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Bands Aww

The document outlines the technical specifications for a fully automatic double column horizontal band saw machine designed for cutting various materials with high accuracy. It details the machine's construction, features, control systems, and operational capabilities, including automatic and manual cutting, adjustable clamping, and a coolant system. The machine is intended for continuous operation and is equipped with advanced monitoring and safety features to ensure efficient and safe cutting processes.

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0% found this document useful (0 votes)
24 views10 pages

Bands Aww

The document outlines the technical specifications for a fully automatic double column horizontal band saw machine designed for cutting various materials with high accuracy. It details the machine's construction, features, control systems, and operational capabilities, including automatic and manual cutting, adjustable clamping, and a coolant system. The machine is intended for continuous operation and is equipped with advanced monitoring and safety features to ensure efficient and safe cutting processes.

Uploaded by

mhetreswapnil999
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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TECHNICAL SPECIFICATIONS FOR FULLY

AUTOMATIC DOUBLE COLUMN HORIZONTAL BAND

SAW MACHINE OF MIN. DIA 400 MM


TECHNICAL SPECIFICATION FOR FULLY AUTOMATIC DOUBLE COLUMN
HORIZONTAL BAND SAW
1. SCOPE

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:

4.1. Machine Construction:


The job to be cut will be placed horizontally and the blade direction shall be perpendicular i.e., in
vertical direction. The machine shall be designed with dual column parallel servo down feed with
ball screw design and constructed out of seasoned Cast Iron / high tensile Fabricated Steel. The
machine base shall be made of heavy, torsion and vibration free and in box construction with
arrangement for coolant tank as well hydraulic unit.

4.1.1. Saw Frame


The saw frame shall be rigid, torsion and low vibration and made of seasoned Cast Iron
construction/high tensile Fabricated Steel with linear & heavy duty guide system. Height adjustment
of the saw frame shall be fully automatic according to the material level. Provision shall be given for
the material height sensing and the frame shall move in rapid speed just above the material to reduce
the idle time during cutting, followed by saw feed speed. All the processes shall be automatic. The
Saw frame feed shall be steplessly (servo or hydraulically) adjustable from rest to 300 mm/min.

4.1.2. Saw Drive:


Power of motor shall be suitable (Min. 5 kW) for cutting various materials with varying hardness and
max. sizes. The cutting speed shall be adjustable from 20 m/min to min 100 m/min by using variable
frequency drive. Provision shall be given to adjust the cutting speed displayed at the control desk
using the LCD/HMI panel which shall be an interface for input and out put i.e., cutting speed. All
rotating parts shall be covered suitably for safe operation.

4.1.3. Saw Band Guides:


The saw band shall be guided through minimum of Four set of (Each Set consists of two nos. of
bearings i.e. total Eight nos. of bearings) roller bearings and carbide guides. According to width of
the section to be cut, band guides shall be adjusted automatically. i.e. Independent adjustment of the
movable saw blade guidance to material width.

4.1.4. Saw Blade tensioning:


The machine shall have provision for adjusting blade tensioning for cutting different materials. The
machine shall have hydraulic saw band tension and electrically monitored with automatic pressure
reduction after switching off the machine. Safety device for stopping of the machine in case of
breakage/jamming of blade shall be provided. Electronic monitoring of minimum speed of rotation
shall be provided. Blade integrity shall be monitored continuously and upon breakage machine shall
stop immediately. The necessary signal/alarm shall be given to operator regarding blade breakage.
Tenderer shall give in detail mechanism of blade breakage detection along with offer.

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°.

4.1.5. Saw Blade Cleaning:


A mechanized on-line cleaning system with suitable chip removal metallic brush shall be provided.
The brush shall have independent motor and should run synchronously with the saw blade cutting
speed.
4.2. Down Feed Control:
The saw downfeed shall be controlled electronically by servo drive via suitable mechanism viz. ball
screw. Saw down feed shall adjust automatically according to the cutting material and
varying/constant material cross sections, hardness so as to ensure constant cutting force while
cutting. The details of mechanism of working like cutting pressure control system, shall be given
clearly given in the offer.
4.3. Blade deflection monitoring
Machine shall have automatic blade deflection monitoring system, for detection of blade
wear/ taper cutting. If the blade deflection exceeds certain value, the machine shall be stopped, with
suitable indication to Operator to avoid taper cutting. The complete details of the systems shall be
provided along with the offer.

4.4. Coolant system


A well designed cooling fluid system with re-circulating facility shall be provided. The coolant shall
be supplied over minimum 3 nozzles to the cutting point. Each nozzle shall be independently
regulated. The metal chips generated during cutting shall be filtered out before re-circulating the
coolant fluid. Zirconium alloys chips are pyrophoric nature and hence coolant system shall always
ensure flooded cutting area while cutting single or multiple or bundle cutting across the surface. The
pump shall have capacity of Min. 30 LPM at Min. 2 bar.
The capacity of coolant tank shall be suitable to supply coolant to the 3 nozzles to the cutting point.
Coolant tank shall be removable construction for quick &easy cleaning.
The design of the system shall facilitate the lowest spillage of coolant on plant shop during
operation. A separate line with spray gun shall be provided for coolant flow for spilling away chips,
turnings etc.

