Multipurpose Fire Tender with Water Mist System -Technical specifications

General Description

Design, fabrication and supply of multipurpose fire tender with water mist system to

be built on TATA LPT 2518/48, TC BS III. CE marked pump made in accordance to EN

1028 1&2 norms, Multi pressure Centrifugal Fire Pump having discharge capacity of 3000

LPM at 7 kg/cm2 pressure & High pressure discharge of 300 LPM @ 35 kg/cm2 pressure

with automatic Reciprocating type priming system, 1x100mm suction inlet and 4x63mm

delivery outlet with gun metal valve, Power Take Off (PTO) unit having ratio of 1:1:27,

Auxiliary plunger pump driven by gear box side PTO having discharge capacity of 150 LPM

at 100 kg/cm2 for water mist generator with delivery assembly consist of spray gun, indirect

cooling system, 6000 liters capacity Water Tank fabricated out of 304L fabricated out of

5mm thick sheet for bottom, 4mm thick sheet for other sides and 3mm thick sheet for

baffles, 2000 liters capacity Foam Compound Tank fabricated out of SS 304 L , 5mm thick

sheet for bottom, 4mm thick sheet for other sides and 3mm thick sheet for baffles,

automatic around-the-pump proportioning system, multipurpose monitor (water-cum-foam

Monitor), piping and fitting, pick up tube, open circuit type indirect cooling system, 1 x

20mm x 60m long and 1x20 mmx30 m long high pressure hose reel for main pump with

high pressure fog gun, 2 x 16 mm x 60mtr high pressure hose reel with water mist nozzle

for ultra high pressure pump, driver cabin with double compartment, Breathing Air (B.A) set

locker for accommodating B.A. sets (2sets), equipment lockers with aluminum rolling

shutters, light bar with inbuilt Public Address (PA) system, VHF base station- 1 No., 2 x 50

kg DCP Extinguishers with hose, 2x22.5kg CO2 cylinders with manifold hose and

discharge horn, one no. battery operated siren and one no. manually operated bell, Ladder

gallows for accommodating trussed type 10.5 m double extension aluminum ladder,

Lockers, standard accessories, control panel, tool box, CCE approved spark arrester,

trickle battery charger, wind screen wipers (electrically operated), best workmanship and

finish, instruction book, inspection/acceptance test, marking, etc. as per IS:10460 with

accessories as per Annexure-A.

All components to be used shall be CE/PESO approved/UL listed. Quote should

indicate the BRAND/MAKE of the components/systems without which offers are liable for

rejection.

Detailed scope of work and specifications are given below:

Scope

Design, Supply of material, Fabrication of Multipurpose Fire Tender on TATA LPT

2518/48, TC BS III Cowl Type Truck Chassis (free issue by IPRC) with multipurpose utility

(Water-6000 Ltrs, Foam-2000 Ltrs & DCP-2X50 Kg, CO2- 2X22.5 kg) as per IS: 950 along

with listed accessories. The Fire Tender shall be fabricated with the best material and good

workmanship, ensuring effective & efficient operation of the tender. All wiring shall be

properly fixed in position & be protected against heat, oil & physical damage and wherever

necessary wiring shall be passed through PVC sleeves. All important electrical circuits

shall have separate fuses suitably indicated & grouped in a common fuse box located in an

easily accessible position. Drag Hook or eye of adequate strength & design shall be

provided at the rear and front of chassis.

Vehicle Chassis

The purchaser shall free-issue the vehicle chassis. The chassis shall be collected by the vendor from IPRC, Mahendragiri, Tirunelveli District, Tamilnadu after producing BG for the value of the chassis. The value of the chassis is Rs.16,10,000/- (Sixteen Lakh Ten thousand ) only. The BG shall be valid till the delivery of the fire tender at IPRC.

After body building, the fire tender shall be handed over to the Purchaser at IPRC, Mahendragiri, Tirunelveli Dist, Tamilnadu by the vendor.

Documents to be submitted

Vendor shall submit documents like detailed drawing of the vehicle including load

distribution, computation of CG of the vehicle with full load and empty condition,

overall dimensions & part numbers of major components, including MAKE and

MOC of parts, before commencement of fabrication. For detailed list of

documentation, please refer to Annexure-C

Delivery period: The vendor should deliver the finished fire tender within SIX

months from the date of receipt of approved drawings from IPRC, Mahendragiri.

Water Tank

The water tank shall be of 6000 Lts capacity made out of SS 304 L grade

having 5mm thick sheet for bottom ,4 mm thick sheet for other sides and 3 mm thick sheet

for baffle plates complete fitted on the chassis so as to allow full flow of water to pump.

Material for pipes and fittings shall be A312 TP 304 & A403 TP 304 respectively. The tank

shall have baffle plates in longitudinal direction to avoid surge when the vehicle is braking,

accelerating and cornering. Tank shall be mounted on the chassis in a manner keeping in

view the proper load distribution of the axles. The baffles shall be arranged in a manner to

facilitate the passage of a man throughout the tank for cleaning purposes. Tank shall be

mounted on three cross bearers to counteract stresses caused by chassis flexing and shall

be so secured that it can be removed. The bolting shall be so designed and mounted as to

bring the centre of gravity off set the as low as possible. Tank shall be rectangular in shape

and the mounting of the tank also shall be flexible type to prevent the tank’s distortion due

to the chassis flexion. The mounting shall permit full contents of the tank flow into the

pump. Welding of the tank shall be carried out by GTAW process. All welding area shall be

smoothened. Water fill test shall be conducted and the tank shall be cleaned and dried

before integrating with the chassis.

