Page 1 of 2 Contract NE-03: Supply, Installation, Testing and

Page 1 of 2

Contract NE-03: Supply, Installation, Testing and Commissioning of E&M, Fire Detection,

Fire Suppression System for Elevated Corridor of : Noida- Greater Noida Section (21

Stations, 29.139RKM) Line-1 ext.: Dilshad Garden to New Bus Adda ,Ghaziabad (8

Stations) Line-3 ext: Noida Sector-32 to Noida Sector-62 (6 Stations) i/c DG sets of Noida-

Greater Noida and rolling Stock Depot at Greater Noida.

ADDENDUM No.1

(SUMMARY SHEET)

Modifications to Tender Documents

S.

No.

Document Clause No. /Page No. In place of Please read as Remarks

Volume-1 (NIT, ITT and FOT)

1 NIT Clause 1.1.2 Page 1R Page 1R1 Key Details Modified

2 NIT Clause 1.1.2 Page 2R Page 2R1 Key Details Modified

3 ITT Clause C2.3 Page 24 Page 24R Clause Modified

4 ITT Clause C7 Page 36 Page 36R Clause Modified

5 FOT Appendix-1 Page 82 Page 82R Clause Modified

S.

No.


Volume-2 GCC, SCC

1. SCC Clause No.41 Page 21 of 28 Page 21R to 28 Clause Modified

2. SCC Clause No.59 Page 27 of 28 Page 27R to 28 Clause Modified

S.

No.


Volume - 4 (Particular Specification)

1. PS Part-A Chapter-3,Clause

3.1.3 & 3.1.4 Page 22 Page 22R Clause Modified

2. PS Appendix –A Added in Part-A After Chapter-4

- Page 37 to 39 Added

Page 2 of 2

3. PS Part-B Clause 4.10.3 Page 98 Page 98R Clause Modified

4. PS Part-B Chapter-9 Page 138 to 143 Page 138R to

143R Chapter Modified

5 PS Part-B Chapter-12 Clause – 12.8.1.1

Page 189 Page 189R Clause Modified

6 PS Part-B Chapter-12

Clause – 12.8.2.1(a) Page 189 Page 189R Clause Modified

7 PS Part-B Chapter-12 Clause – 12.8.3(i)


8 PS Part-B Chapter-12 Clause – 12.8.3(l)


9 PS Part-B Chapter-12 Clause – 12.8.4



Clause – 12.8.5 (g) and (i)


11 PS Part-B Chapter-12 Clause – 12.8.5 (n)

Page 192 Page 192R Clause deleted

12 PS Part-B Chapter-12 Clause – 12.8.5 (o)

Page 192 Page 192R Clause Added




Clause – 12.8.8.1(b) Page 192 Page 192R Clause Modified



16 PS Part-B Chapter-12 Clause – 12.8.9 (a)


17 PS Part-B Chapter-12 Clause – 12.8.9 (g)



Page 203 Page 203R Clause Added


Clause – 14.16.1 (j) Page 391 Page 391R Clause Modified

20 PS Part-B Chapter-16 Page 473 to 510 Page 473R to

513R Chapter Replaced

21 PS Part-B Chapter-17 - Page 514 to

518 Chapter Added

S.

No.


Volume-7 BOQ

1. BOQ - - - Replaced

2. BOQ - - - Preamble Added

Contract NE-03

DMRC/Contract NE-03/Vol-1/NIT Page 1R1

NOTICE INVITING TENDER (NIT)

1.1 GENERAL

1.1.1 Name of Work:

Delhi Metro Rail Corporation (DMRC) Ltd. invites Open e-Tenders from eligible applicants

who fulfil qualification criteria as stipulated in clause 1.1.4 of NIT, for the scope:

“Supply, Installation, Testing and Commissioning of E&M, Fire Detection, Fire

Suppression Systems for Elevated Corridor of: Noida-Greater Noida Section (21

Stations, 29.139 RKM), Line-1 ext: Dilshad Garden to New Bus Adda, Ghaziabad(8

Stations), Line-3 ext: Noida Sector 32 to Noida Sector-62 (6 Stations) i/c DG Sets of

Noida-Greater Noida Section and Rolling Stock Depot at Greater Noida under the

CONTRACT PACKAGE – NE-03”

The brief scope of the work and site information is provided in ITT clause A1 & Employer

Requirements (Volume –3 & Volume 4)

1.1.2 Key details :-

Approximate Cost of work = INR 160 Cr. .

Tender Security amount INR 1.60 Crore

Completion period of the Work 20 24 months

Tender documents on sale From 12.10.2015 to 16.11.2015 24.11.2015 (upto

11:00 Hrs) on e-tendering website

www.tenderwizard.com/DMRC

Tender document can only be obtained after

registration of tenderer on the website

www.tenderwizard.com/DMRC. For further

information on this regard bidders are advised to

contact on 011-49424307, 011-49424365 or 011-

23417910.

Cost of Tender documents INR 21,000/- (inclusive of 5% DVAT) Non-

Refundable (Demand Draft /Banker’s cheque) in

favour of “Delhi Metro Rail Corporation Ltd” payable

at New Delhi.) Cost of tender documents i.e,

D.D./Banker’s cheque, in original, shall be accepted

only up to 15:00 hours on 16.11.2015 24.11.2015 in

the office of Executive Director/Contracts at below

mentioned address.

Last date of Seeking Clarification 19.10.2015 (Queries from bidders after due date shall not be acknowledged)

Pre-bid Meeting 23.10.2015 @ 1100 Hrs

Last date of issuing addendum 02.11.2015 05.11.2015 09.11.2015

http://www.tenderwizard.com/DMRC


Contract NE-03

DMRC/Contract NE-03/Vol-1/NIT Page 2R

Date & time of Submission of Tender 16.11.2015 24.11.2015 @ 1500 Hrs

Date & time of opening of Tender 16.11.2015 24.11.2015 @ 15:05 Hrs

Authority and place for purchase of

tender documents, seeking

clarifications and submission of

completed tender documents

Executive Director/Contracts,

Delhi Metro Rail Corporation,

5th floor, A-Wing, Metro Bhawan,

Fire Brigade Lane, Barakhamba Road,

New Delhi –110 001

1.1.3 Source of Funds: Memorandum of Understanding has been signed between Noida Metro

Rail Corporation (NMRC) and Delhi Metro Rail Corporation (DMRC) for execution of the

Metro work of Noida- Greater Noida corridor, with execution being done by DMRC. Funds

shall be provided accordingly. This is a NON-JICA funded contract.

1.1.4 QUALIFICATION CRITERIA :

1.1.4.1 Eligible Applicants :

(i) The tenders for this contract will be considered only from those tenderers (proprietorship

firms, partnerships firms, companies, corporations, consortia or joint ventures) who meet

requisite eligibility criteria prescribed in the sub-clauses of Clause 1.1.4 of NIT. In the case of

a JV or Consortium, all members of the Group shall be jointly and severally liable for the

performance of whole contract.

(ii) (a) A non-Indian firm is permitted to tender only in a joint venture/JVA or consortium

arrangement with any other Indian firm having minimum participation interest of 26% or

their wholly owned Indian subsidiary registered in India under Companies Act-1956 with

minimum 26% participation.

(b) A tenderer shall submit only one bid in the same tendering process, either individually as

a tenderer or as a partner of a JVA/ Consortium. A tenderer who submits or participates

in, more than one bid will cause all of the proposals in which the tenderer has

participated to be disqualified. No tenderer can be a subcontractor while submitting a

bid individually or as a partner of a JVA/ Consortium in the same bidding process. A

tenderer, if acting in the capacity of subcontractor in any bid, may participate in more

than one bid, but only in that capacity.

(iii) A Tenderer and all partners constituting the Tenderer shall not have a conflict of interest. All

Tenderers found to have a conflict of interest shall be disqualified. A Tenderer may be

considered to have a conflict of interest with one or more parties in this tendering process, if:

a. Tenderer and all partners constituting the Tenderer has been engaged by the

Employer to provide consulting services for the preparation related to procurement for

or implementation of the project;

b. Tenderer and all partners constituting the Tenderer is any associates / affiliates

(inclusive of parent firms) mentioned in subparagraph (a) above; or

c. A Tenderer and all partners constituting the Tenderer lends, or temporarily seconds

Contract NE-03

DMRC/Contract NE-03/Vol-1/ITT Page 24R

(cc) Annexure 7 to ITT: – Bank Guarantee for Tender Security (see paragraph C18).

(dd) Annexure 8 to ITT: – Confirmation of Performance Security Provider (see paragraph

F5

(ee) Annexure 9 to ITT:– Additional Bank Guarantee

(ff) Annexure 10 to ITT: – Not Used

(gg) Annexure 11 to ITT: – Undertaking for Downloaded Tender Documents

A declaration by the bidders as per Annexure -11 of ITT must be submitted stating that

the tender document has been downloaded from official website of e-tendering portal

www.tenderwizard.com/DMRC and no changes, what so ever, has been made by the

bidder.

Bids received without the declaration are also liable to be rejected at any stage.

(hh) Any further documents which have been requested in accordance with paragraph B

4.2 above

(ii) Annexure-12 to ITT: Sample Format For Banking Reference For Liquidity

NOTE: - All Appendices shall be complete in all respect and supported with the

Required Documents

C2.3 The Tenderer shall submit with his Tender the documents that are identified in paragraphs

C2.3 (a) – C2.3 I (i) (ii) inclusive. Such documents will be used for the purposes of evaluating

and analysing the Tender but will not form part of the Contract unless the same shall have

been expressly incorporated into the Contract in accordance with paragraphs B4.1 or B4.2

above.

(a) Full details of ownership and control of the Tenderer (see paragraph A 4.3 above);

(b) Tender Programme including Design Submission Programme (see paragraph C8);

(c) Understanding of scope of works (see Annexure-4 of ITT);

(d) Details of works including specialized works if already decided to be sub-contracted (see

paragraph C11 & submit details in Annexure-4 of ITT);

(e) Details of providers of performance guarantees (see paragraph C19 below);

(f) Details of Contractor’s Equipment (see paragraph C13 below);

(g) Not Used

(h) Any further documents which are requested in writing by Employer before submission of the

Tender by way of evaluation documents but which are not to form part of the Contract;

(i) Following information shall be furnished:

(i) Extent of participation by each member of the JV/JVA/Consortium in terms of

percentage of the value of the proposed Contract.

Member % of participation

A


Contract NE-03

DMRC/Contract NE-03/Vol-1/ITT Page 36R

as required to confirm the correction of arithmetic errors discovered by the Employer in the

evaluation of the tenders in accordance with paragraph E5.

E4 Evaluation of Tenders

Only Technical Tenders and alternative Technical Tenders read out at tender opening shall

be considered for evaluation. No tender shall be rejected at the opening of Technical Tenders

except for late tenders, in accordance with Clause D2.

Tender Security and Technical Package will first be evaluated which will cover following

items:

E4.1 General Evaluation: First of all it will be determined whether each tender is accompanied

with the valid tender security i.e. the required amount and in an acceptable form. Tenders not

accompanied with the valid tender security shall be rejected and may not be evaluated

further. Other aspects of general evaluation will be done as per Clause 1.1.4 of NIT and

clauses A4.1, A4.2, A4.3, A 4.4.1, A4.5 and A5 of ITT.

E4.2 Evaluation of Qualification criteria – This evaluation will be done to check if the tenderer

qualify the minimum eligibility criteria of “Work Experience”, “Financial Standing” as laid down

in Clause 1.1.4.2 of NIT and “Bid Capacity” criteria as laid down in Clause 1.1.4.3 of NIT.

Tenderers, which do not qualify in any of the minimum eligibility criteria or Bid Capacity

criteria, shall not be considered for further evaluation of technical package and shall be

rejected.

E4.3 Evaluation of Responsiveness

The employer will determine whether each tender is substantially responsive to the

requirements of the Tender Documents i.e. it conforms to all terms, conditions and

specifications of the tender document. In case of any inconformity, the tender shall be

disqualified and rejected.

E4.4 Evaluation of Material deviation or reservation

Each tender shall be evaluated for any material deviation or reservation. Material deviation or

reservation is one:

which contains unauthorized changes to the Memorandum of Understanding from the

Memorandum of Understanding accepted for qualification if any.

which affects in any substantial way, the scope, quality or performance of the Works;

which limits in any substantial way, is inconsistent with the Tender Documents, the

Employer’s right or the Tenderer’s obligations under the Contract; or

whose rectification would affect unfairly the competitive position of other tenderers

presenting responsive tenders.

Tender having any material deviation or reservation shall be disqualified and rejected.

E4.5 Evaluation of qualifying conditions

Contract NE-03

DMRC/Contract NE-03/Vol-1/FOT Page 82R

FORM OF TENDER – APPENDIX-1 ( NE-03) [REQUIREMENTS UNDER GENERAL CONDITIONS OF CONTRACT (GCC)]

S.N

DESCRIPTION REF TO CLAUSE NO.

REQUIREMENT

i Amount of Performance Security Clause 4.2 of

the GCC

10% of the Contract Price in types and proportions of

currencies in which the contract price is payable. In

the event of variations during the execution of the

contract which result in payments to the Contractor

over and above the contract price, the Performance

Security shall be suitably adjusted.

ii Latest „date for commencement‟ of

the Works

Clause 8.1 of

the GCC

Date given in LOA or Employer‟s Notice to Proceed

iii „Time for completion‟ of the work

from the date of commencement of

the work

Clause 8.2 of

the GCC

24 months

iv Liquidated Damages Clause 8.5 of

the GCC

As per the referred clauses of GCC and SCC

v „Defects Liability Period‟ for the

whole of the Works

Clause 10 of

the GCC

As per clause 23 of SCC Starts after the date of

issue of Taking-Over Certificate for the Whole of the

Works.

vi Amount of advance payment

Clause 11.2

of the GCC

As per clause No. 26 and 27 of SCC

vii Amount of Professional Indemnity

Insurance (PII).

Clause 15.1

and 15.5 of

the GCC

AOA (any one accident) limit equal to 6% of the

contract value against of BOQ in respect of „design

and construct‟ with AOY (any one year) limit of 2

incidents in a year. In the Professional Indemnity

insurance Policy the deductable amount shall not be

more than 5% of AOA limit. PII Policy shall be

obtained within four weeks from „date of

commencement‟ and shall be

valid for five years after date of issue of

‘Performance Certificate’. Wherever the contractor

submits policy for shorter period / annual renewable

policy, the same shall be renewed before its expiry

date. In such situation, the performance guarantee

(5% of contract value) shall be retained till required

validity period. The contractor‟s submission of such

shorter period / renewable policy shall be construed

as their irrevocable consent for retention of the

performance guarantee.

viii Insurance cover for Contractor‟s All

Risk and other requirements as

specified in the GCC

Clause 15 of

the GCC

100% of the Total Contract Price.

ix Amount of Third Party Insurance Clause 5.8

and 15.3 of

the GCC

INR 0.50 Million for any one incident, with no. of

incidents unlimited.

x Period in which all insurances have

to be submitted

Clause 15.5

of the GCC

Within 4 weeks from the “date of commencement of

work”

xi Contract Key Dates Clause 8.5 of

the GCC

Refer Appendix 1A of FOT

Contract NE - 03 Special Conditions of Contract

Page 21R of 28

within 60 days of the receipt of notice by the Conciliator.

The parties shall not initiate, during the conciliation proceedings, any

arbitral or judicial proceedings in respect of a dispute that is the subject

matter of the conciliation proceedings.

40. Sub-Clause 17.11 Cost of Arbitration NOT USED

41. Additional Clause Retention Money(Not Used)

Retention money equal to 10 percent of the amount due to the

Contractor from each on account payment will be retained, so as to

maintain a reserve in the hands of the Employer equal to 5 percent

of the Contract Price.

The Retention money shall be held by the Employer without

obligation to invest them or account for interest thereon or to place

them in a designated account. No interest of whatsoever nature

and type will be payable by the Employer in respect of Retention

monies.

Retention money shall become due to the Contractor on the date

of issue of the Taking Over Certificate of works in respective

sections/corridors.

42. Additional Clause Manufacture, Construction, Execution, Supply, Installation,

Testing and Commissioning (Including Integrated Testing and

Commissioning) Methods

The Contractor shall submit complete documents and information

pertaining to the methods of manufacture, construction, execution,

supply, installation, testing and commissioning (including Integrated

Testing and Commissioning) which the Contractor proposes to

adopt or use. The Engineer will then check to see whether, if such

methods are adhered to, the Works can be executed in accordance

with the Contract and without detriment to the Works (when

completed) and to other works comprising the Project.

The Engineer shall inform the Contractor in writing within a

reasonable period after receipt of the above information;

a) that the Contractor's proposed methods of manufacture,

construction, execution, testing and commissioning (including

Integrated Testing and Commissioning) have the approval of

the Engineer; or

b) in what respects, in the opinion of the Engineer, the

Contractor's proposed methods of manufacture, construction,

execution, etc:

I. fail to comply with the Employer's Requirements;

II. would be detrimental to the Works and/or to the other

works comprising the Project;

Contract NE - 03 Special Conditions of Contract

Page 27R of 28

The contractor shall be responsible for maintaining the site. The

daily sweeping and cleaning of the area under his possession/work

shall be his responsibility.

In case of repeated aberrations noticed by the engineer a minimum

penalty of Rs. 5000/- shall be imposed for each instance.

57. Additional Clause Material not as per approved makes

Once the contractor has got the vendor approved the contractor

shall procure the material from the ‘approved’ sources. In the event,

material found at site from the unapproved sources, the engineer

can decide not to pay the BOQ price for the same.

58. Additional Clause BOCW (Building and Other Construction Works) Cess

Bidders need to judge the applicability of BOCW for the work. Any

liabilities on account of BOCW at any stage shall be on part of

bidder and the quoted price shall be inclusive of BOCW charges.

BOCW cess shall be deducted on installation, alteration, repairs,

maintenance or demolition excluding the cost of any items directly

bought out by DMRC. Where the supply and installation portion of

the contract value pertaining to erection, testing and commissioning

are not separately identifiable in the contract and the invoice raised

is composite one, BOCW shall be deducted on the 15% value of the

invoice assuming that 85% value is for supply.

If same is not applicable, the bidder needs to submit required

undertaking/certificates. The DMRC shall make the deduction

accordingly and deposit the amount to the concerned authorities.

59. Additional Clause Safe Custody Bank Guarantee (Not Used)

(Applicable for items specifically mentioned in the contract).

Please Refer Preamble of Pricing Schedule, Volume-7

The Contractor shall submit a Safe Custody Bank Guarantee in the

format given in Schedule 9 against payments made for Plant and

Equipment dispatched to sites and stores in DMRC network in

Delhi/NCR. The amount of safe custody Bank Guarantee shall be

equal to 95% percent of the amount due as per the relevant clause

of (BOQ) wherever applicable. The value of the Safe Custody Bank

Guarantee would be adjusted for the equipments already

commissioned.

60. Additional Clause Bought-out items

For the bought out items (items purchased from vendor) being

incorporated in the system, Contractor shall ensure the

following:-

(i) During Design stage, a confirmation from the vendor is to

NE-03 PARTICULAR SPECIFICATION PART-A

Page | 22R

3. VENDOR APPROVAL & LIST OF APPROVED MAKES

3.1.1 Contractor shall use the material of approved make as indicated below unless specified otherwise in BOQ or as approved by the Employer’s representative.

3.1.2 The Contractor shall ensure the correct selection of the approved make meeting the specification and application duties. The technical submission made by the contractor should clearly indicate deviation or improvements if any, for specification/BOQ. Before placing order for procurement the Engineer may ask for the sample of proposed make to be got verified for its suitability to the specification and application duty. However in case Employer’s representative/engineer considers that the make/model proposed by the contractor does not meet the requirement, the contractor will be required to propose an alternative make acceptable to the Employer’s Representative. The decision of engineer/employers representative in this regard shall be final and binding on both parties.

3.1.3 The contractor shall quote the rate for material and equipments as per the list of approved makes. In the event of contractor wanting to use alternate makes other than those stipulated for any reason, the contractor can send a proposal after ensuring that what he proposes at least meets both the quality, and safety standard of the stipulated makes and specifications as stated in the Particular specifications. He shall also stand full guarantee to his alternate proposal. The alternate makes can be used only after an approval accorded by the Employer, whose decision will be final in the matter.For this vendor approval procedure is given as APPENDIX-A.

3.1.4 Vendor selected by the contractor should be capable of providing good after sales service available in Noida/Greater Noida area during DLP and thereafter. * NOTE:-This list is indicative and not restrictive. New vendors may be proposed as per Clause 3.1.3 above.

