PART-II, TECHNICAL SPECIFICATION FOR “HEAVY DUTY HYDRAULIC OPEN DIE FORGING PRESS OF CAPACITY 3000

TON INTEGRATED WITH TWO RAIL BOUND MANIPULATORS”

Cl. No. Clause Header Description Bidder's
Compliance
(Y/N)
1.0 NAME OF 3000 Ton Capacity Open Die Hydraulic Forging Press with 2 numbers Rail
PLANT bound Manipulators (Capacity 20 Tons of each) with Accessories.
2.0 SCOPE OF The Forging Press is to be supplied on Turn-key basis to Metal & Steel
SUPPLY factory, Ishapore (MSF). The scope of supply shall include:

i) Design, Manufacture and Supply of One No. heavy duty hydraulic Open
Die Forging Press of capacity 3000 Ton (Normal Pressing Force) and
Upsetting force minimum 10% higher than Normal pressing force of 3000
Ton along with Two numbers rail track bound Manipulators working in
sync with Forging Press.
ii) Related Civil works as specified in the specification.
iii) Supply of all the Accessories, Toolings, Dies and Fittings, Auxiliaries,
Electrical Equipments, Mechanical & Hydraulic Equipments,
Instrumentations, measuring instruments, all interconnecting Piping and
Cabling required for completeness of the Forging Press.
iv) The Control equipments and softwares for integration of Forging Press
and two rail bound Manipulators. Latest Siemens TIA (Totally Integrated
Automation) , WINCC or equivalent System to be used with desktop PC
for Operation, fault monitoring and diagnosis in the control room.
v) Die magazine consisting of five (5) Dies and 1 empty slot for movement.
vi) Non-Contact Type Dimension and Straightness Measurement System.
vii) Soft water cooling system for cooling of hydraulic oil through heat
exchanger/exchangers including supply of soft water generation plant.
viii) Air Compressor with accessories and distribution pipelines as required
if any.
ix) Erection and Commissioning of the Press with all associated
equipments.
x) Tools and tackles required for operation & maintenance of the Forging
Press.
xi) Hydraulic oil/ fluid, Gases and Lubricants for first filling with 25 % extra
for further use.
xii) Training of Purchaser’s personnel.
xiii) The 3D model / isometric drawing of the entire forge facility as they
relate to the practical application of actually running the machine in
production showing the proposed equipment along with the preliminary /
approximate dimensions, as per the Layout Drawing enclosed as Annexure-
A, shall be submitted within six months after award of contract to ensure
complete system is accommodated in the proposed MSF site. Also any
improved layout over the proposed layout shall be submitted.
xiv) Plant Layout, General Arrangement & other relevant drawings for
approval before supply.
xv) Submission of Operating & Maintenance Manuals, Hydraulic &
Electrical Circuit Drawings, Components Technical Specifications with
make/ model/ country of origin for Spares Management before
commissioning of the Plant.
xvi) Suitable Fire Detection and Protection (Suppression) System and other
safety devices as applicable shall be provided at appropriate places of the
Plant.
xvii) Spares for operation and maintenance for 2 years considering
continuous operation excluding scheduled maintenance periods.
3.0 DESIGN
3.1 DESIGN (i) The Press and Manipulators shall be of latest state of the art model
incorporating latest developments in technology.
(ii) The machine is intended for a very long running period of life span of
minimum 20 years. Design features should be such as to sustain the
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 accuracy over long period of continuous running at its design capacity. The
design shall incorporate adequate factors of safety as per applicable codes
of practice and regulations.

