (d) Verification of Span and diagonal dimensions, Checking of Wheel Alignment, Mechanical Assemblies and Total Alignment - Contractor to comply. (e) Free running of the CT and Hoist mechanisms - Contractor to comply. (f) Check of Crane span and diagonal -10 kg pull should be applied while checking - Contractor to comply

(g) Measurement of CAMBER in the bridges - Contractor to comply. (h) Full/ Rated Load Test and deflection test - Contractor to comply. (j) 125% Rated-LOAD Lifting ability check - Contractor to comply . (12) CRANE ERECTION & COMMISSIONING (a) Unloading & Erection : Unloading the consignment at site will be carried out by the Contractor. Contractor shall shift the all crane material to site and erect the crane at MES site. Necessary tools and equipments required for erection shall be brought by the Contractor. (b) Crane Commissioning : Prove out for the Crane’s Capacity and Smooth Functioning of the Crane (at site) shall be the responsibility of the Contractor. Final Load testing as per ISS at 125% of rated load shall be conducted at site by the representative of Accepting Officer in the presence of Engineer-in-Charge. Load shall be arranged by contractor from location at site shown by Engineer-in-charge. (c) All safety equipments like safety boot,saftey belt, helmet, gloves, loader, googles etc required for erection personnel shall be brought bt contractor-contractor to comply .

(13) TOOLS & SPARES : (i) Tool box with standard tools shall be supplied with the crane. (ii) Recommended spares for two years normal working of equipment shall be furnished. Details of bearings, oil seals used should be supplied with the crane. (14) O & M Manuals : (a) Five (05) sets, of Erection, Operation and Maintenance Manual along with two sets of CDs, containing the following technical drawings and details shall be submitted. All copies shall be hard bound in high quality leather folders, encased in decent individual boxes. (b) Contractor is required to measure all necessary dimensions i.e. Span, Head room, Clearances between rail centre to existing coloumn and rail size etc, at site before starting of the crane design/ manufacturing.

(15) ADDITIONAL NOTES : (a) The details refered to above will be considered as our offer. (b) Any ‘T’ bid details even after all confirmation are found missing or left out, the details and specifications given in the tender documents shall be followed.