S.No. ITEMS APPROVED MAKES *

LV MAIN SWITCHBOARD INCLUDING DB

1 MV/LV Switchboards Tricolite Electircal Industries, L&T, GE, Schneider,

Unilec, Neptune, Adlec, Suddhir Genset Ltd, ABB,

2 415 Volts ACBs L&T, Siemens, ABB, Schneider

3 Moulded case Circuit

Breakers(MCCB)

L&T, Siemens, ABB, Merlin Gerin, Legrand

4

Distribution boards L&T Hager, Legrand, Siemens, ABB, Havells, GE,

Tricolite, Schneider, Unilec, Neptune, Adlec, Sudhir

Gensel Ltd,

5 RCBO/RCCB L&T Hager, Legrand, Siemens, Merlin-Gerin, ABB

6 Miniature circuit

breakers (MCB)

L&T Hager, Legrand, Siemens, Schneider, ABB

7

Switch fuse units with

HRC fuses

L&T, GE, Siemens, Controal & Swicthegear ltd, ABB,

Merlin-Gerin, Crompton-Greaves

8 Protective relays Alstom (AREVA), ABB, L&T, Siemens, Schneider

9 Capacitors Crompton, Mehar(Schneider), L& T, Siemens, Ducati,

ABB

10 Cast resin current

transformers

AE,Kappa,control & Switchgear, Precise, G&M

(Gilbert & Maxwel)

11 Meters (digital) MECO,DUCATI,Allen-


Page | 37

Appendix A: Vendor Approval

a) It shall be obligatory for the Contractor to obtain Notice of “No Objection” from the Engineer for the selection of the vendors for all items of work, even if the name of the vendor is specified in the Contractor‟s Technical Submission and the works to be done including purchase of materials and equipment is in accordance with the Standards specified in the Contract.

b) In case of vendor selected from the approved list provided in the contract. I. A list of approved vendors is provided in this contract. These are the

vendors, who have been approved by DMRC in such installation of DMRC commissioned earlier.

II. Contractor in general shall use the material of approved make as per approved vendor list unless specified in BOQ of makes meeting the tender specifications as approved by the Employer‟s representative.

III. The contractor shall ensure the correct selection of the approved make meeting the specifications and its application. Before placing the order for procurement, the sample of approved make shall be verified for its suitability to the specification and application. In case Employer‟s representative/engineers, (whose decision will be final and binding on both parties) considers that the make/ model proposed by the contractor does not meet the tender requirement the contractor will be required to propose an alternative make acceptable to the Employer‟s Representative.

c) The contractor will submit a list „A‟ of vendors for all the items of the BOQ contract

I. The list should include the items for which the contractor is proposing the product of the approved vendor.

II. The contractor will be advised „No Objection‟ with following caveat:- The model etc. to be supplied will be the latest or superior one. The contractor will be required to submit the technical proposal

for the scrutiny III. For the items, contractor desires to propose new vendor, proposal to be

submitted in accordance as List „B‟. IV. The contractor will submit the undertaking the above lists i.e. List „A‟ and

list „B‟ includes all the items required in the contract. d) Vendor to be selected who are capable to provide good after sales services

available in Delhi NCR during DLP and thereafter.

Vendor Approval and Selection Procedure

a) In the event of contractor wanting to use alternate makes other than those stipulated, for any reason, the contractor can send a proposal after ensuring that what he proposes at least meets the specifications both, the quality and safety standard of the stipulated makes and the financial benefit that will accrue to the employer. The alternate proposed product should be a proven one. He shall also stand full guarantee to his alternate proposal and if at any stage it is found that the material and provide the material from the approved vendor without any additional cost to DMRC. The alternate makes can be used only after an approval accorded by the Employer, whose decision will be final in the matter.

b) The approval of any equipment or product to be used shall be done in two stages:-

I. Stage-I Assessment of capability of proposed Vendor to supply a

particular equipment or product, with quality and performance requirements, as required by specifications as well as other contract conditions. The proposed product should be a proven product in service for at least 3 years.


Page | 38

Assessment of the financial and functional strength of the Vendor to supply the requisite quantity of equipment and product as per delivery schedule acceptable to contractor and engineer to deliver the project in time.

II. Stage-II Stage-II called as Technical Submission Approval Stage,

selection of Equipment or product from the equipment/ products manufactured/ supplied by the approved vendor will be done. This stage includes thorough technical assessments about the conformance of the offered equipment/ product to the specifications and other requirements.

III. To obtain Vendor Approval the Contractor must apply with the four sets

of the following documents to the Engineer Company Profile and Experience of the Vendor Clause wise compliance of the relevant Clauses of

Specifications. Details of supplies/ orders executed in last ten years for the type

of equipment/ product offered. Supplies/ orders executed for Underground Metro Systems shall be specifically mentioned

Details of the facilities available at the Works/ Manufacturing Unit where the proposed equipment/ product shall be manufactured.

ISO 9000 Certification for the Works/ Manufacturing unit where the proposed equipment/ product shall be manufactured (The Works /Manufacturing Unit where the proposed equipment/ product shall be manufactured must have ISO 9000 Certification)

Proof regarding compliance to Manufacturer‟s Qualifications. The offered products must be proven in service.

Audited Financial Statements open Vendor for the last three years.

type test certificates/ Performance certificate from accredited laboratories for the proposed type of equipment/ products to establish the technical capability of the vendor (In case, specific requirements are mentioned in the relevant sections of Specifications with regard to type testing, same shall also be complied additionally).

The vendor shall not have been blacklisted by any Govt. Agency in India.

Any other item as required by Employer/ Employer‟s Representative.

IV. Contractor must certify the check list provided that vendor Proposal is complete and all the above documents are available in the Vendor Proposal. In addition, the Contractor must check/ certify compliance to the Specifications before forwarding the same.

V. Incomplete Vendor Proposal will not be treated as a submission and will be returned.

VI. Engineer will give Approval to the Vendor Proposal (received complete with all the documents mentioned above) expeditiously.

VII. Technical submission shall be accompanied with the calculations/ other technical documents to justify the selection of any particular model of equipment/ product, detailed technical features/ parameters of the selected product, type test certificates from the accredited laboratories for the offered products, any other document required by the Engineer.

VIII. Engineer will give Approval to the Technical Proposal (received completed with all the documents mentioned above) expeditiously.


Page | 39

c) It may be noted that Approval of Vendors as per Point III above shall only be done by Employer/ Engineer after the award of the work. Vendor submissions shall not be evaluated during the tender evaluation. Conditional Tender offers received from Tenderers with particular Vendors for supply for equipment/ products will not be evaluated during evaluation and will be dealt with after award of the work.

d) It may further be noted that Employer/ Engineer shall be under no obligation to accept equipment/ products manufactured by the successful Tenderer, unless it meets the entire criterion mentioned above.

The Engineer’s decision on contractor’s proposal shall be final and binding.

For sourcing the equipment from indigenous manufacturing facilities, following conditions shall be complied:-

a) In case the vendor uses his own facilities for indigenization after part supply of equipment from the approved manufacturing unit, no change in design, component type/make, quality standards, manufacture procedure, etc. shall be made without specific approval of the Engineer.

b) In case OEM wants to use manufacturing facilities in India (other than his own) for items for which the OEM has been approved, it shall enter into an agreement with such selected Indian equipment manufacturer and obtain prior approval from DMRC. No change in composition, rating, type, model no., manufacturing process, quality standards, design, etc. and make of the components used in assemblies/sub-assemblies of such equipment as manufactured by the approved parent vendor shall be made without specific approval of the Engineer.

c) In case OEM wishes to change/make/type specifications, etc. of any sub-components for supplies to be sourced from Indian facility, specific prior approval of the Engineer shall be obtained for changes made, model, specification, etc. responsibility for obtaining such prior approval shall rest solely with the contractor.

Format for submitting the vendor approval request shall be given to the contractor during initial stages and approved format shall be followed throughout the contract.

NE-03 PARTICULAR SPECIFICATION PART-B

Page | 98R

c) Atmosphere - The equipment shall be designed to work in coastal, humid, salt laden and corrosive atmosphere.

d) Housing, if not used as a heat sink shall be made of 0.5 mm thick CRCA sheet / Extruded Aluminium (2 mm) or pressure die cast (PDC-2 mm), conforming to relevant standards, polyester powder coated of at least 40 microns) and high U.V. & corrosion resistance.

e) Heat sink used should be extruded Aluminium or Pressure Die-Cast Aluminium having high conductivity preferably ADC 12 or LM 6.

f) Luminaries should be covered with suitable Glass or diffuser with High Transitivity.

g) Outdoor luminaire shall be with clear toughened glass or clear polycarbonate cover.

h) Lighting fixtures and accessories shall be designed for continuous trouble free operation under diverse atmospheric conditions without deterioration of materials. Degree of protection of enclosure shall be at least IP-65 for outdoor fixtures. However, down lighter and other internal fixture shall be provided with at least IP-20 protection.

i) The fixture should have a surge protection of 2 KV. j) The fixture should conform to applicable IS 10322 / IEC 60598 (All parts &

amendments) and should have the associated LM-79 report (for Electrical and photometric test methodology for LED lighting) from accredited lab. Test report shall be submitted along with relevant catalogues.

k) The fixture shall be surface suspended or recessed type depending on the application area.

l) Reflector (if) shall be a high quality aluminium reflector and shall have efficiency more than 85% to achieve a wide light distribution. The anodic film shall have a minimum thickness of 2.5 micron.

m) The fixture shall be provided with separate wiring channel with cover plate and earth terminal.

n) Provision shall be made for main connection directly at the back of housing.

4.10.3 LED Features

4.10.3.1 Approved makes are as per the approved list of makes.Manufacturer should have LM-80 report and projected life of the chip. Manufacturer has to submit the test report along with relevant documents.

4.10.3.2 High lumen efficacy LEDs suitable for the application along with following features shall be used:

a) LED Efficacy at the chip level shall > 120 lumen/watt (For High power LED) I. The efficiency of the LED at 85 Degree C junction temperatures

shall be more than 85%. II. The system luminous efficacy of LED luminaire’ shall be as under:-

Efficacy > 60 lumen/Watt for low wattage luminaries (<45W); and

Efficacy > 80 lumen/watt for high wattage luminaries (>45W) b) Adequate heat sink with proper thermal management shall be provided. c) Minimum view angle of the LED shall not be less than 1200 120 Degrees. d) Power factor of complete fitting shall be more than 0.9 e) LED shall be surface mounted type duly soldered to PCB by Reflow system or

COB type. The Solder used shall be ROHS compatible for environment friendliness.

f) Input frequency range shall be between 50Hz±3%. g) Colour rendering index CRI >=70 as specified in item description.


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9. SANDWITCH BUS DUCT, LV LIGHT BUS TRUNKING & RISING MAIN

9.1 GENERAL

This section covers technical specifications of Compact Sandwich Type Aluminium conductor bus duct suitable for outdoor/Indoor installations.

9.1.1 This specification is intended for design, manufacture, transporting, installation and testing at site of compact sandwich type Aluminum/Copper conductor LT Bus Bar Trunking system (Bus duct) suitable for indoor/outdoor installations as specified in the attached data sheet.

9.1.2 415 V, 3 Phase, 50 Hz, self cooled, sandwich construction Al/Cu bus duct as per the specific requirements shall be supplied. The bus bar systems offered shall be complete with all necessary accessories like elbows, off sets, reducers etc.

9.2 STANDARDS

9.2.1 Updated and current Indian Standard Specifications and Codes of Practice will apply to the equipment and the work covered by the scope of this contract. In addition the relevant clauses of the following standards as amended up to date shall also apply. Wherever appropriate Indian Standards are not available, relevant British and/or IEC Standards shall be applicable.

STANDARDS DESCRIPTION

IS 8623 (Part-1) 1993 Low voltage switchgear and controller assemblies: Part-1 Requirement for type tested and partially type tested assemblies

IS 8623 (Part-2) 1993 Low voltage switchgear and controller assemblies: Part-2 Particular requirement for busbar trunking system (bus ways)

IS 8623 (Part-3) 1993

Low voltage switchgear and controller assemblies: Part-3 Particular requirement for equipment where unskilled persons have access for their use

IEC 61439-6 Low-voltage switchgear and control gear assemblies - Part 6: Busbar trunking systems (busways)

IEC 61439-1 Low-voltage switchgear and control gear assemblies - Part 1: General rules

IEC 60529 Degrees of protection provided by enclosures (IP Code)

Indian Electricity Act 2003

Indian Electricity Rules 1956

National Building Code 1994

National Electric Code 1985

Code of Practice for Fire Safety of Building (general)

IS 1641 General Principal and Fire Grading

9.3 TECHNICAL REQUIREMENT

415 V, 3 Phase, 50 HZ, self cooled, sandwich construction, Aluminium/Copper (as specified) bus duct as per the following specific requirements shall be supplied -

9.3.1 BUS BARS


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a) For Aluminum Bus duct, Bus bar shall be fabricated from aluminium and the conductors shall be continuously nickel/ tinned / copper / suitably plated for the entire length. For Copper Bus duct, the bus bars shall be of high conductivity

copper of 99.9% pure grade and shall be continuously nickel/ tinned / copper /suitably plated for the entire length. Rating of busbar shall be as per data sheet, and it shall be 3Phase +100% Neutral+ 50% integral earth including bends.

b) Busbar conductors shall be insulated with single/multilayer of insulation of classF. Electric connection shall be made at joints by single/multi bolt joint construction which ever suited. Joints shall be realized by a torque spanner (wrench) and shall be set as per the manufacturer design. To prevent the joints to be damaged during transport, they shall be protected by plastic caps, which shall be removed before installation. Standard or designed locking system shall be put in place to prevent loosening of any screw and requiring any tightening schedule during maintenance. The design should have a provision to identify unraveling of the screw/nut by a degree and a marker to indicate, if the bolt has shifted from net position.

c) Each busbar shall be jointed to the adjacent section by single/multi bolt-joint clamps without drilling the busbar. Joint between two sections shall be such that a complete sub assembly is removable so that isolation of individual sections is possible without disturbing other sections.

d) Inspection windows shall be provided over the joints to check tightness. e) Flexible connections shall be provided by braided or multi leafed conductors for termination

9.3.2 ENCLOSURE

a) The enclosures of Bus Ducts shall be totally enclosed non ventilated type. The enclosures shall be fabricated from galvanized sheets of minimum 1.6 mm thickness. The enclosures shall be epoxy polyester painted RAL7032.

b) Enclosures shall be provided with M6 screws applied at every 10 cm along the entire

length.Ingress protection for the enclosures shall be IP54 for indoor Busduct and IP 65 for outdoor busduct as per IEC 60529.The enclosure of Bus Trunking System shall be fabricated from 1.6 mm thick CRCA sheet steel/GI/Extruded Al and shall be powder coated to colour shade RAL 7032 after regress metal treatment process. Enclosure shall be rendered dust proof and vermin proof by adequate gasketing etc. to provide ingress protection of not less than IP 54 for Indoor Busduct and IP65 for Outdoor Busduct as per IEC 60529. as per IS 2147 The Bus Trunking System shall be manufactured in convenient section to facilitate easy transportation and installation.

c) The busbar Trunking System shall be manufactured in convenient section to facilitate easy transportation and installation.

d) The sections shall be connectable to form vertical or horizontal runs as required. Each section shall be provided with suitable support arrangement from walls / ceilings as required.

e) Expansion joints may be provided as per manufacturer’s design and recommendation.Bus trunking system shall be provided with two independent earthing GI conductors size 50x6 (mm)

through the length of the system. Effectively connected to the enclosure by riveting /bolting End covers shall be provided as required.

9.3.3 FLANGED END BOX

a) Flanged end box shall be provided to accommodate flange end for connecting the bus trunking with the flanges of panels, transformers and DG Sets etc. through flexible connections.

b) Phase matching of bus trunking with equipment shall be done prior to installation.

9.3.4 EXPANSION JOINTS

a) The bus bar system shall be equipped with standard expansion joints or with expansion bolts in each unit length to compensate thermal elongation of the bus bar.As far local conditions permit, the longest bus bar unit lengths shall be used to minimize electrical losses at the butt or bolted connections of the bus bars.

b) The bus bar junction points shall be suitably marked for identification.

9.4 SYSTEM PARAMETERS OF BUS DUCTS

9.4.1 Bus Ducts shall be suitable for following system parameters.

Type Compact Sandwich type bus duct with insulated bus Conductors

Supply system 3 phase, 4 wire, AC 415, Volts 50 Hz

Rated Insulation Voltage (Volts) 1000


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Number of Conductors 3 Phase 4/5

Power Frequency Withstand 2500 Volts

Current Rating 4000 Amps 3P +100% N+ 50% integral

Temperature Rise 50ºC above 45º C ambient. Design data in support of temperature rise being within permissible limits shall be

furnished along with the tender.

Short circuit ratings Minimum short circuit ratings 65 KA for 1 sec.

9.4.2 The Bus Bar Systems offered shall be complete with all necessary accessories like elbows, off sets, reducers etc.

9.5 BUSBARS

9.5.1 Busbar shall be fabricated from 19501 grade aluminium or 99.9% pure ETP grade copper as applicable. Rating of busbar shall be as specified in drawings /Schedule of quantities. Rating of the busbares shall be as per Schedule of Quantities. Each busbar shall be individually insulated by means of 3 layers of Polyester, insulation Material shall be Flame Retardant type to give minimum class B (bus temperature 130 Deg C) insulation. Each busbar shall be jointed to the adjacent section by single bolt-joint clamps without drilling the busbar. Joint between two sections shall be such that complete sub assembly is removable so that isolation of individual sections is possible without disturbing only sections. The Joints shall be of one bolt type which utilizes a high strength steel bolt and washers to maintain proper pressure over a large contact surface area. The bolt shall be torque indicating and at earth potential, it shall be two headed design to indicate when proper torque has been applied and require only a standard long handle wrench to be properly activated. Access shall be required to only one side of the busbar trunking for tightening joint bolts.. Flexible connections shall be provided by multi leafed conductors for termination.

9.5.2 Removable bolted disconnect links shall be provided in the bus wherever required for the purpose of isolation if required.

9.5.3 All matching flanges, fittings, supports etc as may be required for terminating the bus ducts/rising mains at the switchgear and/or transformer end shall be included

9.5.4 Busbar conductors shall be insulated with 2 layers of extruded polypropylene sleeves and 3 layers of Mylar (Polyester film) between conductors. Electric connection shall be made at joints by single bolt joint construction and each joint shall have 2 “Belleville” washers. The joints shall be manufactured of glass reinforced polyester. Joints shall be realized by a torque spanner (wrench) set at 80 Nm. To prevent the joints to be damaged during transport, they shall be protected by plastic caps, which shall be removed before installation. To prevent the joints bolt from loosening there shall be locker pieces on both sides of the bolt.

9.5.5 Current density shall not be more than 1 amp per sq. mm Each busbar shall be individually insulated by means of 4 layers of glass mica and polyester insulation to give minimum class F (bus temperature 155 Deg C) insulation.

9.5.6 Each busbar shall be jointed to the adjacent section by single bolt-joint clamps without drilling the busbar. Joint between two sections shall be such that a complete sub assembly is removable so that isolation of individual sections is possible without disturbing other sections. Inspection windows shall be provided over the joints to check tightness.

9.5.7 Flexible connections shall be provided by braded or multi leafed conductors for termination.

9.6 ADDITIONAL REQUIREMENTS

9.6.1 RISING MAIN PLUG –IN TAP OFF BOXES FEATURES

a) Tap off Provision i. 415V three phase, 50Hz rising mains of 3P+ N /3P+2N+E or as specified in BOQ shall be totally enclosed, dust and

vermin proof, shall have IP 54 ingress protection with low impedance compact switch type aluminium busbars rated for insulation voltage of 1000Volts and withstand the fault level of 35KA for 1 secound or as specified in BOQ.


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ii. Rising Mains shall have provision to install tap off boxes minimum 3 locations in standard length of 3m. Plug in points shall have a hinged sheet metal that provides IP-55 IP protection Similar to the specified for Bus Duct. There shall be Provision for upto 3 plug in tap off boxes. Rating of plug in tap off boxes shall start from 100 ampere and shall be upto and including 400 ampere. Plug in tap off boxes shall have an electrical interlock mechanism which also ensures that plug in tap off box cannot be removed mechanically from the busbar when the box is at ON position. Tap off boxes shall be suitable for any brand of MCCB. Contacts of plug in tap off box shall be silver plated. Tap off boxes shall be manufactured of Similar material and color as main Bus Duct.sheet and shall be epoxy painted RAL 3020 .Tap off boxes shall be plug in type with earth contact to make first and break last. Tap off boxes shall have spring loaded contacts for uniform contact pressure on busbars. Tap off boxes shall be provided with door interlocking and interlocking with bus trunking to ensure plug in and plug out possible on in OFF condition. All tap off boxes shall be compatible with all rating of bus trunking and shall be suitable for interchanging between sandwich/air insulated trunking. Tap off outlets shall be available as required by the system design. Tap off outlets shall have safety shutters to prevent access to live busbars when not in use. Degree of protection in the open conditions of with shrouding shall be IP 2X to offer personal safety protection.

iii. Rising mains shall have provision of tapping power as required.It shall be provided with all required accessories like clamps, elbows,end covers,flexible connections and GI earthing for body earthing.

iv. 415V three phase, 50Hz Feeder Boxes of 3P+ N /3P+2N+E or as specified in BOQ shall be suitable for use with rising mains for receiving power supply through cables

v. 415V three phase, 50Hz Tap-Off Boxes of TPN/4P plug in type suitable for use with rising main to feed power supply from rising mains at typical floors.