3.2 Press frame and (i) The design of the frame and critical press components subjected to
Critical extreme loading shall be calculated based on Finite Element Method (FEM)
components in order to avoid localized concentration of stresses. The FEM analysis
should be done taking into account all safety requirements of the frame
under extreme load conditions. The Firm shall submit the FEM report along
with self-certification conforming to their design parameters. The joints
between the frame parts shall be arranged on sections which are expected
to experience minimum loads.
(ii) The press shall have mechanism to minimise the generated vibration to
avoid any gradual damage to the press structures. The Firm to provide the
details of the same in their offer.
(iii) There shall be a provision to monitor the alignment/ tilting of Press
Columns. There must be measurement system to measure the tilting and
this value must be incorporated in safety interlock of press operation.
(iv)The press frame shall be designed to give maximum visibility to the
press operator at the control desk.
3.3 Press Column (i) The Press columns shall be of suitable strength steel forging and
ultrasonically inspected. The actual material used in the column shall be
clearly specified in the relevant drawing in the manual. (ii) Suitable
arrangements shall be provided for protecting the columns from heat
radiations during forging operation.
3.4 Cross Head The movable and top fixed cross head shall be made from high quality
steel forgings/castings/ Welded Steel Fabricated structure. The same shall
be ultrasonically tested as per relevant national/ international standard
and shall be suitable to cater the static / dynamic load with suitable factor
of safety. Ultrasonic Test report shall be submitted during PDI. The bidder
shall provide the drawings of the movable and top fixed cross head
structures along with their bid. The actual material used in the movable
and top fixed cross head shall be clearly specified in the relevant drawing
in the operation / maintenance manual.
3.5 Cross Head (i)The movable cross-head shall move on Press column through guides. It
Guide shall be so designed as to permit easy use and adjustment. Their design
shall be such as to compensate for the elongation of the moving cross-
head caused by radiation of heat during forging operations.
(ii) The length of the column guides, material used and detailed drawings
shall be provided with the manual.
3.6 Pressing/ Main (i) The pressing cylinders shall be manufactured from ultrasonically
Cylinder inspected steel forgings. The firm shall mention the actual type and quality
of steel used for the same in the manual. They shall be suitably housed in
such a way that these can be easily removed for repair/maintenance and
provide suitable protection against accident due to sudden leakage of
hydraulic oil/fluid. It shall have in built arrangement to collect leaked oil
from main cylinders in case of any damage of seals to avoid direct falling
on the hot material to prevent fire accident.

(ii) The packing/seals shall be of reputed make. The material used for the
packing, their configuration and normal life shall be mentioned in the
maintenance manual and drawings shall be provided at the time of actual
supply. The packing in the cylinder shall be easily accessible and capable of
replacement without dismantling the pistons, liners or cylinders.

3.7 Return Cylinders The return cylinders shall be located behind the press column for
protection against heat radiation. The return cylinders shall have such
arrangement which shall help in easy maintenance (replacement of seals,
packs and other parts).
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3.8 Shifting Table The shifting table shall lie in the line of axis of the manipulator travel. It
shall have movement on both sides of the centre line of the press. The
sliding surface of the base plate over which the shifting table shall move,
shall be equipped with suitable wearing plates. The top of the shifting
table shall have suitable arrangement for proper clamping and mounting of
the forging tools/dies. The shifting table shall be hold in position with the
hydraulic cylinder with overload-protecting system.
3.9 Cross Table The cross table shall move in a direction at right angle to the direction of
movement of the shifting table. It shall have suitable arrangement to take
and hold required die from tool magazine and place it at working position
of press. The hydraulic cylinder for actuation of the die slide shall lie under
floor level and suitably protected by cover plates.

The hydraulic cylinders for shifting table as well as cross table shall be
fitted with high quality packing which shall be replaceable without
complete dismantling (partial dismantling is allowed) of the cylinders.
Details of the packing/seals shall be provided in maintenance manual.
4.0 Input & Output Requirements

