Bands Aww
Bands Aww
The specification covers Design, Fabrication, Assembly, Testing At Manufacture’s Works, Supply,
Erection, Commissioning And Performance Demonstration at Purchaser’s site of fully automatic
double column band saw cutting machine with Bundle Cutting Attachment. The machine shall be
complete with mechanical, hydraulic/pneumatic, electrical and electronic equipment, and other
essential accessories needed for safe un-interrupted and efficient operation of the machine.
2. PURPOSE:
The machine is required for automated & manual cutting of profiles, solid, bar-stocks or billets,
bundle of tubes, rods and structures in various soft to very hard materials including Stainless steel,
titanium, Zirconium alloys, super alloys etc. with high accuracy. The machine is required to operate
three shifts operations a day across the year.
3. DESIGN BASIS
The application parameters of the machine are detailed in the following table. In addition, machine
shall be suitable for cutting of extremely thin wall tubes (e.g. OD 125 x 2 WT mm) without
distortion of tube. Arrangement for adjustable clamping pressure shall be available in the machine.
Sr No Parameter Details
Bundle of Solid Bar Stock/
1 20 - 400 mm
Billet, Outer Dia
20 x 20 mm - Min. 400 x 400 mm (or) Ø 20 mm to
Flat stock/ Round Size, Ø400 mm
2
Bundle Cross-section Near Square Cross section of 50 nos rods of Ø 16 mm or
150 nos of rods of Ø 14 mm
3 Max. material feed length Min. 1000 mm
4 Taper Cutting Precision Max. 0.1 mm in 100 mm of cutting height
Various grades of soft & hardened Steels, Superalloys,
5 Material
Zirconium and Titanium alloys
Material of Construction, Band
6 Seasoned Cast Iron
Wheels, Band Guiding parts
Servo with ball screw/lead screw or Hydraulic
7 Saw Down Feed
Controlled down feed control
Double Bearing on both side with blade mounted on 90
8 Saw Blade Guide
deg band wheels
Blade size suitable shall have
Min 5500 mm (L) x 40 mm (W) x 1.2 mm (T) (or) it’s
Required blade size
9 inch equivalent
(Bimetallic/ Carbide)
(Blade size shall be standard and readily available in the
Indian market)
Digital Measuring Device & Digital Measuring Device (with Minimum 2 meter) to be
10 Laser light provided to measure Length of cutting material
Laser light for cutting line indication
4. MACHINE FEATURES:
Saw blade shall be inclined with vice bed for distribution of cutting load. The Inclination of saw
blade to vice bed shall be approx. 3°.
6. CONTROL SYSTEM:
Electrical, Electronics and Instrumentation
6.1. 415V with a voltage fluctuation of +/- 10%, 50Hz with a fluctuation of +/-3%, 3 Phase AC
(3 wire system without neutral) power supply will be provided by the purchaser within 10m
from the machine. All cable connections, circuit breakers etc. required for connecting the
power supply to the machine shall be in the scope of supplier. Field control supply shall be
of 24 V DC.
6.2. All electrical components in the cabinets should be mounted on DIN Rail.
6.3. All electrical and electronic panels including operator's panel should be provided with lamps
for sufficient illumination and power receptacles of 220Volts, 5/15 Amp AC. Easy
accessibility for maintenance in the panels should be ensured.
6.4. Motors & other electrical components shall conform to IEC or Indian Standards. Motor
contactors shall be of AC-3 duty rated current.
6.5. All cables moving with traversing axes should be installed in caterpillar / Drag chain.
Additionally, all the cable trays required for laying of cables should be included in the offer.
6.6. In-cycle hour counter with reset facility should be provided. All electrical & electronic
control cabinets & panels should be vermin and dust proof. Control Cabinets shall meet the
latest safety standards.
6.7. Motors inside the machine shall be IP 55 protected (or better). Other electrical equipment
near shall be of suitable protection standards.
6.8. All light fittings, consumables, adapters/receptacles should have compatibility with Indian
equivalent.
6.9. Wiring in the panel for different electrical and electronic components shall be of more than
the rated capacity. All the field cables shall be armored.
6.10. The panel shall consist of all electrical MPCBs & MCCBs needed, with appropriate ratings.
6.11. The machine shall be able to be run in automatic, semi-automatic and manual mode.
6.12. Pre-selection of the quantity and cutting length with precision of 0.1 mm setting accuracy
and display of the actual authenticity in the input job shall be provided.
6.13. Calculation, automatic adjustment of the feeding length and of the repeated cycles when the
cutting length are over the available stroke shall be provided.
6.14. Display and stepless adjustment of the cutting speed in the cutting data.
6.15. The errors and disturbances shall be displayed with suitable error codes.
6.16. The Operating Panel shall have provision to set min. 1000programs into operating panel.
For each program, it should be feasible to set cutting length, number of cutting pieces, saw
blade speed, feed and coolant.
6.17. Controller shall be PLC Controller or CNC Controller
6.18. Display Panel shall be HMI or integrated display panel with controller.
6.19. Drives shall be Servo Drives, Variable frequency Drives, DC Drive.
6.20. Controller shall be latest series of OEM with ProfiNet or equivalent Ethernet based
communication ports.