9.6.2 THRUST PADS

a) Thrust Pads shall be provided in the raising main systems for necessary support to the rising mains and to prevent busbar expansion in down ward direction.

9.6.3 ACCESSORIES

a) Bus trunking system shall be complete with all accessories like bends, busduct, expansion joints, flexible connections etc to suit site requirements. Rising main in addition shall be complete with tap off points, end feed units, end covers, thrust pads and spring hangers at each floor. Bus trunking systems shall be complete in all respects. whether any item is individually listed in Schedule of Quantities or not. All accessories shall be deemed to be included in the unit rate of straight length of the busduct and rising mains.

b) Supports for Rising Mains – Vertical Spring Hangers shall be provided, at least one on each other to provide support for Rising Mains

9.7 TERMINAL ARRANGEMENTS

9.7.1 Suitable arrangements shall be available for cable terminations so that the cable weight doesn’t come on the terminals. The terminal on HV & LV shall be suitable for receiving copper flexible cable and termination with cable gland and anodized hard wire for the cable termination.

9.8 SAFETY

9.8.1 SAFETY FACTOR

a) The contractor will submit the Bus duct support calculation incorporating safety factor not less than or equal to 3 and dead weight of the bus duct along with hanging arrangement detail.

9.8.2 GROUNDING

a) Bus trunking system shall be provided with two independent earthing GI conductors size of at least 50x6 (mm)/ as suitable throughout the length of the system. The earth flats shall be effectively connected to the enclosure by riveting /bolting. End covers shall be provided as required. Neutral shall have same cross section as phases.


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b) All parts of the bus enclosure, supporting structures and equipment frames shall be bonded to the ground bus.

9.8.3 EARTHING

a) Integral earthing need not to be provided as enclosure is available which should be part of the housing itself.comprised of Aluminium of 50% capacity should be provided which should be part of the housing itself. No riveting or bolting is acceptable for earthing.

9.8.4 MAINTENANCE AND LIFE

a) The LT bus duct should be designed for maintenance free best service life in the industry and not less than 30 years for all types of installation & under prescribed environmental conditions.

9.9 TESTING

9.9.1 TYPE TEST

a) LT Bus Bar Trunking System (Bus Duct) offered shall comply to verification and type test requirements of IEC 61439-6.Type Testing Shall be conducted from accredited Lab.Copies of the test Certificate for same rating shall be submitted at the time of vendor approval.These shall not more than 5 years old.

9.9.2 ROUTINE AND ACCEPTANCE TESTS

a) Testing at manufacturer’s works shall be conducted before dispatch as per routine verification requirements as per IEC 61439-6.

9.9.3 TESTING AT SITE

a) Physical check including checking damage/crack in any components, tightness of bolts and connections etc.

b) Insulation test after installation according to manufacturer’s test procedures. c) Testing earth continuity.

9.9.4 Rising Mains/Bus Duct configurations offered shall be CPRI /Independent test house tested. Copies of the CPRI test certificates for same rating & identical switchgear shall be submitted by successful Tenderers at the time obtaining of Vender approval. This shall not be more than 5 years old.

9.10 TESTING AT MANUFACTURERS WORKS

9.10.1 The Bus Ducts shall be tested in accordance with IEC 60439-2: 2000 and the related test certificate shall be from an independent International Test Laboratory.

9.11 INSTALLATION

9.11.1 Installation of the Bus Duct/Rising Main shall be carried out as per manufacturer’s instruction and installation shall be verified by the manufacturer before energising.

9.11.2 For Bus Duct horizontal runs, horizontal expansion units shall be provided at Suitable intervals at least every 40 m and at expansion joints of the building structure and the system shall be supported at every 1.5 m.

9.11.3 Annular space around or Bus Ducts while crossing walls shall be filled up by sealing material by contractor in accordance with the manufacturer’s instruction. No extra claim shall be entertained, for the same.

9.12 DATA SHEET FOR BUS DUCTS

S.NO DESCRIPTION RATED CURRENT OF 3200A

RATED CURRENT OF 4000A RATED CURRENT OF 5000A

1 Type Compact Sandwich Compact Sandwich Compact Sandwich

2 Supply System 3 Phase ,4 Wire ,AC 415V,50HZ

3 Phase ,4 Wire ,AC 415V,50HZ

3 Phase ,4 Wire ,AC 415V,50HZ

3 Busbar Conductor Aluminium Aluminum Copper

4 Insulation Class F Class F Class F

5 Rated insulation 1000 V 1000V 1000V

6 Power Frequency Withstand

2.5KV 2.5KV 2.5KV

7 Short-Circuit Rating 65KA for 1 Sec 65KA for 1 Sec 70KA for 1 Sec

8 Current Rating 3200A,3P,+100%N,+ 3200A,3P,+100%N,+50% 3200A,3P,+100%N,+50%

NE-03 PARTICULAR SPECIFICATIONS PART-B

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12.8.1.1 The scope covers supply, installation, testing and commissioning of automatic Clean agentflooding system complete for electrical panels (Main distribution panel, essential power panel, Fire Pump Panel and any other panel as decided by Engineer in Charge) with fire trace UL approved detection tube, cylinder, valves, integration with fire alarm control panel for annunciation. The work shall cover:

a) Providing fire trace tube UL approved detection inside the panels. b) Arrangement of Clean agent for flooding of the above-mentioned panels. c) Audio-visual annunciation devices for indicating incidence of fire. d) Wiring from alarm initiating devices to the above-mentioned panels with

required conduits as per direction of engineer-in-charge. e) Any other item required to the successful commissioning of the system. f) Providing manual arrangement for discharge of gas inside the above panels.

12.8.1.2 The electrical panel fire suppression system shall be complete with Clean Agent gas storage cylinders of required capacities, extinguishing agent as specified, polymer fire trace tubing, filling and end-of-line adaptors, pressure switches, control equipment and all necessary accessories and fittings to form a complete and working installation to protect the specified areas to the approval of the engineer-in-charge.

12.8.1.3 The panels to be protected shall be determined as per the approval of the engineer-in- charge.

12.8.1.4 This will have an interface with Main Fire Alarm & Control Panel. In case of fire in the concerned Panel, indication & alarm should come in Main Fire Alarm & Control Panel.

12.8.2 Standards

12.8.2.1 The design and installation of the clean agentgas based Fire Trace tube system is based on the latest applicable codes and also as per the manufacturer’s recommendations; the required clean gas quantity is arrived as per the volume of the respective panels to be protected. In addition, the following standards and rules and regulations shall be applicable:

(a)

Fire protection manual of the tariff advisory committee, Fire Insurance Association of India

(b)

NBC Part-IV 2005

National Building Code Part-IV: Fire Safety System

(c)

NFPA-2001

Standard on Clean Agent Fire Extinguishing System

(d)

IS: 7285 - 2004

Refillable Seamless Steel Gas Cylinders - Specification

(e)

Local Fire Brigade/Authority

All standardsmeanthelatest.

12.8.3 System Features

a) The system shall generally comply with as under:


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b) The complete equipment design shall be reliable in operation. All components of the installation should be located, installed or suitably protected to ensure that no mechanical, chemical or other damage is possible which may render these inoperative.

c) The design, manufacturing and installation shall be such that there is no maintenance requirement and shall have built-in features for condition monitoring without requiring opening of any part of the installation. In case it is unavoidable for the vendor, the contractor shall seek approval of the engineer at the time vendor approval with the submittal of maintenance manual.

d) All devices used in the installation shall be capable of functioning satisfactorily between - 29°C and 45°C.

e) For enclosed tight electrical equipment, the quantity of Clean agent for extended concentration of at least 30% throughout the declaration period or for a minimum of 20 minutes.

f) All cylinders in the battery shall be interchangeable. g) Each cylinder shall be provided with its own valve with a dip tube extending to

the bottom inside the cylinder, and valve discharge head, which shall be connected to a common manifold through high pressure connecting pipes or tubes.

h) Flexible hoses used for discharge bend shall preferably be double wire braided (perforated) rubber covered hose suitable to withstand a minimum bursting pressure of 420kgf/cm2 at 54°C.

i) All discharge heads and valves shall be designed taking into consideration the fact that liquefied carbon dioxide expands very rapidly when discharged. The requirements of minimum flow of gas and the temperature at which these arerequired to operate shall also be taken into consideration. These shall conform to IS: 3224-2002.

j) All valves under constant high pressure shall have a minimum bursting pressure of not less than 42MN/m2 (420kgf/cm2) and those not under constant pressure shall have a bursting pressure of not less than 35MN/m2 (350kgf/cm2).

k) Discharge heads and valves shall be designed to permit a minimum discharge of 85% of the Clean Agent in the cylinder is not more than 30s at a temperature of 27± 1°C.

l) Nozzles as applicable shall be sufficient in a number and so located that the gas discharge pattern shall completely cover the enclosure.

m) Nozzles shall be sufficient in a number and so located that the gas discharge pattern shall completely cover the enclosure.

n) The nozzles shall be designed and located in such a manner that an even distribution of gas will be achieved throughout the protected space and at the same time the discharge from the nozzles shall not cause undue splashing of flammable liquids or creation of dust clouds that might aid spread of fire.

o) Panel flooding system shall be integrated with nearby detector, which will send the signal to FACP incase of actuation of Clean Agent gas panel flooding system.

12.8.4 Features of Fire Trace Detection Based Clean Agent Fire Suppression system

12.8.4.1 The system shall be simple self activating system, specifically designed for installation inside enclosures, cabinets and machinery housing to detect automatically and extinguish fire at source, at its very early stage. It should be suitable for application where the potential fire risk is located within an enclosed or confined space e.g. electrical panels etc.


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12.8.4.2 The system should be an automatic self-seeking fire extinguisher, which puts fires where they start by means of a flexible fire detection and delivery tube. The tube shall be manufactured from specially produced polymer material to achieve the desired detection and delivery characteristics. The system shall have capability of linear detection i.e. detection of fire not only at a single stage point but also at any place along the tube’s length.

12.8.4.3 The path of the fire trace tube inside the panel shall be so seleced that it should not get damaged due to functioning of the equipment installed inside the panel.

12.8.4.4 This extinguishing system should be fully integrated with fire alarm system. The system system should consist of a valve, connected to a cylinder and to a flexible detection and delivery system i.e. flexible tube. This tube should be routed within the equipment to be protected. In case of fire, the tube shall melt and bursts at the hottest point and the extinguishing agent is then transported through the Fire trace tube exactly to the origin of fire (i.e. the point of burst).

12.8.4.5 The system should be simple self-activating system without human intervention and suitable for enclosed spaces like engine room, panels.

12.8.4.6 The system should have fast response - less than 10 seconds.

12.8.4.7 The system should extinguish fire at early stage and should trigger automatically and also manually.

12.8.4.8 The system should be safe against malfunction and should not need power supply for detection and extinguishing of fire.

12.8.4.9 The contractor shall submit the quality assurance plan of the vendor for the design, manufacutirng and installation of the arrangement in compliance with the applicable standards followed for bought out item and type test results of others which are manufactured at his end

12.8.5 Technical specifications of fire trace tube clean agent based fire suppression system.

a) The fire trace tube should be a flexible tube made of special polymer. b) The tube should have OD 6mm and ID 4mm or thereabout. c) The fire trace tube should be fire red in colour (or as directed by engineer) to

indicate it is part of fire protection system. d) The tube should be non – conductive, non- corrosive and flexible. e) The tube should be capable of withstanding pressure up to 20 bars. f) The tube under 12 bar pressure should rupture in case of fire between 5 to 45

sec depending upon the rate of temperature. g) The tube must have approval for using to detect fire from Loss Prevention

Council/UL. h) The tube should be routed inside the panel for detecting fire and over heat. No

drilling, soldering or any other damaging activity will be carried out inside the panel for fixing tube to detect the fire.

i) The Clean Agent gas cylinder should have a valve which should operate automatically, in case the pressure in the Fire trace detection tube reduces due to fire and bursting. The cylinder should have a different valve which is made of virgin brass with the following specifications:

j) The valve should be a Direct/indirect high pressure valve. k) It should operate on sensing the drop in the pressure. l) The valve should hold pressure up to 58 bar.


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m) The valve will have provision for connecting pressure switch, Pressure gauge, filling in adapter.

n) The cylinder will be mounted on automatic weight measurement system. o) Clean agent should be having Ozone Depletion Potential equal to 0 and

Global Warming Potential equal to 1.

12.8.6 System Operation 12.8.6.1 Designed for simple installation, often very near the source of a potential fire, fire trace

is a self-activating detection & suppression system that reliably suppresses fires in few seconds. In the event of fire contacting the fire trace tube, the tube bursts at the hottest point. This leads to a rapid reduction of pressure inside the tubing. This will make the differential high pressure valve fitted on the Clean Agent cylinder open instantaneously and the gas stored in the cylinder will get released through the tube at the burst point into the panel.

12.8.6.2 The drop of pressure in the tube followed by reduction in the weight of the gas in the cylinder due to the discharge will activate an audio-visual alarm unit which will be interfaced / connected with the fire alarm system.

12.8.7 Design Criteria 12.8.7.1 Clean Agent gas based fire trace tube system is proposed for the protection of all the

major control panels. The gas system proposed is a direct / indirect release high-pressure system. The required Clean Agent gas quantity and size of the cylinder is selected based on the volume of the protected panel. The contractor will be required to submit calculations for the type of clean agent based system required for respective electrical panel and installation (in case of total flooding system) to ensure system adequacy.

12.8.8 Main components of the system 12.8.8.1 The main features of the system are:

a) Automatic detection of fire b) Automatic flooding of carbon dioxide Clean Agent (NOVEC1230 or equivalent

filled in cylinder) c) Activation of audio visual alarm unit d) Manual release valve option e) Indication & alarm in main fire alarm & control panel

12.8.8.2 The detection of fire is primarily made by a polymer tube, which can detect the fire anywhere along its length. The tube is highly flexible and can be conveniently routed to cover the various hazard areas in electrical panels.

12.8.8.3 The polymer tube shall be a fixed temperature sensing tube made up of a polymer material to cater to long term leak resistance, flexibility accurate and consistent heat sensitivity and high pressure withstanding capacity. One end of the fire trace tube is connected to the Clean Agent cylinder and the other end to a end of line adaptor through a non return value. The Clean Agent cylinder assembly is mounted on a weight monitoring system.

12.8.8.4 Pressure switch is connected to the end-of-line adaptor, which is electrically connected to an audio visual alarm unit.

12.8.8.5 In the event of fire contacting the fire trace tube, the tube starts melting and burst at the hottest point. This leads to a rapid reduction of pressure inside the tubing. This will make the differential pressure valve fitted on the cylinder open out instantaneously and the stored in the cylinder will get released through the tube at the burst point into the panel. The rupturing temperature shall be between 90 degree C and 110 degree C.


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12.8.9 Accessories

The system shall include but not limited to the following.

a) Fire trace Detection tube b) Indirect high pressure valves c) D/I adapters d) Pressure switches e) Spring top f) Alarm units g) Clean Agent cylinder with clean agent (NOVEC 1230 or equivalent) h) Hardware items i) Pressure switch to sense the drop in pressure. j) Filling in adapter to change the tube. k) Ball valve for closing and releasing. l) The spring top to protect the Fire trace tube at the cylinder end. m) Straight fitting for connecting Fire trace tube in case of need. n) Cross fittings o) T fittings. p) Cross panel fittings with external insulating jacket. q) End of line adapter. r) Non return valves.

All these accessories shall be supplied along with Fire trace tube for installation

All accessories should be supplied from approved manufacturer and deliveries should be accompanied with manufacturer’s test certificate.

12.9 DIESEL ENGINE PUMP & FLOAT SWITCH

12.9.8 General

12.9.1.1 The diesel engine shall be of multicylinder type four stroke cycles with mechanical (airless) injection, cold starting type.

12.9.1.2 The engine shall be designed with regard to ease of maintenance, repair, cleaning and inspection. This will also provide interchange ability of parts.

12.9.1.3 All parts susceptible to temperature changes shall have tolerance for expansion and contraction without resulting in leakage, misalignment of parts or injury to parts.

12.9.9 Starting

12.9.2.1 The engine shall be capable of both automatic and manual start. Generally the engine shall start automatically, but in case of the auto-start system failure the engine shall be capable of manual start. Engine shall be able to start without any preliminary heating of combustion chamber; cranking mechanism shall also be provided. All controls / mechanisms which have to be operated in the starting process shall be within easy reach of the operator. A day oil tank of adequate capacity constructed in M S sheet shall be provided as per manufacturer's guide line.

12.9.2.2 A high torque D.C. motor charged by battery shall initiate automatic start of diesel engine. The battery shall hold adequate retainable charge to provide the starting of the diesel engine. Starting power will be supplied from one set of storage batteries. The battery capacity shall be adequate for ten consecutive starts without recharging with a cold engine under full compression.


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IS: 15105 - 2002

Code of practice for design and installation of fixed automatic sprinkler fire extinguishing systems

CPWD Specification for Wet Riser and Sprinkler System

Compliance with the local fire brigade and the fire enforcing authorities.

12.11.3 Introduction

12.11.3.1 Fire fighting installations are to be operated manually. Delay in undertaking manual operation due to late detection and or response, may result in spread of fire. In automatic sprinkler system, sprinkler heads are provided through out the areas to be protected at specified locations such as roof or ceiling, walls, between racks, below obstructions and fitted with water supply lines permanently charged with water under specified pressure.

12.11.3.2 The sprinklers operate at pre-determined temperature to discharge water over the affected area below and provide an adequate distribution of water to control or extinguish fire. Only those sprinklers which are in the vicinity of fire that is those become sufficiently heated operate. Operation of sprinkler results in flow of water which initiates fire alarm. Thus sprinklers perform two functions i.e. first to detect fire and then to provide an adequate distribution of water to control or extinguish it. Water distribution from ceiling level, cools down the hot gas which forms beneath the ceiling of enclosure in which fire is developing. This will prevent spread of fire to adjoining areas and contain damage to limited area.

12.11.3.3 It should not be assumed that the provision of sprinkler system entirely obviates the need for other means of fighting fire and it is important to consider the fire precaution in the premises as a whole. The system shall be installed only where there is no danger of freezing of water in the pipes at any time. Typical layouts of sprinklers shall be as per CPWD specification part V (Wet Riser and Sprinkler System).

12.11.3.4 Sprinkler “K” Factor shall be 80, However Contractor shall submit all calculations regarding the Finalization of “K” Factor before procurement of Sprinkler.

12.11.4 Classification of occupancies

12.11.4.1 Sprinklers are provided in industrial and non-industrial buildings. The design of sprinkler installation depends upon type of occupancy. Buildings are categorized under the following classes for the purpose of designing the installations in IS 15105.

a) Light hazard class. b) Moderate hazard class. c) High hazard class. d) Storage hazards.


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j) Clean Agent Based flooding system

i. The cubicles shall be protected against fire by means of an ‘automatic fire detector and extinguisher system’, ‘Fire trace’ type or equivalent UL Listed, complete with Clean Agent Container, approved by Chief Controller of Explosives, valve, flexible detection and delivery system in the form of a flexible tube made of special polymer, capable of withstanding a normal pressure of 12 bar and a maximum pressure of 20 bar, suitably routed inside the panel for detection of fire. The Clean Agent container shall be suitably mounted on the panel and shall be capable of flooding the cubicle with Clean Agent, within the shortest response time, not more than 10 seconds after the fire is sensed by the flexible detector tube. The contractor shall submit the complete technical data of the system to the Employer, for approval.

14.17 VARIABLE FREQUENCY DRIVESFOR HVAC SYSTEMS

14.17.1 GENERAL REQUIREMENTS

a) This specification covers complete variable frequency drives (VFDs) designated on the drawing schedules to be variable speed. All standard and optional features shall be included within the VFD.

b) The frequency converter shall not be a general purpose product, but a dedicated HVAC engineered product.

c) The VFD and its options shall be factory mounted and tested as a single unit under full load before dispatch.

d) The VFD shall be tested to UL 508C. The appropriate UL label shall be applied. e) The VFD shall be CE marked and conform to the European Union Electro

Magnetic Compatibility directive. f) The VFD shall be UL listed for a short circuit current rating of 100 kA and labeled

with this rating.

14.17.2 TECHNICAL REQUIREMENTS

a) The VFD shall convert incoming fixed frequency three-phase AC power into an adjustable frequency and voltage for controlling the speed of three-phase AC motors. The motor current shall closely approximate a sine wave. Motor voltage shall be varied with frequency to maintain desired motor magnetization current suitable for the driven load and to eliminate the need for motor derating.

b) When properly sized, the VFD shall allow the motor to produce full rated power at rated motor voltage, current, and speed without using the motor's service factor. VFDs utilizing sine weighted/coded modulation (with or without 3rd harmonic injection) must provide data verifying that the motors will not draw more than full load current during full load and full speed operation.

c) The VFD shall convert incoming fixed frequency three-phase AC power into an adjustable frequency and voltage for controlling the speed of three-phase AC motors. The motor current shall closely approximate a sine wave. Motor voltage shall be varied with frequency to maintain desired motor magnetization current suitable for the driven load and to eliminate the need for motor derating.

d) When properly sized, the VFD shall allow the motor to produce full rated power at rated motor voltage, current, and speed without using the motor's service factor. VFDs utilizing sine weighted/coded modulation (with or without 3rd harmonic injection) must provide data verifying that the motors will not draw more than full load current during full load and full speed operation.

e) The VFD shall include an input full-wave bridge rectifier and maintain a fundamental (displacement) power factor near unity regardless of speed or load.