An inspection manhole of not less than 450mm size shall be provided on the top the

tank and shall have a hinged cover so that the manhole shall also act as a filing orifice.

Cover shall be marked “WATER”.

Suitable eyes shall be provided on the shell of the tank to enable it to be lifted off

the vehicle for repairs/replacement as necessary.

A cleaning hole of 250 mm dia shall be provided at the bottom of the tank. The

cleaning hole shall be fitted with a 25mm dia drain pipe with a valve & plug connection and

shall be taken down to a point well below the chassis without reducing the effective ground

clearance.

The tank shall be fitted with a minimum 75mm bore overflow pipe taken down to a

point well below the chassis without affecting the effective ground clearance when fully

loaded and discharge away from the wheels. A 63 mm instantaneous hydrant connection

incorporating a strainer shall be provided close to the pump panel control for filling the tank

through 80mm bore pipe work for feeding the hose reel equipment. An 80mm pipeline shall

be taken from the tank to the suction inlet of the pump incorporating an 80mm quick action

spherical type valve. Drain plugs shall be provided. LED Electronic Level gauge shall be

provided at the control panel calibrated to ¼. ½, ¾ & full & water level indicator shall be

provided at suitable location on panel near operator controls.

The tank shall be connected with the pump and hose reel in such a manner that

pressurization of water tank or water tank pump connection is not possible when pumping

water from an outside source of supply. The plumbing between the pump and the hose reel

shall have a clear unobstructed waterway of not less than 25mm throughout without any

obstruction.

Foam tank

A foam tank of a 2000 Lts capacity shall be suitably mounted on the chassis. The

tank should be fabricated out of plates of SS 304 L grade, having 5mm thick sheet for the

bottom and 4mm thick sheet for sides, top and 3 mm thick sheet for baffles. The tank shall

be of welded construction having suitable eye hooks on the shell of the tank to enable it to

be lifted off from the chassis for maintenance purpose. The tank shall be provided with

baffle plate to prevent surging and adequate arrangement of suitable size for filling of tank.

A suitable sump with drain valve shall be provided at the bottom. One breathing valve shall

be fitted to the tank which shall work both way ie, at the time of filling the tank and drawing

the foam compound when the unit is in operation. Necessary pipelines shall be provided

for feeding the foam compound to the inductor. Metallurgy of all foam compound carrying

pipelines and components shall be compatible with AFFF concentrate. A level indicator

shall be provided for the foam tank.

Foam transfer pump

A suitable hand operated foam transfer pump shall be provided for transferring the

foam compound from drums to foam tank without causing any frothing in the tank.

Necessary connections for transfer the foam compound into the tank shall be provided from

the pump.

Main pump

CE marked /UL listed fire tender specific Fire pump having multi pressure discharge

capacity of 3000 LPM @ 7 kg/cm2 & 300 LPM @ 35 kg/cm2. The pump body shall be

made of high strength light weight Aluminium alloy with SS high tensile pump shaft & shall

be carried in anti friction bearings. Impeller shall be made out of bronze. Shaft seal shall be

of self-adjusting, maintenance free mechanical type. Pump shall be designed to operate in

both High Pressure – Low pressure modes simultaneously and independently. Both the

Impellers shall be mounted on single shaft.

The delivery outlet of pump shall be connected to monitor and 4 Nos. screwed 63

mm delivery female outlets instantaneous type with blank caps at the rear side along with

twist type lugs made of gunmetal. The monitor & other outlets shall be fitted with lever

operated valves. The pump shall have one suction inlet of minimum 100 mm size on rear

side & shall be provided with easily removable strainer. The pump shall be fitted with a

high pressure relief valve that shall operate automatically when the water pressure exceeds

design value. The pump shall also have a thermal relief valve, which shall operate if the

water temperature inside the pump exceeds design value.

Note : Brand/make of the pump, catalogue, performance curves and MOC of each

parts must be enclosed along with offer.

Primer

The main pump shall be fitted with twin piston reciprocating type primer. The primer

shall be capable of lifting water from 7 m at a rate of not less than 23 sec.

Note : Brand/make of the primier must be indicated in the offer.

Ultra High Pressure (UHP) PUMP (Auxiliary Pump)

An additional auxiliary pump shall be provided & shall be of 150 LPM @ 100 kg/cm2

capacity. The pump shall be a six plunger positive displacement type working to the

capacity at not more than 1000 RPM. A by-pass for letting the water back to the tank shall

be provided to release excess pressure generated due to shutting off the hand lines or

while discharging 150LPM @ 40 kg/cm2 or 75 LPM @ 100 kg/cm2 individually. The pump

shall be guaranteed for a minimum life of 5000 hours of operation. The pump shall have

double seal on each plunger with low pressure intermediate chamber to keep the water

seals cool & lubricated. This system shall also permit to re-circulate any leakage from the

high pressure back to pump inlet. The pump shall have pistons made of ceramic material.

The connecting rods shall be of an alloy which has low attrition co-efficient, high wear

resistance & high anti-seize up properties. Hydraulic structure should be designed to

simplify scheduled maintenance procedures (gasket & valve replacement). The pump

suction line shall have inline mesh filters. The pump shall deliver water to hose reel &

cooling system. The main components of the construction should be manufactured by the

pump manufacturer only. The pump shall be CE marked/UL listed.

