P Power S Bhar Sector Rat Hea R Proje Avy Elec Ect Eng Noida India Ctrical Ineeriin A Ls LTD NG Mana Agemen NT

RAI ICHUR POWER P R CORP PORATIO ON LIM ITED (A A JVC O OF KPCL L & BHE EL)
2x x800MW W YERM MARUS SUPER S AL TPP P CRITICA
PROJECT SP PECIFIC C TECH HNICAL SPECIF FICATIO ON FOR R 130/30 0T CAP G HALL EOT CR RANES (DOUB BLE GIR RDER) IN N TAND DEM TG
SP PECIFICA ATION NO.: PE E-TS-36 62-501-A A001
BHAR RAT HEA AVY ELEC CTRICAL LS LTD P POWER SECTOR S R PROJE ECT ENGINEERIIN NG MANA AGEMEN NT NOIDA A INDIA
TECHNICAL SPECIFICATION FOR TG HALL EOT CRANE 2X800 MW YERMERUS STPP
Specification no.: PE-TS-362-501-A001 Rev. 00 Date: Jun 12 Sheet 1 of 1
INDEX S.N. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 DESCRIPTION Project Information Project Technical Data Sheet for 2X800 MW YERMERUS STPP Painting Specification (Annexure I ) Crane Clearance Diagram Drg. No (PE-DG362-501-A001) for TG hall crane Write up for Load test procedure of Lifting beam in Bidders works BHEL standard QAP Ref quality plan for Lifting beam Scope of O&M service to be provided by the bidder Specific Confirmation Documents to be submitted along with offer Annexure C. PAGES 4 9 1 1 5 11 2 2 3 1
Note: 1.0 The Standard Technical Specification PE-TS-STD-501-A002 Rev 03 shall be applicable for this project. 2.0 Any contradiction between project specific specification PE-TS-362-501A001 & Standard specification PE-TS-STD-501-A001 Rev03, the data given in project specific specification will be followed.
RAICHUR POWER CORPORATION LTD

TITLE
SHEET 1
PROJECT INFORMATION
1.0
Owner
Raichur Power Corporation Ltd 22/23, Sudarshan Complex, IInd floor, Sheshadri Road, Bangalore560 009 Karnataka, India M/s Evonik Energy Services (I) Pvt. Ltd.,A-29, Sector 16 Noida-201301(UP), India 2x800 MW Yermarus Power Station Thermal
2.0
Consultant
3.0
Project Title
4.0
Location
Yermarus Raichur Dist Karnataka State, INDIA It is situated at about 8 Kms from Raichur on the Raichur-Hyderabad State Highway-13 and 12 kms away from Bank of river Krishna and about 5 kms from Raichur Thermal Power Station Chicksugur Railway Station which is about 2 kms from site. Hyderabad around 200 kms Chennai around at about 470 kms from site. Latitude 16 16 55.9N Longitude 77 20 38.6E 350-375 meters
5.0
Nearest Railway
6.0 7.0 8.0 9.0 10.0
Nearest Airport Nearest Port Latitude and Longitude Elevation above mean sea level Climatic Conditions (a) Ambient Temperature i. maximum temperature minimum temperature
: :
45o C 6o C
ii.

TITLE
SHEET 2
PROJECT INFORMATION
iii.
Design Temperature for all Electrical/ Mechanical Equipment
50o C Ambient
(b) i. ii. iii. (c)
Relative Humidity Maximum during monsoon Minimum Average Rainfall Annual average rain Max. for one day Max. intensity Period Wind Speed i. Prevailing wind direction ii. Maximum mean wind speed iii. Average : : : : : : : 85% 20% 65% 720 mm 115 mm 38 mm/hr June to September
(d)
: : :
West, South-East, North-West, South-West 15.9 Kms / hr (4.42 m/s) 9.61 Km/hr (2.67 m/s)
11.0
Wind Load Calculations for wind effect shall be in accordance with IS:875- (Part-3) latest revision taking into account the following : (a) (b) (c) (d) Basic wind speed of 39 m/sec as given in Fig.1 of the code. Factor K1 shall be taken as 1.06 Terrain category shall be 2 and corresponding values shall be taken for K2 Factor K3 shall be taken as 1.0
12.0
Wind Loading for Stack (a) For wind pressure as per clause 11.0 above (b) For RC stacks as per IS: 4998

TITLE
SHEET 3
PROJECT INFORMATION
13.0
Seismic data (as per IS:1893 latest issue) (a) (b) Zone Importance factor (I) : : : Zone III (as per IS:1893- latest ) 1.75 Auxiliary electrical equipment to be supplied against this specification shall be suitable for operation on the following supply system. 11000V, 3 phase, 3 wire, 50Hz medium earthed AC 3300V, 3 phase, 3 wire, 50Hz medium earthed AC
14.0
Auxiliary power supply
(a)
For motors rated above 1500 kW For motors rated 175KW and above and below 1499KW. For motor rated 174 kW and below For motor control centre
(b)
(c)
415, 3 phase, 3 wire solidly earthed AC 415V, 3 phase, 3 wire solidly earthed AC 220 V DC, 2 wire, unearthed DC
(d)
(e)
DC. motor starters, DC solenoids, DC alarm, control and protections AC control & protective devices
(f)
110 V 1 phase, 50Hz, 2 wire AC supply. The single-phase 110V AC supply shall be derived by Contractor by providing 415V/110V control transformers of adequate rating with MCCB /MCB on both the primary and secondary sides. 240 V, 1 phase, 50Hz, 2 wire AC supply from UPS system for I&C (including indicator recorders) and UCMS only
(g)
Uninterrupted power supply

TITLE
SHEET 4
PROJECT INFORMATION
(h)
AC solenoids, indicators/recorders, space heaters (for motors rated 30KW and above)
240V 1 phase, 2 wire, 50Hz AC system with effectively earthed neutral. The power supply shall be derived by CONTRACTOR by providing 415V/ 240V transformer of adequate rating with MCCB/MCB on primary/secondary sides. 24 V 1 phase,50Hz, AC with one point earthed. This shall be derived by CONTRACTOR by providing 415V 3 phase, 3 wire, AC supply through an adequately rated stepdown transformer of adequate rating with MCCB / MCB on primary/secondary sides. 24 V DC, 2 wire, supply from Battery chargers for instrumentation system only. 240 V, 1 phase, 2 wire, 50Hz system. 240 V, 1 phase, 2 wire, 50Hz system. 415 V, 3 phase, 4 wire, 50 Hz AC supply with neutral lead solidly earthed.
(i)
Winding heating of motors below 30kW
(j)
Solid state controls (including solenoid valves) Lighting fixtures
(k)
(l)
Lighting fixtures and space heaters in panels Construction supply
(m)
(n)
The above voltages may vary as follows : All devices shall be suitable for continuous operation over the entire range of voltage and frequency indicated below without any change in their performance. i. AC supply : Voltage variation 10% Frequency variation 5% Combined voltage & frequency variation 10% ii. DC supply : Voltage variation +10% -20%
TECHNCIAL L DATA SHEE ET FOR 13 30/30T CAP TG HALL EOT T CRANES YERMERUS STPP ( 2X80 00 MW )
DOC. NO.PE-TS-36 N 62-501-A001 1 REV. 0 DATE E: 4/6/12
Page 1 of 10
S.N.
Des scription
Technical Particulars
1.0
Design, , fabrication n and tes sting of the e crane confirm to o standar rd / code e number r Number of crane/s Crane classific cation Suitable e for outdoor or indoor duty Capacit ty Main ho oist Rated tonnes SWC
-1999 (reaffir rms 2006) & IS 807 IS: 3177-
2.0 3.0
As per T Table 1 M5 for M Mechanical and a Electrical as per IS: 807-2006 and 13834 (part-5)-1 1993 Indoor
4.0
5.0 5.1
As per T Table 1
130T for TG G hall crane (125% of SWC)
Overloa ad Test load d SWC tonnes 5.2 Aux. Ho oists Rated SWC S tones Overloa ad Test load d SWC tones 6.0 7.0 `8.0 8.1 Span Operation from CRANE E PERFORMANCE Crane speed full load Main Ho oist Aux. Ho oist ** with h ed M/Min Full spee 1.6 (TG h hall crane) 7.5
30T (for TG hall crane onlly) (125% of f SWC)
As per at ttached crane clearance diagrams C Cabin + pendent push but tton + radio r remote contr rol
Creep C speed d M/Min 0.16(10% 0 of main speed thru VVVF d drives) 0.75 0 (10% ( of main n speed thru VVVF d drives) 1.5 1 (10% ( of main n speed thru VVVF d drives) 3.0 3 (10% ( of main n speed thru VVVF d drives)
Crab tra avelling speed Crane tr ravelling speed
15.0
30.0
Page 2 of 10
8.2
Lift in Meters M
The liftin g rope shall l be of suffic cient length t to permit the e hook to reach the e zero level. As per at ttached crane clearance diagram As per at ttached crane clearance diagram Refer atta ached crane e clearance diagram d 32 mm N NB Medium class c of IS: 1161 having top and bott tom rail at height of f 1100 mm and 600 mm and vertiical post spa acing not exceedin ng 1500 mm with provisio on of kick pla ate (100 mm high and 6mm thic ck)
Main Ho oist Aux Hoist 8.3 Hook Approaches A
8.4
Hand d rail pipes
9.0 9.1
COMPO ONENT DETAIL LS Trolley Type Method of fabrication Material l conforming g to IS: Fabricate ed Fusion w welded
IS: 2062 Gr. B
9.2
Rope drums Material l (Indicate IS)
Main hoi ist
Aux. Hoi ist
Seamles ss pipe ASTM M A -106 Gr. B or fabrica ated Fe410w w IS: 2062 Gr B & st tress relieved d One for e each hoist Identical Right hand and a Left hand Flanged
Number rs provided Type of grooves Flange /Flangeless / 9.3 Rope de etails Standar rd Construction Factor of o safety Type of core 9.4 Sheave es details Material l
IS:2 2266 Extra a flexible plou ugh steel / 6 x 36 constru uction, Galva anised 5.25 as per r IS Steel/ Fibre Main hois st 5 5.25 as per IS S Steel / Fibre e Aux. Hoist
Fe F 410 WB IS S: 2062 Gr. B B/ CS Gr. 280-520 IS: 1030 0
Page 3 of 10
Diamete er of o Equivale ent sheaves s in mm on o Root Type of provided d 9.5 9.5.1 guard ds
not be less than 62% of o Should n calculate ed main shea ave diameter.
Should n not be less than t 62% of calcu ulated main n sheave diameter r.
Fabricated from rolled steel p plate
Couplin ng & Shaftin ng

