Bharatheavy Electricals Limited

/ Reconditioning of TOS, CSSR make double column Vertical
turning and boring mill Type SK-25A(Asset No.: 01-1440) / Page 1 of 30

BHARATHEAVY ELECTRICALS LIMITED

RAMACHANDRAPURAM:: HYDERABAD – 502032

GT,M&S,F&P,CW,DIVISION

10-REPAIR SHOP

Phone No.: 040--23183290 Fax No.: 040–23020185 email:

TENDER NOTICE NO. HY/M&S/10-RS/RC/11-12/SK25-A/0123/1 Date:23.01.2012

Tender in two parts (Techno-commercial & Price Bid) will be received by the undersigned in sealed cover from the contractors satisfying the prequalification requirements. The following should be legibly written on the cover -- tender notice number, tender date, name of the work, due date of opening, techno commercial bid or price bid on top of cover. Tenders will be opened at 14.30 hrs on the due date in the presence of bidders or their authorized representatives in BHEL, Ramachandrapuram,and Hyderabad.

1. Name of work : Reconditioning of TOS, CSSR makeDouble Column
Vertical Turning and Boring Mill.TypeSK-25A

(Asset No.: 01-1440),as per scope of Work,terms &

Conditionsenclosed

Earnest Money Deposit: Rs. 1, 50,000/-

3. Estimated Cost to BHEL: Rs.62.14 Lakhs (After availing cenvat credit on service tax

Excise duty).

Cost of tender documents : NIL

(non-refundable)

5. Tender sale starts from: Not applicable

6. Tender sale closes on: Not applicable

7. Last date of receipt of tenders: 15.02.2012up to 11.00Hrs.

Date and time of opening of tenders:15.02.201214.30 Hrs.

(Techno-commercial bid only)

Name & Address of the firm:

……………………………………

TENDERERS ARE REQUESTED TO SIGN AND PUT SEAL ON ALL PAGES OF TENDER DOCUMENT AND SUBMIT.

For BHARAT HEAVY ELECTRICAS LIMITED

(G.VIJAYA KUMAR)

MANAGER (M&S) 10 RS

TENDERING PROCEDURE:

Tenders may be dropped before the due date & Time in the M&S Tender box kept in 02-Annexe (Ground floor), M&S (P&C Section) of BHEL, R.C.Puram, Hyderabad – 502 032

The bids shall be submitted in two parts.

Techno-commercial bid. 2. Price Bid

Techno-commercial Bid: The envelop shall contain the Techno-commercial Bid as per the enclosed technical bid pro-forma with relevant documents like copies of ESI, PF code, PAN No., Service Tax Regn. No., TIN No., CST No., Experience, turnover, (ITReturns along with Profit & Loss account copies duly certified by chartered accountant for the 3 previous years to meet turnover point). Theenvelop shall be super scribed “Techno-commercial bid ------(name of work)”.

The second envelope shall contain only the price bid to be quoted. Any other information in the price bid shall not be considered and the quotation is likely to be rejected. Price bid document shall be signed by the bidder at the bottom of the page.The envelope shall besealed and super scribed “Price Bid------(name of work)”.

Both the above two envelopes shall be kept in another sealed cover. The cover shall be super-scribed with“Quotation for ------(name of work )” and shall be addressed to

Sri G.Vijaya Kumar, Manager (M&S)/10-Repair ShopBharat Heavy ElectricalsLimited, Ramachandrapuram, Hyderabad – 502032 to reach at or before 11.00hrson the due date and it should also contain Bidderaddress, Tender No.due date.

BHEL is not responsible for any postal delay. The bids will be opened in BHEL R.C.Puram Hyderabad- 32 on tender due date at 14.30hrs in presence of those bidders who choose to be present.

Date of Reverse Auction for price finalization will be intimated after techno-commercial suitability.

The technical bid consists of technical schedule requiring documentary proof. In case the party has not satisfied all the conditions along with documentary proof, the bid will be rejected.