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16. EOT CRANES &AIR COMPRESSED SYSTEM

16.1 EOT CRANES

16.1.1 Generaldescription

The specification covers the design, manufacture, supply, installation, testing and commissioning of Electric Overhead Travelling (EOT) Cranes to be installed in the following Workshops of N-GN Depot: -

a) Workshop Bay b) Electric Traction Unit (ETU) Bay c) Under floor wheel lathe (UFWL) building d) Inspection Bay

The contractor shall interface with the structural contractor for exact dimensions of long travel, cross travel and height and also during installation, testing and commissioning.

16.1.2 Technical characteristics

The technical Characteristics of the EOT cranes are:

a) The capacity (nominal load), b) Operating speeds in all three three directions at low speed (LS) and high speed

(HS), c) Dimensional characteristics, d) The details of classification in accordance with standards are indicated in

Appendix 1 specify the classification for framework and mechanism. e) The movements of hoisting, traversing and long travelling shall be

operable simultaneously, f) Pendant control and g) Radio remote control

16.1.3 Mechanical part

a) Crane Bridge i. The crane should be rigid, robust and of sturdy construction. The crane

bridge shall comprise of double girders of the plate box type. The connection between crane Girder and End Carriages should be through High strength frictional grip bolts with spacer washer. The inner faces of plate joints containing spacer washers must be given one primer coating with minimum 60 micron layer thickness.

ii. The crane bridge should be carried on end trolleys with double-flanged solid casted wheels of spheroidal graphite impregnated material/C55M.75 forged Steel. The minimum end clearance on each side of the long travel wheels should be 7.5mm. The wheels should be mounted inside the End Carriage and can be conveniently removed, if required. For Underslung type EOT cranes of Inspection bay, flangeless wheels are to be considered for cross and long travel.

iii. Suitable jacking pads should be provided on each end carriage for jacking up the crane while changing track wheels. These jacking pads should not interfere with replacement of long travel track wheels.


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iv. The end carriages should be fitted with suitable safety stops to prevent the crane from falling morethan 25mm in the event of breakage of track wheel, bogie or axle. These safety stops should notinterfere with the removal of track wheels.

v. The diameter of the motorised wheels and the steel grade must be studied to obtain, in all loadconfigurations, perfect braking without any slide. Each end carriage shall be provided with rubberstops adapted to the end buffers.

vi. The EOT Crane Bridge shall be single girder construction having a end carriage at each end, each fitted with rollers running on long travel runways, which will be suspended along the steel structure on the roof.

vii. The bridge (Single) girders should be connected to the end carriages by large gusset plates. Ground tight fit bolts in reamed holes should be used for bolted connections.

viii. The crane bridge should be carried on end trolleys with wheels.The wheels should be mounted on fixed axle or suitable anti-friction spherical roller bearings, should be greases and sealed for life End carriages should be designed to be strong enough to resist all stresses likely to be imposed upon them under varied service conditions, including collision & stops.

ix. End carriages should be fabricated from rolled steel sections or plates, welded together. Under the loaded and unloaded conditions, the crane should not loose balance and tilt.

x. The end carriages should be fitted with suitable safety stops to prevent the crane from falling more than 25mm in the event of breakage of track wheel or axle. These safety stops should not interfere with the removal of wheels. All butt welds on structural members subject to tension should be radiographically tested. All other welds should be subjected to Magnaflux or Dye Penetration Test Connections in general should be as per Clause 26 of IS-800(latest).

xi. Forward and reverse drive shall be provided by means of 2 motor gear reducer-brake units, one at each end. These units shall be mounted on the carriages. The diameter of the motor rollers and the steel grade must be studied to obtain, in all load configurations, perfect braking without any slide. The wheel diameter shall be 150 mm minimum for running on the runways with expansion joints.

b) Trolley frame and hoist i. The trolley frame of all the double girder EOT cranes should be welded

rolled steel section, designed to transmit the load to the bridge rails without undue deflection.

ii. The trolley wheels of all double girder EOT cranes should be double flanged. The Wheel bearings should be either grooved ball bearing or taper roller bearingsor self Aligning Spherical roller bearing as per design specifications.

iii. The top of the trolley frame should be plated (chequered plate) all over at the top, except for opening(s) required for the ropes to pass through. The opening in the trolley frame should besuch as to keep the ropes at a safe distance from any part of the trolley frame or equipment, to prevent damage at all positions of the bottom block.

iv. The trolley should be fitted with substantial safety stops to prevent the trolley from falling more than 25mm in the event of breakage of track wheel, bogie or axle. These safety stops should not interfere with the removal of wheel.


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v. The trolley frame/hoist shall be provided with rubber stops designed to absorb the kinetic energy in the event of a braking fault. Stops shall be designed for a trolley running at high speed under a nominal load. The hoist shall be provided with manual brake release in the event of power failure.

c) Hoist wheels i. The hoist shall be fitted with cylindrical wheels for cross travel. Rubber

stops shall be provided to absorb the kinetic energy in the event of a braking fault.

d) Hook i. The lifting hook shall be secured to a pulley block system with pulleys

designed according to characteristics of the wire ropes. The pulley block system casing shall be provided with two grips. The hook shall be fitted with a safety catch, of spring-loaded type.

ii. The bottom block must be of enclosed design. The rope sheaves of the bottom blocks must be protected with covers, so that the operator’s hand cannot be jammed between the rope sheaves and the rope. The Rope sheaves should be self-adjustable type during Hoisting motion to accommodate the Wire Rope.

e) Rails i. The rails shall be designed with the consideration of building expansion

joints. The bridge rails shall be Square / Rectangular bar of EN8/SNT52 Material or rail section as per IS: 3443. Rail stops welded should be provided to prevent creep in the longitudinal direction. These rails to be directly welded on the Gantry Girders.

ii. Since Under slung cranes of Inspection bay travels on bottom flange of the runway beam, LT Rails are not required for these cranes. However, the contractor should confirm the flange width and thickness of the runway beams to the structural contractor at the stage of building drawings approval.

f) Runways i. The runways shall be designed with the consideration of building

expansion joints. ’I’ sectionGirder shall be installed by structural work contractor. Crane contractor will need to liaison with the designated contractor.

g) Rail wheels i. The rail wheels of all EOT cranes other than that of Inspection bay

should be double-flanged with straight tread. They shall be capable of taking misalignments in span as per VDI 3576/IS:12843:1989, Class IIspecifications. These wheels shall be of spheroidal Graphite impregnated Cast Iron/C55M.75 forged steelmaterial to have minimumhardness of 22 HRC.

ii. The Wheel Blocks to be connected to End Carriage through Pin connection &circlip locking/L Block assembly. Wheels should be with splined hub profileto DIN 5480/keyed as per IS:3177, Residual flange indicator, Dampening element and protected internal bearing arrangement featuring Tapered Roller/Spherical roller bearing. Wheel bearings to be lubricated for life.


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h) Rope drums i. The rope drum shall be designed to withstand the compressive stresses

caused by the wound on rope and the bending stress due to beam action of the drum. The drum shall be designed to take the entire length of the rope in a single layer. Free extra turns shall also be provided. The drum shall be flanged at both ends.

ii. Cranes shall be designed with number of rope falls varying with lifting capacity Upto 15.0 tonnes - 4 fallsin 4/2 reeving i.e. right and left hand groove for true lift.

iii. Rope drums should be with Rope guide made of tough plastic offering smooth rope lead-in by means of hardened pressure rollers mounted on Anti-friction bearings. Inclined pull upto 4o without touching the Rope guide should be possible.

i) Wire ropes i. The Wire rope should be of reputed make and designed according to

FEM 9.661/IS:2266with tensile strength more than 1570 N/mm2. Wire ropes should be with Steel core IWRC.

j) Gearing i. The gearing in all motions should be of suitable case-carburising low

carbon alloy steels and shouldconform to relevant Indian/International standards. They shall generally be in accordance with IS: 4460-1967(or latest) or relevant International standard like DIN. All gears and pinions must be made from forged blanks only. All gears should be hardened and profile ground for longer life and silent operation.

ii. At all stages only helical gears should be used, except in planetary gearboxes, which can be spur type. Overhung or split gears and pinions should not be used. In addition, worm wheels and bevel gearsmust not be used.

k) Gearboxes i. All gearboxes shall be of completely enclosed splash lubricated type. All

gearboxes shall be oil tightand sealed with compound or gasket. All gear shafts shall be supported in bearings mounted in thegearboxes. Gearboxes should be made either of high quality pressure die cast aluminium alloy or of grey cast ironhousing or fabricated stress relieved housing of gear boxes. All gearboxes shall be stress relieved. Adequate radial clearances between the gearbox inner surface and outside diameter of the gears shall be ensured. The facial clearance between the inner surface of the gearbox and the face of the nearest gear/pinions shall be at adequate.

ii. These should be of a modular, integral design. Motors may be either flange-mounted or foot mounted, or a combination of the two. In case of foot mounted motors, split type gearboxes shall also be acceptable. The gearboxes should also be splash lubricated type. Alternatively, VVVF controlled, directly coupled motors can also be offered.

l) Drives i. The wheels of each end carriage should be driven by independent

synchronized drive motors mounted near each end carriage. A separate cross traverse motor should be used for cross traverse drive through a suitable gearbox.


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ii. Alternatively, Two Step Variable voltage variable frequency (VVVF) control of adequate capacity for all the motions of the crane can also be provided. Any alternative design of International standard may also offer VVVF drives of Siemens, ABB, Demag, L&T, Allen Bradley, Vectron shall be used.

m) Brakes i. The hoisting motion shall be provided with fail-safe electro-hydraulic

thruster brakes. Disc brakes are also acceptable. The LT & CT motion may have DC/AC electro-magnetic disc brakes in case of flange mounted motors where integral gearboxes are being offered, to derive the maximum advantage in terms of compactness and weight, but if the motors are not flange-mounted then thrustor brakes should be used.

ii. In case of Thruster Brakes, the maximum braking torque to arrest long travel and cross traverse motions should not less than 100% of full load torque for each brake. For hoist motion, two brakes should be used and the braking torque for each brake should not be less than 125% of full load torque. One of the two hoist brakes shall be applied with a time lag of 3 seconds in relation to the first.

iii. Thruster brakes should also be with Double shoe brakes for each drive. Brakes should be mounted on the input pinion shaft of all gearboxes. The brake shoe should be of hinged type. Brake levers should be forged and hinge pins should be provided with steel bushes at the bearing points. Brake drums should be of forged or cast steel and should be completely machined. Width of brake drum should be about 10mm more than the width of brake shoe on each side.

n) Couplings i. In case of separate drive mechanism, motor shafts for MH/AH shall be

connected to gearbox input extension shaft through flexible gear coupling. For driving the hoist drum gear type flexible coupling shall be used between, the ropes drum and hoist gear box, where the hub should not be integral with the output shaft, so as to avoid replacement of the whole shaft whenever there is wear and tear in the coupling. Solid couplings should not be used.

ii. All couplings shall be of medium carbon steel and shall be designed to suit the maximum torque that can be developed. Hardness of geared portion in the gear coupling shall be more than 250 BHN. Bolted connections shall be easily accessible for inspection and tightening.

o) Rope sheaves i. All sheaves should be of cast/forged steel, they should be identical, with

the exception of the equaliser sheave. The equaliser sheave should be mounted above the trolley floor and should be easily accessible and removable from the trolley floor level.

ii. The equaliser sheave should be arranged to turn and swivel in order to maintain rope alignment under all circumstances. Sheave grooves should be smooth finished for getting increased rope life. The supplier should further ensure that wire ropes are parallel with each other.

p) Bearings i. Ball and roller anti-friction bearings shall be of only reputed makes like

NBC, SKF, FAG, NORMA,NRB, NTN and KOYO. ii. For long and cross traverse wheels, bearings should be either grooved

ball bearing or taper roller bearings or self aligning spherical roller bearings as per design specifications shall be used. Bush bearings should not be used at any location.


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iii. Rated life of ball and roller bearings should not be less than the total life in working hours given in accordance for a particular class of duty.

iv. Independent bearing housings on long shafts are split on the shaft centre line to permit easy removal of the shaft. The bottom surface of all bearing pedestals should be machined, and should bear upon a machined surface.

q) Lifting hook i. The hook shall be secured to a pulley block system with pulleys

designed according to the characteristics of the wire ropes. The pulley block system casing shall be provided with two proper grips.

ii. Standard plain shank type trapezoidal section hooks should be used. These hooks should conform to the relevant Indian Standard Specifications IS: 15560 (latest) / DIN standard 15401.

iii. Hooks should be mounted on grease lubricated anti-friction thrust bearings and a protective skirt should be fitted to prevent rotation of the hook. The hook block should have handle recess to provide improved safety against hand crushing. The bottom block must be of enclosed design. The rope sheaves of the bottom blocks must be protected with covers, so that the operator’s hand cannot be jammed between the rope sheaves and the rope. The Rope sheaves should be self-adjustable type during Hoisting motion to accommodate the Wire Rope. The hook shall be fitted with a safety catch of spring-loaded type.

r) Buffer i. Spring loaded or other suitable buffers should be fitted on the four

corners of the crane and also at the four ends of the bridge girders. Buffers should be rigidly bolted in place, preferably along the centre line of the crane rail or trolley rail as the case may be.

ii. All buffers should have sufficient energy absorbing capacity to stop the bridge or trolley in either direction when travelling at its rated speed.

s) Lubrication i. Individual/Group lubrication, one for each of the end carriage and one for

the trolley platform, should be provided for all grease-lubricated bearings, parts of the hoist, cross traverse and long travel. The grease battery nipples should be located to facilitate regular greasing by the operator with standard equipment.

ii. All gears and bearings enclosed inside gearboxes should be splash lubricated. Bottom blocks and pedestal bearings should have independent greasing points. All lubricating pipe work should be securely fixed and protected from damage, and be accessible throughout.

iii. A lubricating chart should be provided in the manual, indicating all lubrication points, the type of lubricants required and the recommended frequency of lubrication. These details should be repeated, and amplified, in the Maintenance Manual.

t) Maintenance Platform i. Each Double Girder crane shall include one maintenance walkway

installed along the crane box girder structures & one Short platform on other side of the crane. Walkway shall be of a length equal to that of a box structure and the other shall be of a length equal to that of the traversing trolley.


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ii. Crossover from one walkway to the other shall be via a platform, mounted on the hoist trolley. Plating shall be of the anti-skid type. Walkways shall be provided with guardrails designed in accordance with safety standards. Whereas for Under slung crane maintenance platform is not applicable.

16.1.4 Electrical part

The Contractor shall carry out all electrical work from power supply switch to the cranes. The available electrical power supply is 360-440V, 50±3% Hz, three-phase, 4-wires. The equipment and gear to be supplied mainly includes:

i. one latchable isolating switch and MCCB, ii. down shop leads, iii. electric switchboard and control panel , iv. various motors, v. power and control wiring, vi. limit switches, vii. the lighting (2Nos. H.P.M.V Under bridge lamps - 400W)- In case of

double girder cranes only, viii. the control switch

a) Latchable isolating switch

i. It is provided for maintenance purpose and shall impede any movement of the EOT CraneWhen Maintenance work is in progress.

b) Down Shop Leads i. The down shop leads shall be of enclosed type with copper conductors. ii. The conductor system shall be compact in construction finger safe to IP-

23. The conductor material shall be insulated by a high impact gloss finish PVC compound which shall have a step/groove shrouded all along its length for effective moulding of the conductor system.

iii. The conductor section shall be minimum four mtrs. in length to be jointed with moulded joint of the same material as the conductor and these conductors shall be supported by way of a single piece moulding, four pole hanger with single bolt fixing.

iv. The current collector trolley running inside the enclosure should be with spring loaded sliding contacts offering positive contact with copper conductor. The cable from current collector trolley should be totally insulated, fully enclosed and double insulated within the collector arm with a proven performance.

v. Necessary wearing components for maintenance during DLP shall be provided. The Contractor shall size the copper section of the conductor in accordance with the necessary power, and voltage drop requirements with the approval of the Employer.

vi. The bays are provided with power supply to the down shop leads with four sets of power-on indicator lights. The power supply for crane will be provided at workshop working level through TPN MCCB.

vii. The cabling from TPN MCCB to down shop leads shall be in crane scope of work. Down shop leadsshall be connected to power supply at single / multiple points, as per the design requirements.

c) Switchboards and gear i. Control gear shall be mounted in one or more switchboards depending

on the type of EOT Crane. The protection index shall be IP 54.


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ii. The trip circuit of the circuit breaker shall be designed such that it should prevent the circuit breaker from being enclosed when main contactor of any of the motions has failed to open, although the corresponding controller has been brought to OFF position. Suitable protective features to trip the circuit breaker with the operation of limit switches and emergency push buttons shall also be provided.

iii. For protection of each drives, motor against over loads adjustable inverse time lag manually reset electro-magnetic, type relays shall be provided for each motor. Alternatively, electronic type relays shall be acceptable. These relays shall be mounted in respective contactor panels and shall be set to trip the circuit of motion being controlled when current exceeds 200% of normal value for more than 10 seconds. Each motor feeder shall be protected with no volt trip device & short circuit, and with instantaneous trip current sensitive type single phasing cum phase reversal preventor. Isolating switches fitted with protection shall be provided for the following branch circuits:

Lighting and hand lamp socket outlets

Control circuit. iv. Each control circuit branch to every contactor panel shall be provided

with facility for isolation andprotection against short circuits and sustained high overloads by means of appropriately ratedminiature circuit breaker.

v. The electrical switchboard shall be key locked. The door shall include a 3-position switch provided for no-load testing of control circuits and shall be connected to the cabinet via an earth braid.

vi. All terminals and wiring shall be marked in accordance with the electrical diagram.

d) Control Pendant The controls shall be given from a push-button control pedant, which shall be:

i. sealed, insulated to IP65 and unbreakable, ii. be capable of moving along the EOT Crane independently from the

movement direction of the hook, be suspended with a stainless steel wire

iii. The pendant control shall be capable of withstanding rough handling without being damaged. The cover shall be firmly secured & made out of Nylon fibre.

iv. The function of the push buttons shall be identified by means of engraved labels (refer to appendix 3). The various types of push buttons used are as follows:-

v. Safety means shall be provided to prevent inadvertent operation from floor while maintenance work is being carried out on the crane.

vi. Adequate guards shall be provided to prevent accidental contact of pendant ropes or holding wire rope/chain with cross traverse.

vii. released, not held, for all movements and for the hooters, viii. held for switching on and lighting, ix. Turn to unlock for the emergency stopping.

e) Radio Remote Control

i. The wireless control facility shall incorporate control of movements in all directions, with speedsidentical to those provided for the pendent control.

ii. The facilities to be provided shall incorporate but need not to be limited to the operations featureslisted below:

Emergency stop button


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Emergency alarm button

Normal ON/OFF button

Low/High speed button

Directional movement control buttons

Radio/Pendent control selection buttons

iii. Overall, weight of remote control hand set (transmitter) not to exceed 0.5 kgs. Approx. The system shall be so designed that in the event of mal-function it should be possible forthe user to switch over to pendent control through suitable by pass switch facility. The general scope of supply Radio Remote Control equipment shall be as follows:

1 no. Transmitter-Push button type

1 no. receiver

1 no. Antenna and cable

Two sets of Alkaline battery size AA iv. The transmitter shall be provided with a shoulder belt and shall be in

IP65 enclosed. The system shall be microprocessor based and shall have watchdog circuit. The range of operation should be 40 meters minimum. The crane supplier shall be responsible for commissioning the system.

v. Tenderer shall ensure adequate supply of spares and availability of maintenance spares support within the country.

vi. Equipment supplied should be certified by internationally recognised inspection agency.

f) Contactors i. All contactors shall be of AC 4 Class of duty with rating sufficiently

higher than the full load currentof the respective motors at the specified duty cycle. The directional contactors of all motions shall be suitably interlocked for correct sequence of operation.

ii. Electrical & mechanical life of the contactors shall be indicated. For AC 4 Class of duty Electrical life shall be minimum 2, 00,000 cycles of operations. The contactors shall have high contact reliability with preferably double break parallel bridge contact and facility of time saving termination. All contactors shall be of Telemechanique, ABB, Siemens, L&T and Cutler Hammer make. Test certificate of the manufacturers shall be submitted in support of life and rating of the contactors.

g) Limit switches i. All hoist motions shall be provided with limit switches to prevent crane

from over hoisting and overlowering. Limitation of the motions at the upper and lower Hook positions should be effected byGeared Limit switch, provided with 4 contacts. The design should be such that the limits can be set as per the requirements during crane installation at site.

ii. Two stages Limit switch for hoist cross and long travel motion shall be supplied installed and wired by the manufacturer.

h) Control panel i. Variable voltage variable frequency control (VVVF) if considered, should

be of adequate capacity for all the motions of the crane shall be provided. VVVF drive of Siemens, ABB, L&T,Allen Bradleymake shall be used. Independent AC variable frequency control for main hoist, aux. Hoist, CT& LTshall be used by using independent variable voltage variable frequency drives. However, common controller for both the motors of LT may be used.