Coupling g details (between n motor and gear box x) Type Guards and a Enclosure es
Main Hoist
Aux. Hoist
Cross C Travel l
Long Travel T
Flexible ge eared type Prov vided C Cross Travel Lo ong Travel Flexible ge eared type Prov vided Main Hoist A Aux. Hoist
9.5.2
Coupling g details (gea ar box and wheels) Type Guards and a Enclosure es
9.5.3
Coupling g details (gea ar box and rope drum) Type Guards and a Enclosure es
Flexible gea ared coupling g housed with hin the drum m Prov vided
9.5.4
Shafting g (Output) Design Of O shafts Arrangem ment of Lubricatio on Type of Lubricant L
As per IS : 3177-1999 Grease cups/ Nipples Gre ease
9.6 A.0
Gear bo ox details Hoist Motions M Type of f mounting of o gear box x Classific cation Type of gears Type of o lubrication n (grease / splash / pump lu ubrication) Heliical MH MH Micro AH AH micro
Horizonta al / Vertical Suitable fo or M5 duty NA Helica al NA N
Splash Lubrication
Page 4 of 10
Difference in Ge ear and pinion hardness s Material ls (gear/pinions) Casings s B.0 Travel Motions M Type of o gear box x mounting g CT Vertical
Min 20 0 BHN
Main Gea ars En 9/ 55C8/ IS2707 Gr. G 1or 2. Piinions En 19 9/EN 24.
Hardn ness confor rming to IS: : 3177

F Fabricated Fe e 410w IS: 20 062 Gr B & s stress relieve ed CT micro NA LT Vertical/ Horizontal M5 duty Helical NA Helical NA N NA N LT micr ro
Classific cation Type of gears Type of o lubrication n (grease / splash / pump lu ubrication) Difference in Ge ear and pinion hardness s Material ls pinions) ) Casings s 9.7 Wheels s details Material l Hardnes ss Type Number rs provided Specific cation conform ming to Arrange ement lubrication 9.8 Lifting hooks h Type of o 4 nos. (gear /
Splash Lubrication
Min 20 0 BHN
Main Gea ars En 9/ 55C8/ IS2707 Gr. G 1or 2. Piinions En 19 9/EN 24.
Hardn ness confor rming to IS: : 3177