Note : Brand/make of the pump, catalogue, performance curves and MOC of each

parts must be enclosed along with offer.

Hose Reels

Two high pressure hose reels with1x20mmx30 m and 1x20mmx 60 m

long shall be provided to facilitate operation of the Main Pump & shall be mounted so as to

be easily accessible. Working pressure of hose shall not be less than 40kg/cm2. The hose

reel shall be fitted with fog and jet gun. The Ultra High Pressure Pump (UHP pump) shall

operate through a separate hose reels of 60 m length – 2 Nos. which shall be provided at a

suitable place on the appliance. The hose used for the hose reel should be rated for 130

kg/cm2 working pressure (180 kg/cm2 test pressure) & shall be of minimum 16mm ID. It

shall have auto rewinding system. At the discharge end of the hose reels, high pressure

mist nozzle shall be provided which shall be capable of discharging 75LPM @100 kg/cm2

pressure in mist pattern. The jet range shall not be less than 20 m and the size of water

drop lets in the spray form shall be less than 250 microns at an angle of 45º.

Power Take Off (PTO) Unit for Main Pump

Heavy duty full torque PTO unit shall be fitted behind the engine gear box, to drive

the pump at the rear. The lever of the PTO unit shall be fitted in the driver’s cabin. A

suitable cooling system (copper coil) shall be inbuilt in the PTO to cool the oil in the PTO.

Maximum through torque of the PTO shall not be less than the maximum through torque of

the chassis engine. The PTO shall be connected to the chassis gear box & the pump

through heavy duty propeller shafts and centre bearings etc.

Note : Brand/make of the PTO must be indicated in the offer.

PTO unit for Auxiliary pump

The auxiliary pump shall be driven with the help of the side PTO provided by the

chassis manufacturer. If not provided, the party should provide the side PTO. The

connection from the side PTO shall be such that the pump does not put stress on the main

driving components and at the same time does not stress the engine also. Cooling for the

engine shall also be suitably provided.

Cooling system for the chassis engine

Indirect cooling system of open circuit type consisting of a special heat exchanger

shall be provided on the chassis to enable full power output to be maintained during the

pumping out without overheating.

Automatic Foam Proportioning System

Automatically governed around the pump proportioner inductor type shall be

provided between suction and delivery of the pump to induct 3% foam solution in the water

stream with no loss in delivery pressure from the pump. Automatic foam proportioner can

induce foam liquid proportionally to water discharge, for using monitor and any number of

foam branches in combination. Manual adjustment must be possible on proportioning.

Water – Foam Monitor

Water foam monitor made up of gun metal with aluminium alloy having discharge

capacity of 3000 LPM @ 7kg/cm2 duly treated with anticorrosion treatment shall be

mounted on the top of the appliance in such a manner that it can be manually operated by

a crewmember. The monitor shall be capable of traversing through 360º in horizontal

plane. Elevating from horizontal to 45º & depressing from horizontal to not less than 15º &

full rotation in both directions. The monitor shall be capable of projecting the foam

discharge to an effective distance of not less than 45 to 50 m in still air when operated at

design pressure. Monitor shall be provided with Jet-spray type Nozzle.

Note : Brand/make of the Water-Foam monitor must be indicated in the offer.

Water – Foam piping

All piping shall be sized so as to have minimum pressure drop & achieve the

required pressure & flow at various locations. All pipe fitting & valves (except butterfly

valves) shall be SS304. All piping shall be designed for 10% over the maximum pressures

encountered in the pipe. The piping shall be flanged for ease of maintenance. All lines

shall be hydraulically tested at 1.5 times the design pressure however in no case shall the

lines be hydraulically tested below 18 kg/cm2. All lines shall have suitable supports so as to

provide rigidity & avoid vibrations. All lines less than 38mm size shall be socket welded.

All lines above 50mm size shall be butt-welded with full penetration welds. All bolting shall

be of SS 304. The draw off pipe shall be provided in such a manner & in such a position

that sludge does not pass into foam piping. Necessary hydro test certificate shall be

provided.

Control Panels

Adequate illuminated pump operating control panel shall be provided on the rear

side of the Fire Tender. All controls of the system shall be spaced properly & marked for

easy operation. All valves shall be of lever operated type and shall be made of SS with

Teflon seats. All other controls like electrical siren, PA system and VHF base station shall

be provided at driver’s cabin. All control panels shall have clearly written operating

instruction plate.

Further following also to be provided on rear side or near control panel

Level indicators for water tank and foam tank

Compound gauge, normal pressure and high pressure gauge

Auxiliary throttle control of the engine

Cooling water circuit control

Hydrant connection for water tank filling pipes

Delivery outlets of the pump along with blank cap with chain

Suction inlet of pump along with black cap with chain

Operating instruction plate and flushing out instruction plate

Control for water tank to pump valve

Control for flushing out piping

- Pump to hose Reel

- Hydrant to Hose Reel

- Pump to Monitor

Light point for pump panel

Drain valve

In addition to the items mentioned above, any other items that may be essential shall also

be provided. Any of these items, which are also required in the driver’s cabin, shall be

provided at suitable locations.