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ii. The components inside the Control panel should be mounted in such a way that all the components are easily accessible. The clearance between cable tray and each component should be minimum 25mm.

iii. GA drawing of control panel should indicate internal layout of the components. Instrument cutoutsshould be exact and without burrs or unevenness. Location of outgoing terminals should be minimum100mm above the gland plate. Gland plate should be sufficient to accommodate outgoing cables.

iv. Proper stiffeners should be provided to avoid buckling and unevenness. Control panel should have selfadhesivetype gazetting arrangement. Control panel box and base plate should have identificationlabel bearing details of project, electrical drawing number along with revision number.

v. Minimum steel thicknesses to be used are:

Base plate –2.0 mm

Front Facia –2.0 mm

Other sides –2.0 mm/1.6mm

Frame –2.0 mm vi. All power and auxiliary contactors, individual overload relay shall be

mounted in sheet steel cubicalwith lockable-hinged doors. The door hinges shall be of such type that during the repair works inside the panel the entire door can be lifted out and placed away enabling better access inside the panel. A common panel with separate compartment for each motion shall be acceptable. Interiors of panel shall be dust and vermin proof. Panels shall be front wired with readily accessible terminal blocks for making connections in the external equipment. Panels shall be pre-wired into terminal strip. Single core, copper conductor shall be used for control circuit wiring in the panel.

vii. All the equipment’s shall be so mounted in panel as to enable its easy removal/replacement from the front.

viii. All equipment’s inside the panel shall have permanent identification labels in accordance with circuit diagram as also the power and control terminals. Terminal blocks shall be of robust and of such construction as to preclude possibility of cable connections getting loose during vibration on crane. Contactor panels shall be well braced to the crane structure and each panel shall be provided with adequate number of lifting lugs. Updated and current Indian Standard specifications and codes of practice will apply to the equipment and the work. Wherever appropriate Indian standards are not available, relevant British and/or IEC standards shall be applicable.

i) Interlocking i. Suitable key locking arrangement shall be incorporated to ensure that 25

kV supply on the particular track has been switched off before working the EOT Crane. Also the arrangement Shall be made to ensure that 25 kV OHE cannot be switched on unless the crane has been placed in the extreme position. (Crane is parked at the one end of bay with hook in maximum position and cross travel also at one end) and power supply to the crane switched off.


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ii. Suitable electrical circuitry interlocking to be provided along with mechanical interlocking operated with the help of a key. The crane cannot be operated till the key is inserted. The key should not be released until the crane is parked in extreme position (as mentioned above) and power to crane is switched off. The successful bidder is required to obtain approval from the engineer in charge for detail electrical circuit diagram & mechanical locking arrangement for the interlocking system.

j) Cabling i. Control wiring and signal wiring should be separate as far as possible.

Phase control wiring should be 1.5 Sq. mm gray while neutral wiring should be black in colour. Power wiring should be minimum 2.5 Sq. mm size and R, Y, B colour coated for R, Y, B phases. Maximum loading of PVC cable should be 60% of cable tray capacity. Wire bends should not be sharp to damage the conductors.

ii. Proper support for outgoing cables should be provided with proper Ferruling. Wiring more than 5 cm length should not be exposed. Wiring should be properly bunched or spiralled. Wiring should run parallel only, no crossing of two wires is permitted. Common point of star connected current transformers should be earthed.

iii. Where ever required, a separate instrument earth should be provided, which is separate from main earth. Earthing can be done as per cable size and application requirement, also creepage distance could be decided as per IEC standard / switch gear manufacturer requirement. Control and power links between the EOTCraneBridge and the hoist are made of flat cable, laid as a garland, with appropriate carriers.

iv. Any cables exiting from a steel tube must be protected by an insulating end fitting. Power cable shall be of FRLSH XLPE type. Labels of permanent nature shall be provided on supports of all switches, fuses, contactors, relays etc, to facilitate identification of circuits and replacement. All panels, controllers, resistors etc. shall be properly marked for each motion. All power control cable, lighting and other cables shall be ferruled at both end as per cables numbers indicated in the supplier’s drawing. All equipment terminals shall also to be marked likewise.

k) Emergency stop push button i. A mushroom head type of push button shall be provided on pendent so

that the main incoming circuit breaker can be tripped under any emergency conditions by pressing the operating head. A pilot lamp incorporated in the control circuit shall glow when any of the switches is operated.

l) Motors i. Motors shall be of the asynchronous or squirrel cage type with a built-in

electromechanical ormagnetic brake. The ingress protection level of motors shall be IP55.

ii. Motor selection for lifting andtravel applications should be according to rule FEM 9.683/IS:325. The motors must be suitable for theoperating conditions and ensure safe operation under related conditions. All motors shall haveinsulation class B. The criteria for motor selection should be as below:

Required power – the thermal power is also included in these required powers.

Maximum rated torque and maximum acceleration torque.


Page | 484R

Cyclic duration factor.

No. of cycles / hour.

Type of control (type of braking)

Speed regulation.

Degree of protection.

Ambient Temperature. iii. This brake shall be applied automatically in case of power failure during

lifting or travel.

m) Lighting i. For all double girders EOT cranes other than that of Inspection bay

should have high bay light fitting with metal halide lamps of 400 W and associated control gear shall be securely fitted at two different locations below the crane platform. These units shall be supplied with 230 V via a contactor controlled from a switch on the pushbutton pendant. A switch for the tubes shall be provided on the walkway.

ii. Tool Receptacle shall be provided on crane platform – 2 Nos. sockets (1 No. – Single phase, 20Amps and 1No. – Three Phase, 32 Amps) to provide power supply for maintenance purpose.

n) Identification of circuit cables i. Labels of permanent nature / ferruling shall be provided on supports of

all switches, fuses, contactors, relays etc, to facilitate identification of circuits and replacement. All panels, controllers, resistors etc. shall be properly marked for each motion. All power control cable,lighting and other cables shall be ferruled at both end as per cables numbers indicated in the supplier’s drawing. All equipment terminals shall also to be marked likewise.

o) Earthing i. Earthing to the crane shall be effected through track rails of crane

structure. As such, all the electrical equipments mounted on crane shall be connected to the crane structure by means of earthing links. The crane structure in turn shall be made electrically continuous by providing jumpers over bolted joints. Equipments fed by flexible cables shall be earthed by means of spare core provided in the flexible cable.

16.1.5 Protectionandsafety

In addition to the various recommendations enumerated in the previous paragraphs, the Contractor shall include the protection systems scheduled in the standards and consider the following recommendations:

i. all metal parts shall be earthed, ii. all movements (lifting, forwards/ reverse, traversing) shall include limit

switches, The lifting movement shall be fitted with:

an over travel switch cutting off the power circuit which may be reset from the crane walkway,

a load limiter, which cuts off the power supply to all movements except lowering

abuzzer to warn the persons working near the crane operating zone when crane is in working condition.

16.1.6 Standards


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The entire supply shall satisfy the requirements of Indian Standards mentioned below or equivalent International/European/British standards/ DIN Standards and regulations in force:


IS 3177 :1999 Indian Standard Code of practice for EOT Cranes

IS 807 : 1976

Indian Standard code of practice for

design, manufacture, erection and

testing (structural portion) of cranes

and hoists

IS 3938 : 1979 Indian Standard code for electric wire

rope hoists

IS 2266 : 1976 wire ropes

IS 4460: 1967 Gears

BS 466

specification for power driven overhead

travelling cranes, semi-goliath and

goliath cranes for general use

BS 2573 Part 1 & 2 - Rules for design of cranes

BS 5395 Stairs, ladders and walkways

DIN 15018 Crane classification

DIN 15401 Lifting hooks for lifting appliances

FEM 9.683 selection of lifting and travel motors

FEM 9.661 Rules for design of series lifting equipment

DIN 15020 Principles relating to Rope Drives

16.1.7 Finish

a) Paintwork i. Preparatory works prior to painting:

Outsides: brushing, degreasing, grit blasting. Copper Slag blasting to the second quality finish (Swedish Standard grade SA 2.5) and blowing clean.

Hollow bodies: these areas shall be treated prior to assembly by applying a coat of anti- corrosion paint.

The thickness of this coat after drying shall not be less than 180 microns.

ii. Painting of External parts and ancillary parts shall receive:

Type: Primer cum finish paint

Make: Hempel fast dry 45410/ sigma cover 350/ intergard 345

Nos. of coat: 2Nos.

Gloss Level: Semi Gloss (40-50%)

Total DFT: 125 Micron

The paints to be applied on walkways, access ladders and handrails shall have a good abrasiveresistance. All equipment shall be painted golden yellow (RAL 1004). On site, the Contractor shall touch-up paintwork which may be made necessary by equipmentinstallation.

b) Unpainted parts

All friction parts or parts which mast remain polished shall be coated to protect them from corrosion until equipment start-up.


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c) Identification

i. Two identification plates shall be fixed to each crane on either side of the main structure. These Identification plates shall indicate:

Safe working load in Tonnes

the year of manufacture,

the unit item number. ii. The Constructor’s identification plate may be affixed.

All nuts, bolts, washers etc shall be GI except where provided otherwise.

16.1.8 Checks and tests

a) In-manufacturer’s-plant i. During manufacture, and prior to delivery, verifications and checks shall

be carried out in order toensure that the supply is in accordance with the technical specification and with the approved design documents.

ii. All quality checks shall be carried out, as required, during manufacture on the Contractors or on the sub-contractorspremises.

iii. The Contractor shall provide for quality check of supplies on his sub-contractors premises prior to delivery of these supplies to his workshops.

iv. Operation of safety and protection devices shall also be checked. The Contractor shall also carry out the following practical tests:

the various operating configurations with no load,

insulation,

proper operation of dynamic tests including:

verification of speeds,

Crane behaviour during start-up, acceleration, deceleration and braking.

In particular, the efficiency of the brakes, limit switches, load limiters, good collection of power and the various currents, heating of electrical and mechanical devices, etc. shall be checked.

These tests shall be carried out only on forward, reverse and lifting movements. Traversing movements shall be tested on the site.

b) At-Site i. After assembly and erection of the EOT Cranes at site, all tests

mentioned in this chapter shall be carried out in presence of a representative of the Employer.

ii. In addition, the tests pertaining to the traversing movement and the verification of the anti-collision devices shall be carried out after assembly on the site alongwith the load test at 100% loading and over load test at 125% loading for determining crane Girder deflection. After these tests, the load limiter shall be adjusted to its normal value and tested. The Main contractor shall be responsible for arranging loads at site for load testing.

16.1.9 Training

The contractor shall provide following training for operation and maintenance staff for EOT

working days training for four staff on operation of crane


Page | 487R

Working days training for four staff for maintenance of the crane. Two sets training material shall be provided to the trainees.

16.1.10 Documents tobeprovided

All documents shall be provided in English.

a) In the Bid

The Contractor shall provide, for each overhead travelling crane:

i. a detailed technical note including a description of the equipment, main dimensions and total electrical power required,

ii. photographs or sketches of similar equipment with a list of references, iii. general drawings substantiating the good installation of the equipment, iv. references of the sub-contractors, v. the various speeds for each of the movements, vi. the standards and specifications that the main components used in the

installation satisfy.

b) For Execution of Work

Prior to manufacture of equipment, the Contractor shall send the following documents for approval:

i. detailed dimensional drawing of the elements of the machine, and dimensions of the cabinet,

ii. general, detailed assembly drawings and drawings of mechanical parts, iii. a note, indicating that the provisions in the civil work are

compatible with the equipment offered, iv. characteristics of the drum and the pulley block system, v. detailed calculation notes, vi. references and characteristics of the main standard parts, vii. detailed electrical diagram for troubleshooting including cable index, viii. detailed electrical diagram for troubleshooting including cable index, ix. electrical power required at each workstation, including switchboard

equipment breakdown, x. list of basic spare parts to be kept in stock for repairs, during DLP, xi. documentation, drawings, notes and references of sub-contractors, xii. installation and commissioning procedure, xiii. Schedule of work and completion period.

c) At Completion of Work

The Contractor shall provide the entire documentation, upto date:

i. the general nomenclature of the supply including sub-contractors, ii. mechanicaldrawingsandelectricaldiagrams requiredformaintenanceand

troubleshooting of the machine, iii. illustrated lists of mechanical and electrical parts itemised in accordance

with the diagrams and drawings mentioned above and including the addresses of the various contractors,


Page | 488R

iv. Two sets of maintenance and adjustment manual with summary of circuits and functions and among other information, a lubrication manual including location of lubrication points, type of lubricants, frequencies and quantities,

v. Two sets of an operating manual including start up and user’s instructions,

vi. complete documentation on motors, vii. test reports or certificates for conformity of the equipment, viii. list of recommended spare parts for two years requirements.

16.1.11 Commissioning

After Completion of work, the crane shall be commissioned and all the commissioning tests shall be jointly carried out by Contractor and approved by Engineer Contractor and approved by The Engineer. All the equipment, tools & tackles and measuring instruments shall be arranged by the contractor. All consumables shall be arranged by The Contractor.

16.1.12 EOT crane for inspection bay general description and scope of supply

The specification covers the design, manufacture, supply, installation, testing and commissioning of Electric Overhead Travelling Cranes to be installed for handling of Rolling stock roof-mounted A/c units, pantograph and Vacuum circuit breaker (VCB) in the Inspection Bay of Depot. The Inspection Bay is a covered shed provided with 25 kV Over Head Electrification (OHE) contact wire system at a height of about 5.4 m. All the 4 lines intwo bays shall be provided with EOT Cranes. I shaped girders supported at the roof truss throughoutthe length of Inspection shed shall be provided by the civil contactor. The E&M contractor supplying the cranes shall have to liaison with civil contractor/structural contractor for furnishing the requirement of steel structure. The Contractor shall supply and install the EOT cranes complete on the steel structure. The down shop leads for the power supply shall be suitably fixed on the steel girders by the crane contractor. The scope of supply shall cover and down shop leads and all equipment and accessories that are required to make the EOT Crane fully functional (this includes the rails for long travel, arrangement of DG sets/ power backup for initial testing & commissioning by the main contractor) and the cost of such accessories shall be included in the basic price of the EOT Crane. First fill of the oil/grease with sufficient quantity of lubricants for commissioning of the EOT Cranes and one set of tools shall

APPENDIX 1

FOR EOT CRANE OF 5T IN WORKSHOP GREATER NOIDA DEPOT MECHANICAL CHARACTERISTICS

Crane Ref. No.

Location Capacity

(Ton)

Classification Speeds, in m/min

Frame work

Mechanism Lifting Traversing Travelling

Group FEM Rating/ IS:3177 M5

LS(m/min)

HS(m/min)

LS(m/min)

HS(m/min)

LS(m/min)

HS(m/min)

EOT 1 Workshop bay 15/2 3 2m/M5 0.5/ 0.5

5/12.5 2 20 4 40

EOT 2 Workshop bay (Common bay)

5 3 2m/M5 0.5 12.5 2 20 4 40

EOT 3 Inspection bay I 1.5 3 2m/M5 0.5 12.5 5 30 2 20

EOT 4 Pit wheel Lathe

Building 5 3 2m/M5 0.5 12.5 2 20 2 20


Page | 489R

LS: Low Speed, HS: High Speed

DIMENSIONAL CHARACTERISTICS

Crane Reference Number

Capacity (Ton)

Span of overhead travelling crane (m)

(Approximately)

Clearance under hook

(m)

Hook level in “down” position

(0.00-FFL)

Level of running way (m)

Approximately length of running way

(m)

Approximately space from running way

axis to face of adjacent column

(m) EOT 1 15/2 18.48 5.10 -1.20 5.40 135 0.3 EOT 2 5 18.48 5.10 -1.20 5.40 135 0.3 EOT 3 1.5 3.00 5.80 -2.13 7.00 99 0.3 EOT 4 5 10.16 5.10 -1.05 5.40 22.5 0.3

Note: The contractor has to submit the design calculation for the approval of DMRC before placing the procurement order.

Classificationofliftingdevices


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NOTE:This classification must be defined according to European Union of handling Rules (F.E.M.)/IS:3177-1999.

Classification of Frame works

a) TABLE I: LOAD STATUS

LOAD STATUS DEFINITION RELEVANT SPECTRUM

0 (Very light)

Device which lifts its rated load only exceptionally

and which usually lifts very light loads only.

p = 0

1 (light)

Device which only seldom lifts its rated load and

which usually lifts loads equal

to about one-third its rated load.

p = 1/3

2 (average)

Device which rather frequently lifts its rated load and which usually lifts loads Between one-third and two-

thirds its rated load.

p = 2/3

3 (heavy)

Device regularly loaded close to its rated load.

p = 1

b) TABLE II: CLASS OF USE

CLASS OFUSE FREQUENCY OF USE OF THE LIFTING MOTION

CONVENTIONAL NUMBER OFLIFTING CYCLES

A Occasional, non-regular use,

followed by extended idle periods

6.3 x 104

B Regular use in intermittent

duty 2 x 105

C Regular use in intensive duty 6.3 x 105

D Use in severe intensive duty,

for instance over several shifts

2 x 106

Note: The above factors in the table I,II can alternatively be as per IS:3177& IS:807.


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c) TABLE III: GROUP

(Deduced from tables I and II above)

Status of loads or strain status for one element

Class of use and conventional number of lifting cycles or of strain cycles for one element

A

6.3x104

B

2x105

C

6.3X105

D

2x106

0 (very light) p = 0

1 2 3 4

1 (light) p = 1/3

2 3 4 5

2 (average) p = 2/3

3 4 5 6

3 (heavy) p = 1 4 5 6 6

Classificationofmechanisms

a) TABLE A: STRAINING STATUS

STRAININGSTATUS DEFINITION

1 (p = 0)

Mechanisms or elements thereof which aresubjected onlyExceptionally to their maximum

strain and which are usually subjected to markedly lower strains. 2

(p = 1/3) Mechanisms or elements thereof which are

subjected to low,average and maximum strains for markedly equal periods. 3

(p = 2/3) Mechanisms or elements thereof which are

mostly subjected tostrains close to maximum.

b) TABLE B: OPERATING CLASS

Operating class Assumed average daily operating time, in hours

Total theoretical time of operation , in hours

V 0.25 < 0.5 < 800 V 0.5 > 0.5 and < 1 1,600 V 1 > 1 and < 2 3,200 V 2 > 2 and < 4 6,300 V 3 > 4 and < 8 12,500 V 4 > 8 and < 16 25,000 V 5 > 16 50,000


Page | 492R

c) TABLE C: GROUP

(Deduced from tables A and B above)

The following data shall also be marked externally on the circuit-breaker.Manufacturer name and trade mark.ype designation or serial number.tilization category.ated operational voltage(s) Ue.Value (or range) of the rated frequency (for example 50 Hz).Rated service short circuit withstand capacity (Ics) at the rated corresponding voltage Ue.

Rated ultimate short circuit breaking capacity (Icu) at the rated corresponding voltage Ue.rated short-time withstand current (Icw), and associated short-time delay, for utilization category B.line and load terminals, unless their connection is immaterial.

Straining status

Operating classes

V 0.25 V 0.5 V 1 V 2 V 3 V 4 V 5

1 1mB 1mB 1mB 1mA 2m 3m 4m

2 1mB 1mB 1mA 2m 3m 4m 5m

3 1mB 1mA 2m 3m 4m 5m 5m


Page | 493R

16.1.13 DATA SHEET FOR THE EOT CRANE

S. No. Description Remarks

01. Total weight of crane, including electrical equipment

02. Safe working load in tonnes

03.

Trolley

Wheel span

Wheel base

04.

Bridge

Wheel span

Wheel base

05. Detailed wheel diameter calculation for long travel and cross traverse wheels

6.

Electrical details of

Motors

Manufacturer, type & enclosure

Rating, output in kw

AC voltage across phases

Speed in RPM

Class of stator insulation

rame size

Starting current, normal full load current

Max. starts per hour for which motor is suitable

Class of duty (S1, S2, S3, S4 etc.)

Suitable for voltage range

Motor horse power calculation

efficiency & power factor at ¾ load & ½ load

Type of drive (Direct gear drive etc.)

Control gear

Rating of AC4 Contactors with min. 2,00,000 cycles of operation

Protections for the motor like; Short circuit

by HRC fuses, no volt & over volt trip, instantaneous trip current sensitive single phase preventor


Page | 494R

07.

Make & type of the following:

Motors

Cables

Contactors

Time relays

Limit switches

Overload relays

Moulded case circuit breakers

Resistors

Control panels

Shrouded DSL conductors & collectors

Thrusters brakes

Electrical isolators

Variable voltage variable frequency drive

08.