F Fabricated Fe e 410w IS: 20 062 Gr B & s stress relieve ed Cross tra avel Long trave el
C 55 Mn 75 / EN 9 (55 C 8 8) 300 350 BHN Double flanged 8 nos. IS: 317 77-1999 Gre ease
MH Ramsho orn shank wi ith safety latc ch swiveling g type as per latest editio on of IS: 574 49 130 T f for TG hall as s per IS 5749 9
AH y latch Plaiin with safety swiveliing type as per p latest ed ition of IS: 15 5560 30T fo or TG hall as s per IS: 15560
Safe lifti ing capacity
Page 5 of 10
Material l 9.9 A.0 Brakes Hoist Motions M Type of brake Number r motor provided d/
Class 2 / IS: : 1875
Clas ss IA or 3/ IS S: 1875
MH
MH micro EHT+DCEM
AH H
AH H micro
1+1
NA
1+ 1
NA NA LT T micro
Braking capacity B.0 Travel Motions M Type of brake Number r motor provided d/
1 50% CT
NA CT micro EHT+DCEM
150 0% LT T
1+1
NA NA
1+ 1
NA NA
Braking capacity 9.10 Bearing gs Type Method lubrication Bearing life 9.11 Bridge girder Type & Quantity Vertical Deflection Type of connection n to end carriage c 9.12 Rails-Bridge girder r Type / section s of o
1 25%
125 5%
Ant tifriction ball / roller beari ngs Grease lubrication with w separate e pumps
10,00 00 working hours. h
Box type 2 nos, Material: IS 2062 2 Gr. A / B Span / 900 By fitted bolts
LT rail
CT rail
Rails sec ctions as per r IS: 3443 Grade 50 C 12 2. Joint to be buttwelded b by thermit we elding & fusio on welding IS: 3443 3
Standar rd conform ming to Material l 10.0 10.1 Motors Hoist Motions M MH
Rail Steel Suita able for ambient tempera ature of 500 C MH micro o A AH AH micro
Page 6 of 10
Type
SC, su uitable for Inver rter duty T TEFC 1
NA
SC, suit table for Inverte er duty TE EFC 1
NA
Enclosu ure Number rs furnished Voltage, phase and d frequenc cy Class of f protection Rated capacity (KW)
NA NA
NA NA
415V + 1 10%, 3 Ph, 50 5 Hz, 5 % Combined d voltage & frequency f variation = 10% abso olute IP 55 g should have minimum m margin of 15% over Selected motor rating m continuous s load deman nd including voltage and maximum er factor. rise and othe frequenc cy variation, temperature t Motor na ameplate rating at 50 oC shall s have at t least 15% margin m over the input power requirement t of driven eq quipment at rated r duty poin nt. 40 % CDF Cllass F for sq q. cage moto ors with temp p rise limited to that of class B
Rating Class of f insulation
Number r hour 10.2
of
star rts/
150 sta arts / hr
Travel Motions M Type
CT SC, su uitable for Inver rter duty T TEFC 2
CT micro NA
L LT SC, su uitable for Invert rter duty TE EFC 4
LT micro NA
Enclosu ure Number rs furnished Voltage, phase and d frequenc cy Class of f protection Rated capacity (KW)
NA NA
NA NA
415V + 1 10%, 3 Ph, 50 Hz, 5 % Combine ed voltage & frequency va ariation = 10 % absolute IP 55 g should have minimum m margin of 15% over Selected motor rating m continuous s load deman nd including voltage and maximum er factor. rise and othe frequenc cy variation, temperature t Motor na meplate rating at 50 oC shall have at least 15% % margin over the i nput power requirement of driven eq quipment at rated r duty point. 40 % CDF C Class F for sq. s cage motors with tem mp rise limited to that of class B
Rating Class of f insulation
Number r
of
star rts/
150 sta arts / hr
Page 7 of 10
hour Space heater h requirem ment 11.0 Limit sw witches Main n hoist Rotary y gear + Gr ravity 1+1 For motors abo ove 30 KW ra ating
Aux. Hois st
Cros ss Trav vel Lever t type 2
Lon ng Travel
Type
Rotary gea ar + Gravity y 1+1
Lev ver type 2
Number r provided Control voltage/ Enclosu ure 12.0 Power conductors s (DSL) Type
110 V/ IP 54
LT: PVC shrouded Cu C conductor r bus bar. CT: Flexible trailing cable mounting on re etracting sup pport (Fest toon type) ER RP insulated Cu conduct tor as per IS: 9968
Length 13.0 Control l panel Material l Number rs and location Degree of Protection n 14.0 Master Control llers Number r of steps Voltage rating Location n 15.0 Cable Material l Size Type Voltage grade Voltage drop & curren nt Main n Hoist
Su uitable for en ntire bay leng gth
Rolled sheet steel s 2mm siz ze One e each for MH, , AH, CT and d LT located on bridge pla atform
IP 54 Aux Hoist t** Cros ss Trav vel 4 ng Travel Lon
5 110 V/10 V A In cabin Power r
Control Copper Min. 1.5 mm m2 FRLS S PVC 110 00 V
Copper Min. 2.5 mm2 for Cu.
Cable fr rom main iso olating switch h (1.5M abov ve operating floor) to
Page 8 of 10
motor t terminal shall be so sized d that the vo ltage drop do oes not ex xceed 3% of f rated voltag ge. 16.0 17.0 18.0 19.0 Contact tors AC 4 du uty for revers sing applicat tion. AC 3 du uty for non re eversing applic cation AC 23 for motor r application, , AC 22 for o other applicat tion. HR RC Tem mperature com mpensated bi b metallic wit th single pha asing preve entor.
Switche es Fuses Overloa ad relay
20.0
Portable Fire Extingu uisher Type an nd size Location n 5.0 kg , DCP D type One in i cabin** and Three on b bridge 415 V, 3 phase, 3 wire w supply at operating fl floor at centre e of bay leng gth with chan nge over swiitch. Qty / Rating R 2 X 100 % / 415/110V One / 415/240V
21.0 22.0
Power Supply S
Transfo ormer Control Lighting
23.0
Illumina ation In cabin 40W f florescent fix xture + Bulk head h fitting w with 60W inca andescent lamp 1 each, 2n nos. 24V 5A A 3 pin indu ustrial socke et. 4 nos 60 0 W Bulk-hea ad fittings wit th incandesc cent lamps and 4nos. 24V V - 5A - 3 pin industrial so ocket 4 nos 4 400 W HPSV V lamps One (1) p portable 40W W (SLS lamp with enclose ed type batte ery and wire guar rd) hand lam mp with min. half h span len ngth flexible cable c for inspectio on of crane co omponents One e (1) no. Elec ctric fan in ca abin. Cross Trav vel 4 Long Travel 4
Over Br ridge Under bridge b For inspection of o crane co omponents 24.0 25.0
Ventilat tion Buffer Number r Type
Spring g loaded/ hyd draulic type rubber buffer . To be desig gned to the loaded cr rane to rest from f speed o of 50 % of the rated bring t s speed at a de eceleration rate r not exce eeding 5 m/s2.
Page 9 of 10
26.0
Type of o platform m required d on the e bridge. Position n of access s point Emerge ency escape Type of access s platform m to cabin Length Provided d sides on both h
Ch hequered pla ate platform 6 mm thick a as per IS :3502
From cabin Rung ladd der at ends By Sta aircase Full spa an length Yes
27.0
Operato ors Cabin Type of construction n Area an nd minimum clear he eight Operato ors seat Warning g gong Closed typ pe with AC 2 500/1850 mm with a cle ear head room m of 2000mm m. Revolving type Foot o operated Bra ass gong sus spended outs side the cabin and operated d from inside e. Suitable for 240 V AC o of noise leve el 95 dBA at 3.5 m In front/ f side of operators c chair
Position n of controlle ers 28.0 Type of f control for r Hoists/ CT/LT operatio on Painting g
Through VVVF V drive
29.0
Shall be as per Annexure A Ib below
30.0
Whethe er tandem operatio on required Liftingbe eamandsling g foropera ationtandem m
YE ES
31.0
5T capacity lifting l beam with w slings sh hall be provid ded 235
Page 10 of 10
PAINT TING SPE ECIFICATI ION FOR D DOUBLE GIRDER G EOT E CRAN NES A) Structural l Surf face prepar ration : De greasing an nd Mechani ical cleaning g with wire brush or ha and tool. ( SA A 1/ ST 2 / S ST 3 as app plicable) Prim mer : Red oxide o Zinc chromate as a per IS: 20 074 ( Alkyd d medium)- 2 coat , Minim mum DFT 3 30 per co oat. : Synth hetic ename el (Alkyd me edium) as per p IS: 2932 2- 2 coats, Minim mum DFT 3 35 per coa at. : 125-1 145
Finish Coat
al DFT Tota
B) Electrical /Control / Pa anel Surf face prepar ration : Sev ven tank pro ocess Prim mer : Zinc phosphate ( Alkyd med dium)- 2 co oat , er coat. Minimum DFT 25- 35 pe hetic ename el (Alkyd me edium) as per p IS: 2932 2- 3 coats, : Synth Minim mum DFT 2 20-25 per coat. : 110 - 145
Finish Coat
Tota al DFT COLOR R SHADE S. No 1 2 3 4 5

Item escription De Cr rane Structu ure Bo ottom block k ass sembly Ho ooks En nd carriage sw weep Pa anels and mo otors
Color r Shade Golden n yellow, sh hade 356 as per IS-5 Golden n yellow, sh hade 356 as per IS-5 Golden n yellow, sh hade 356 as per IS-5 Golden n yellow, sh hade 356 as per IS-5 Steel g grey/as requ uired by Purcha aser.
Remarks
With black k strip With 100 m mm wide black zebra ra strip With black k strip
2X800MWYERMERUSTGHALLCRANEOF130/30TCAPACITYINTANDEM
WriteuponLoadTestingLiftingBeamTestingatManufacturersWorks This writeup briefly describes the procedure for carrying out the load testing of lifting beam at manufacturers works by the successful bidder for the said project. Intention here is not to elaborate on step by step procedure for testing of lifting beam but to broadly outline the type of load test for the lifting beam required to be carried out by the bidder. Load testing of the beam can be carried by anyofthefollowingthreealternatives.Briefprocedureforloadtestingoftheliftingbeamwithallthe threealternativesismentionedisasunder:
ALTERNATIVEI
a) Lifting beam assembly (lower and upper lifting beam) shall be hung suitably from a structure capableofholdingtheloadforwhichtheliftingbeamisdesigned(235T)withmargins,atthe pointsfromwheretheliftingbeamissupposedtobeheldwiththehooksduringactualcrane operation in tandem. Actual lifting pins shall be used for hanging the lifting beam. Suitable wireropes/chainsshallbeusedforhangingtheliftingbeamthroughpinstothestructure. b) Load shall be applied on the lower lifting beam exactly below the above mentioned hanging arrangement with the help of hydraulic jack of suitable capacity. Duration of application of loadshallbe30minutes. c)Loadcellsshallbefixedbelowthehydraulicjacktoascertaintheloadapplied. d) Deflection of the lifting beam shall be measured at the centre and noted down under loaded condition. e) After 30 minutes, the load shall be removed and the deflection of the lifting beam shall be measuredatthecentreagaintofindoutthepermanentdeflection,ifany. f) Maximum deflection in the lifting beam should not exceed the allowable deflection as per relevantIS/equivalentstandard. g) Load testing of the lifting beam at manufacturers works shall be acceptable in horizontal conditionalso(incasethebidderdoesnthavearrangementforverticaltestingofthebeam). However, in such cases, necessary fixtures / arrangements shall have to be arranged by the bidder to demonstrate testing of beam under similar condition of loading as will be seen by thebeamduringactualtandemoperationofthecranes.
ALTERNATIVEII a) Lifting beam shall be placed on elevated pedestals instead of hanging from the fixed structure, as mentioned in the alternative I above and the load shall be applied with the help of hydraulicjackfrombelow. b)AllotherrelevantconditionsshallremainsameasmentionedinalternativeIabove.
ALTERNATIVEIII
a) Lifting beam shall be placed on the elevated pedestals as mentioned in alternative II above. However the load shall be applied from the top of the lifting beam. Either dead load or hydraulicloadcanbeusedforthispurpose. b)IncasebidderpreferstogowithAlternativeIII,biddershallberequiredtotestthelowerlifting beamalsointhesimilarfashionastheupperliftingbeam.c)Allotherrelevantconditionsshall remainsameasmentionedinalternativeIabove.