Body work & Stowage

The cabin shall be designed, fabricated for better & wide vision, enough working

room inside the cabin & to have enough aesthetic value. Enclosed accommodation for six

to eight persons shall be provided in the driver cab-cum-crew compartment including the

driver and the in-charge of the crew. The cabin shall be double compartment without

partition. The driver seat & Fire crew leader seat shall be of an adjustable type (free

adjustable). All the seats shall have foam cushion and shall be covered with best quality

Rexene. Provisions shall be made to store BA sets in the back rest of the driver, officer

and the crew seats with suitable clamps and brackets where the BA set (2sets) ,single

cylinder shall rest and shall not be kept in a hanging condition. Two doors on each side

shall be provided on the driver cab cum crew compartment. Doors shall be fitted with

safety glasses and be of horizontally sliding type window. The wind screen glass shall be

toughened glass. The glasses on all the windows and doors shall be fixed in aluminum

sections & shall be fitted on rubber beading including wind screen glass to absorb the extra

pressure / jerks when the fire tender is moving. The sliding glasses shall be provided with

spring loaded locks operated from inside the cabin. Below the crew seat, space shall be

provided for storage of equipments like spare cylinders of the BA set of the same capacity,

mechanical tools etc. The doors shall be hinged type opening outwards, hung forward,

catch locks and flush type handles. Also six hangers for fire man’s helmets above crew

members sitting arrangement shall be provided.

The cabin and the lockers shall be of composite construction with sufficient rigidity,

reinforcement and as far as possible 32mm x 32mm x 2mm thick M.S. square tube of

sufficient strength shall be used for the super structure. 16 gauge aluminum sheets shall

be used for exterior paneling work all over. For inner lockers-walls 18 gauge aluminum

checkered sheet shall be used. 2 mm thick aluminum checkered plate shall be used on all

lockers and cab floors and top roof.

Lockers shall be provided for secure stowage of all accessories and equipments

provided with Fire vehicle. The lockers doors shall be provided with Aluminium rolling

shutters. All equipment shall be stowed very scientifically & systematically in the lockers

and each piece of equipment shall have its designated location so that at the time of

Emergency the required equipment can be very easily located & removed for use. Location

of equipment (labels) shall be provided on lockers for immediate identification. Each

equipment shall be properly clamped and strapped in the lockers to prevent shifting of the

equipment while the vehicle is in motion. The lockers shall have smooth operation. Locker

doors shall be equipped with electric switch to provide automatic switch on/off compartment

lights. All the space below the rear body and chassis shall be utilized for making lockers for

storage of equipment. These lockers shall be covered with flap type doors opening

downwards. Heavy duty chains and hinges shall be provided on these doors so that these

doors when open can be used as climbing steps for access to the lockers above it. Guide

rails over entire length on both sides shall be provided.

Suitable arrangement shall be provided to carry four 2.5 m, 4 nos. of suction hoses

in convenient location on top of the vehicle. Also one through locker behind crew cabin to

be provided where one side stowage for portable pump and other side stowage for various

equipments with drawer type latest arrangement to be provided.

Base Frame & Super structure:

MS (surface treated) tubular/square pressed sections of minimum 3 mm thickness

shall be used.

No welding shall be attempted on the vehicle chassis.

MS frame made from ISMC 100 (minimum) shall be clamped to the vehicle chassis.

All parts of the fire tender like tanks, pump, ladders, stowage cabins etc., shall be derived

only from this base frame. The above said MS frame shall be sand blasted and suitably

surface treated as per approved codes and norms.

The entire super structure shall be of aluminum pressed and profiled sheets.

In case of super structure all fasteners (U clamps, washers, bolts, and studs) shall

be surface treated and suitably hardened.

Other Construction Details

Grab rails & non-slips steps of heavy chequered plate shall be provided wherever

necessary. The entire structure of appliance shall be welded structure made of MS only,

square tubes, angles and channels. The paneling shall be done from 16g aluminium sheet

for outside & 18g aluminium sheet/chequered plate for inside. Complete flooring shall be of

16 gauge aluminium chequered plate. The vehicle shall be covered from top with 16g

chequered plate having rainwater channel at both side. The openings for equipments shall

be sealed properly to ensure no water goes inside. For all water fittings necessary

arrangement shall be made to enable the operator to locate the desired equipment instantly

& thereby save valuable time at the time of fire. This arrangement shall be such that none

of the items damage the internal paneling & thereby increase the life of the vehicle.

Suitable clamps, brackets, holders etc. shall be provided for all other items.

Ladder gallows

Gallows shall be provided to carry a 10.5 m trussed type extension ladder. The

design shall be such that the ladder can be released without difficulty from a reasonably

accessible position & shall embody rollers to permit easy withdrawal by one man. Means

shall also be provided for locking the ladder when stowed. The ladder shall be CE marked

as per JCDD 10 standard/IS: 4571.

Public address system and VHF base station

Battery operated lighting bar and Multi-tone hooters/mike with amplifier shall be

provided. A light bar operated with battery, having hooter & PA system in built amplifier

and a microphone and VHF base station shall be provided in front of officer’s seat in the

driver’s cabin.

Note : Brand/make of the PA system and VHF base station and catalogue must be

enclosed along with offer.

Electrical System

All important electrical circuits shall have separate fuses suitably indicated & shall

be grouped into a common fuse box located in an accessible position in Driver’s cab and

fitted with means for carrying spare fuses. All the wiring shall be dipole & properly fixed in

position and not be exposed to the atmosphere for protection against heat, oil & physical

injury. Conduits shall be used wherever necessary.

All equipments lockers shall have individual lights and these shall be

operated by means of a master switch (two way) on the dash board in the driver’s cabin as

well as from the local ie. from lockers.