Bidder to confirm following features of AC Drive: Inverter offered should be suitable forcrane application for all motion Drive sizing should be done accurately considering type ofpanel environment conditions etc. the drive should be capable of taking 125% overload for one minute at the slow speed of 20% and at full speed as per crane IS standard. Inverter offered should have slip compensation feature in both UP/ Down motions (even during regeneration) Inverter offered should be with built in modes of control strategies Viz. standard V/F, Open loop vector & flux vector so that the same inverter can be used for all motions selecting the control mode. Inverter offered should be provided with accurate brake coordination signals

Note:ThebiddershallprovidedataofeachtypeofEOTcraneinseparatesheets.

16.2 AIR COMPRESSOR FOR WORSHOP – 170 CFM

16.2.1 General Description

Air compressors are required for production of compressed air for the Workshop at Depot. The specification covers the design, manufacture, supply, installation, testing and commissioning of Air Compressors. The compressor shall have high efficiency & low power consumption. The supply shall comprise stationary type, electric motor driven, self-lubricating Rotary Screw type complete with suction filter, air/oil separator, air cooled after cooler, oil filter, oil cooler integrated refrigerated air drier & moisture trap, microprocessor based control panel all housed in silenced package provided on anti-vibration mounts. The supply shall include air reservoirs (01nos), air filters, pipes and pipe couplings, electric controls, and all other accessories to make the equipment & installation fully functional. A set of service tools and special tools shall also be supplied along with compressor. The compressor and installations shall be designed considering ease of maintenance and requiring minimum service in order to optimise down time.


Page | 495R

16.2.2 Technical Characteristics

Technical Particulars Each compressor shall be capable of giving an output of 170 CFM of air at an operating pressure of10 Kg/cm2.Singlecompressors shall work together in the system with full synchronisation and redundancy. The compressors shall be provided with capacity control system to reduce the load on motors at the time of start and to give reduced output to match with the requirements. Arrangement shall also be incorporated for automatic shutdowns in the event of prolonged off-load operation. The compressor units shall be equipped with condensate separator with both auto & manual drain. The compressors shall be driven by adequate capacity TEFC squirrel cage type 3-phase Induction motors (30 kw), having insulation class F, through preferably a permanent alignment geared drive (any better arrangement shall be explained with advantages in the offer). Star-delta type starter with contactor relays and single-phase prevention shall be used. The ingress protection of all motors shall be IP55. Pre wired connections between the motor and starter should be provided. The compressor shall be suitable for continuous and heavy-duty operation. The contractor shall submit the compressor drive installed motor power (in kW & hp). The manufacturer shall use all modern techniques of vibro-acoustics optimisation for extremely low noise and vibration level. The compressors permissible noise level measured at a distance of 1m from the acoustic enclosure shall be less than 70 dbA. The compressor shall be provided with integrated oil removal filter with filtration level of 0.01ppm. The temperature of air leaving the compressor unit shall not be more than 10ºC above the ambient. The contractor shall submit equipment and piping layout drawing (preferably a 3 dimensional drawing) considering space available in the compressor room & reservoirs outside. Depot layout drawing with compressor room marked is enclosed.


All the equipment of the compressor package shall be mounted on a common base frame for foundationless installation. The base frame shall be made sturdy with facility for mobile crane & fork lifting arrangement. A twin element suction air filter on the intake side of the compressor, a compressed air-oil separator, oil cooler and a non-metallic cartridge type oil filter shall be provided.

a) Suction filters i. The dust filter (pre-filter) shall be capable of filtration up to 1 micron

absolute with 99.5 % efficiency for solid particles. Heavy-duty dry type intake air filter, conveniently located for quick and easy replacement with cyclonic separation and arrangement for pre-filter separation shall be provided.

b) Compressor i. Single stage self-lubricated rotary screw compressor having high

efficiency and reliability shall be provided. It shall be equipped with: -

The air intake valve should be maintenance free pneumatically controlled vacuum controlled without spring Intake valve assembly for Load/ No load regulation.

Non-return valve at element discharge.

Automatic oil stop valve

vacuum gauge adopter


Page | 496R

c) Air & Oil separator i. Compressor shall have air and oil separator which shall consist of

vertical design welded vessel that secure excellent oil perspiration, oil separator element to provide clean quality air by separating oil and the carry over is less than 1.5 ppm along with minimum pressure valve, Safety valve, Delta Pressure sensor before oil separator and oil draining arrangement.

d) Air after cooler & Oil cooler i. The air after-cooler should be aluminium block type to cool the

compressed air and shall be high efficiency air cooled after-cooler and oil cooler. A suitable capacity fan cooling arrangement shall be provided.

ii. Full flow type oil filter with thermostatic bypass valve (the TEV should be stainless steel or cast iron and it may be integrated in the oil filter housing to enable the compressor to reach its temperature immediately after start up ) to avoid condensation and Oil restrictor to regulate oil flow shall also be provided. The water separator unit should be integrated in the aftercooler and should be capable of removing 100% condensate without any loss of air.

e) Capacity regulation system i. The compressor shall be equipped with transducers to set discharge air

pressure to desired limits/pressure band, Load/No load system with automatic start/stop through solenoid control valves & timer, moisture separation trap in the regulating line for separation of water and control tubing.

f) Compressor control i. Each compressor shall be provided with advance microprocessor based

graphical 3 to 5 inch high definition colour display with clear pictograph and self-explanatory navigation with real time operating system with ergonomic user interface .The control shall have following features:-

Maximise energy efficiency by controlling the main drive motor by regulating system pressure within predefined pressure band (+/- 0.1 bar band).

Simultaneous multiple compressor control from any of the compressor control.

Continuous monitoring of critical parameters including service and warning indications, errordetection, compressor shutdown and maintenance scheduling.

Using an ambient sensor to monitor the required dew point suppression, the control shall start and stop the dryer when the compressor has stopped thereby minimising energy use andprotecting the air system from corrosion due to moisture.

The compressor shall draw no starting current peaks and shall have high power factor.

ii. The general equipment shall include the following:

Automatic (timer controlled) start-up and shutdown,

Auto start facility after power failure,

load indicator & an additional gauge (pressure gauge),

emergency shutdown button, iii. Identification plate with the following information:

Type, capacity and serial number of compressor,

Type, capacity and serial number of motor.


Page | 497R

iv. All electrical and electronic control, regulation and other items shall be contained in a dust-tight cabinet, part of the compressor package. It shall be designed such that all parts are easily accessible for inspections, repairs and general maintenance.

g) Air dryer i. The compressor shall have an integrated air cooled type refrigerant

dryer in the downstream of the compressor within the same canopy & the design shall make the installation more compact. The air drier shall stop working atomically when the compressor stops functioning.

ii. The output quality of air shall be 3ºC-7ºC at dew point and pressure drop across the dryer should not be more than 0.2 bar-0.3 bar. To ensure optimum removal of the water contained in the air it shall have main design features like:-

Compact size air to air & air to refrigerant heat exchangers for maximum heat transfer and minimal pressure drop.

Hermetically sealed refrigerant compressor. Type of Refrigerant used shall be explained with advantages in the offer.

Shall be conceived as a sliding module

Integrated water separator with automatic/manual drain.

Digital display of lowest air temperature on the panel.

Large capacity condensers to convert refrigerant gas in to liquid for efficient cooling these dryers shall be installed on a vibration-damped base.

A pre-filter shall be fitted on the intake side of the dryer and final filter on the outlet side of the dryerat the downstream of the dryer, an oil trap filter (final filter) retaining oil aerosols shall be installed. Its efficiency shall be 99.5% at 0.1 micron.

This efficiency test should be carried out at manufacturer site in presence of employer’s representative. The filter element shall be made of thermo compressed glass micro fibers or equally effective other material and the supplier shall submit comparative advantages. The output pressure sensor must be installed at the output of the compressor after the refrigerated air dryer and shows the pressure after considering the losses among the dryer.

h) Reservoir i. The Contractor shall install 1500 litres reservoirs in an area downstream

of the dryers. The reservoirs shall be suitable for service pressure of 10 Kg/cm2 and shall have an inspection hole at the top as well as an automatic condensing bleeder. The inlet and outlet pipe flanges shall be designed for the full rated output of two compressors working separately. These shall be equipped with a 0 to 15 Kg/cm2 pressure gauge as well as a safety valve. One isolation valve should be provided at inlet of each receiver tank to isolate the reservoir tank from each other.

ii. Moisture trap unit should be provided at the bottom of the reservoir. There shall be no air loss due to condensate drain.

i) Pipe connection i. Stainless steel, quarter-turn ball type valves of sufficient dimensions

shall be provided. Compressor reservoir connection shall enable flexibility in connecting the compressors to the reservoirs. A schematic diagram shall be provided for approval before execution.


Page | 498R

ii. A valve shall be provided to enable isolation of each compressor from airline. One isolation cock between each workshop line, inspection line, interior cleaning & Pit wheel lathe building should be provided. Condensate drain taps unit are required in each of the lines.

16.2.4 Electrical installation

Power supply: 360-440V, 50 Hz + 3%, three-phase, 4 wires

a) Electrical switchboard/control cabinet shall comprise of: i. A three-pole main isolating switch fitted with HRC fuses or equivalent

isolating device. ii. A main circuit breaker, Star delta starter for each compressor motor or

equivalent soft starter, with over loadprotection for both main and fan motor.

iii. Contactors for other appliances, iv. Phase sequence relay to avoid operation of the motor in reverse

direction, v. Thermal/magnetic protection for each appliance, vi. Single phasing protection vii. The location of this cabinet shall be proposed according to its

dimensions and theelectrical power supply distribution point.

It shall comply with the regulations in force and its front panel shall have indication lamps (one orange lamp per phase). The degree of protection of the cabinet shall be IP 55 and ventilation shall be through louvers. The electrical supply to both compressors shall be given at one point.

All terminal boards and power supply cables shall be marked in accordance with the electrical schematic diagrams. The functions of the main components shall be identified by engraved labels whose contents shall be identical to the electrical schematic diagrams.

b) Cabling Each appliance shall have its own cabling and wiring from the cabinet. The main cable should be XLPE insulated.

16.2.5 Protection and safety

All equipment shall be designed for operation in a railway environment. In particular, the equipment shall be protected from the detrimental effects caused by:

a) Numerous interference phenomena caused by nearby high-current equipment likely to frequently switch on and off, nearby apparatus generating high frequencies (radio, telephone, converters, etc.),

b) Miscellaneous interference noise, as well as against power supply anomalies such as high undulation rates, high over-voltages, slow voltage variations,

c) The compressor should have inbuilt protection for high air oil temperature should start givingwarning of temperature at 110 degree centigrade and will trip at 120 degree centigrade,

d) The compressor should have protection for all moving parts like pulleys, belts, etc.

16.2.6 Standards


Page | 499R

The entire supply shall comply with the requirements of the standards in force. Work related to the production of the equipment shall comply with the relevant Indian/European Standards, Codes of Practice and latest statutory requirements of India including the following:


BSEN287 Approval testing of welders for fusion welding

BSEN288 Specification and approval of welding procedures formetallic materials

BS5304 Code of practice for safety of machinery

BSEN60073 Specification for coding of indicating devices and actuators by colours and supplementary means.

BSEN60529 Specification for degrees of protection provided by Enclosures (IP code).

16.2.7 Finish

a) Equipment (compressors, dryers, electrical cabinet) All metal parts shall be painted & all bolting and fasteners shall be made of high tensile steel.

b) Ventilation ducts and Electricity cableway The ducts and all attaching parts (on the partitions or others) shall be galvanised prior to assembly. After manufacture, the machined components or duct parts shall be galvanised.

c) Partitions, floor The necessary paint touch-ups shall be executed on the walls and floor of the room after erection of the installation.

d) Valves Handles of normally open valves shall be painted green and Handles of normally closed valves shall be painted red.

e) Piping All the compressed air piping shall be galvanised. The MS pipe of various sizes i.e. 100mm, 60mm, 25mm, 20mm, 15mm dia shall be provided wherever required. The MS pipes shall conform to IS:1239(PART I) “C” Class – 1979 and B 3589 complete with all fitting such as elbows, sockets, tees, unions, reducers, flanges, clamps, plugs and etc. with threading, jointing and making connections including cutting holes in wall/floor/slab and making good the same to its original finish. No sharp bend shall be permitted. All the pneumatic piping up to the supply point of UFWL machine shall be done with heavy duty pipe & and high quality connectors , valves, gauges and all other accessories to connect and supply for under floor wheel lathe machine. Wherever pipes are passing through wall or floor etc. same shall be repaired after completion of work and restored to original finish.


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16.2.8 MS Pipe CONFIRMS TO IS: 1239 (PART I) “C” Class – 1979 and BS 3589

Nominal Bore (MM)

Outside Diameter

(MM)

Heavy (C-Class)

Thickness (MM)

Weight (Kg/Mtr.)

3 10.32 2.65 0.493

6 13.49 2.9 0.769

10 17.1 2.9 1.02

15 21.43 3.25 1.45

20 27.2 3.25 1.9

25 33.8 4.05 2.97

32 42.9 4.05 3.84

40 48.4 4.05 4.43

50 60.3 4.47 6.17

65 76.2 4.47 7.9

80 88.9 4.85 10.1

100 114.3 5.4 14.4

125 139.7 5.4 17.8

150 165.1 5.4 21.2

16.2.9 Assembly and miscellaneous services

a) Connections to the appliances Connections of piping to all appliances shall be such that removable parts can be disassembled without requiring disassembly of the control systems, valves and plugged accessories. It shall be possible to remove all piping elements placed in the way of removable items.

b) Welding Visual inspections and ultra-sonic inspections shall be carried out during and after performance if necessary.

c) Reliability and maintenance All component parts, and especially relays, shall be heavy-duty type providing high reliability under normal machine operating conditions. All sub-assemblies performing the same function shall be 100% identical and interchangeable.

d) Identification All the following electrical and pneumatic equipment shall be marked by an engraved plastic label indicating the function and the code number: -

Appliances

valves,

cocks and fittings,

Measuring and control equipment. All symbols shall be in accordance with the standards and shall be marked on the drawings, schematics and maintenance manuals.


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The normal flow direction of the fluids shall be indicated with white, black or conventional coloured arrows, depending on the background colour so that satisfactory visibility is provided due to the contrast. Presentation of labels:

white lettering on back background : minimum letter height 6mm,

Attached by rivets.

Wherever possible, the labels shall be affixed to the equipment itself.

Labels for valves and special accessories and gear shall be secured with a chain and by gluing.


a) In-manufacturer’s plant i. During manufacture, and prior to delivery, verifications and checks shall

be carried out as per BS standards in order to ensure that the supply is in accordance with the technical specification and with the approved design documents.

ii. All quality checks shall be carried out, as required, during manufacture on the Contractor’s or on the sub-contractorspremises. The Contractor shall arrange for quality checks on all supplies on his sub- contractorspremises prior to delivery of these supplies to his workshops. The measure of FAD shallbe carried out as per ISO1217, Ed-3, and Annexure-C 1996. Operation of safety and protection devices shall also be checked. All the checks & tests carried out during FAT (factory acceptance test) shall be recorded and shown for verification to the DMRC inspecting engineer.

b) At-site i. SAT (Site acceptance test) after installation of the equipment, operating

tests shall be carried out to check that equipment design makes it suitable to fulfil the scheduled functions. The purpose of the tests is to record and acknowledge that the equipment is capable of performing regular service under different operating conditions.

16.2.11 Spare parts

The contractor shall supply along with the machinery Spare Parts required for two years after the expiry of defect liability period. The quantities of spare parts shall be sufficient for the full operation of the machinery for the first two years following the expiry of the Defects Liability Period for the works. The list shall be provided in the offer.

16.2.12 Training

The contractor shall provide following training for operation and maintenance staff

One week training for four staff for operation of Compressor.

One week training for four staff for maintenance of the Compressor. (One week means six working days with eight working hours)

All required training material should be provided for the intended training.

16.2.13 Maintenance


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The contractor shall maintain complete installation during the Defect Liability Period. It shall include labour, parts and consumables like oil, filters (air filter, oil filter, and oil separator etc), various types of oils for top up etc. During DLP each and every item including manpower etc shall be arranged by the contractor.

16.2.14 Documents to be provided


16.2.15 For Execution of Work

Prior to manufacture of equipment, the Contractor shall send the following documents for approval well in advance:-

a) Dimensional drawing of the foundations and anchoring of the elements of the machine, and dimensions of the cabinet,

b) A detailed technical note indicating the weight of components and removable parts, and including a list of all parts with the respective sub-contractor’s references,

c) General equipment & piping layout drawings and detailed assembly drawings, detailed drawings of mechanical parts, pneumatic diagrams, detailed descriptive and operating note, detailed electrical diagram for troubleshooting including cable index, onnection diagram with markings, documentation, drawings, notes and references of sub-contractors, installation andcommissioning procedure, Schedule of work and completion period.

16.2.16 At Completion of Work

The Contractor shall provide the entire documentation, up to date:

a) the list of general drawings and detailed drawings of electronic and electrical diagrams with complete nomenclature, the general nomenclature of the supply including sub-contractors, mechanical drawings, electrical, electronic, pneumatic and hydraulic diagrams required for maintenance and troubleshooting of the machine, illustrated lists of mechanical and electrical parts itemised in accordance with the diagrams and drawings mentioned above and including the addresses of the various contractors two sets of maintenance and adjustment manual with summary of circuits and functions and among other information, a lubrication manual including location of lubrication points, type of lubricants, frequencies and quantities,

b) two sets of operating manual (start up and user’s instructions),

complete documentation of equipment from sub-contractors,

Complete documentation on motors and major components.

16.2.17 Gunmetal ball valve

A ball valve is a valve with a spherical disc, the part of the valve which controls the flow through it. The sphere has a hole, or port, through the middle so that when the port is in line with both ends of the valve, flow will occur. When the valve is closed, the hole is and perpendicular to the ends of the valve, and flow is blocked. The handle or lever will be in line with the port position letting you "see" the valve's position. Ball valves should durable and work to achieve perfect shutoff.

The details are as under:-


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a) Ports: 100 mm/65 mm/50 mm/25 mm/15 mm (BSPP, BSPT & NPT). b) Body width: As per size. c) Flow: 89-136 CFM. d) Working pressure: 7-15 Kg/sqcm. e) Design pressure: 38 Kg/sqcm. f) Temperature:1 to 60 degree centigrade. g) Body: Gun metal. h) Ball: Stainless steel. i) Handle: GI or stainless steel. j) Seats: Teflon. k) Seal: Teflon. l) Fully opening: 90 deg angle.

16.2.18 Auto drain valve

Auto Drain Valves help in purifying the air by getting it rid of the pollutants periodically and automatically. These Drain Valves and air drain valves are used to remove the condensate from the pneumatic piping.

The details as under:

a) Material of construction: Aluminium/Brass. b) Media: Air/Water. c) Direct acting/External pilot type: 1/2” Inlet. d) On time setting: 0 to 99 sec Variable. e) Off time setting :0 to 99 Min settable & variable in steps of 1 min. f) Pressure range: 1-15 kg/sqcm. g) Operation: Normally open / Normally closed. h) Seat: VITON/Neoprene/Teflon. i) Temperature: 2 degree centigrade to 60 degree centigrade. j) Coil Enclosure: Fly lead/Terminal Box.

16.2.19 Pressure gauge

Bourdon type pressure gauges covering ranges between 0-15 Kg/sqcm consist of `C' type/ helical type Bourdon Tubes made of non ferrous/ AISI 316 SS, closed at the upper end and the open end is soldered/argon welded firmly to the connecting socket. Pressure cause the Bourdon to expand or contract. The motion of the closed end of the Bourdon tube is transferred to the pointer mechanism through rack and pinion arrangement. Any backlash error is being completely eliminated by providing suitable hair spring. The gauge with the Bourdon tube is suitable under normal operating conditions for measuring Air.

The details as under:-

a) Material: Sheet metal casing-brass internal. b) Body dia: 150 mm. c) Pressure: 0-15 Kg/sqcm. d) Range: Plus/minus 2%. e) Robust but lightweight.

16.2.20 Filter regulator


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Filter regulator provides unsurpassed sensing, regulation and filtration performance for pneumatic system. It can provide the clean dry air necessary to achieve the peak performance required by fluid power system. The connectors should simplify the plumbing of all components. Its innovative one touch fitting technology provides dramatic time savings during the installation of both air fittings and pneumatic flow controls.

The general features are under:

a) Ports:1/2” (BSPP, BSPT & NPT). b) Body width: 60 mm or as required. c) Flow: 89-136 CFM. d) Pressure: 7-15 Kg/sqcm. e) High efficiency 5 micron element. f) Excellent water removal efficiency. g) Robust but lightweight aluminium construction. h) Positive bayonet latch to ensure correct & safe fitting. i) Aspiration plus balanced poppet that provides quick response and

accurate pressureregulation.