(BiddersSignaturewithSeal)
MANUFACTURER'SNAME&ADDRESS ITEM:
MANUFACTURINGQUALITYPLAN
QPNO:PETSSTD501A001 REV: DATE:
QUANTUM OFCHECK REFERENCE DOCUMENT
PROJECT: PACKAGE:DOUBLEGIRDERCRANES CONTRACTNO: CONTRACTOR: VENDOR'SQAPNo:

AGENCY FORMATOF M C N RECORDS D* ** 10 9
SL. NO. 1
COMPONENTS& OPERATION 4
CHARACTERISTCS 3
CLASS 4
TYPEPF CHECK 5
ACCEPTANCE NORMS 8
REMARKS 11
1
a
Fabricatedcomponents BoxGirder,EndCarriage,CrabFrame,RopeDrum
Material Chemical&TensileProperties (Y.S.,UTS&%Elongation) Major Corelation withT.C. Checktestin absenceofT.C. Ultransonic Major Measurement 1/Heat/Batch IS:2062GrA/B IS:2062GrA/B Mfr'sT.C/ Vendor's T.C. ASTMA435 Components drawings T.C./I.R. Vendor's inspection report MTC/LabTC
P V V
Refernote:1
U.Tofplates. b weldsetup dimensions
100% 100%for buttjoints
ASTMA435 Components drawings
P V V
P
U.T.ONABOVE25MMTHICKPLATE
1A
2 a
Corelationwith 1/heat/batch ASTMA106GrB TC,checkin absenceofTC WeldingWPS(Weldingprocedurespecification)inlinewithASMEsec.IX(QW482)ForBoxGirder,EndCarriage,CrabFrame,RopeDrum Checkforwelding procedurequlification, welder'sperformance Weldingparameters Major check&test 100% ASMESecIX
Seamlesspipe
Chem,tensile,elongation,macro&flattening
major
ASTMA106GrB
P V V Refernote:1
ASMESecIX
QW482,QW483 QW484ASPER
P V V Welder/procedurequalifiactionwill
bewitnessedbycustomer/BHELas perapprovedWPS.IncaseWPS& Welderqulificationapprovedby otherrenownedagencieslike Lloyds/TPL/NTPCisalreadyavalable, requlificationnotrequired. P V V
asmeSecIX
Backchipping
surfacedefect
Major
DPT
100% ASMESecVIII, DivI,Appen8
ASMESecVIII, DivI,Appen8
ASMESecVIII,CL UW51
Vendorinsp. Report Vendorinsp Repot RTfilm
ButtWelds
WeldQuality
Critical Gammaray Radiography
100%inten sion25%in compression zones&100% forbuttweld ofropedrum

100%
ASMESecVIII
P V V Reviewofinspectionreport&
radiographyreportandRTflims. Refernote:2
Critical DPT
IS:3658
ASMESecVII, Vendorinsp Repot Appen8
P W V DPtestoffilletweldfor ropedrumtobeconducted afterfinalmachining
RandomwitnessbyBHEL LEGEND:
D*RECORDSINDETIFIEDWITH'TICK'()SHALLBEESSENTIALLY INCLUDEDBYCONTRACTORINQADOCUMENTATION **M:MANAFACTURER/SUBCONTRACTOR MANAFACTURER/
CONTRACTOR
C:BHELCQS
INDICATE"P"PERFORM"W"WITNESSAND"V"DOCUMENTREVIEW
SUBCONTRACTOR
SIGNATURE
N:CUSTOMER
REVIEWEDBY
NAME&SIGNOFAPPROVINGAUTHORITY&SEAL
Format: QS-01-a1-P-9/F1/R1
BHEL-QAP
2 of 11

FORMATOF AGENCY M C N RECORDS D* ** 10 9
SL. NO. 1
CHARACTERISTCS 3
CLASS 4
TYPEPF CHECK 5
ACCEPTANCE NORMS 8
REMARKS 11
filletwelds
Sizeandsurfacedefects
Major Visual
100%
Component ComponentDrg. Drg. ASMESecVIII Div1 Append8

VendorMfg.Drg.
Venderinsp. Report
P V V
Major DPT finalinsectionoffabricated componentslistedinSr.1 DimensionsforGirder,end carriageropedrumetc. above

Heattreatmentofropedrum Camber,Verticality,bend etc Stressrelieving
10%RANDOM
ASMESecVIII Div1 Venderinsp. Report Append8

VendorMfg.Drg. vendorroute card/vendor inspreport
P W V
Major Dimensional
Measurement
100%
P V V
Major
ReviewofSR chart
100%
ASMESecVIII,DivI ASMESecVIII,Div SRChart I
P V V IffabricatedfromM.SPlate
Gearboxcasing Material
Surfacecondition
Major
Visual
100%
ComponetDrg.
ComponetDrg.
Vendorinsp Report T.C.&I.R.
Refernote1
Chemical&mech
Major
Measurement Correlationwith T.C.Checktest inabsesnceofT.C. Correlation Measurement ReviewofSRchart
100% 100%
ComponetDrg. IS:2062
ComponetDrg. IS:2062
P V V
b c
welding Heattreatment
Welding&Dimensionalconformity stressrelieving
Major Major
100% 100%
ComponetDrg. ComponentDrg./
Vendorinsp Report ComponentDrg./ Vendorinsp Report
ComponetDrg.
P V V
ASMESecVIII,Div ASMESecVIII, I DivIfor procedure. 4 PLATFORMS Dimensionalconformity Minor Measurement 100% ComponentsDrg.
ComponentsDrg. Vendorinsp Report ComponentsDrg. Vendorinsp Report ComponentsDrg. Vendorinsp Report ComponentsDrg. Vendorinsp Report
Refernote:1
L.T.FRAMES
Dimensionalconformity
Minor
Measurement
100%
ComponentsDrg.
HANDRAILINGS
Minor
Measurement
100%
ComponentsDrg.
CABIN
Minor
Measurement
100%
ComponentsDrg.
P V
LEGEND:
D*RECORDSINDETIFIEDWITH'TICK'()SHALLBEESSENTIALLY INCLUDEDBYCONTRACTORINQADOCUMENTATION **M:MANAFACTURER/SUBCONTRACTOR
MANAFACTURER/ SUBCONTRACTOR
CONTRACTOR
C:BHELCQS
BHEL-QAP
3 of 11

SL. NO. 1
CHARACTERISTCS 3 N:CUSTOMER
CLASS 4
TYPEPF CHECK 5
ACCEPTANCE NORMS 8
REVIEWEDBY
REMARKS 11
SIGNATURE
BHEL-QAP
4 of 11