The switch of the siren shall be provided on the left corner of the dash

board. (Near from left side)

Two fog lamps shall be suitably attached to the front bumper of the

appliance. Reverse lights with on-off buzzer, on either side shall be fixed suitably.

At the rear of the appliance with wire mesh in such a manner to prevent accidental

damage by the firemen while mounting the tank top.

Accessories

The vehicle shall be provided with the following accessories in addition to those

normally fitted to the chassis.

Reversing lights-lamp suitable to assist reversing 1set

Tools – All tools required for normal routine maintenance of fire tender

excluding the kit for the chassis

1set

Search light with rechargeable battery and charger – Adjustable to give flood

or beam light, mounted in convenient position with a beam range of 500 m.

1 No.

Tail lamps – Two of combined stop and tail 1set

Rear reflectors 1set

Adjustable spot light 1 No.

Portable inspection lamps 1 No.

Public address system and light bar LED 1 No.

Fire siren shall be mounted externally and shall be capable of being operated

from within driving compartment

1 No.

General requirements

The vehicle shall conform in all respect of the provisions contained in the M.V. Act

1988 and M.V. Rules 1989 or to any other statutory modifications or re-enactments thereon

from time to time. All the equipment necessary for RTO.’s clearance shall be provided on

vehicles.

Instruction Book, Accessories & Equipment

Instruction books for the guidance of the user, including both operating and normal

maintenance procedure shall be supplied. The book(s) shall include illustrated spare parts

giving reference numbers of all the wearing parts.

Dry Chemical Powder System (DCP)

The quantity of supplementary extinguishing system shall be 2X50 kg of Dry

Chemical Powder & conform to IS: 4308 – 1982. 50 kg Capacity Dry Chemical powder fire

extinguisher shall be provided at the convenient position on the appliance. Dry chemical

powder extinguisher system shall have 5 m high pressure hose with pistol type discharge

nozzle. The dry chemical powder vessel shall be fitted with CO2/N2 cylinder for expelling

dry powder. Extinguisher shall be ISI Marked and Expellant cylinder shall be approved by

Chief Controller of Explosives (CCE), Petroleum and Explosives Safety Organisation

Note : Brand/make of DCP cylinders must be mentioned in the offer.

CO2 System

2 x 22.5 kg capacity CO2 cylinders connected with one manifold of two cylinders

shall be provided with hose reels for CO2 discharge, reel fitted with 15 m long high pressure

hose. These cylinders shall be placed in lockers at a convenient position in the tender.

CO2 cylinders shall have CCE, PESO, Nagpur approval and ISI Marked.

Note : Brand/make of CO2 cylinders must be mentioned in the offer.

Annexure –A

Schedule of Equipment to be supplied with the appliance

Note : Brand/make of equipment, wherever applicable must be mentioned in the offer

1 Trussed type Extension Ladder 10.5 m as per JCDD 10 / IS:4571 1 No.

2 PVC suction hoses 100 mm dia in 2.5 m length fitted with round

threaded make and female couplings, heavy duty, made of

copper alloy of 100mm size conf. to IS:902

4 Nos.

3 Delivery hose 63 mm dia conforming to IS:636 type – B with ISI

Mark in 15 m. Length fitted with GM 63mm male & female instant

couplings IS:903 (hose & couplings are ISI Marked )

10 Nos.

4 Suction Metal strainer, 100mm size for item 2 1 No.

5 Basket strainer 100mm size for item 2 1 No.

6 Dividing breaching 63 mm with control valve made of light alloy

gunmetal

1 No.

7 Collecting breaching 63mm size made of light alloy gunmetal 1 No.

8 Wrenches for 100mm suction couplings Universal type 1 No.

9 Long line 50mm manila 30 m long IS:2080 1 No.

10 Short line 50mm manila 15m long IS:1084 1 No.

11 Hose bandages , rubberized IS:561 (Part 2) 10 Nos.

12 Hose clamps IS: 5612 (Part 1) 6 Nos.

13 Hydrant valve key and bar 1set

14 Gunmetal branch pipe Universal 63mm size 1 No.

15 Gunmetal branch pipe with revolving head 1 No.

16 Gunmetal short branch pipe complete with 63mm size male

instantaneous connection with gunmetal detachable nozzle as per

IS:903 (ISI Marked)

2 Nos.

17 Gunmetal nozzle of sizes 12mm, 16mm, 20mm ,25 mm and

32mm (2 Nos. each)

10 Nos.

a. Adaptor for 100 mm suction female screw coupling and 63mm

male inst.

1 No.

b. Adaptor double female instantaneous patter 63mm. IS: 901- 1 No.

1975

c. Adaptor double male instantaneous patter 63mm. IS: 901-1975 2 Nos.

18 Nozzle spanner 2 Nos.

19 Portable electric box lamp with rechargeable accumulator 2 Nos.

20 Hand lamp (torch – 4 cells) 2 Nos.

21 First aid box for 10 persons 1 No.

22 Hand gloves-heat and electric resistant, CE marked 2 pair

23 Asbestos gauntlets 1 pair

24 Fireman axe with belt and pouch tested at 20,000 V as per

IS:927

1 No.

25 Spade 1 No.

26 Fire beater 1No.

27 Pick axe 1 No.

28 Crow bar as per IS 704:1968 1 No.

29 Sledge hammer 6.5 Kg as per IS:841 1 No.

30 Power driven saw 1 No.

31 Hydraulic jack – 20 ton 1 No.

32 Fire Hook IS:927/1981 1 No.

33 Tool kit 1 No.

34 5 KVA portable generator- 4 stroke, petrol engine 1 No.