16.2.21 Non return valve

Wafer type (Plate type) check valve/NRV has short face-to-face dimensions and low weight allows a simple space saving installation between the companion flanges. The valves are suitable to mounting between weld neck or slip on type companion flanges of different standards. Opening and closing of the valve will take place at an extremely low-pressure difference over the valve disc. The eccentric disc shaft combination with the disc seat guarantees a positive shut off returning media. It should be compact in design.

Features

a) Body Type: Single Plate, Short Type. b) Material: Cast steel. c) Suitable For Horizontal and Vertical Mounting. d) Shorter overall length, mounting requires minimum space. e) Low Pressure Drop. f) Maintenance Free. g) End Connection: Wafer Type, Flangeless. h) Size Range: 60mm to 100mm. i) Pressure Rating: 15 kg/sqcm. j) Seat Leakage: Zero Leakage, Tight Shut Off. k) Temperature Range: 1 to + 70 C. l) Mounting Between: ASA 150 flanges.

16.2.22 Cast Iron Body-Butterfly Valve

The butterfly valve should suitable for isolating or regulating air flow. The closing mechanism takes the form of a disk. It should be lighter in weight. The disc should positioned in the center of the pipe, passing through the disc is a rod connected to an actuator on the outside of the valve. Rotating the actuator turns the disc either parallel or perpendicular to the flow.


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The butterfly should be a metal disc mounted on a rod. When the valve is closed, the disc is turned so that it completely blocks off the passageway. When the valve is fully open, the disc is rotated a quarter turn so that it allows an almost unrestricted passage of the fluid. The valve may also be opened incrementally to throttle flow.

The general features are as under:

a) Type: Wafer type. b) Material: Cast Iron PN 16, IS: 210 FG 220. c) Test pressure: 15 Kg/sqcm. d) Suitable For Horizontal and Vertical Mounting. e) Suitable for ASA 150 standard flanges. f) TemperatureRange: 1 To + 70 C. g) Low Pressure Drop. h) Maintenance Free. i) SizeRange: 60 mm to 100 mm. j) Pressure Rating: 15 kg/sqcm. k) Seat Leakage: Zero Leakage, Tight Shut Off.

16.3 AIR COMPRESSOR FOR PIT WHEEL LATHE – 21 CFM

16.3.1 General Description

Air compressor 1 no. is required for production of compressed air for the Pit Wheel Lathe at Depot and 1 no. The specification covers the design, manufacture, supply, installation, testing and commissioning of Air Compressors. The compressor shall have high efficiency & low power consumption. The supply shall comprise stationary type, electric motor driven, and self-lubricating Rotary Screw type complete with suction filter, air/oil separator, air cooled after cooler, oil filter, oil cooler integrated refrigerated air drier & moisture trap. All compressor housed in silenced package provided on anti vibration mounts. The supply shall include air filters, pipes and pipe couplings, electric controls, and all other accessories to make the equipment & installation fully functional. A set of service tools and special tools shall also be supplied alongwith the compressor. The compressor and installations shall be designed considering ease of maintenance and requiring minimum service in order to optimise down time.

16.3.2 Technical Characteristics

The compressor shall be capable of giving an output of 21 CFM of air at an operating pressure of 10 Kg/cm2. The system shall be equipped with inlet air filter, inlet check valve, compressor, oil separator element and minimum pressure valve.

The compressors shall be single stage and self-lubricating, rotary screw type and shall be mounted on steel deck suitable for 100% continuous duty.

The system shall have heavy duty dry type inlet air filter, conveniently located for quick and easy replacement with cyclonic separation and arrangement for prefilter separation. The compressor unloading assembly shall be provided with piston type unloader to release safe inside pressure. The unit shall have not-return valve at suction element.

The compressor shall be provided with all the components required for a complete installation & with first fill of oil & lubricants for integrated commissioning.


Page | 506R

The supply shall include pressure regulation safety valve, pressure regulator outlet valve, pressure gauge, periodic electronic condensate drain and pre piped. All connections shall be optimized to minimize pressure drip & reduce and potential for air leaks.

Arrangement shall also be incorporated for automatic shutdowns in the event of prolonged off-load operation. The compressor units shall be equipped with condensate separator with both auto & manual drain.

The compressor shall be driven by adequate capacity TEFC squirrel cage type 3-phase Induction motors (5.5 kW), having insulation Class F, DOL type starter with contractor, relays and single-phase prevention shall be used.

The ingress protection of all motors shall be IP55. Pre wired connections between the motor and starter should be provided. The compressor shall be suitable for continuous and heavy-duty operation. The contractor shall submit the compressor drive installed motor power (in kW & hp). The manufacturer shall use all modern techniques of vibro-acoustics optimisation forextremely low noise and vibration level. The compressors permissible noise level measured at a distance of 1m from the acoustic enclosure shall be less than 70 dbA. The compressor shall be provided with integrated oil removal filter with filtration level of 0.01ppm. The temperature of air leaving the compressor unit shall not be more than 10ºC above the ambient. The contractor shall submit equipment and piping layout drawing (preferably a 3 dimensional drawing) considering space available in the compressor room & reservoirs outside. Depot layout drawing with compressor room marked is enclosed.


All the equipment of the compressor package shall be mounted on a common base frame for foundationless installation. The base frame including the tank shall be made sturdy with facility for mobile crane & fork lifting arrangement. A twin element suction air filter on the intake side of the compressor, a compressed air-oil separator, oil cooler and a spin on type oil filter with internal NRV shall be provided.

a) Suction filters

The dust filter (pre-filter) shall be capable of filtration up to 1 micron absolute with 99.5 % efficiency for solid particles. Heavy-duty dry type intake air filter, conveniently located for quick and easy replacement with cyclonic separation and arrangement for pre filter separation shall be provided.

b) Compressor

Single stage self-lubricated rotary screw compressor having high efficiency and reliability shall be provided. It shall be equipped with: -

i. The air intake valve should be maintenance free pneumatically controlled vacuum controlled without spring Intake valve assembly for Load/ No load regulation.

ii. Vacuum gauge adopter.

c) Air/Oil Separator/Oil cooler


Page | 507R

The system shall have provision for oil reservoir, oil cooler, thermostatic valve block and oil filter. The system shall have oil level indicator and oil filling arrangement. Oil separator shall be mounted outside air tank, minimizing the oil carry over, integrated minimum pressure valve, safety valve and oil draining arrangement. Oil cooler shall be equipped with high efficiency block type cooled aluminium oil cooler. It shall have axial flow fan for cooling, oil filter and oil restrictor to regulate oil flow. The system shall consist electro pneumatic regulation system with air/oil receiver blow down mechanism to reduce No-load power consumption and pressure switch to set discharge air pressure to desired limits.

All oil lines shall be of rigid steel pipe and with minimum number of high temperature hoses.

d) Reservoir

The compressor package with electro pneumatic control panel shall be mounted on a 200L air reservoir (ISI/ASME approved as standard).The reservoir shall be suitable for service pressure of 10Kg/sqcm. The moisture trap shall be provided at the bottom of reservoir. There shall be no loss of air due to condensate drain. The air compressor shall be placed directly on firm floor near to the consumption point & needs no foundation.

e) Pipe connection

Stainless steel, quarter-turn ball type valves of sufficient dimensions shall be provided. Compressor reservoir connection shall enable flexibility in connecting the compressors to the reservoirs. A schematic diagram shall be provided for approval before execution. Condensate drain taps unit are required in each of the lines.

16.3.4 Electrical installation

Power supply: 360-440V, 50 Hz + 3%, three-phase, 4 wires. Compressor unit shall be driven by V- belts with XPZ profile, coupled with 5.5 KW motor of Power supply 3 phase AC. Motor shall have TEFC square cage, F class insulation with IP 55 standard of likely make Siemens. Motor bearing shall be greased for life long.

a) Control Panel

The Control Panel shall comprise of:

i. DOL starter for each compressor motor or equivalent soft starter, with over load protection for both main and fan motor,

ii. a three-pole main isolating switch fitted with HRC fuses or equivalent isolating device,

iii. a main circuit breaker, iv. Dryer ON/OFF button, v. Regulator with relays, vi. Hour-meter to indicate total hours of operation, vii. Start/Stop button with lamp indicating compressor operation, viii. Indicator for auto operation, ix. Easy access for service points,


Page | 508R

x. a phase sequence relay to avoid operation of the motor in reverse direction,

xi. thermal/magnetic protection for each appliance, xii. Single phasing protection.

The location of this cabinet shall be proposed according to its dimensions and the electrical power supply distribution point.

The degree of protection of the cabinet shall be IP 55 and ventilation shall be through louvers. The electrical supply to both compressors shall be given at one point.

All terminal boards and power supply cables shall be marked in accordance with the electrical schematic diagrams.

The functions of the main components shall be identified by engraved labels whose contents shall be identical to the electrical schematic diagrams.


Page | 509R

b) Cabling

Each appliance shall have its own cabling and wiring from the cabinet. The main cable should be FRLS XLPE insulated.

16.3.5 Protectionandsafety

All equipment shall be designed for operation in a railway environment. In particular, the equipment shall be protected from the detrimental effects caused by:

a) numerous interference phenomena caused by nearby high-current equipment likely to frequently switch on and off,nearby apparatus generating high frequencies (radiotelephone, converters, etc.),

b) Miscellaneous interference noise, as well as against power supply anomalies such as highundulation rates, high over-voltages, slow voltage variations.

c) The compressor should have inbuilt protection for high air oil temperature it should start givingwarning at 110 degree centigrade temperature and will trip at 120 degree centigrade.

d) The compressor should have protection for all moving parts like pulleys, belts, etc.

16.3.6 Standards

The entire supply shall comply with the requirements of the standards in force. Work related to the production of the equipment shall comply with the relevant Indian/European Standards, Codes of Practice and latest statutory requirements of India including the following:


BSEN287 Approval testing of welders for fusion welding

BSEN288 Specification and approval of welding procedures for metallic materials

BS5304 Code of practice for safety of machinery

BSEN60073 Specification for coding of indicating devices andactuators by colours and supplementary means.

BSEN60529 Specification for degrees of protection provided byenclosures (IP code).

16.3.7 Finish

a) Equipment (compressors, dryers, electrical cabinet)

All metal parts shall be painted & all bolting and fasteners shall be made of high tensile steel.

b) Ventilation ducts and Electricity cableway

The ducts and all attaching parts (on the partitions or others) shall be galvanised prior to assembly.After manufacture, the machined components or duct parts shall be galvanised.


Page | 510R

c) Partitions, floor

The necessary paint touch-ups shall be executed on the walls and floor of the room after completion of the installation.

d) Valves

Handles of normally open valves shall be painted green and Handles of normally closed valves shall be painted red.

e) Piping

All the compressed air piping shall be galvanised. The MS pipe of various sizes i.e. 100mm, 60mm, 25mm, 20mm, 15mm dia shall be provided wherever required. The MS pipes shall conform to IS:1239(PART I) “C” Class – 1979 and B 3589 complete with all fitting such as elbows, sockets, tees, unions, reducers, flanges, clamps, plugs and etc. with threading, jointing and making connections including cutting holes in wall/floor/slab and making good the same to its original finish. No sharp bend shall be permitted. All the pneumatic piping up to the supply point of UFWL machine shall be done with heavy duty pipe & and high quality connectors , valves, gauges and all other accessories to connect and supply for under floor wheel lathe machine. Wherever pipes are passing through wall or floor etc. same shall be repaired after completion of work and restored to original finish.

16.3.8 MS Pipe CONFIRMS TO IS: 1239 (PART I) “C” Class – 1979 and BS 3589

Nominal Bore (MM)

Outside Diameter

(MM)

Heavy (C-Class)

Thickness (MM)

Weight (Kg/Mtr.)

3 10.32 2.65 0.493

6 13.49 2.9 0.769

10 17.1 2.9 1.02

15 21.43 3.25 1.45

20 27.2 3.25 1.9

25 33.8 4.05 2.97

32 42.9 4.05 3.84

40 48.4 4.05 4.43

50 60.3 4.47 6.17

65 76.2 4.47 7.9

80 88.9 4.85 10.1

100 114.3 5.4 14.4

125 139.7 5.4 17.8

150 165.1 5.4 21.2


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16.3.9 Assembly and miscellaneous services

e) Connections to the appliances Connections of piping to all appliances shall be such that removable parts can be disassembled without requiring disassembly of the control systems, valves and plugged accessories. It shall be possible to remove all piping elements placed in the way of removable items.

f) Welding Visual inspections and ultra-sonic inspections shall be carried out during and after performance if necessary.

g) Reliability and maintenance All component parts, and especially relays, shall be heavy-duty type providing high reliability under normal machine operating conditions. All sub-assemblies performing the same function shall be 100% identical and interchangeable.

h) Identification All the following electrical and pneumatic equipment shall be marked by an engraved plastic label indicating the function and the code number: -

Appliances

valves,

cocks and fittings,

Measuring and control equipment. All symbols shall be in accordance with the standards and shall be marked on the drawings, schematics and maintenance manuals. The normal flow direction of the fluids shall be indicated with white, black or conventional coloured arrows, depending on the background colour so that satisfactory visibility is provided due to the contrast. Presentation of labels:

white lettering on back background : minimum letter height 6mm,

Attached by rivets.

Wherever possible, the labels shall be affixed to the equipment itself.

Labels for valves and special accessories and gear shall be secured with a chain and by gluing.


c) In-manufacturer’s plant iii. During manufacture, and prior to delivery, verifications and checks shall

be carried out as per BS standards in order to ensure that the supply is in accordance with the technical specification and with the approved design documents.

iv. All quality checks shall be carried out, as required, during manufacture on the Contractor’s or on the sub-contractorspremises. The Contractor shall arrange for quality checks on all supplies on his sub- contractorspremises prior to delivery of these supplies to his workshops. The measure of FAD shallbe carried out as per ISO1217, Ed-3, and Annexure-C 1996. Operation of safety and protection devices shall also be checked. All the checks & tests carried out during FAT (factory acceptance test) shall be recorded and shown for verification to the DMRC inspecting engineer.

d) At-site


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ii. SAT (Site acceptance test) after installation of the equipment, operating tests shall be carried out to check that equipment design makes it suitable to fulfil the scheduled functions. The purpose of the tests is to record and acknowledge that the equipment is capable of performing regular service under different operating conditions.

16.3.11 Spare parts

The contractor shall supply along with the machinery Spare Parts required for two years after the expiry of defect liability period. The quantities of spare parts shall be sufficient for the full operation of the machinery for the first two years following the expiry of the Defects Liability Period for the works. The list shall be provided in the offer.

16.3.12 Training

The contractor shall provide following training for operation and maintenance staff

One week training for four staff for operation of Compressor.

One week training for four staff for maintenance of the Compressor. (One week means six working days with eight working hours)

All required training material should be provided for the intended training.

16.3.13 Maintenance

The contractor shall maintain complete installation during the Defect Liability Period. It shall include labour, parts and consumables like oil, filters (air filter, oil filter, and oil separator etc), various types of oils for top up etc. During DLP each and every item including manpower etc shall be arranged by the contractor.

16.3.14 Documents to be provided


16.3.15 For Execution of Work

Prior to manufacture of equipment, the Contractor shall send the following documents for approval well in advance:-

d) Dimensional drawing of the foundations and anchoring of the elements of the machine, and dimensions of the cabinet,

e) A detailed technical note indicating the weight of components and removable parts, and including a list of all parts with the respective sub-contractor’s references,

f) General equipment & piping layout drawings and detailed assembly drawings, detailed drawings of mechanical parts, pneumatic diagrams, detailed descriptive and operating note, detailed electrical diagram for troubleshooting including cable index, onnection diagram with markings, documentation, drawings, notes and references of sub-contractors, installation andcommissioning procedure, Schedule of work and completion period.

16.3.16 At Completion of Work


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The Contractor shall provide the entire documentation, up to date:

c) the list of general drawings and detailed drawings of electronic and electrical diagrams with complete nomenclature, the general nomenclature of the supply including sub-contractors, mechanical drawings, electrical, electronic, pneumatic and hydraulic diagrams required for maintenance and troubleshooting of the machine,

d) illustrated lists of mechanical and electrical parts itemised in accordance with the diagrams and drawings mentioned above and including the addresses of the various contractors two sets of maintenance and adjustment manual with summary of circuits and functions and among other information, a lubrication manual including location of lubrication points, type of lubricants, frequencies and quantities,

e) two sets of operating manual (start up and user’s instructions),

complete documentation of equipment from sub-contractors,

Complete documentation on motors and major components.

16.3.17 SPECIAL REQUIREMENTS

The system shall be designed to operate at the normal workshop temperature Arrangement shall also be incorporated for automatic shutdowns in the event of prolonged off-load operation. The compressor shall be capable of direct placement on firm floor near to the consumption point. High discharge air temperature shut down system should be provided to limit the compressed air temperature up to 120 deg C.

The sound level for the overall of the installation shall not exceed 70 dB at a distance of one meter and shall, in no case whatsoever, create vibrations in the ground or in the partitions. Anti Vibration


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17. WATER TREATMENT PLANT

17.1 GENERAL

17.1.1 This Section specifies the furnishing and installation to complete and operate softening plant for reducing the Hardness of raw water to below 5mg/lit commercial zero so as to generate water fit for make up requirements for Cooling Towers of HVAC system.

17.1.2 All materials shall be new and of the best quality conforming to specifications and subject to the approval of Engineer-in-charge-in-Charge.

17.1.3 All equipment shall be of best available make manufactured by reputed firms.

17.1.4 All equipment shall be installed on suitable foundations, true to level and in a neat work-man-like manner.

17.1.5 Equipment shall be so installed as to provide sufficient clearance between the end walls and between equipment to equipment.

17.1.6 Piping within the pump houses shall be done so as to prevent any obstruction in the movement within the pump house.

17.2 STANDARDS

17.2.1 IS: 8419 Requirements for water filtration equipment: Part I Filtration media – sand and gravel.

17.2.2 IS: 2825 Code for unfired pressure vessels

17.3 QUALITY CONTROL

17.3.1 Engage the services of a specialist for initial cleaning and pre-treatment.

17.3.2 Specialist’s services shall include monthly laboratory testing of water samples and adjustment of water treatment system.

17.3.3 A complete testing report regarding the quality of the supplied water together with the recommended water treatment system shall be submitted for Approval prior to ordering.

17.4 SOFTENING PLANT

17.4.1 The softener vessel shall be made of Mild steel (rubber lined) pressure vessel conforming to IS:2825, upflow "Cation" Ion Exchange typ.

17.4.2 The softener plant shall be designed to generate water commercial zero hardness at rated output at given raw water quality without any operational problem. Any additional provision required to make the item complete shall be deemed to be included in the price.

17.4.3 The softening plant shall be complete with Initial charge of Ion Exchange resin, regeneration assembly comprising of power valve, ejector, brine suction valve, and all necessary piping. The Contractor is required to submit the make, grade and quantity of resin being offered by him and the quantity of regenerate required for each regeneration.


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17.4.4 The Softening System shall consist Dual Media Filter (DMF) pressure vessel type pre-filter of made of mild steel (rubber lined) conforming to IS:2825. The rate of filtration of DMF shall not be more than 15 cu.m/hr/sq.m. Working and test pressures shall be as per BOQ. Thickness of vessel rubber lining not less than 3mm.

17.5 UNDER DRAIN SYSTEM

17.5.1 Each filter shall be provided with an efficient under drain system comprising of collection pipes, polypropylene nozzles of manufacturer’s design. The entire under draining system shall be provided on M.S. Plate or cement concrete supports provided by the contractor

17.6 FACE PIPING

17.6.1 Each filter shall be provided with interconnection face piping comprising of inlet, outlet and backwash complete with diaphragm valves/ball valves.

17.7 ACCESSORIES

17.7.1 Each vessel shall be provided with the following accessories:

a) Air release valve with connecting piping. b) 100mm dia bourden type gunmetal pressure gauges with gunmetal isolation

cock and siphon on inlet and outlet. c) Sampling cocks on raw water inlet and filtered water outlet. d) Individual pressure tight manhole, drain connection with ball valves. e) Connection with valve for air scouring. f) Rate of Flow Indicators in the raw water inlet line. g) Quantity meter in the filter water outlet line

17.8 FILTER MEDIA

17.8.1 Each filter shall be provided with clean and washed filter media, conforming to IS: 8419 (Part-I) following is recommended.

Coarse Silex Pabbles 6.0 - 10.0mm size (150mm deep)

Fine Silex Sand 1.4 - 2.5mm size (600mm deep)

Anthracite 0.80 - 1.6mm dia (600mm deep)

17.8.2 The above filter media arrangement may be altered to suit contractor’s own design for the most efficient performance.

17.9 TEST KITS

17.9.1 Provide one test kit with initial requirement of reagents for the following:

a) Hardness Test Kit b) Residual Chlorine Indicator c) PH meter (electronic) d) The contractor shall supply the details of equipment (Including Test kit) with

literature for the equipments quoted by him along with.