Bids received mixed with both technical & Price bid documents without individual envelop will be rejected.

EMD Payment:

An amount of Rs.1,50,000/- (RupeesOne Lakh Fifty Thousand only) towards EMD shall be Deposited in cash at BHEL Cash office or by way of Demand Draft / Bankers cheque drawn in the name of M/S Bharat Heavy Electricals Limited payable at Hyderabad and shall be enclosed to the tender bid. No other means of payment will be accepted, no interest on EMD will be payable.

Cash office timings: 09.30 AM to 11.30 AM & 1.30 PM to 3.30 PM

BHARAT HEAVY ELECTRICAS LIMITED

RAMACHANDRAPURAM:: HYDERABAD-502 032

GT, M&S,F&P, CW, DIVISION

10-REPAIR SHOP

TECHNO- COMMERCIAL BID

Tender Notice No :HY/M&S/10-RS/RC/11-12/SK25-A/0123/1 Date: 23.01.2012

NAME OF THE WORK:Reconditioning of TOS, CSSR make Double Column Vertical

Turning and Boring Mill. TypeSK-25A (Asset No.: 01-1440), as per

Scope of Work, terms &Conditions enclosed

THIS IS AN INDIVISIBLE WORKS CONTRACT AND THE CONTRACTOR SHALL FILL REMARKS COLUMN AGAINST ALL ITEMS.

This tender schedule must be submitted along with the General Conditions, Special conditions etc. enclosed herewith duly signed and stamped on each page with bidder’s covering letter. Quotations should be TYPED on tender schedules only. Any deviations / deletions should be brought out separately on bidder’s letter pad and enclosed to thebid documents.

The following are to be filled up by the Bidder:

Name of the Contractor:

Full Address:

Name of contact person:

Phone No. :

Fax No.:

E-mailId.:

Mobile no.:

Sn. / Description / Contractor’s Remarks
1 / PF CODE NO
2 / ESI CODE NO
3 / PAN No.
4 / Service tax regn. no.
5 / TIN No.
6 / CST No.
7 / Validity: 90 days from techno-commercial bid opening date.
8 / EMD : Rs.1,50,000/-,Cash receipt / bankers cheque details
9 / Security Deposit clause : acceptance (See terms and conditions for details)
10 / Taxes and duties : mention whether included and firm during contract period OR extra as applicable
11 / Payment Terms: Progressive payments as mentioned in the scope of work enclosed for the work completed successfully in all respects.

SPECIFICATION OF THE MACHINE:

DOUBLE – COLUMN. VERTICAL TURNING AND BORING MILL TYPE SK-25 A

Technical data:

Diameter of faceplate : mm 2400
Maximum diameter turning by the side head : mm2500
Maximum diameter turning by the rail- head, when the latter

is lowered below the faceplate level: mm2600

Maximum distance – faceplate plate and the tool holders of

Rail-heads: mm1600

Maximum weight of work piece: tons10
Maximum effective torque on faceplate plate : kgcm638,000
Maximum total cutting force on 1,500 mm dia. at 55 m/min.

cutting speed : kg8500

Maximum section of chip at nominal motor output for steel

having 60 kg / mm² strength, ks = 200 kg /sq.mm², and at V

= 55m /min,: mm² 42

For cast iron up to Brinell hardness of 200° kg = 100 kg mm²,

and at cutting speed of 55 m/ min.: mm² 84

Section of tool: mm50 x 50
Number of tools in the tool holder:1
Number of heads :rail- heads:2

Side – head:1

Number of clamping jaws: 4
Dimensions of T- slots in provided in the faceplate – width: mm28
Holes provided in the heads for the tool post, metric taper: dia.mm 100
Clearance between columns :mm2700
Oblique Distance table centre and column edge, : mm1400
Distance from table centre tool post of side head

Maximum: mm1300

Minimum: mm500

Maximum height of side head tool holder above face plate: mm1340
Maximum amount of dip of side head ram centre below

Face plate level approx:mm220

Minimum dia. of hole turned side- headsapprox:mm360
Diameter range of work pieces clamped between jaws. from :mm450