4.5. Chip/Swarf Conveyor


The chips generated during cutting shall be removed through a suitable submerged chip/swarf
conveyor system. The chip conveyor shall be effective such that all the chips (including fine in
nature) generated during cutting shall be collected to a suitable storage bin for easy
collection. Zirconium alloys chips are pyrophoric nature and hence chip conveyor system shall have
submerged coolant system.

4.6. Double Clamping vice


The machine shall have vice such that the clamping of the job is on both sides of the blade. The job
shall be held in the hardened clamping vice firmly during complete cutting range. The clamping
pressure shall be infinitely variable to hold extremely thin walled tubes as well as regular
components during cutting.

4.7. Hydraulic Power Pack:


The hydraulic power pack shall be rigidly mounted in the machine base with necessary pump,
valves, filters, motor etc.. The hydraulic motor power shall be min. 1.5 kW.

4.8. Band Wheels:


The band wheels shall be made of Seasoned Cast Iron with surface suitably heat-treated. The design
shall facilitate very low vibration and maximum band life. The wheels shall be optimally inclined to
minimize the blade twist from wheel to guide arm.
4.9. Minimal Rest Piece Length
During operation, minimum rest piece length shall be Max.75 mm.

4.10. Central Lubricating System & Lighting:


Automatic lubrication system for all lubricating points shall be provided for points that require
lubrication at regular intervals. A flexible lamp (Min. 150 lux at the cutting area) shall be mounted at
the saw frame.

4.11. Feed Roller Tables & Material support Height


Motorised Inlet long job feed tables and Motorised outlet job feed table shall be provided with the
machine each of minimum 2.0 meters at inlet and outlet. The pitch of the roller shall be approximate
150 mm. The system shall be robust and shall be designed for max. weight of the input
material. Cover plates shall be provided between each roller, roller conveyor and machine. A
coolant collecting pan shall be provided below the roller conveyor to collect the coolant passes
through the ID of the cutting tubes. Material support height shall be approx. 800 mm.

4.12. Automatic Material Cutting:


The machine shall automatically cut the required length of the job with required number of cut
pieces.
Provision shall be made in the machine to feed the length of cut piece required and number of cut
pieces. The machine shall have provision for precise positioning & feeding of the job being cut in
automatic operation. Necessary screen display shall be provided on machine for operator to know the
number of jobs set for cutting, number of jobs cut & length of jobs cut etc. The Automatic cycle
operation shall be as follow
a) After placing of the material in conveyor the feeder clamp shall be held.
b) Start of the automatic operation by automatic recognition of the leading edge of the material.
c) Feeding to the required length of job as entered by operator prior in auto cycle.
d) If single stroke of the feeder is not sufficient to feed the required length, the feeder shall
shuttle multiple time to and fro until material reaches the required length. Each time feeder
unclamps the material for taking reverse movement, positive clamping of the material in front
wise shall be ensured.
e) After automatic cutting cycle, the kerf/swarf channel shall be automatically widened to
separate the blade from material when lifting the saw frame.
Material feed length per stroke and maximum feed length that can be set in automated cutting for the
machine offered shall be given by the tenderer.

4.13. Bundle cutting Attachment:


An additional vertical clamping attachment viz. Bundle Cutting Attachment shall be provided for
cutting multiple bar/tubes in multiple layers. The machine shall be capable of handling a bundle of
min square 20 x 20 mm to Min. Square 400 x 400 mm (or) Ø 20 mm to min Ø 400 mm. If the bundle
cutting is done in multiple layers, the minimal rest piece shall be max 75 mm during operation.

4.14. Machine layout:


The layout of the machine should enable proper and easy approach for maintenance. All supporting
sub-units like coolant system, lubrication system, hydraulic power pack, pneumatic console, input
and out feed table geared motors etc. should be mounted optimally (most favourable) from/along the
main table and columns. It should go along with the design of the machine and at the same time
allow for highly productive operation of the machine. Electrical and Operating panels also should be
positioned in the same manner.
5. CUTTING ACCURACY
5.1.The maximum taper allowed across the cut section, for both automatic and manual operation
is 0.1 mm per 100 mm cutting height,
5.2.The machine shall also confirm to straightness and evenness for the cut surface specifications
as per IS 2102 Part 2- tolerance class K for nominal size of 30mm,
5.3.The precision of the cutting length achievable for single bars and lengths over 6 mm shall
correspond to IS 2102 Part 1-f (fine). (i.e positional accuracy of 0.1 mm).

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

10. TECHNICAL DOCUMENTATION


10.1. The following documents shall be submitted along with the offer
a) Technical specification of the offered machine and clarifications/confirmations point-wise vs
the machine being offered
b) Details of explicit points to be furnished at various clauses of the specification
c) BoM of major bought-out items like Controller, HMI, VFD etc.