17.10 PAINTING AND FINISHES

17.10.1 General


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a) All exposed metal surfaces, after inspection and testing either in the factory or on Site shall be thoroughly cleaned of all dust, oil, grease, dirt, scale and rust by grit or shot-blasting to the satisfaction of the Engineer.

b) Surfaces of castings, steel work, piping and plant and machinery which are to be in direct and permanent contact with concrete shall be properly painted and covered, prior to dispatch from the Contractor's premises, with a substantial coating of cement wash or other proprietary coating plus a lapping of weatherproof tape. The method of coating and waterproof tape shall be approved by the Engineer.

c) Except where otherwise specified, all embedded pipes and fittings located in inaccessible positions (e.g. in pipe trenches, pits) shall be externally coated by dipping in acid-free hot bituminous compound. The coating thickness shall be approved by the Engineer. The pipe or fitting shall then be lapped with a layer of anti-corrosion tape which shall be approved by the Engineer.

d) The internal surfaces of all oil service ferrous pipes and fittings shall be carefully inspected to ensure that all scale and other particles or contaminants have been removed and shall then be protected in a manner approved by the Engineer to prevent deterioration during transport and subsequent erection.

e) The external surface of accessible ferrous pipes and fittings shall be treated with two coats of primer paint approved by the Engineer prior to dispatch from the place of manufacture.

f) The external surfaces of all Building Services Equipment in damp environments shall, unless made of non-ferrous metal, be coated with a bituminous compound approved by the Engineer. All access ladders and platforms and associated supporting steelwork provided by the Contractor shall be galvanized.

g) All other exposed surfaces, except where otherwise specified, shall be thoroughly cleaned of all dust, oil, grease, dirt, scale, rust or other contaminants by power tool operated metal brush, or preferably by shot or grit blasting, and shall then be coated immediately with one coat of primer paint.

h) Any damage to priming coats made good by the Contractor on completion of installation shall be finally painted in colours approved by the Engineer.

17.10.2 Paint Finish Schedule

a) Unless otherwise specified in the particular specification, a paint finish to a colour to be approved by the Engineer shall be applied to all exposed services including but not limited to supporting rods and brackets, cable ladders, cable trays, trunking, lighting fittings, pipework, ductwork, access doors / panels, surface conduits and accessories and other equipment installed in the following areas

Station concourse public area;

Station platform public area;

Station entrances, passageways; public areas and subways and passenger exits; and

Back of house areas, offices and staff areas without suspended ceilings. b) Unless otherwise specified, all machinery / equipment shall be finished in a

color to be specified by the Engineer at the time of installation / manufacturing. Unless conforming to the general color scheme specified, the manufacturer's standard finish color may not necessarily be accepted.

c) The requirements of paint finish shall be as follows:-


Page | 517

All equipment casings and metal parts shall undergo different stages of pre-treatment such as chemical cleaning, abrasive blasting, acid pickling, galvanizing or electro-galvanizing before painting. There shall be at least one coat of corrosion resistant primer, one undercoat and two finish coats to suit the intended duty and operating requirements. Details of pretreatment shall be submitted to the Engineer for approval prior to application.

If damage to paint is found during transportation, storage or installation, the contractor shall repaint the whole equipment without extra cost.

Replace all damaged parts or components and repaint the whole equipment without extra cost if rust is found on any equipment due to inadequate painting material or poor workmanship or incorrect handling during transportation, storage or installation. Removal of all the existing paint, chemical cleaning, rinsing and other necessary pretreatment shall be included in repainting before applying primer, undercoats and top coats. Details shall be submitted to the Engineer for approval.

17.10.3 MATERIALS

a) Primer Paint

For synthetic finishing paints on internal and external metalwork, paint shall be zinc chromate primer or metallic zinc-rich primer to BS 4652, Type 2.

For synthetic or non-toxic paints on galvanized metal, use an etching primer with a zinc chromate base.

For polyurethane paint on internal and external metal work, paint shall be metallic zinc-rich primer to BS 4652, Type 2.

b) Undercoat Paint

For metal work installed internally, paint shall be a linseed oil modified alkyd based undercoat highly pigmented to appropriate shade.

For metal work installed externally and exposed to weather, paint shall be a polyamide epoxy pigmented with titanium oxide.

c) Finish Paint

For metal work installed internally paint shall be a linseed oil modified alkyd with glossy finish and fungus resistant characteristics.

For metal work installed externally and exposed to weather, paint shall be a polyamide epoxy.

d) Identification Colors

All finish coat color shall be to BS 381C and identification colour shall be as per mentoned under colors scheme of this specification. Colours not covered in clause shall be agreed with the Engineer.

e) Valves

All valves shall be painted as the same colour as the pipe to which it is fixed, except that handles installed in plant rooms or on roofs shall be painted red, No. 540 regardless of the service.

17.10.4 Colour bands / materials and workmanship

a) Colour bands shall be provided at intervals not exceeding 2 m and whenever necessary at bends, tees, when pipes pass through from one room or zone to another, and when two or more pipes run in parallel. Colour bands for each pipe shall be at the same locations.

b) Bands shall be of 100 mm width.


Page | 518

c) Hangers, spring isolators, and supports shall be painted as for the equipment unless otherwise specified.

17.10.5 Colours Schedule

a) All equipment, unless otherwise specified, shall be finished in a colour to be specified by the Engineer at the time of installation. The Contractor shall obtain the Engineer’s requirements on this in good time.

b) After painting and cleaning of piping and insulation (in case of Hot Water Pipes) is complete, exposed services systems shall be finished generally in accordance with BS 1710 and shall be identified by means of coloured stenciled or prefabricated legends with flow arrows as follows unless otherwise specified. The colour numbers as stated below are those of BS 4800 for ready mixed paints.

Service Colour Colour No. (Reference to BS

4800)

Water Pressuriesed (Salt) Sea Green 16 C 37

Water Pressurised (Fresh &

cleansing) Dark Blue 18 F 53

Drainage Black 00 E 53

PREAMBLE

TABLE OF CONTENTS

1. General Requirements

1.1 Quantities

1.2 Units and Currency

1.3 EXPLANATION OF BOQ

The Bill of Quantities (BOQ) has been divided into 7 Parts as under:

PART- 1 : E&M work of depot

PART- 2 : E&M work of station

PART- 3 : DG for stations and Depot

PART- 4 : E&M, ECS Work of Admin Building

PART- 5 : DLP

PART- 6 : E&M work of Dilshad Garden-New Bus Adda Gaziabad

PART- 7 : E&M work of Noida Sector-32 to Sector-62

1 General Requirements

The Tenderer's attention is drawn to the General Conditions of Contract (GCC) , Special Conditions of

Contract (SCC), Specifications and Tender Drawings, General Specifications, SHE Manual which are

to be read in conjunction with the Bill of Quantities. This Preamble shall serve as a definitive guide to

the measurement of quantities and payment.

The Tenderer should quote the rates considering that this contract is on Turnkey basis.

This contract is a re-measurement contract for E&M, fire detection and fire

Suppression system for Elevated stations of NOIDA-GREATER NOIDA Metro

Corridor.

A Detail Design Consultant (DDC) have the responsibility up to the CRD &CSD

stage Bidders are required to coordinate.

Tender Prices

The tenderer is required to note the following while quoting his prices:-

(i) The tenderer is required to carefully study the provisions under the GCC clause11.1.1 and

.SCC clause 24 and consider them while preparing his offer. Tenderer shall be solely

responsible for obtaining the benefits that they have considered in their tender and in case of

failure to receive such benefit the Employer shall not compensate the Tenderers. It will be the

responsibility of the contractor to avail the maximum benefit available to DMRC in terms of the

above provisions

(ii) The rates and prices quoted for each item in the Bill of Quantities shall be as per SCC clause 24.

1.1 Quantities

For the purpose of this Contract, all unit quantities given in the Bills of Quantities are the estimated

quantities of the Works and are intended in the first instance to provide a common basis for Tendering

and Tender Evaluation. When a contract has been entered into, the function of priced Bills of

Quantities is to provide for the valuation of the work executed.No alteration of any rate or price shall

be allowed on account of any difference between the quantities billed and the actual quantities

measured from the drawings.

The Tenderer shall make himself completely acquainted with all conditions, obligations, specifications,

drawings, etc. of the Tender Documents before giving his prices.He shall have no right to claim any

price revision on the basis of ignorance of the Tender Documents or local conditions, or to make any

claims as regards the integrity of the unit prices of the Bills of Quantities.

The Fan Pressure, pump heads and Sound power given in the BOQ/ Drawings

are indicative and will be used for payment of item close to the rating

specified in the BOQ. The contractor shall be responsible for determining the

final fan pressure and pump heads as per their detailed engineering drawings,

acoustic treatment requirement, and motor power based on the equipment

offered , site installation and final duct routing before ordering the

equipments. Any required modification to the system (e.g fan, motor,

switchgear, cables etc.) necessary to meet the required duties and space

conditions shall be at the contractor’s account. The contractor shall submit

the calculations for acceptance of the engineer.

1.2 Units and Currency

All sizes and quantities entered in the Bills of Quantities are in metric units.

The Tenderer shall fill in each column with unit rate or lump sum, whichever the case may be, for

each bill item of the various Bills, provided that he should consider it a reimbursable item, on the basis

of the Tender Documents and pre-tender survey. The rates and the total amount against each item

has to be filled in by the tenderer.

The Tenderer are required to submit his priced offer in Indian Rupees, and/or in Japanese

Yen/ US Dollar/ Euro or any combination of these currencies as per ITT Clause C16. The

detail of currencies utilised in the tender offer shall be submitted in Annexure- 10 of ITT.

Progress payments in relation to each Section will be certified and paid, in accordance with

the provisions of Clause 11.6 of the GCC in the currencies shown against the relevant Bill

item in the Bill of Quantities.

Plant & equipment to be supplied from abroad and foreign component (if any) of installation

services may be quoted in freely convertible international trading currencies as specified

above. All plant & equipment and installation services etc shall be quoted only in INR.

1.2.1 Rates and Sums to be for Work Complete

Tenderers shall be deemed to have read the Tender Documents and reviewed the Drawings to

ascertain the full scope of the requirements included in each item prior to filling in the rates and

prices. The entered rates and prices to include the full scope of the Contract, including overheads

and profits and shall bear a proper relationship to the cost of carrying out the work described.

Notwithstanding any limits that may be implied by the wording of the individual items and/or the

explanations in the Preamble, the rates and sums, which the Tenderer enters in the Bill of Quantities,

shall be for the work finished complete in every respect.

The Tenderer shall be deemed to have taken full account of all requirements, liabilities, obligations

and risks, whether expressed or implied, and to have priced the items accordingly. The Items in the

Bills of Quantities are the only items against which payment will be made. The cost of any item of

work not specifically described or measured in the Bills of Quantities but required for the execution of

the Contract shall be considered included in the unit rates for the measured items in the Bills of

Quantities. The rates and sums shall therefore include all incidental and contingent expenses and

risks of every kind necessary to supply, install, test and commission (including Integrated Testing and

Commissioning) complete, and remedying any defects in the whole of the Works in accordance with

the Contract.

1.2.2 Allowances in rates

Full allowance shall be made in the rates and sums against the various items in the Bills of Quantities

for all costs involved in performing the following except to the extent that work is specifically described

and paid for in the Bills of Quantities. The list below is not exhaustive and the Tenderers are

expected to take all costs involved while quoting the rates that will not be subject to variation on any

account.

a) all setting out and survey work;

b) temporary access , watching and security , lighting;

c) paying fees and giving notices to Authorities;

d) payment of all patent rights and royalties;

e) safety precautions and all measures to prevent erosion and suppress fire and other

hazards;

f) interference to the Works by persons, vehicles, and the like being legitimate users of

the facilities on or in the vicinity of the Site;

g) supplying, maintaining and removing on completion, the Contractors own

accommodation, offices, depots, stores, workshops, transport, welfare services and

other facilities including telephones and facsimile machines and all charges in

connection therewith;

h) The supply, inspection, testing, packaging and transportation of materials and of the

Works as specified includingthe provision and use of equipment and arrangements

for the Engineer's Inspectors and others for Pick- Up and drop at site for Testing and

Measurement Purpose and office assistance.

i) providing, transporting to the Site, setting to work, operating (including all fuel and

consumable stores), maintaining and removing from the Site upon completion all

Construction Plant and Contractor's Equipment necessary for the execution of the

Works and including the cost of all tests and other requirements in respect of such;

plant and equipment;

j) working adjacent to or across existing services and installations;

k) co-ordination and interference to the Works by the works of Designated Contractors

and others employed by DMRC being legitimate users of the facilities on or in the

vicinity of the Site;

l) remedying of defects and shrinkage, and works of amendment, reconstruction,

replacement of other faults, fair wear and tear excepted, during Defects Liability

Periods;

m) protections to be implemented against Electro magnetic interference effects following

line energisation.;

n) Insurance, including all risks in supply, erection, storage, transit, third party,

Workmen‟s Compensation and others;

o) All tools, and equipment required for all tests prior and after delivery, and for testing

and commissioning installed systems;

p) Carrying out all modifications to the given drawings, preparing construction detailed

drawings and supplying originals, copies, and electronic files in accordance with

employer‟s requirement.

q) All risk Insurance after arrival of goods in India

r) Custom clearance / Port Clearance

s) Handling at Port of arrival in India

t) Inland transportation from port of arrival to site of work

u) Various bank guarantees/warranties/undertakings

1.2.3 Tender Pricing

The Tenderer shall take regard of the actual site conditions and the estimated quantities entered in

the various bills. The Tenderer shall price his tender accordingly and the unit prices entered against a

bill line item shall be the full and only price paid for all work performed against that item except as

described in the Tender Documents.

The Tenderer shall price the Bills of Quantities in Indian Rupees, and/or in Japanese Yen/ US

Dollar/ Euro or any combination of these currencies as per ITT Clause C16. The detail of

currencies utilized in the tender offer shall be submitted in Annexure- 10 of ITT.

Items described in BOQ but against which no rate or sum is entered by the Tenderer, whether

quantities are stated or not, shall be regarded as covered by other rates in the Bills of

Quantities.

The Stage Payment shall be made as under :

Sr.

No.

Item Description Payment

after material

being

brought to

site

Payment

after

Erection

Payment after

successful

Testing and

Commissioning

Payment

after issue of

completion

certificate

1 MV Switchgear 75% Nil 20% 5%

2 Distribution Boards 75% Nil 20% 5%

3 MV Cabling 75% Nil 20% 5%

4 Conduit wiring 50%(after

laying of

Conduits)

25%(after

laying of wire)

20% 5%

5 Indoor Lighting and Fans 75% Nil 20% 5%

6 Protective Earthing 60% 15% 20% 5%

7 Lightning Protection 60% 15% 20% 5%

8 External Lighting 60% 15% 20% 5%

9 Air Conditioning and

Ventilation

60% 15% 20% 5%

10 Fire Alarm &

Annunciation System

60% 15% 20% 5%

Sr.

No.

Item Description Payment

after material

being

brought to

site

Payment

after

Erection

Payment after

successful

Testing and

Commissioning

Payment

after issue of

completion

certificate

11 Fire Hydrant System 60% 15% 20% 5%

12 Piping for Fire Fighting

System

60% 15% 20% 5%

13 Sprinkler System 60% 15% 20% 5%

14 Portable Fire

Extinguishers & EXIT

Signages

60% 15% 20% 5%

15 EOT Crane 60% 15% 20% 5%

16 Compressor 60% 15% 20% 5%

17 Deleted 60% 15% 20% 5%

18 UPS System 60% 15% 20% 5%

19 CO2 Flooding System 60% 15% 20% 5%

1.2.4 Measurement and Payment

1) This Contract is primarily a re-measure contract with items that are described herein. For the re-

measure items the total price paid for a work item will be varied by the quantities actually

performed. The contract also contains some lump sum items for which special payment terms

are described.

2) The measurement and payment described is for the purpose of making a valuation of the work

acceptable to the Engineer, and Interim Payments to the Contractor, as work proceeds. The

works as executed will be measured for assessment of progress for interim payments in

accordance with the method adopted in the Specification, the Bills of Quantities and under the

items as set forth notwithstanding any custom to the contrary.

3) Building works will be measured in accordance with the local practice as proposed by the

Contractor and accepted and approved by the Employer. For the measurement of “Numbers” and

“Sets” these shall be by count, using dimensions and contents as described in the specifications.

4) For the purposes of making interim payment for Lump Sum items and line items not subject to re-

measure, such as described as “Lot”, the Contractor shall submit with his tender a breakdown of

the rates making up the total for those items for which the Contractor may wish to receive interim

payments. These breakdowns shall be subject to the approval of the Engineer, and no interim

payment shall be made on such items until the breakdown has been approved, with the approval

of Engineer. The items described as „set‟ may also be broken down in a maximum of two lots for

the purpose of interim payment under exceptional circumstances when it is established that the

contractor is not able to complete the „set‟ for reasons not attributable to him.

5) Notwithstanding anything stated herein the Engineer retains the right to withhold payment on any

pay item due for payment when the service to be performed is not performed, or is not carried out

to the Engineer‟s satisfaction.

6) Prices for documents, drawings, design calculations, test procedures, interface co-ordination

documents, operation and maintenance manuals and the like for review by the Engineer shall be

the full compensation for documents and the like in accordance with the specifications.

Compensation shall include for the preparation, submission, and all subsequent revisions,

changes required and re-submittals as necessary as required by the specifications until accepted

by the Engineer.

7) Not Used

8) Prices for Integrated Testing and Commissioning shall be full compensation for the integrated

testing and commissioning of plant and equipment supplied under the Contract in accordance

with the drawings and specifications. Compensation shall include for preparation, submittal, and

revisions as required by the Engineer of testing plans and procedures; co-ordination with other

Designated Contractors; conduct of approved tests as directed by the Engineer on equipment,

sub-systems, and systems; revisions, re-testing, fault finding, adjustments and reworking as

necessary; submittal of all test reports and other documents all to the approval of the Engineer.

The Contractor will make payment for each Section after certification and acceptance of the

Employer‟s representatives that the sub-systems and systems, including all equipment have

successfully completed the test procedures, and have been set-to-work and all test results and

other documentation, as described in the specifications.

9) Prices for supply items shall be for the full compensation for supplying the items in

accordance with the drawings and specifications. Compensation shall include for all costs

incurred in procurement/manufacture, testing, inspection, shipping, hauling, off-loading,

storing at site in Delhi. For major equipment the separate items are indicated in the BOQ,

therefore the tenderer is expected to price for the supply of these major equipment against

the respective BOQ items. For the remaining BOQ items if the supply and delivery to site is

involved for any material / equipment then prorata payment upto 75% of the cost of the

respective BOQ items shall be considered by the engineer subject to compliance to other

relevant clause of contract document. Payment will be made for the items delivered and

stored in a place and manner approved by the Engineer. Payment on delivery will be made

against the following documents:

- provision of Indemnity bond ;

- proof of insurance; and

- Packing list

- Type Test Certificates

10) Prices for installation/erection of items of plant and equipment shall be for the full compensation

for the installation/erection of plant and equipment in accordance with the drawings and

specifications. Compensation shall include for all costs incurred for transporting to location, off-

loading and moving to point of installation/erection; provision of specified foundations; preparing

for installation/erection and mounting on foundations; supply of left out items, aligning, fastenings

and securing devices; adjusting as necessary, making good and clearing the location on

completion, all to the approval of the Engineer. Payment will be made for each item of installed

plant and equipment completed and accepted by the Engineer.

11) Testing and commissioning shall be full compensation for the testing and commissioning of Plant

and equipment forming the Works in accordance with the specifications. Compensation shall

include for all testing and putting-to-work of all equipment, sub-systems, and systems; re-testing,

fault finding, adjustments and reworking as necessary; submittal of all test reports and other

documents all to the approval of the Engineer. Payment will be made after certification by the

Contractor and acceptance by the Engineer that the sub-systems and systems, including all

equipment have successfully completed the test procedures, and have been set-to-work and that

all test results and other documentation, as described in the specifications, have been approved

by the Engineer.

1.3 Explanation for BOQ (Bill of Quantities) NE-03.

The Bill of Quantities (BOQ) has been divided into 7 Parts. as under:

PART- 1 : E&M work of depot

PART- 2 : E&M work of station

PART- 3 : DG for stations and Depot

PART- 4 : E&M, ECS Work of Admin Building

PART- 5 : DLP

PART- 6 : E&M work of Dilshad Garden-New Bus Adda Gaziabad

PART- 7 : E&M work of Noida Sector-32 to Sector-62

Detailed Scope of works for AMC beyond DLP under the contract is given in the

Specification, and Details of Spares for which the price is to be quoted is placed in the

Specification.

The item descriptions are intended to briefly describe the work to be performed under that item

and to identify associated work. It is not a full and complete description of the work to be

performed. The Contractor shall carry out all the work necessary to meet the requirements of the

Specification.

1.4 DMRC reserves the right to award the work of AMC beyond DLP through a supplementary contract.

1.5 The Bidders are required to assist in operation of plants for initial period of 6

Months beyond the revenue operation date/equipment commissioning

date whichever later.

1.6 The prices for AMC shall be inclusive of service tax. Bidders need to submit the performance guarantee for an amount of 10% of supplementary contract value at the time of signing of supplementary agreement.

1.7 The bidder has to quote in figures only. The same will automatically convert to words. Bidder has to check the same.