4.1 Types of Forging Press shall be used to perform following hot forging operations:
operations (i) Cogging.
(ii) Swaging.
(iii) Upsetting.
(iv) Planishing.
(v) Smoothing.
(vi) Shearing/Parting Operation.
Vii) Straightening of Stepped Shafts in the temperature range 500-550°C.
4.2 GRADE OF Steel of various compositions such as Nickel-Chrome-Molybdenum, Low
INPUT Alloy steels, High Nickel-Chrome Steel, Tool Steel ( H-11, H-13), Die Steels,
MATERIAL High sulphur steel, Plain Carbon Steel, Deep drawing steel, etc. to be
forged.
4.3 TEMPERATURE Heated material with sufficient soaking shall be made available at Forging
OF INPUT Press site at temperature of 1100-1200°C and Forging Operation shall be
MATERIAL carried out above 900°C.
4.4 INPUT Ingot/Slug Shape : Cylindrical/ Rectangular / Polygonal
MATERIAL FOR Ingot/Slug Diameter : 400 -1350 mm (Max. across the corner in case of
NORMAL polygonal Cross-section)
FORGING Ingot/Slug Length : 800mm to 4000mm
Ingot/Slug Weight : 4 - 15 MT
4.5 SHAPE/SIZE OF Shape: Bloom, billet, shaft, stepped shaft, flat, bar, block
OUTPUT Size: Dia/thickness from 150 mm to 1250 mm and job length up to 12
FORGINGS meter.
4.6 SHAPE/SIZE FOR Input: Initial Dia 570mm to 1000mm, Initial Length: upto 2500mm
UPSETTING Output: Dia upto 1350 mm
OPERATION
4.7 FORGING IN Forging in Single Heat:
SINGLE HEAT All forgings having final length less than 8 meter shall be done in single
heat i.e. without any reheat. For long stepped forgings i.e. greater than 8
meter in length and upto 12 meter in length, it shall not take more than
one intermediate reheat.
5.0 SITE CONDITIONS AND CLIMATE DATA
5.1 SITE (a) Metal & Steel Factory is located at the bank of river Ganga in Ishapore,
CONDITIONS Kolkata so water table is very high (- 500 mm from GL) and soil is sandy.
AND CLIMATE The equipment shall be suitable for installation at a place having tropical
DATA climate, where indicative weather conditions change as follows:
SUMMER WINTER MONSOON
MAX. TEMP. 46 °C 32 °C 39 °C
MIN. TEMP. 18 °C 5 °C 21°C
AVG. RELATIVE HUMIDITY 70% 58 % 83 %
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 Dusty squalls and thunderstorms frequently occur during summer season.
The average annual rainfall is around 1800 mm.