SL. NO. 1 8
COMPONENTS& OPERATION 4 Currentcollerctorarms
CHARACTERISTCS 3 Dimensionalconformity
CLASS 4 Minor
TYPEPF CHECK 5 Measurement
6 100%
7 Mfr.Catalog
ACCEPTANCE NORMS 8 Mfr.Catalog
REMARKS 11
Vendorinsp Report
9 10
DSLGuard Rails
Dimensionalconformity Dimensionalconformity,
Minor Minor
Measurement Measurement
100% 100%
Chemical&hardness 11 A MECHANICALCOMPONENTS
Major
Checkchemical& hardness
One/Cast
ComponentsDrg. Vendorinsp Report G.A.drg./IS:3443 G.A.drg./IS:3443 VendorReport/T Vendore Vendore T.C./Appd.Data T.C./Appd.Data Sheet Sheet IS3443 IS:3443 VendorReport/T
ComponentsDrg.
P V V
P V V
a)wheels
i)Materials Chemicalscompositionand MechanicalProporties. ii)Machined a)Dimensions b)Hardness Major Major Corelationwith mfr'sTC Measurement Mechanical 100% 100% 100% Mfg.drg./IS:1570 /BS970 Component Drawing ApprovedData Sheet/Mfg.Drg. ReferNote:6 8 Component Drawing, BS:970/IS:1570 ApprovedData Sheet 100% 100% 100% ASMESecV Mfg.drg.& ApprovedData Component Drawing ASTME165 Mfg.drg./IS:1570 Test /BS970 Certificate P V V
P V V ReferNote:1
Component Vendorinsp. Drawing ApprovedData Report Sheet/Mfg.Drg. ReferNote6 App8 Component Drawing, BS:970/IS: 1570 ApprovedData Sheet ReferNote6 Mfg.drg.& ApprovedData Component Drawing Vendorinsp. Report
P V V P V V P W V P V V
c)UT b)Gears,Pinions,Shafts, Axlesetc d)DPT i)ChemicalsComposition &heattreatment,Mech Properties. Major
NDT NDT Correlationwith mfr'sTC Checktestin absenceofTC checkforUT (above50mmdia) checkfor Hardness Measurement
100% 100% 100%
ii)UT(afterproofmachining)
Major Major Major
Vendorinsp. Report Vendorinsp. Report Vendorinsp. Report
P V V HardnesswitnessingbyBHEL
beforeteethcutting.
iii)Hardness iv)Dimensions
P W V
P V V P V V
V)D.P.Testonteeth
Major
NDT
100%
NoCrackandline Vendorinsp. of indication Report
LEGEND:
D*RECORDSINDETIFIEDWITH'TICK'()SHALLBEESSENTIALLY INCLUDEDBYCONTRACTORINQADOCUMENTATION **M:MANAFACTURER/SUBCONTRACTOR MANAFACTURER/
SUBCONTRACTOR
CONTRACTOR
C:BHELCQS
BHEL-QAP
5 of 11

SL. NO. 1
CLASS 4
TYPEPF CHECK 5
ACCEPTANCE NORMS 8
REVIEWEDBY
REMARKS 11
SIGNATURE
BHEL-QAP
6 of 11

SL. NO. 1 B
CHARACTERISTCS 3
CLASS 4
TYPEPF CHECK 5
ACCEPTANCE NORMS 8
REMARKS 11
Pulleys,Brakedrums,coupling&othermajorsteelcastings&forging
i)Materials Physical/Chemical/Hardness exceptpulleys. a)Dimensions Major Corelationwith mfr'sTC Measurement 100% Components Drawing Components Drawing Components Drawing Components Drawing Mfr'sT.C.
P V V
P V V
ii)Machined
Major
100%
Vendorinsp report
b)DPTingrooveafter C Gearboxassy&idlerunning machiningforpulleysonly. Checkforoilleakage,Noiselevel, backlash,riseintemp.after2 Hrs.ofrunning.
Major Major
NDT Visual& Measurement
100% 100%
ASTME165 Vendorstandard
No.crack/Liner
Vendorinsp.
P V V P V V Vendor'sstandardtobeapproved
byBHEL
indication Report Smoothrunning Vendorinsp. no oilleakage,Noise Report 85dbat1Mtr. Max.Temp.rise
a)Topblcok,bottomblock
dimensionalconformity
Major
Masurement
100%
b)Hook
i)Chemicalcomposition,Heattreatment, Mechanicalpropertiesonintegeral testbar ii)UTonrawmaterialofhook iii)Forgingoperationofhook iv)Proofloadtest
Major
Chemical& Tensile
100%
40Caboveamb Assemblydrawing Assembly Vendorinsp. drawing Report Profile:IS:IS5749/IS15560 TestCertifacte& Insp.Report Material:ClassIIIS:1875
P V V
P V V
Major Major Major
UT Visual Mechanical
100% 100% 100%
ASMEsecv IS:5749/IS:15560 IS:5749/IS:15560
Annex1 (Attached) IS:5749/IS:15560 IS:5749/IS:15560
P V V P V V P W V Witnessabove15Tonly P W V Witnessabove15Tonly
v)UT&MPIafterproofloadtest (UTonshankportiononly)
Major
UT&MPI
100%
ASMEsecv
Annex1forUT& Nocrack&linear indication(For Toleranceasper Vendorinsp drg Report
Ropedrumassembly
Diemnsionalconformity
Major
Measurement
100%
Component Drawing
P V V
LEGEND:
D*RECORDSINDETIFIEDWITH'TICK'()SHALL BEESSENTIALLY INCLUDEDBYCONTRACTORINQA DOCUMENTATION **M:MANAFACTURER/SUBCONTRACTOR MANAFACTURER/
CONTRACTOR
C:BHELCQS
INDICATE"P"PERFORM"W"WITNESSAND "V"DOCUMENTREVIEW
SUBCONTRACTOR
BHEL-QAP
7 of 11

SL. NO. 1
CLASS 4
TYPEPF CHECK 5
ACCEPTANCE NORMS 8
REVIEWEDBY
REMARKS 11
SIGNATURE
BHEL-QAP
8 of 11

SL. NO. 1 12 a) b) c)
COMPONENTS& OPERATION 4 Electricalcomponents Motors(=<50KW) Brakes Controlpanel
CHARACTERISTCS 3 Routinetest Routinetest Interlockingfuctional,IR, HV,Sheetthikness Overalldiemsnions,painting shade,Panelsurfacefinish, Thickness,adhesivetest, Componentfixing,Degreeof protectionbypaperinserting method HV,IR,Temp,rise,measurement ofresistancevalues HV,IR,Functional
CLASS 4 Major Major CR
TYPEPF CHECK 5 Reviewmfr'sTC Reviewmfr'sTC TestforHV functional& routinecheck
6 100% 100% 100% IS:325 Mfr.Std
ACCEPTANCE NORMS 8
REMARKS 11
IS325/Mfr'sT.C. Mfr'sT.C. Mfr.Std Mfr'sT.C.
P V V ReferNote3. P V V P W W ReferNoteNo.4
VFDTestCertificatetobe submittedfromapp.Vendor forverification.
Relevantdrg.&IS Vendrsinsp :3177/ Generallyconfirm App.PanleDrg.&Report to BOM IS:3177/App. PanleDrg.& BOM
Relevantdrg&
d)
Resistanceboxes (Ifapplicable) Mastercontrollers
Major
Verfication
100%
IS:3177/App. BOM
IS:3177/App. BOM
Mfr'sT.C.
P V V P V V ReferNoteNo.4 P V V P V V
e)
Major
Verfication
100%
BOM/Mfr.Catalog BOM/Mfr. Catalog Approved drawings ,IS:9968 IS1554Part1 Approved drawings ,IS:9968 IS1554Part1
Mfr'sT.C.
f)
Limitswotches
HV,IR&Functional
Major
Verfication
100%
Mfr'sT.C.
g)
Trailingcable,Power andControlCable.
Routine&aceptancetest insulationresistancevalues
D RECORDSINDETIFIEDWITH TICK ()SHALL BEESSENTIALLY Q DOCUMENTATION **M:MANAFACTURER/SUBCONTRACTOR
Major
Verfication
100% 10%min
Mfr'sT.C.
LEGEND:
MANAFACTURER/
CONTRACTOR
C:BHELCQS
INDICATE"P"PERFORM"W"WITNESSAND "V"DOCUMENTREVIEW N:CUSTOMER
SUBCONTRACTOR
SIGNATURE
REVIEWEDBY
BHEL-QAP
9 of 11