6.21. Controller System shall support OPC UA protocol for further integration of the
system/equipment. Hardware or software or license, as required are in the scope of
supplied.
6.22. Licensed Programming packages for supplied Controller, HMI & Drives are in scope of
supply. Required cables and adaptor for interfacing with the computer are also in scope of
supply.
6.23. I/O Details:
A. Each type of Module shall be of same part no. for one to one replacement.
B. Minimum 20% spare channels of each type used shall be available for future usage.
Spares channels shall be wired upto terminal strip for further field connections.
C. All input and output modules shall have galvanic isolation and have control voltage of
24 V DC only.
D. Feedback: MCCB/Contactor/MPCB/MCB feedback shall be wired to PLC digital
inputs and in turn displayed in HMI.
E. Emergency Switches shall have 2 NC contacts.
6.24. Power supply: separate power supply shall be used for Controller and for IOs. All SMPS
incoming shall be through Isolation Transformer.
6.25. Relay boards: PCB mounted relay boards, with relays of one change over contact shall be
mounted on mounting sheet. Type: single changeover, coil voltage: 24 V DC, Contact
rating 230 V AC, 2A. Relay contact shall be on-board fuse protected.
6.26. CONTROLLER supply shall not be utilized for interrogation supply of the inputs, for
which separate supply shall be provided.
6.27. Drives shall be protected with input chokes and semiconductor fuses (for short circuit
protection) and shall be of min. 20% higher than the motor rated capacity.
6.28. Controller, Display Panel and Drives shall of same make.
6.29. All feedback systems & field sensors, limit switches, proximity switches, pressure switches,
Encoders should be for heavy duty application and wired up with flexible PVC insulated
screened cables. All field elements shall have easy accessibility for maintenance. All Field
elements shall be tagged for ease in identification.
6.30. Display Panel: minimum size 10 inches shall be provided.
6.31. Control Panel shall be provided with side mounted Panel AC of suitable rating.
6.32. Panel shall have Door Limit Switch with Audio-Visual Alarm generation and feedback to
Controller.
6.33. Panel shall be double earthed.
6.34. Password protected Maintenance mode shall be provided.
6.35. Multifunction Meter shall be installed for incoming supply and following parameters shall
be displayed in Display Panel:
i. Voltage
ii. Current
iii. Power
6.36. All cable terminations shall be tagged & ferruled as per latest industry standards.
6.37. Passwords implemented in Control system project shall be submitted to NFC during
commissioning of the system.
6.38. All sensors in field shall be tagged for their identification & Controller Digital/Analog
Input number.
6.39. All terminals shall be minimum 200 mm above panel base and shall be mounted at 45 deg
for ease in termination & maintenance.
6.40. Screen for maintenance purpose shall be provided, which include interlocks & IO status.
Screen for maintenance purpose shall be provided, which include interlocks & IO status.
7. UTILITIES:
The required utilities shall be provided by NFC at one location.
Power Supply - 415V +/- 10%, 50Hz +/-3%, 3 Phase AC
Compressed Air - Min. 5 kg/Sq. cm
8. MANDATORY SPARES:
Tenderer shall quote for mandatory spares as per the list in tender.
The cost of above all spares will be considered for tender evaluation. The Vendor shall note that
Collective lowest offer will be considered for evaluation & recommendation purpose. Part offers
will be summarily rejected.
9. SAMPLING PLAN
To ascertain capability of the supplier in manufacturing of highly accurate cutting machine,
following sample plan is prepared.
a) As per NFC drawing no. NFC/BAROP/DISC/01 enclosed with the specification.
The parameters for cutting above sample shall be suitably decided by the vendor, however,
maximum allowed time for single cut shall be as follows:
Diameter Maximum Allowed Accuracy
cutting time
400 mm 60 minutes As per point no. 5
In the event of Purchase Order, the successful tenderer shall submit the following documentation:
12 NOTE TO VENDORS:
12.1. Vendors shall explicitly note that mere signing and stamping of the tender specification
does not qualify the vendor technically. Vendors must furnish all required documentation,
data as per VEC, failing which the offer will not be considered for evaluation.
12.2. Before erection and commissioning, the vendor should submit valid medical fitness
certificate and police verification certificate for all of his technicians who will be deputed
for erection and commissioning works. Also, the Vendor must depute one qualified
Supervisor who will along with supervision of works will ensure safety of the vendor’s
personnel,
12.3. The Vendor shall ensure that all his labors who are engaged in work are covered under
ESI/sufficient insurance from any reputed company,
12.4. The Vendor and his personnel shall be abide by all safety regulations issued by NFC from
time to time,
12.5. Child labor (below 18 years) and labors with age above 60 yrs shall not be employed,
12.6. In case of any untoward incidence/accident leading to his personnel injury or unfortunate
event of death, the Vendor shall solely bear full medical expenses and compensation. NFC
or its any of the official would not be responsible for paying any compensation in any form
or whatsoever.
12.7. All the terms and conditions shall be complied as per our standard DPS terms & conditions.
12.8. Deviation to technical specifications and terms and conditions, if any shall be clearly
brought out in the part-I offer, without which offer shall be considered as incomplete.
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