Plant Location : Metal & Steel Factory, Ishapore

City : Kolkata
District : North 24 Parganas
State : West Bengal, India
(b) All the functions of the equipment, its hydraulic system, electrical
system and control system, shall be tropicalised to work trouble free
and with full efficiency under above conditions, continuously for at least
20 hours a day.
(c) The equipment design shall take care of increase in temperature over
ambient due to heat generated by the equipment offered.
(d) Performance tests will cover working in the above environment as
detailed separately.
6.0 TECHNICAL REQUIREMENTS OF FORGING PRESS
6.1 CAPACITY The Press Shall have normal working capacity of 3000 Ton (Normal
Pressing Force) and Upsetting force minimum 10% higher than Normal
pressing force of 3000 Ton . Firm shall provide detailed Force calculation
sheet with technical bid.
6.2 TYPE OF PRESS Push Down, Hydraulic driven, Open Die Type
6.3 UPSETTING Minimum 10 % higher than Normal Pressing Force.
FORCE
6.4 PRESS COLUMN It shall be consisting of rigid frame having Four Column / Two Column with
pre-stressed tie-bars of suitable design. Firm to specify the No. & shape of
Column in their offer.
6.5 NO. OF MAIN As per design.
CYLINDERS
6.6 FORGING FORCE The press will need to manage a diverse range of components that exhibit
SELECTION significant differences in terms of size, weight, and shape. To effectively
deal with the varying component sizes, the press must feature a Force
selection option. This will enable the operator to input any value up to the
maximum force.
Alternatively, the press should offer a minimum of 3 stages of force
selection between the minimum and maximum range. All of this
functionality will be accessible through the operator's console.
6.7 ALLOWED +/- 250 mm (max.) from centre of working die.
ECCENTRICITY
6.8 MOVEABLE To suit all types of products to be forged including upsetting operation.
CROSS HEAD
STROKE
6.9 OPENING OF To suit all types of products to be forged including upsetting operation,
THE PRESS (DAY with sufficient clearance for working between job and upper Die.
LIGHT)
6.10 PRESS SPEED Variable speed, any value between zero to max speed.
6.11 SPEED OF 92 mm/sec (Minimum) [For all types of input material at temperature
PENETRATION range of 900-1200°C].
AT 3000 TON
6.12 COGGING/ROU At least 14 stroke/min at 240 mm length of stroke.
GH FORGING
6.13 PLANISHING/IN At least 38 stroke/min at 60 mm length of stroke.
TERMEDIATE
FORGING
6.14 SMOOTHENING At least 90 stroke/min at 15 mm length of stroke.
6.15 PRESS HEIGHT Press height above floor level: Available height from Zero (floor) level is 9.2
ABOVE FLOOR meter Max. Press to be designed according to available height.
LEVEL
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6.16 PRESS DEPTH Considering site condition as mentioned in Clause No. - 5.1 pit depth
BELOW FLOOR should be kept minimum (preferably less than 5 meter below the floor
LEVEL level). Pit should be bone-dry construction.
6.17 FORGING Within +5 mm in diameter/thickness throughout the length and +10 mm in
TOLERANCE each step length of forged job which are to be measured in hot condition.
7.0 TECHNICAL REQUIREMENTS OF MANIPULATOR
7.1 TECHNICAL Two number hydraulically operated rail-bound forging manipulators
PARAMETERS integrated with press. Each Manipulator shall have capacity to
OF independently hold and manipulate a hot steel job in balanced and normal
MANIPULATOR condition during forging operation.
(a) Carrying Capacity : 20 MT (min.) of Each Manipulator.
(b) Load Moment of each manipulator w.r.t. End of Tongs : 750 kNm
(min.).
Each Manipulator must have the capability to operate smoothly and
maintain balance when handling a round job
(i) weighing 13 MT having length of 11 meter.
(ii) weighing 12 MT having length of 12 meter.
Make: Preferably GLAMA/ DANGO/OEM of the Press
7.2 MANIPULATOR The jaws shall be suitable to effectively handle all types the input material
JAW CAPACITY and finished forged products as specified and capable to hold jobs of
dimension 1500 mm (max.) to 150 mm (min.) with/without extra
insert/tool with quick changing tool mechanism. The manipulator jaw must
be designed to hold and forge material after upsetting operation.
7.3 TYPES OF The Manipulators shall perform following types of motions : a) Forward
MOTIONS and reverse Manipulator travel on the track.b) Step wise travel and
rotation.c) Travel to position.d) Automatic Axis Regulation (horizontal).e)
Precise Angular Rotation (Tilting).f) Opening and closing of the tongs. g)
Continuous or intermittent rotation of the tongs in both clock-wise and
anticlockwise directions about the longitudinal axis.h) Lifting and lowering
the tongs parallel to the floor.i) Tilting the tongs above and below
horizontal central line.j) Side shifting or lateral movement of tongs.
7.4 CONTROL & All the motions mentioned in clause 7.3 shall be suitably linked to the
MEASUREMENT automatic run of the Manipulator integrated with the Press. All functions
OF of Manipulator shall be controlled from the control desk in Automatic
MANIPULATOR mode as well as in Manual mode. All the motions of the manipulator shall
MOTION be measured and suitably displayed at control desk. The position of the
Manipulator with reference to a datum zero position shall be indicated at
the control desk and the control shall admit the stoppage of the
manipulator travel at a pre-determined position automatically.
7.5 PERFORMANCE The rotational accuracy of the Manipulator shall be less than +/-0.5°.
CAPABILITY OF Angle of rotation of Jaw : Any angle selection from 0 to 360 ° in clockwise
MANIPULATOR and anticlockwise from HMI.
All motions shall be variable, hydraulically driven and proportionately
controlled.
All motions shall be continuous and controllable through joy stick/pedal
etc.
Manipulator travel shall be backlash free.
The Manipulator shall be designed to enable the movement of a forging in
all directions and its rotation on its own longitudinal axis.
7.6 MANIPULATOR As per design. However it shall be able to get accommodated within the
TRACK LENGTH space available as per the Layout Drawing enclosed as Annexure-A . Track
& WIDTH length on both side should be sufficient to load and unload 12 m length
job.
7.7 PUMPS FOR Type, Working pressure, Test Pressure, Output, Running pressure and No.
MANIPULATOR of Pumps. to be specified by the firm.
One additional standby pump of same capacity shall be installed in the
circuit to handle breakdown of pumps.
7.8 Lantern Rack Lantern rack should be placed outside the Track for easy maintenance.

