Compliance Statement for Segment Rotators

Whether complies or not

COMPLIANCE STATEMENT FOR SEGMENT ROTATORS

1.0 SCOPE OF WORK

No. / Yes/ No / Deviations, if any
1.1 / The scope of supply includes design, procurement of materials, supply, commissioning and load testing of following segment rotators / 1)10 (ten) sets of flame proof having capacity 8 T (each set includes one drive unit and one idler unit mounted on independent frames)
2)10 (ten) sets of non-flame proof having capacity 5 T (each set includes one drive unit and one idler unit mounted on independent frames)
3)Spares for the above
4 (four) nos. of spare roller wheels to facilitate easy replacement of the rollers (either for drive unit or idler unit)in case of sudden requirement

2.0 SPECIFICATIONS

2.1 / Capacity / 1)8,000 kg- flame proof rotator (for a set of two units, i.e., one drive and one idler)
2)5,000 kg – non flame proof rotator (for a set of two units, i.e., one drive and idler
2.2 / Load per unit / 1)4,000 kg – for flame proof rotator
2)2,500 kg – for non flame proof rotator
2.3 / Diameter of the specimen to be rotated / 1300 mm (nominal)
2.4 / Mounting of units / 1)Driver and idler units (flame proof) shall be mounted on a single structure with a span of 2000mm apart between them, firmly secured using suitable fasteners.
2)Each unit (driver/idler) shall be mounted on individual structure and firmly secured to them using suitable fasteners.
2.5 / Roller size / 350 mm diameter and 250 mm width
2.6 / Center to center distance within each unit (driver/idler) / The roller wheels are to be positioned in such a way that the specimen of overall diameter 1300 mm will be supported at a choke angle of 60 degrees (normal)
2.7 / Total height (Ground level to the top of the roller) / 630 mm (Nominal)
2.8 / Total width of each unit (drive/idler) / 750 mm (approximately)
2.9 / Length, width & height of the mounting structure alone / To be specified by the party
2.10 / Direction of rotation / Both clockwise and anti-clockwise
2.11 / Roller material / Shall be steel wheels moulded with neoprene rubber shall be 70 shore A.
2.12 / Speed of the roller wheel / Shall be between 1 rpm.
2.13 / Drive Arrangement / One wheel shall be driven in the driving unit. Other wheel should be idle and to be movable to adjust the distance between the rollers.
1 / Longitudinal movement / Longitudinal movement arrestors should be provided on both sides of the segment rotators. Arrestors are to be provided with rollers (steel wheels moulded with neoprene rubber). Suitable provisions to be incorporated to handle segments of length varying from 4000mm to 6000mm.
2 / Manual rotation / Suitable provision shall be made for manual rotation also. For this purpose, a rotating handle should also be supplied for each rotator. Care should be taken to ensure that in no case, the driving effort required for manual rotation shall be more than 5 kgf.
3 / All Electric motors & starters shall be selected to meet the following conditions / Ambient Conditions :
Temperature : 18 °C to 50 °C
Relative Humidity : 40 % to 98 %Saline atmosphere
ELECTRIC MOTOR :
Voltage : 415 V ± 6 %, 3 Phase
Frequency : 50 Hz ± 3 %
Type of Motor : Flame proof (for 8 T rotators)
Crane Duty Squirrel cage induction motor
conforming to IS 325
Gas group: Gas Group –II A, II B, Zone I as
per IS 2148
Winding Insulation: Class ‘F’ with temperature rise
limited to Class ‘B’
Duty: S4
Winding configuration: Delta
Temp. Classification: T4 (135 °C)
Enclosure Protection: IP 65
4 / The motor selected shall be such that when it drives 8 T / 5 T load (supported at a choke angle of 60°), it should draw only 90% of its rated current. / STARTER: The starter and its associates shall be with flame proof enclosures (8 T rotators ) suitable for Group – II A, II B, Zone I as per IS-2148 with IP 55 protection and of following specifications:
Type of starter: Direct On Line (DOL), push button Control : Main TPNSFU. Forward and reverse
starter suitable for the motor selected.
Protection : Fuses, overload protection suitable for the motor selected.
The contactors selected shall be twice the capacity of motor rated current.
All the cable terminations shall be with double compression type flame proof glands (only for 8 T rotators) suitable to hazardous zone indicated above.