SL. NO. 1 13 a) b) c)
COMPONENTS& OPERATION 4 Boughtouritems Wirerope OtherItems Bearing
CHARACTERISTCS 3 Identification,Grade&dimensional conformitybreakingstrength Dimensionalconformity Type&Size
CLASS 4 Major Major Major
TYPEPF CHECK 5 Visulcorelation withTC ReviewTC Verfication
6 100% 100% IS:2266
ACCEPTANCE NORMS 8 IS:2266 RelevantDrg. T.C.
REMARKS 11
P V V
P V V
RelevantDrg.
Vendor Confirmation
Appd Appd drg/Mfr'scatalogu drg/Mfr'scatalogu e e
P V V
14 a) b) c)
Assemblyofcranes BridgewithLT Crabassembly FinalInspection(atworks) withactualpanel,RRCand pendent
Dimesions,wheellevel alignment Dimesions,wheellevel alignment Overalldimension:Span,Diagonaldimension check,Eqp.Layoutonbridgeplatform,No LoadrunningofLTmachineryfordirection andspeedwithVFD,elevations/levelsetc NoLoad&LoadTests a)Noload:Hoists,CT,LTspeed &currentmeasurement.. b)SWL:Hoists,CTspeed,current &Deflectionmeasurement
Major Major Major
Measurement Measurement/ Visual Measurement
100% 100% 100%
GAdrg/IS:3177 GAdrg/IS:3177
GAdrg/IS:3177 GAdrg/IS:3177
Vendorinsp. report Vendorinsp. report Vendorinsp. report
P W V P W V P W W
Approveddrgs./IS Approved :3177 drgs./IS:3177
Major Major
Measurement
100% 100%
Approveddrgs GAdrg/IS:3177
Approveddrgs GAdrg/IS:3177
Vendorinsp. report Vendorcranetest report
P W W
P W W
Tech.Specification Tech. Specification Major Operational Check GAdrg/IS:3177 GAdrg/IS:3177
c)Overload:Hoists,CTmovement&current measurment (at125%SWL) d)Operationcheckofbrakesandlimit switches. Liftingbeam(incaseoftandem Dimension,Visualandloadtest operation) ReviewofQAdocumentation CleaningandPainting Surfacepreparetion& Painting
Vendorcranetes report
P W W
Tech.Specification Tech. Specification
d) 15 16
Major
measurement, check
100%
Major
Visual
Approveddrgs/doc Approved IR drgs/doc Asperapproved QAP AsperClient's AsperClient's Vendor's specs specs Report
P W W
V V V P V
LEGEND:
CONTRACTOR
C:BHELCQS
SUBCONTRACTOR
SIGNATURE
REVIEWEDBY
BHEL-QAP
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SL. NO. 1
CHARACTERISTCS 3
CLASS 4
TYPEPF CHECK 5
ACCEPTANCE NORMS 8
REMARKS 11
BHEL-QAP
11 of 11