35 VHF base station 1 No.

Annexure-B

Inspection details

Inspection Procedures for water and foam tanks and related piping

The following test procedures shall be followed for the tanks

1. Approval of Welding Procedure (WPS) and welder qualification (PQR) as per

ASME

2. Review of Mill Test Certificates (MTC) and check on stamping of plates flanges &

nozzle and before start of fabrication

3. 100 % DP test of all socket welds and 25% X-Ray radiography of butt welds

4. DP test of all nozzles to shell (i.e) reinforcement pads for water and foam tanks

5. Visual and dimensional check of water and foam tanks before mounting on chassis

6. Water fill hold test of completed water and foam tanks at atmospheric pressure for

24 hours.

7. Hydrostatic test at 1.5 times design pressure for 30 minutes for pipelines

Inspection Procedures for Water pump and UHP Auxiliary pump

The following test procedures shall be followed for pump

1. Review of MTC for material of casing, impeller, shaft and mechanical seal

2. Review of manufacturers Test report for dynamic balancing of impeller, Hydro test

of casing and performance of pump for characteristic curves as per code

3. Performance testing of pump for duty point conditions including four-hour

mechanical run test (including noise & vibration measurement).

4. Parameters at maximum and minimum allowable speeds to establish performance

curves at these speeds

5. Visual and dimensional check

6. Performance test of primer (Main and auxiliary) at rated conditions

Inspection Procedures for Foam cum Water Monitors and valves

1. Review of MTC

2. Hydro test at 1.5 times design pressure. (if applicable)

3. Availability of the specified flow, throw and pressure of water and foam as per

specification.

4. Performance testing of valves and Monitor to establish the performance at rated

output.

Inspection Procedure for PTO units

All standard tests as specified by the PTO supplier

1. Review of mill test certificates for material of construction

2. Four-hour mechanical run test along with the pump on test bench with shop driver

3. Visual and dimensional check

Note: All the above inspections and tests shall be carried out at pump manufacturer’s shop

prior to dispatch. Stage inspections shall be carried out to review the internal documents

for the tests carried out by the manufacturer from time to time and be witness to the critical

test being carried out by the vendor during the final stage inspection.

Inspection Procedure for Fire Tender

The following test procedures shall be followed for Tender

1. Review of mill test certificates and Visual inspection of raw materials for framework,

cladding, flooring, fasteners etc. used for structure and body fabrication before start

of fabrication.

2. Inspection of framework (for cabin & body) for soundness of welding and fitment of

chassis and dimensional check including 10% DPT.

3. Inspection for proper installation of pumps, tanks, piping with supports and their

dimensional checks.

Inspection Procedures for completed vehicle

The following test procedures shall be followed for completed and fully laden fire tender

1. Check on actual payload on chassis, performance of engine, PTO engagement,

transmission and electrical systems at full load

2. Dimensional check, ground clearance check and suspension effectiveness.

3. Fire tender performance test Maximum speed, acceleration, turning radius and

grade ability test as per codes (NFPA1901/IS)

4. Vehicle sturdiness test (NFPA1901) – Cab interior sound level test, low and rated

voltage electrical system test, service and auxilary braking test.

5. Stability test: The stability of the appliance shall be such that when under fully

equipped and laden condition, if the surface on which the appliance stands is titled

to either side, the point at which over turning occurs is not passed at an angle of 27º

from horizontal.

6. Road test of vehicle to ensure all parameters are as specified by chassis

manufacturer for 15kms of paved and 8 kms of gravel road

7. Pump endurance test: The rating of pump shall be minimum 4 hrs. The pump

shall be tested for a continuous period of four hours non stop and the water shall

not be replenished in the radiator during this test. The engine shall not show signs

of over heating during this test. Test for water pump and associated equipment

while discharging water from water monitors and outlets individually and in

combination

8. Priming test: The priming shall be tested as per the latest standards and the

system shall be subjected to a test at a suction of 7 m. The priming shall be

achieved in less than 23 seconds.

9. Shower test: After completion of the fabrication, the vehicle shall be subjected to

shower test as per the norms laid down under BIS. The appliance shall not show

any signs of leakages during this test.

10. Foam proportioning system tests.

11. Functional testing of each hose outlet individually and in combination

12. Tests related to condition monitoring of pumps & shafts.

Stage wise inspection details for Fire tender

Stage – 1

After completion of understructure

i. Verification of material test certificates (MTC), components / subassemblies

identification, before fabrication

ii. Check dimensions of understructure on chassis, fabricated components as per

specifications & approved drawings

iii. Verification of all manufacturers / fabricators document including documents of

imported items

iv. Approval of welding procedure (WPS) welder qualifications (PQR) as per relevant

ASME codes / standard.

Stage - 2

After completion of paneling

i. Check overall dimensions, body work, cab interior fittings

ii. Verification of UT / Radiography/ DP test of SS / CS plates and nozzles of foam and

water tank, DCP vessel as applicable as per relevant procedure and standards

iii. Verification of NDT records of butt welded joins as per ASME sec.-V, (X-ray

radiography 25% for tanks & pipelines).

iv. Check construction details of water tank and foam tank and carry out water fill hold

test at atmospheric pressure. Check all piping fittings, internals, bolts & nuts of the

tanks for material. Leakage test for both the tanks for 24 hours. Check all piping

hydraulic test pressure of 18 kg/cm2 for a minimum 30 minutes

v. Check location / placement of control panel, instruments, controls, other equipment

& accessories etc.

vi. Test power take off units (PTO)

vii. Test the foam induction & foam compound proportionate system

viii. Verify monitor position and its movements

ix. Carryout hydrostatic test of pump (centrifugal) as per specification.