To :mm2230

Cross rail stroke account: mm1400
Cross – rail traverse rate .min: mm 525
Swivel angle of rams, i.e, swivel of tool from vertical towards centre: 45°

away from centre : 30°

Stroke amount of rail head ram: mm1000
Horizontal travel of side head ram: mm800
Horizontal travel of rail- heads, away from machine centre

towards ram Centre in its extreme position: mm1630

Vertical displacement of side head, from its lowermost position
Below face plate : mm1700

r.p.m. of faceplate with sleepless adjustment

I. Step of speed : 1.18 - 32. 5

II.Step Speed :4. 25 - 117

Range of adjustment with steady output

Step of speed : n =11 .8 - 32. 5
Step Speed :n = 42.5 - 117

Cutting speed of 60 m /min. is available from dia,: mm164
Minimum cutting speed on maximum dia. of turning: m / min9.6
Number of feeds to rail heads and side - head: 14
Vertical and horizontal rapid traverse of rail- heads per min: mm1,920
Horizontal hand feed of rail head per 1 revolution of gear: 1 mm/ rev.

MAIN DRIVE:

Details of the existing DC motor:MEZ, Czechoslovakia make DC motor type: MYT1024-4K,

8/80/80KW; 90/900/2470 RPM; 76/440/440V; 208/208/208A;Field 5.7/5.7/1.6A

Regulation motor of a compensated type 8/80/80 kw,90/900/2470rpm., 440 Volts,

Extraneous excitation 124 Volts, 9.16 Amp Including a fan with an electric motor 2800 r.p.m kw 1.5 And tacho dynamo 150 W , 330v , 2800 r.p.m., extraneous

Excitation exciting of 220 Volts

Electric motor for elevation and lowering ofcross-rail, N=1440: Kw 7.5
1 electric motor for locking the cross-rail in position N=1420 ; Kw 0.5
3 electric motors for rapid traverse of heads, n=2800 ;a 3 Kw Kw 9
2 electric motors for actuating the multi-disc clutches inside the feed gear boxes, n=2,800, a 0.5 kw Kw 1
1 electric motor for pump drive-lubrication of the center and the bearings. Kw 0.1
4 electric motor for in small sized pumps inside feed gear boxes, Inside the side-head and feed movement transmition, a 0.05 kw0.2
1 electric motor for actuating the drive box pump kw 0.2
1 electric motor to drive the pump for hydraulic control of the back gear Inside the feed gear box. Kw0.375
Total output of all motors approx. kw 150

Electromagnetic brakes for feed gear boxes and side-head 6 nos.

Sl.
No. / PRE-QUALIFICATION REQUIREMENTS
(Proofs to be enclosed for verification): / Contractors Confirmation Yes/No
A1 / All the following conditions are to be satisfied by the bidder. Documentary proof is to be enclosed with techno-commercial bid satisfying all these conditions. In case the bidder fails to enclose the same the offer is liable to be rejected.

The party must be a reputed Machine tool Builder / Reconditioner and Retrofitter of Medium /Heavy/ machine tools with at least 3 years experience in the last 5 years (From 01.04.2006) in this field(Copies of work orders and work completion certificates / final bills should be submitted as proof for verification. The partymust have executed minimum one order as referred in sl.no 5 for Govt./ Public sector under takings). List of the customers along with respective contracting officer’s addresses (including phone no. and e-mail Id) for whom machines were built / reconditioned and retrofitted shall be enclosed to the offer for verification.

Average Annual financial turnover during the last 3 years, ending 31st March 2011 should be at least 80 Lakhs (CA certified copy of Balance sheet / P&L statements to be enclosed)

Latest Banker’s Solvency (not older than six months from date of tender notice) for an amount of Rs.25Lakhs from any nationalizedbank.