SL. NO. 1
CHARACTERISTCS 3
CLASS 4
TYPEPF CHECK 5
ACCEPTANCE NORMS 8
REMARKS 11
Note1: OriginalTCs/Photocopiescertifiedinoriginalbymillshallbefurnishedforreview.TestInabsenceofcorrelatedTCsChecktestshallbecarriedoutfromeachplate/barfor above10mmthk.,certificatesshallbeofferedforreviewatthetimeofstageinspectionofcomponents/assembly.Suppliershallensurethatpittedmaterialisnotused. Note2: XRaytobetakenforthicknessupto19mmandGammaRayforthicknessabove19mm.IfGammaRayisusedforlowerthicknessslowspeedfilmlikeD2orequvalent whichgivesenoughreadableandinterpretablefilmqualitytobeusedforclarity.AllNDTshallbecarriedoutbyQualifiedLevelIIpersonnel. Note3: ForMotorsof50KWratingandaboveRoutineTestwillbewitnessedbyBHELandTypeTestCertificatewillbereviewedforvalidityandconformance.Forbelow50KWrating supplierofcraneandTypetestreviewedforvalidityandconformance.PhotocopiesofTypeTestcertificatesareacceptablebutshallbedulyauthenticatedbyManufacturer Note4: Perofrmanceofelectrical&controldevicesalongwiththeinterlocks,protection&sequencetobecheckedduringcraneassemblyandparkedatworks. Note5: AcceptancenormsforUT(Normalprobetobeusedofnotlessthan2MHzfrequency):Followingdefectsarenotacceptable:/Vendor'sUTProcedureapprovedbyBHELmay alsobeused. (i)Cracks,flakes,seamsandlaps (ii)Defectsgivingindicationslargerthan6mmdiameterequivalentflaw. (iii)Groupsofdefectswithmaximumindicationlessthanthatfroma6mmdiameterequivalentflawwhichcannotbeseparatedattestingsensitivityifthebackechois reducedtolessthan40%. Note6: AcceptancenormsforUT(Normalprobetobeusedofnotlessthan2MHzfrequency):Followingdefectsarenotacceptable:/Vendor'sUTProcedureapprovedbyBHELmay alsobeused. (i)Cracks,flakes,seamsandlaps (ii)Defectsgivingindicationslargerthan4mmdiameterequivalentflaw. (iii)Groupsofdefectswithmaximumindicationlessthanthatfroma4mmdiameterequivalentflawwhichcannotbeseparatedattestingsensitivityifthebackechois reducedtolessthan50%. (iv)Defectsgivingindicationsof2to4mmdiameterequivalentflawseparatedbyadistancelessthanfourtimethesizeofthelargeroftheadjacentflaws Forhooks,forcarryingoutUTontheareaswherethereislossofbackwallechoduetogeometry,thecalibrationshallbedoneonblocksofsamematerialofsimilarthickness Note7: Allmaterialofconstructionshallbeasperapproveddrg./datasheet/specifications
LEGEND:
CONTRACTOR
C:BHELCQS
SUBCONTRACTOR
SIGNATURE
REVIEWEDBY
BHEL-QAP
12 of 11
MANUFACTURER NAME & ADDRESS
MANUFACTURING QUALITY PLAN QP. NO. : ITEM: 235T LIFTING BEAM ASSEMBLY FOR 130/30 D/G EOT BHEL DRG. NO.: CRANE Rev. 0 DATE : TYPE OF CHECK 5 Co-relation with T.C. Check test in absence of T.C. Ultrasonic Measurement QUANTUM OF CHECK 6 1/heat/batch REFERENCE DOCUMENT 7 IS:2062 ACCEPTANCE NORMS 8 IS:2062
PROJECT : 2 X 800 MW YERMARUS STPP PACKAGE :-TG HALL EOT CRANES CONTRACT NO.:-
SR. NO. 1 1)
COMPONENT & OPERATIONS
CHARACTERISTIC
CLASS
FORMAT OF RECORD 9 Mfgr's TC or test report intrrnal insp . Report inspection report D M P
AGENCY
REMARKS
3 4 2 For lifting beam (lower & upper lifting beam) Chem. & Phy. Major Material UT on plates Dimensional conformity Chem. & Phy. . . . U.T Identification,Grade & dimensional conformity breaking strangth Major Major
10 C V
11 N V
i)
100% 100% for butt weld joint 100%
ASTM A 435 Component drawing
ASTM A 435 Component drawing
P P
V
-
V
-
UT on 25 mm & above 25 mm thick plate
ii) iii)
Weld set up Pins for Slings & Hooks
Major
Major
vi) 2) i)
Wire rope
Co-relation with T.C. Check test in absence of T.C. U.T Visul corelation with TC
100%
Mfg.drg/EN-9(070M55) / BS - 970-1983. . . ASTM A388 IS:2266
Mfg.drg/EN-9(070M55) / Mfgr's TC or test report BS - 970-1983. . . ASTM A388 T.C. IS:2266
P . . . P P
V . . . V V
V . . . V V
IF DIA >= 50mm UT to be Applicable. . . (U.T Procedure Attached)
Welding Welding parameters Check for welding procedure qualification & welder's performance
Major Review of earlier appd. WPS/WPQ/ PQR records
100%
ASME SEC IX
ASME SEC IX
WPS/WPQ/P QR records as per ASME SEC -IX format
WPS already approved by NTPC shall be valid. In case NTPC/BARC/NPCIL/ IRS/TPL/LIOYDS qualified welders already available & doing the same job regularly, requalification is not required. Alternatively welder qualified by above agences will be utilised.
ii)
Back chipping
Surface defects
Major
DPT
100%
IS-3658
ASME - Sec. VIII Div 1 Appen.-8 ASME SEC VIII Clause UW -51 IS :3658 / ASME SEC VIII Appnd. 8
FOR CUSTOMER USE
inspection report RT report & Film inspection report
Weld Quality a) Butt-Weld
Critical
Gamma ray radiography DPT
100% in tension & 25% in compression. 100%
ASME SEC VIII
Review of inspection report, Radiography report & film is CHP.
Major
IS: 3658
LEGEND:
RECORDS IDENTIFIED WITH 'TICK ( ) SHALL BE ESSENTIALLY INCLUDED BY CONTRACTOR IN QA DOCUMENTATION
Manufacturer/ Contractor sub-contractor
SIGNATURE
"M" MANUFACTURER/ SUBCONTRACTOR "C" CONTRACTOR(BHEL) "N" CUSTOMER ( NTPC ) INDICATE "P" PERFORM, "W" WITNESS AND "V" VERIFICATION AS APPROPRIATE. " CHP" SHALL IDENTIFIED IN COLUMN " N " NOTE: ITEMS NOT COVERED IN MQP, MAY BE CLEARED ON BASIS OF "CERTIFICATE OF CONFIRMANCE"
1 of 2
REVIEWED BY
APPROVED BY
APPROVAL SEAL
MANUFACTURER NAME & ADDRESS
MANUFACTURING QUALITY PLAN QP. NO. : ITEM: 235T LIFTING BEAM ASSEMBLY FOR 130/30 D/G EOT BHEL DRG. NO.: CRANE Rev. 0 DATE : TYPE OF CHECK 5 Visual QUANTUM OF CHECK 6 100% REFERENCE DOCUMENT 7 Component Drawing ACCEPTANCE NORMS 8 Component Drawing
PROJECT : 2 X 800 MW YERMARUS STPP PACKAGE :-TG HALL EOT CRANES CONTRACT NO.:-
SR. NO. 1
COMPONENT & OPERATIONS 2
CHARACTERISTIC
CLASS
FORMAT OF RECORD 9 inspection report D M P
AGENCY
REMARKS
3 Surface defect & size
4 Major
10 C V
11 N
b)
Fillet Weld DPT 10% at random 100% IS:3658 Individual component drawing GA drawing of lifting beam /IS 3177 & Tech-Specification. Free from linear indication Individual component drawing GA drawing of lifting beam / IS 3177 & Tech. Specification. AS per approved QAP
iii)
Visual & dimensional Inspection of fabricated lifting beam Final assembly of Lifting Beam Review of QA Documents Load Test at manufacturers' works as well as Site Visual & Dimensional .
Major Dim ensional & measurement Major . . Visual & Dimensional check
inspectio n report inspectio n report interrnal inspection report.
P P
W V
V V
W: After Complete fabrication
3) 4) 5)
100%
P V P
W V W
W V W
CHP
Visual
Major
Visual
100%
Load Test Procedure
Load Test Procedure
Inspection Report
LEGEND:
RECORDS IDENTIFIED WITH 'TICK ( ) SHALL BE ESSENTIALLY INCLUDED BY CONTRACTOR IN QA DOCUMENTATION
FOR CUSTOMER USE
Manufacturer/ Contractor sub-contractor
SIGNATURE
"M" MANUFACTURER/ SUBCONTRACTOR "C" CONTRACTOR(BHEL) "N" CUSTOMER ( NTPC ) INDICATE "P" PERFORM, "W" WITNESS AND "V" VERIFICATION AS " CHP" SHALL IDENTIFIED IN COLUMN " N " NOTE: ITEMS NOT COVERED IN MQP, MAY BE CLEARED ON BASIS OF "CERTIFICATE OF CONFIRMANCE"
REVIEWED BY
APPROVED BY
APPROVAL SEAL
2 of 2
2X800 MW YERMERUS STPP, 2 NO'S 130/30T TG HALL EOT CRANE OPERATION AND MAINTENANCE SERVICES FOR 2 YEARS SHALL INCLUDE BUT NOT LIMITED TO FOLLOWING 1.0 For Operation of the Crane An experienced crane operator shall be available as and when required by BHEL for at least 16hrs a day, daily. For Maintenance of the Crane a) Break-Down Maintenance i) In case of any break-down of the crane during the contract period, service engineer shall be made available at site within 72 hrs. ii) All the critical spares and consumables, as deemed necessary by the manufacturer shall be made available at the site. No delay in crane maintenance shall be allowed by BHEL due to non-availability of required spare at site. b) Preventive Maintenance i) Following work should be carried out quarterly
Bridge and Trolley Checking for wear, flat spots and cracks in flange. Ensure wheel assy drive wheels are of the same diameter. Runway Checking alignment and elevation of gantry track. Checking rail clamp bolts. Machine Bolts Checking all foundation bolts of Electrical and Mechanical equipments for tightness. Structural Bolts Checking for tightness. They should also be checked after the first month of operation. Flexible Couplings Checking pins and teeth for wear, cleaning and greasing. Cross-shaft Dismantling cap. Cleaning and checking oil seals and to be Plummer Blocks packed with fresh grease. Trolley Collectors Checking of cable trolleys / cabling / chain. Ensuring connection of trolley wheels is kept through entire length of span. Brakes All Brake assembly will be checked for loose connection, earthing connection, linings for wear, leakages and adjustments to ensure brake is not rubbing the brake drum during operation. Greasing pins and operation adjustment of brakes. Resistor Checking, tightening connections at grid joints and at cable Connections terminations. Control Station Clean out control cabinets. Checking of all connection at push buttons, master controllers contact tips, cams and terminals. Control Panels All Control Panels will be checked for loose connection and cleaning the contactor contacts, if required will be replaced. Electrical Motors All motion motors connection will be checked for loose contacts in terminal box loose crimping of wire lugs, loose
2.0
Safety Switches Main Collectors
Electrical connections
contacts on slip ring assembly with carbon brush. Earthings connection with motor. All limit switches will be checked for desired operation and limits. Emergency switches will be checked. Checking of worn collector shoes, sag in main runway wiring, ensuring contact is kept through entire length runway properly. Checking throughout electrical equipments for loose connection such as selector switches, junction boxes, min isolator switch etc. All gear box and thrusters oil level will be checked. All bearings, couplings grease will be checked. After completion of checking and required rectification, trolley will be checked for idle operation, for brake operation, limit switch operation & safety switch operation. All motor currents will be checked on no load.
Lubrication Testing
ii)
Following work should be carried out annually.