In the event of Purchase Order, the successful tenderer shall submit the following documentation:

10.2. Before taking up fabrication of equipment


a) General assembly drawing
b) Foundation drawing
c) Drawings for electrical equipment, single line drawing indicating rating, ranges of all
equipment / devices, cable size, metering, protection interlocks etc., cable routing diagram,
schematic control circuit drawing etc.
d) Makes & model no. of all major bought out items.
The manufacturer shall start fabrication only after getting approval of the above
drawings. It maybe explicitly noted that approval of drawings does not absolve the supplier
for the responsibility of proving performance of the equipment as per PO.

10.3. Along with supply of equipment


a) Instruction manuals for operation and maintenance for the equipment including bought out
items in English language.
b) Equipment layout and drawings of major sub-systems
c) Detailed and as-built hydraulic drawing and pneumatic Drawing (as applicable)
d) As-built Electrical Drawing
e) As-built Controller, Display panel, Drives editable program/ configurations. Controller logic
shall be sufficiently commented (in English Language) for ease in Maintenance.
f) Bill of Material of all Electronic & Electrical Items including sensors.
g) Test & Calibration reports of major bought out items like Controller, Display Panel, drives
etc.
h) List of Alarms & Their remedy.
i) List of Safety & Operation Interlocks.
j) Operation & maintenance manual.
k) Commissioning Report.
l) All the drawings and documents submitted shall not be generalized and shall be replication of
exact system supplied.
m) The drawings / documentation shall be supplied in 4 sets of prints and one soft copy on
electronic media in English language.

11. PRE-DISPATCH INSPECTION, TESTING, ERECTION, COMMISSIONING &


PERFORMANCE DEMONSTARTION:
The machine will be inspected before dispatch at manufacturer’s works. The Erection,
commissioning and testing of the machine shall be done by the supplier at NFC, Hyderabad.
11.1. Pre-Dispatch Inspection at Manufacturer’s Works
After complete assembly, the supplier has to demonstrate the performance of the machine at
their works prior to dispatch. The Cutting/Sampling Plan will be as per clause no. 9.
The MS/SS material required for the above trials shall be arranged by the supplier.
Supplier shall demonstrate the following in presence of NFC representative at the
manufacturer’s works.
i) Machine capability, features as per PO and spares,
ii) Maximum and minimum Cutting capacity,
iii) Automatic material handling and minimal rest piece length achievable,
iv) Cutting accuracy as per clause 5.1 and sampling plan as per clause 9 for at least one
piece.
Samples to be arranged by supplier. Shipping Release will be issued only after acceptance of the
equipment as per above during PDI.
11.2. Erection, Commissioning, Performance Demonstration at NFC, Hyderabad
The erection, commissioning, performance demonstration at NFC is under scope of Supplier.
The required general tools and tackles are to be arranged by the Supplier. Civil Works are in the
scope of NFC. However, all the anchoring bolts and related material supplier is in scope of the
supplier. Spares / items consumed during erection and commissioning of the equipment until
completion of performance demonstration shall be arranged by the firm.

11.3. Item Acceptance Criteria at NFC, Hyderabad


At NFC, Hyderabad, the purchaser shall demonstrate the capability & features of the machine as
per PO and to cut maximum and minimum width job with cutting precision as per clause 9. The
purchaser will arrange the material (Zr, Ti, SS or Superalloy) for the purpose. However, the
responsibility of performance demonstration lies with supplier only. The machine will be
accepted subject to demonstration of following by the Supplier at NFC.
i) Maximum and minimum Cutting capacity,
ii) Capability of equipment and Automatic material handling and minimal rest piece length
achievable,
iii) Sample Cutting as per clause no. 9 for at least 5 samples of any size upto 400 mm
iv) Cutting accuracy for above cuttings as per clause 5.1,
v) Bundle of size min. 400 mm x 400 mm – 5 cuts
vi) Machine capability, features as per PO and spares.
11.5 Training
The supplier shall impart training to the 5 no.s of purchaser’s personnel in the operation and
maintenance of the machine during commissioning for at least 5 days.
Apart from above training, Installation & Maintenance Training on supplied Controller,
Display Panel and Drives models shall be imparted to minimum 3 officials of NFC.

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.

13 VENDOR EVALUATION CRITERION:


13.1. The offer of Original Equipment Manufacturer (OEM) or valid authorized dealer of OEM
shall only be considered. The authorized dealer shall submit valid authorization certificate
from OEM along with the offer.
13.2. The vendor shall furnish atleast one successfully executed PO copy of similar item
(similarity in cutting capacity as per clause 3.0 or higher and accuracy as per clause 5.1 or
better) and proof of successful execution (viz. Test Certificate or Commissioning Certificate
or Performance Certificate) in the last 10 years along with the offer. The accuracies
exhibited by the machine shall be evident in Test Certificate or performance Certificate or
Commissioning certificate. The vendor/ Authorized dealer can furnish POs executed by the
Principals (OEMs) for which Authorized dealership Certificate is furnished.
14 IMPORTANT TIME SCHEDULE

a. Submission of drawings after PO- Within two months after placement of PO


b. Delivery after PO- 12 months from the date of placement of PO

-------------------------------End of Annexure-------------------------------

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