Experience of having successfully completed similar works during last 5 years ending 31stDec. 2011 should be either of the following:-

a)Three similar completed works costing not less than the amounteach equal to 40% of the estimated cost.
Or
b)Two similar completed works costing not less than the amounteach equal to 60% of the estimated cost.
Or
c)One similar completed work costing not less than the amount equal to 100% of the estimated cost.
5.Similar works definition :
Manufacturing / Reconditioning and Retrofitting of Medium/Heavy/CNC machine tools like
a) Lathes of minimum Job weight of 8 Tons and / or job lengths of 3 m.
b) Horizontal Borers of Minimum Spindle Diameter 130 mm.
c) Vertical Borers of minimum table diameter 2000 mm.
d) Multi Spindle Plano Milling machines with each spindle motor rating of 7.5 HP and table length of 1.0 m.
e) Special Purpose CNC Machines like HMC/H.BORER/VERTICAL BORER

SCOPE OF WORK IN BRIEF:

Complete Reconditioning of TOS, CSSR make double column vertical turning & boring mill type SK-25 A (01-1440) comprising of labour (mechanical, hydraulics, electrical and electronics), replacement of complete electrical controls along with panels and operator panels (Rittal make IP-54) units along with AC unit, manufacturing of new electrical control panel with new switchgear, replacement of existing DC Motor & Drive of Table with New AC Drive & Motor of SIEMENS/ Fanuc/ Indramat/ABB make, replacement of motors for Tools Heads and cross rail with new AC motors. Provision of linear incremental scales for all axes, replacement of all cables with Lapp make, control transformers, regulated power supply units of reputed make end limit switches and proximity sensors; scraping and blue-matching using Turcite-B anti-friction bearing material, repair of the machine, replacement ofTable Hydrostatic bearing and system and all initial and joint inspection spares identified. Prove out of the machine at BHEL works.