After completion of fitment & painting

i. Check stability of the unit after mounting all equipment and accessories. It should

be free from undue rattling and vibration

ii. Each appliance shall be clearly and permanently marked

iii. Check proper functioning of all types of signal lights, alarms, Bell etc.

iv. Check quality of workmanship

v. Painting of exterior / Interior of Foam Tender, Fire service Insignia conforming to

IS/IPRC norms.

vi. Check completeness of equipment for any deficiency in quantity to standard quality

or non-conformation to specification should be rechecked

vii. Check calibration of instruments, gauges, tools, accessories etc.

viii. Check operation of various levers, locks, caps, fitment of tanks, linkages, markings

and plumbing work

ix. Check storage space for adequacy.

Performance test

The following Performance test shall be carried out at vendor’s site

i. Pump Test: the pump shall be run for a period of four hours nonstop delivering the

rated output with a lift of 3 m. During the test all parameters like cooling system,

temperature of the engine oil, PTO sump oil temperature shall match as per

manufacturer’s recommendation

ii. Vehicle tests as defined in Annexure-B

iii. The pump casing and impeller shall be subjected to a hydraulic pressure 1.5 times

of maximum operating pressure to detect leakage performance etc.

iv. Priming Test: The primer shall be capable of lifting water at least 7m in less than 23

seconds.

v. Hose Reel: Performance shall be tested as per tender specification

vi. Foam making system

Introduction 3% at all five settings

Throw 40/20 m Monitor / branch

Expansion 8 time monitor & branch

vii. DCP system - Complete operation including flushing (DCP and N2 gas to be

provided free of cost by vendor for this test)

Functional test & Road test

Functional test & Road test shall be carried out as mentioned under “Inspection Procedure

for Completed vehicle”.

PROCEDURE FOR MECHANICAL CLEANING, DEGREASING, PICKLING,

PASSIVATION & PAINTING

SS TANKS (WATER & FOAM)

Mechanical cleaning

All metallic surfaces inside and outside having scales and foreign materials and

all welded surfaces have to be cleaned. This can be done by scrubbing with metallic brush

(stainless steel) followed by buffing to get a polished surface. The loose scales and

powders obtained from the above process can be cleaned by blowing, sucking or washing

with water. Mechanical cleaning and buffing shall be carried out after stress relieving but

before hydro test.

Pickling and passivation

Pickling and passivation shall be carried out as per the following method for the tanks after

buffing and hydro testing

Tank outer surface Tank inner surface

Swabbing method using Barium Sulphate Filling / Swabbing method

as an acid carrier

Method for Degreasing, pickling and passivation:

Degreasing

Degreasing has to be done by soaking with hot detergent solution of Lissapol at 60deg C to

70 deg. C for at least 2 hours till satisfaction.

Pickling

Pickling is to be carried out with solution containing Nitric Acid 15% by volume, hydro-

fluoric acid (HF) 2% by volume and balance potable water

Temperature : Ambient

Duration : 1 to 2 hours

Rinsing

Thorough potable water rinsing has to be carried out until all traces of acid are removed

from the surface.

Passivation

Passivation is to be carried out with solution of Nitric Acid 20-25% by volume and balance

potable water

Temperature : Ambient

Duration : 2 hours

Thorough rinsing with potable water has to be carried out until pH of the final rinse water is

between 6.5 to 7.5 to minimize residual stain. Surfaces must not be permitted to dry

between successive steps of the acid cleaning or passivation and rinsing procedures.

The concentration of iron should not exceed 5% by weight in case of pickling solution and

2% by weight in case of passivation.

Preparation of paste for Swabbing Method

The pickling and passivation of the outer surface shall be done with a solution as described

above and barium sulphate as carrier (chloride level <25ppm) in the form of paste. For

each of pickling and passivation operations, the paste has to be applied on the surface and

has to be kept for at least two hours. Paste has to be removed with waste cotton in each

operation and finally the surface has to be rinsed with potable water.

Checking

All the relevant tests shall be carried out to ensure proper pickling and passivation as per

ASTM A 380

Painting

a. All stainless steel plates, sheets, pump parts shall be suitably pickled & passivated

by means of filling / swabbing method

b. All metal surfaces including steel material shall be applied with a coat of epoxy

primer of minimum thickness 100 ± 10 microns followed by polyurethane finish paint

(of fire red colour – shade No. 536 of BIS-5) of minimum thickness 50 ± 10 microns,

so that to get an overall Dry film thickness (DFT) of minimum 160 microns.

c. The Chassis and under carriage including support legs of water tank shall be

applied with suitable anti-rust intermediate primer (Zinc chromate).

Annexure-C General conditions Inspection

Stage wise inspection and Pre-delivery inspection will be done by IPRC/ISRO Engineers at various milestone / stages as defined in the Annexure-B.The supplier shall provide at least one week advance intimation for participation in the testing.

Guarantee

The manufacturer shall guarantee the design, material workmanship and the

performance of the complete unit for a period of 18 months from the date of

delivery of completed vehicle. Any mechanical defect, faulty workmanship or

operational defects found during this period shall be rectified by the vendor at

owner’s premises within reasonable time without any extra cost to the buyer

(including transportation).Performance Bank Guarantee certificate to the extent

of 10% PO value shall be furnished along with supply.