Oil seals will be checked, if required will be replaced. Gear and pinion teeth will be checked. Drain the oil cleaning gear box and refill fresh oil. All motors insulation test and meager test will be carried out. All resistance boxes step resistance value will be checked.
Gear Boxes
Motor Resistance Box
iii)
Besides the quarterly and annual preventive maintenance schedule mentioned above, operator shall carry out any daily, weekly, monthly maintenance schedule as deemed necessary and shall operate the crane only when the fitness of the crane for operation has been ensured.
SPECIFIC CONFIRMATION / COMMENTS REQUIRED FROM BIDDER TITLE: DOUBLE GIRDER EOT CRANE FOR TG HALL PROJECT: 2X800 MW YERMERUS STPP S.N. 1.00 1.01 DESCRIPTION MECHANICAL Bidder to confirm that the Data sheet attached along with project specific Technical Specification No. PE-TS-362-501-A001 Rev. 00 are acceptable without any deviation. Bidder to confirm the same. In case of any deviation, the same has been furnished in the separate Deviation schedule attached along with the Technical Specification. Bidder to note that deviation mentioned elsewhere will not be taken cognizance of in any case. Bidder to confirm the same. Bidder to note that QAP indicated in the standard technical specification PE-TS-STD-501-A001 R03, is the minimum requirement. Finalisation of the same shall be as per final approval by BHEL/CUSTOMER. Bidder to confirm Bidder to confirm that there is no deviation from the Crane Clearance Diagram no. PE-DG-362-501-A001 Rev 01A . Bidder to specifically note that in no case any deviation from the Crane Clearance diagrams given by BHEL shall be accepted. Bidder to confirm the same. Bidder to confirm that there is no deviation from the makes of various sub vendors items as given in annexure-I Makes of Sub-vendors Items , volume II-B, section-C. of standard technical specification PETS-STD-501-A001 Rev. 03 Bidder shall confirm the compliance The material offered is equal or better in grade than specified. Bidder shall confirm the compliance Bidder to note and confirm that there will be no price implication for variation in Span, Lift and baylength upto 500 mm. Bidder to confirm Bush as a antifriction bearing shall not be used. Bidder shall confirm the compliance
SPECIFICATION: PE-TS-362-501-A001 VOLUME-II B SECTION-C REVISION:00
REPLY / COMMENTS BY BIDDER CONFIRMED / NOT CONFIRMED
1.02
CONFIRMED / NOT CONFIRMED
1.03
1.04
1.05
1.06 1.07 1.08
CONFIRMED / NOT CONFIRMED CONFIRMED / NOT CONFIRMED CONFIRMED / NOT CONFIRMED
1.09
1.10
1.11
1.12
SPECIFIC CONFIRMATION / COMMENTS REQUIRED FROM BIDDER TITLE: DOUBLE GIRDER EOT CRANE FOR TG HALL PROJECT: 2X800 MW YERMERUS STPP Bidder to specifically note that there is specific requirement of the painting for this particular project. Bidder to confirm the compliance to the attached Painting specification.( Annexure I) Bidder to confirm that in case of award of order, Hook drawing shall be submitted to BHEL within one week of receiving the LOI. Bidder also to submit Unpriced Purchase Order copy of Hook within 15 days from LOI . Bidder to confirm Bidder to confirm that in case of award of order, Motor Sizing calculations shall be submitted within 15 days time of receiving the LOI by the bidder. Bidder to confirm the same. Bidder to note that lifting beam has to be sourced from BHEL approved suppliers only. Also the testing of the lifting beam at manufacturers works shall have to be carried out by the bidder as per BHEL approved QAP. List of sub-vendors and reference MQP (to be finalized during detail engineering) for Lifting beam testing at manufacturers works, are being furnished along with the specification. Bidder to confirm acceptance. ELECTRICALS CABLES All CONTROL AND POWER cables shall be as per BHEL specification. Bidder shall confirm the compliance Makes of cables shall be as agreed in between BHEL / Customer during contract stage and approved make shall only be supplied. Bidder shall confirm the compliance Cable required between isolating switch / change over switch and DSL included in the scope. Bidder to confirm the same. MOTORS Class of insulation of Sq. cage motors shall be "F" and the temperature rise to limited to class "B". Bidder shall confirm the compliance
2.00 2.01 a b
CONFIRMED / NOT CONFIRMED CONFIRMED / NOT CONFIRMED CONFIRMED / NOT CONFIRMED
2.02 a
b c
SPECIFIC CONFIRMATION / COMMENTS REQUIRED FROM BIDDER TITLE: DOUBLE GIRDER EOT CRANE FOR TG HALL PROJECT: 2X800 MW YERMERUS STPP Motor size shall be subjected to the approval of motor calculation. Bidder shall confirm the compliance The successful bidder shall submit the data sheet -C of LV motors during detailed engineering and the same is subjected to customer approval without any cost implication on account of the same. Bidder shall confirm the compliance The minimum requirement indicated in the BHEL's Standard QAP shall be complied for Electrical Items. Bidder shall confirm the compliance Bidder to confirm that there is no technical deviation on "Electrical portion of StanderdTechnical specification" and "Data sheet of Electrical portion". Bidder to confirm the same.
d e
Annexure-C
VENDOR HAS TO SUBMIT ONLY FOLLOWING DOCUMENTS ALONG WITH THE OFFER, FOR TECHNICAL EVALUATION OF THE BID:-
1.0 Specific confirmation / Comments from the bidder as per BHEL Format. 2.0 NO DEVIATION CERTIFICATE Clearly mentioning that bidder has considered No - Deviation from the technical specification provided by BHEL. OR DEVIATION Sheet, indicating clause wise technical deviation if any. 3.0 Unpriced format, duly mentioned Quoted against each Sl.no. below each column.
Note1:- Any other standard document/ details furnished by the bidder i.e. Data sheet / Crane clearance diagram/ GA Drawing/ QAP etc. shall not be taken in to consideration for evaluation. Note 2:- Bidder to note that if the bidder does not submit the documents mentioned in Sl. No. 1.0 ,2.0, and 3.0 along with their offer then their offer is liable to be rejected.

P Power S Bhar Sector Rat Hea R Proje Avy Elec Ect Eng Noida India Ctrical Ineeriin A Ls LTD NG Mana Agemen NT

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P Power S Bhar Sector Rat Hea R Proje Avy Elec Ect Eng Noida India Ctrical Ineeriin A Ls LTD NG Mana Agemen NT

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RAI ICHUR POWER P R CORP PORATIO ON LIM ITED (A A JVC O OF KPCL L & BHE EL)

2x x800MW W YERM MARUS SUPER S AL TPP P CRITICA

SP PECIFICA ATION NO.: PE E-TS-36 62-501-A A001

TECHNICAL SPECIFICATION FOR TG HALL EOT CRANE 2X800 MW YERMERUS STPP

Specification no.: PE-TS-362-501-A001 Rev. 00 Date: Jun 12 Sheet 1 of 1

RAICHUR POWER CORPORATION LTD

6.0 7.0 8.0 9.0 10.0

RAICHUR POWER CORPORATION LTD

Design Temperature for all Electrical/ Mechanical Equipment

(b) i. ii. iii. (c)

RAICHUR POWER CORPORATION LTD

Auxiliary power supply

Uninterrupted power supply

RAICHUR POWER CORPORATION LTD

Winding heating of motors below 30kW

Solid state controls (including solenoid valves) Lighting fixtures

Lighting fixtures and space heaters in panels Construction supply

DOC. NO.PE-TS-36 N 62-501-A001 1 REV. 0 DATE E: 4/6/12

-1999 (reaffir rms 2006) & IS 807 IS: 3177-

130T for TG G hall crane (125% of SWC)

30T (for TG hall crane onlly) (125% of f SWC)

Crab tra avelling speed Crane tr ravelling speed

DOC. NO.PE-TS-36 N 62-501-A001 1 REV. 0 DATE E: 4/6/12

Main Ho oist Aux Hoist 8.3 Hook Approaches A

Hand d rail pipes

IS: 2062 Gr. B

Rope drums Material l (Indicate IS)

Main hoi ist

Aux. Hoi ist

Fe F 410 WB IS S: 2062 Gr. B B/ CS Gr. 280-520 IS: 1030 0

DOC. NO.PE-TS-36 N 62-501-A001 1 REV. 0 DATE E: 4/6/12

Fabricated from rolled steel p plate

Couplin ng & Shaftin ng

Shafting g (Output) Design Of O shafts Arrangem ment of Lubricatio on Type of Lubricant L

As per IS : 3177-1999 Grease cups/ Nipples Gre ease

Horizonta al / Vertical Suitable fo or M5 duty NA Helica al NA N

DOC. NO.PE-TS-36 N 62-501-A001 1 REV. 0 DATE E: 4/6/12

Hardn ness confor rming to IS: : 3177

Hardn ness confor rming to IS: : 3177

Safe lifti ing capacity

DOC. NO.PE-TS-36 N 62-501-A001 1 REV. 0 DATE E: 4/6/12

Class 2 / IS: : 1875

10,00 00 working hours. h

Standar rd conform ming to Material l 10.0 10.1 Motors Hoist Motions M MH

DOC. NO.PE-TS-36 N 62-501-A001 1 REV. 0 DATE E: 4/6/12

SC, su uitable for Inver rter duty T TEFC 1

SC, suit table for Inverte er duty TE EFC 1

Rating Class of f insulation

Number r hour 10.2

150 sta arts / hr

Travel Motions M Type

CT SC, su uitable for Inver rter duty T TEFC 2

L LT SC, su uitable for Invert rter duty TE EFC 4

Rating Class of f insulation

150 sta arts / hr

DOC. NO.PE-TS-36 N 62-501-A001 1 REV. 0 DATE E: 4/6/12

Cros ss Trav vel Lever t type 2

Rotary gea ar + Gravity y 1+1

Lev ver type 2

Su uitable for en ntire bay leng gth

IP 54 Aux Hoist t** Cros ss Trav vel 4 ng Travel Lon

5 110 V/10 V A In cabin Power r