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8.0 HYDRAULIC SYSTEM

8.1 Drive System As per design to achieve speed and force specified through out this
specification.
8.2 HYDRAULIC The Firm shall furnish details of the complete hydraulic system including
SYSTEM hydraulic circuit used for the Press, Manipulators and its auxiliaries. The
Firm shall provide the capacity of the hydraulic fluid tanks, delivery
volume, pressure, working temperature etc with technical bid. The
hydraulic system shall be provided with necessary instruments such as
pressure, temperature, level and flow transmitter to monitor the system.
8.3 HYDRAULIC Hydraulic fluid type to be specified in the technical bid. The detailed
FLUID technical parameters of used hydraulic fluid type to be provided at the
time of commissioning.
8.4 Pumps for Press Type, Working pressure, Test Pressure, Output, Running pressure and No.
of Pumps to be specified by the firm in the offer.
Pumps shall be fitted with pressure regulating and safety devices. Each
hydraulic pump shall run independently. The pumps shall be designed for
smooth running and trouble-free operation during normal useful life.
One additional standby pump of same capacity shall be installed in the
circuit in ready to use condition to handle breakdown of pumps.
8.5 Pipes Press, manipulator and auxiliaries shall be supplied complete with both the
high pressure and low pressure pipes. High pressure pipes shall be
seamless and of high strength to avoid bursting due to pressure shocks or
any other reason during working of the press. The joints of high pressure
and low pressure pipes shall be sealed with requisite high quality materials
to prevent any leakage, particularly from the point of view of long life of
press and manipulators (minimum 20 years).Piping shall be so arranged
that pressure may be tested at in-built checking positions, which are easily
accessible. The pressure checking positions are to be indicated in circuit
diagram.
8.6 Cooling, (i) There shall be a Main Tank and a Reserve Tank (double the capacity of
Filtering & main tank for maintenance and storage ) for hydraulic fluid in Press
Hydraulic Fluid hydraulic system. The Main Tank shall be equipped with continuous
Storage System cooling and inline filtering system, level and temperature indicators and
display of same on operator's desk. The Reserve Tank (with level indicator)
shall have facilities to transfer the hydraulic fluid to Main Tank and vice
versa. Also the reserve tank shall have the facility to receive the hydraulic
fluid from external sources.
(ii) Hydraulic fluid tank capacity of each Manipulator shall be as per
design, however it shall be equipped with continuous cooling and filtering
system, level and temperature indicators for hydraulic fluid and same shall
be displayed in operator's desk.
(iii) Suitable arrangements shall be provided to remove suction strainers
without draining the hydraulic tank.
(iv)The press shall have in built hydraulic fluid condition monitoring system
(Atleast NAS value, moisture content parameters) in the return line.
(v) All hydraulic fluid storage tanks for Press & Manipulators shall have
level indication in litres and same shall be displayed in Operator's console
PC.
(vi) Firm shall supply heavy duty water separator/remover machine(s) and
electrostatic filter machine(s) for separation of water and contamination
from hydraulic oil. The capacity of these machines shall be suitable for
handling capacity of Press Main Tank. It shall be integrated with the
hydraulic systems of Press and Manipulators.
9.0 INTSTRUMENTATION & CONTROLS

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9.1 Control System (i) The plant shall have latest Siemens (TIA, WINCC) system or equivalent
for operation and control. It shall have min. 32" LED monitor at operator’s
desk for plant operation, fault monitoring and error diagnosis. The
operator’s PC should elaborately indicate remedial measures in the event
of each fault. The control elements of this equipment shall be of
internationally reputed make and must be available in India and suitable
for use under tropical conditions. The control equipment shall be complete
in all respects to enable integration of press with either and both of the rail
track bound manipulators in automatic and manual mode.