The number of cable entries and suitable number of glands shall be decided based on the requirement. The cables used shall be of flexible armored type.
The starter shall be wall mountable for 8 T capacity rotators.
For 5 T capacity rotators, the starter unit shall be permanently fixed on the drive unit itself at convenient height of operation.
Each drive unit for 5 T capacity rotators shall be provided with a male socket with flexible armored cable. Also, wall mountable female sockets suitable for the male sockets shall be provided. Supply shall be as indicated below:
3 phase, 415 V, male sockets (4 pin) with flexible armored cable of 3 m length – 10 Nos.
3 phase, 415 V, wall mountable female sockets (4 pin) – 10 Nos.
The flexible armored cable of 3m length shall be provided for each 8 T rotators also.
3.0 PAINTING
3.1 / Sand blasting / Sand / steel grit blasting conforming to SA 2 ½ shall be done for cleaning the surface of all steel structural members.
3.2 / Cleaning of structural members / After sand / steel grit blasting, all the surfaces have to be cleaned free from dust, moisture, oil, etc.
3.3 / Zinc rich epoxy primer coating / Zinc rich epoxy primer shall be applied to a dry film thickness (DFT) of 75 microns minimum.
3.4 / Polyurethane enamel paint coating / Two coats of polyurethane enamel paint (colour: apple green) to a dry film thickness of 40 microns minimum each (total 80 microns for two coats) shall be applied.
3.5 / Paint thickness measurement / The supplier shall measure the thickness of paint in the presence of the representative of the purchaser at random locations selected by the representative. The supplier shall use his own paint thickness measuring instrument.
3.6 / Box section painting / Wherever box sections are provided, the inside surface shall be cleaned and brush painted with zinc rich epoxy to a thickness of 65 microns (DRT) prior to closing the section.
DESIGN DRAWINGS
3.7 / GA drawings / Party shall submit GA drawings, giving overall dimensions, etc., for approval by RPP, VSSC within two weeks of receipt of Purchase Order.
3.8 / Power and torque ratings / Power and torque ratings of motor gearboxes, shafting details, size of rollers, thickness of rubber, etc. shall also be included in the GA drawing.
3.9 / Design calculations / The design calculations shall also be submitted to the purchaser along with GA drawings. Any change in the design pointed out by the department shall be incorporated without any extra cost. The fabrication shall start only after clearance of the GA drawings by the department.
3.10 / Vendor responsibility / While the design calculations are sought for perusal by the Department, it shall be the sole responsibility of the supplier to ensure that the item so designed shall meet all the functional criteria as required by the users.
3.11 / Process details / Process details of securing neoprene on the metal wheels are also to be mentioned for information.
3.12 / Frame structure / The frame structure shall be suitably designed for L/900 deflection criteria.
3.13 / Fasteners / All fasteners used shall be electro-galvanized.
3.14 / DP testing / All welding shall be DP tested after final weld. All welds shall be free from cracks or any other defects. Four lifting brackets shall be welded on the frame of each unit for balanced horizontal lifting of the unit.
3.15 / Drive systems / All drive systems should be provided with proper coverings as a safety measure against interference with persons and other systems. Open gearing is not acceptable.
3.16 / Specimen support / Specimen will be supported at 1000 mm (approx) from ends on both units, i.e., specimen will be projecting for about 1000 mm from both idler as well as driver units. Hence no drive system or any other part should interfere with the free rotation of the specimen placed on the segment rotators. The specimen overall diameter is 1300 mm at the support points resting on rotators and in the remaining portions (including overhang portions) the overall diameter of the specimen is 1400 mm. Hence suitable clearance should be available between the drive system and the specimen. A minimum clearance of 200 mm may be provided between the roller wheel top to any other member / system of the segment rotator.
3.17 / Provision for handling / Provision for handling the idler and drive units by using a forklift should also be provided.