Training

Vendor shall give undertaking to impart a comprehensive training to IPRC fire

service staff on use of Fire tender including operation and maintenance of various

components and accessories supplied along with fire tender, at IPRC, Mahendragiri

premises for a minimum period of one week. Training shall be imparted by

experienced and well-qualified instructors who have got first hand training for above

referred components and accessories.No costs shall be applicable for providing the

training.

Documents

After placement of order

The following documents are required to be submitted in 3 sets and got approved prior to

fabrication. Construction shall be carried out as per approved drawings only.

1. GA and cross sectional drawings of chassis and fire tender

2. Final load distribution and reaction diagram of major elements with respect to axles

3. Characteristic curves and other details of pumps & PTO

4. Flow diagram showing all piping tanks, pumps, valves etc.

5. Fabrication drawing of super structure and base frame

6. Single line flow diagram of water & foam piping systems

7. Line diagram for electrical circuits & schematics

8. Thickness calculation and fabrication drawing of DCP & CO2 vessels and piping.

9. Fabrication drawing of water tank and foam tank

10. Cross sectional and GA drawings for water monitor and valves

11. Cabin layout schematic

12. Drawings showing layout of all equipment, lockers, cabin etc.

13. Quality Assurance Plan for inspection and testing

14. Detailed technical specifications of all elements

15. Catalogues of all major components (pump, PTO, water monitor etc.)

16. Dimensional detail of pump, PTO & water monitor

After Completion of Order

The following documents are required to be submitted (3 sets & 1 soft copy) in the form of

Production Master File (PMF).

1. As built drawings of vehicle under chassis & tender

2. As built drawings of all fabricated tanks, DCP & CO2 systems.

3. Isometric drawing of water & foam pipelines and as built flow diagrams

4. As built drawings of power transmission systems and electrical circuits

5. Operation and Maintenance (O&M) manual and spare parts book of truss ladders,

pneumatic tools, instruments etc.,

6. Operation and maintenance (O&M) manual and spare parts book of instruments,

electronics and electrical items

7. Vehicle documents

8. Manufacturer’s test reports & performance test reports in ORIGINAL of individual

componentS (Pump, Engine, Hose, Monitor, Nozzle etc.)

9. Overall performance test report of Fire Tender

10. CCE Approvals for DCP and CO2 systems

Note : Imported elements, if any shall confirm to EN safety directive/ equipment norms

from country of Origin.

Annexure – D

Format for Quote

Sl.No. Description Brand / Make

If applicable Rate in Rs.

1. Water tank & Foam tank

Material : SS 304L

2. Main water pump

Cap:3000 LPM @ 7kg/cm2 & 300 LPM

@ 35kg/cm2

3. Priming pump

4. Ultra High Pressure pump (UHP)

Capacity : 150 LPM @ 100kg/cm2

5. Hose reels

a. 1 x 20mm x 30m b. 1 x 20mm x 60m c. 2 x 16mm x 60m

6. PTO for Main Water Pump

7. PTO for UHP pump

8. Cooling system for the chassis engine

9. Automatic foam proportioning system

10. Water – foam monitor

11. Control panels and related components

12. Piping systems for both water & foam

13. Accessories as mentioned in the tender

enquiry (9 Items)

14. Stowage Equipment as per annexure –A (35

Items)

15. DCP and CO2 systems

16. Electrical related works

17. Structural work and complete body

construction works

18. Painting

19. Chassis collection and delivery after

completion of body construction

20. Testing of pumps and vehicle

21. Cleaning, pickling and passivation

22. Any other cost

Vendors are free to add any other items and quote accordingly. Brand / make of the

components must be clearly indicated wherever applicable.

INSTRUCTIONS FOR TWO-PART TENDER

I PART I : TECHNICAL & COMMERCIAL BID Part – (a) Technical

i. This part should contain detailed specifications of the items quoted by you along with Technical literature,performance curves for pumps,brand/make of components and catalogue if any.

ii. A compliance statement showing the compliance of the item quoted by you with that of item tendered by us should be prepared and enclosed to this.

iii. Any other information called for in the tender related technical and specifications can also come in this part.

iv. Prices should not be indicated in this cover.

Part – (b) Commercial terms: (WITHOUT PRICES)

i. The commercial terms applicable for the item quoted by you should be indicated in this part.

ii. If any compliance statement is called for the commercial terms / contractual terms and conditions, the same is to be attached in this part.

iii. Prices should not be indicated in this part. However a copy of the price bid (without prices) can be enclosed in this part to enable to understand whether all the items required to be quoted by you have been quoted in the price bid. Alternatively a statement is to be made indicating that you have quoted prices for all the items as per the tender and enclosed in the Price Bid as per the format.

iv. The Commercial terms such as delivery terms, delivery period, payment terms, Warranty, validity of the offer, installation & commissioning, duties and taxes etc., shall come into this.

v. Company’s profile, Fire tenders supplied in the last FIVE years and the purchasers’ address, performance certificate issued by any organization, if any should be enclosed.

vi. Company’s turn over for the last FIVE years in the form of Profit & Loss statement,Audited Accounts Statement and Current financial status should be provided.

II PART II : PRICE BID

i. The prices applicable for the items, item-wise in response to the tender shall come into this part.

ii. Tenderer shall indicate very clearly item-wise prices with reference to their technical offer.