Sl.
No. / DESCRIPTION OF WORK / Contractor Remarks
Agreed/Not Agreed
A. / MECHANICAL :
1. / Noting the condition of machine w.r.t the following
-measurement and recording the geometrical accuracies as per manufacturer’s charts
-measurement / observation of vibration / noise
The above works are to be done at BHEL by the contractor with his personnel and measuring instruments.
2. / Removing the machine from foundation, dismantling it into transportable lots and minimum packing required for further transportation to contractor works. The necessary personnel and tools are in contractor’s scope. Transportation and transit insurance both ways in BHEL scope and cost.
3. / Dismantling of machine assemblies and table (Chuck) into individual parts, de-greasing, chemically cleaning; pre-painting of structural parts, joint inspection to finalize the detailed list of
1) Spares to be bought out
2) Spares to be manufactured
The list should be approved by BHEL. Drawings of spares to be manufactured and specifications for bought-out items shall be prepared and submitted to BHEL for approval.
4. / Replacement of all bearings (with SKF/FAG make only) irrespective of their size and present condition As per list.
5. / Replacement of 4 Nos.Screw rods & Box nuts ( 2 nos.of length 2.5mtrs and Dia 55mm, 2 nos.of length 3 Mtrs and dia 55mm), worn out gears / other parts with new ones to I.S. standards and specified quality materials complying with the original manufacturer’s specified tolerances.
6. / All slide ways of column, guide ways of cross slide (deep scratches are found) have to be ground and blue-matched, Pasting of Turcite-B anti-friction bearing material with mating parts to obtain final alignment.
7 / Cross rail feed is Jerky, the same needs to be rectified
8 / Play in Feed shafts observed it is to be rectified. All the drive screw rods and box nuts to be replaced, if necessary. And accuracies of the machine to be improved.
9 / Cross slide elevating gear boxes to be renewed
10 / Oil leakage from table (Chuck) gear box, Noise, and vibration in gear box (observed at high speeds), in low range speeds Table (chuck) is not rotating Overhauling of table (Chuck) gear box. Existing lubrication system to be upgraded.
11 / Table (Chuck) brake system not functioning properly, to be rectified.
12 / Right hand side tool post horizontal movement is hard. It is to be rectified. Gear Box End cover to be fixed, and oil leakage from gear box to be arrested. Threading Operation is not Working, to be rectified.
13 / Left Hand Tool post feeds and rapid movements are not functioning properly, to be rectified. Oil leakage from gear box to be arrested.
14 / LH &RH Tool posts feed selection shifters not holding in their position, to be rectified, Checking and setting of clamping units.
15 / Centralized lubrication system (2 nos.) along with necessary accessories and piping to be provided for columns, cross rail and tool posts (one for left side and another for right side).
16 / Replacement of all seals, O-rings, wipers, rubber packings etc.
17 / All levers and handles shall be Nickel plated
18 / Dials, name plates, instruction plates shall be replaced with new ones.
19 / General assembly of machine at contractor’s works
20 / Table flushing guards, axes bellow covers are to be replaced with new ones.
21 / Table Lubrication feedback system to be modified. In line flow switch, and pressure switch to be provided. Table lubrication pump (1 no) spare to be provided.
22 / PAINTING :
Machine outside body shall be painted with two coats of Apcolite (Asian paints) Premium enamel alpine green colour paint. Interior of the machine has to be painted with two coats of red enamel paint. Wherever oil comes in contact with interior of the body, oil resistant paint to be used. Letters, numerals etc. will have to be painted with a different color as required / as indicated by BHEL at the time of final painting. For electrical panel boxes the inside is to be painted with two coats of white enamel paint. Painting should be carried out according to the standard procedure for painting including cleaning and removing old paint, applying metal primer putty etc. Good finish should be ensured. Overall Machine aesthetic view should be taken care of.
B. / ELECTRICAL AND ELECTRONICS
1. / Dismounting all motors, control panels, interconnected cables and complete wiring on the machine.
2. / Design and manufacture of suitable brackets and fixtures to mount and align linear scales and DROs for LH & RH tool posts & Table Motor.
3. / Design, manufacture and mounting of suitable protective guards to protect the above devices.
4. / Replacement of existing MEZ make Table DC Motor, Siemens make DC drive with equivalent New AC Motor and Matching new digital AC Drive. Make of new drive and Motor should be Siemens/Fanuc/Indramat/ABB. The scope should include necessary transformers, choke, contactors, Fuses etc to make Table (Chuck) drive operated all these should be housed in new control panel as covered under point B.9
Details of the existing DC motor:
MEZ, Czechoslovakia make DC motor type: MYT1024-4K,
8/80/80KW; 90/900/2470 RPM; 76/440/440V; 208/208/208A;Field 5.7/5.7/1.6A
Please Note that Table is having 2 Ranges of Gear change.
5 / Replace the following motors
I)For Elevating cross rail
II)For cross rail tool heads rapid feed motion 4 nos (Rapid 2 nos, arrow changing 2 nos.)
6 / All the motors have to be serviced, if necessary they have to be rewound and replaced with new bearings. Insulation values to be improved. Terminal blocks to be replaced. All motors to be tested on no-load and resistance values, insulation values, currents and voltages to be recorded.
7 / Replacement of existing DROs & Track encoders with new Digital Read Outs (DROs) and Linear Magnetic Scales for X- & Y-axes of both LH & RH tool posts, along with cables, conduits & accessories.
Details of DROs & Scales to be provided by vendor:
a)4 No’s of linear Incremental Magnetic scales working on Magnetic principle (2 each for LH post & RH post) of Heidenhain/Fagor/Givi/ Sony make with +/- 10 micron/meter accuracy & 5 micron resolution.
b)Measuring Lengths of Scales shall be 1250 mm (2 No.s) & 1000 mm (2 No’s).
c)No. of 2-axes DROs required: 2 (totally 4 counters) 1 each for LH post & RH post, suitable for the above scales. Make of DROs shall be Heidenhain/Fagor/Givi/Sony.
d)DROs should have provision for standard features such as Selection of absolute/increment value, inch/metric conversion, radius/ diameter display, Inversion of counting direction, Zeroing/resetting of counter, Multiplication/calibration factor, Presetting of desired value etc.