4.0 INSPECTION

4.1 / Stage inspection / The representative of the purchaser shall have access and right to inspect the work at all times, during the course of fabrication. Any work, which is proved faulty, shall be corrected by the supplier without delay.
4.2 / Responsibility of vendor / The purchaser has no obligation to discover defects in the work performed and it shall be the sole responsibility of the supplier to ensure such completed work is defect free and meets the technical specifications / requirements.
4.3 / Intermediate and final inspection / During intermediate and final stages of fabrication, the items shall be offered for inspection to the representatives of the Centre Level Inspection team of the Department at your site.

5.0 DELIVERY SCHEDULE:

5.1 / Schedule / The item shall be delivered to VSSC within six months of receipt of Purchase Order followed by a period of one month for erection, commissioning and load testing at our site.

6.0 MAKES OF BOUGHT OUT ITEMS

6.1 / FASTENERS / TVS, GKW, UNBRAKO
6.2 / BEARINGS / SKF, FAG (SEALED FOR LIFE TYPE)
6.3 / GEAR BOXES / ELECON, RADICON, SHANTI GEARS
6.4 / ELECTRIC MOTORS / CROMPTON GREAVES, BHARAT BHIJLEE, KIRLOSKAR, NGEF, SIEMENS
6.5 / STARTER COMPONENTS / SIEMENS, L & T, BCH
6.6 / PLUMMER BOXES / FYH, NTN
6.7 / COUPLINGS / FENNER, ELECON, RADICON, SHANTHI, NEWTECH, ALL-FLEX, HI-CLIFF
6.8 / PUSH BUTTON / SIEMENS, BHC, L & T
6.9 / LIMIT SWITCHES / STERLING CONTROLS, ELECTROMAG
6.10 / PAINTS / ASIAN PAINTS, BOMBAY PAINTS, BERGER PAINTS, NEROLAC
6.11 / FLAME PROOF PLUG & SOCKETS / M/s BALIGA LIGHTING EQPTS. PVT. LTD. & FCG

7.0 QUALITY ASSURANCE PLAN

7.1 / Before Fabrication /

• The fabrication shall start only after the clearance of the fabrication drawings by the purchaser.
• Test certificates from Government approved test houses for chemical composition of the raw materials to be used for fabrication should be produced to the Department.

During Fabrication: /

• All the weldments shall be DP tested after final weld. All the welds shall be free from cracks or any other defect.
• The thickness of the paint shall be measured after final painting by the supplier in the presence of the representatives of the purchaser and shall meet the specification.
• Repair works, if any, shall be carried out only after approval from the purchaser.

After Fabrication: /

• The supplier has to produce a quality report incorporating all the certificates / documents as mentioned above.
• Before dispatch, the supplier has to assemble the items and show the satisfactory performance of the system at the time of inspection (by the representative of the purchaser) at supplier’s site.
• The supplier has to do final assembly and show the satisfactory performance of the performance of the items with load as per the following conditions at the time of commissioning at site in RPP,VSSC. (Necessary test loads will be provided by the purchaser).

• The segment rotators shall be run at no load.
• The current drawn by the motor shall be within rated values.
• The operation should be smooth.
• The rotators will then be loaded with 8 T/5T (ie. rated load).
• The current drawn by the motor should be within 90 % of rated current of the motor when driving 8T/5 T load.
• The operation should be smooth.
• The RPM of the roller wheel will be measured and it should be as per specification, i.e., 1 rpm.
• The maximum deflection observed in the stand should be below the L/900 value.
• Rotators have to be tested for overload (125 % of SWL,
• After load test, the rubber should not debond from the metal.

8.0 DESPATCH

8.1 / Inspection & Clearance / The items are to be dispatched to VSSC, Trivandrum only after inspection & clearance for dispatch by the representatives of the Centre Level Inspection team of the purchaser.
8.2 / Damages during Transportation / Any damages during transportation are to be rectified free of cost by the party.

9.0 GUARANTEE

9.1 / Guarantee period / Guarantee period shall be for a period of 12 (twelve) months from the date of commissioning, acceptance & taking over by the purchaser. During the guarantee period any defect noticed in the design, materials, workmanship shall be rectified by the supplier, free of cost.