(ii) The entire system shall be monitored and supervised through latest
lifetime licensed Siemens TIA, WINCC software or equivalent.

(iii) The Plant shall have:

a) Operator Consoles - It should be ergonomically comfortable to avoid
operator fatigue during long run production runs. Controls should be
simple and easy to learn.
b) HMI's
c) PLC Controls
d) Motor Control Centres

(iv) The firm shall give complete detailed technical specification of the
electronic control and shall mention all special features, the various
possibilities, and any additional features not covered in this specification,
which may improve the performance of forging plant.
9.2 Integration of The Forging Press shall be equipped with two nos. rail track bound forging
Press and manipulators, the control of which would require integration with that of
Manipulators the forging press. The control for the manipulators shall also be housed in
the press operator’s control desk. The integration of said controls shall
ensure actuation of traverse and peel/jaw-rotation of the manipulators
and the press motion during forging (approach, penetration and return) of
the press operated in pre-determined sequence. It shall be possible from
the operator’s control desk to adjust the sequence, incremental movement
of manipulators travel, incremental rotation of the peel/jaw, peel/jaw
torque of the manipulators and approach, penetration and return of the
press movements. The integration of press and manipulator shall permit a)
Integration of pre-selected manipulator peel/jaw rotation with forging
movement of the press for stepped rotary planishing /finishing
operation.b) Integration of pre-selected incremental manipulator travel
with the forging movements of the press for forging of the components
requiring longitudinal repositioning by a pre-determined travel length after
each press strokes.c) Integration of pre-selected manipulator peel/jaw
rotation, (incremental part rotation) per stroke of the press and rotation of
the peel/jaw by one or more than one complete round.The Integration and
control of Press and Manipulators shall be flexible as per operation
requirement of the forging so that these can be operated as follows: (a)
Press and both Manipulators in Manual mode(b) Press in Auto and both
Manipulators in Manual mode(c) Press , one Manipulator in Auto and
other Manipulator in Manual mode(d) Press and both Manipulators in
Integration in Auto mode
9.3 Automatic All the stocks to be forged and handled by the press shall require close
Position and control over the longitudinal steps and diametric values. For this purpose,
Stroke Control the press shall be equipped with reliable, automatic position and stroke
of Forging Press control devices together with other control system.

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9.4 Setting of The control system shall permit setting of following variables from
Variables operators control desk:
(i) Ram/moving crosshead position in all mode of press operation for
control of thickness value of stock.
(ii) Approach speed
(iii) Slowing down speed
(iv) Penetration rate
(v) Press force/stage selection
(vi) Return traverse rate
(vii) A maximum time limit for the upset operation to avoid overloading of
pumps (firm shall indicate the maximum time limit)
(ix) Electronic power limiting feature where in the control system limits the
maximum power (at maximum pressure) thus protecting motors from
overloading.
(x) Adjust the sequence, incremental movement of manipulators travel.
(xi) Incremental rotation of the peel/jaw of manipulator.
(xii) Peel/jaw torque of the manipulators.
9.5 Easy All control valves and instruments shall be located in a proper places for
Maintenance easy accessibility during maintenance.
9.6 Recipe system (i) The Forging software shall have recipe management to feed in the
details of Input ingot and output product dimensions.
(ii) There shall be provision for storage of different forging recipes, forging
programmes and same shall be easily accessible by operator from the
memory in future for ready to use.
(iii) The system shall be capable to automatically forge the required output
product once the job is held with Manipulator, recipe selected and
activated.
9.7 Data Acquisition (i)All the parameters such as Pressure ,Force, Press Position, Penetration
System Rate, Forward Speed, Return Speed, Strokes/min., continuous logging of
the ingot temperature over the forging anvil till the completion of forging
by non-contact type pyrometry system, pump pressure, hydraulic fluid
temperature (Press & Manipulators), hydraulic fluid level (Press &
Manipulators), power consumption of the plant, errors shall be logged in
operator's console PC. In addition to this if the firm want to envisage some
more parameters for effective monitoring of the Forging plant shall be
given in the offer. All the data shall be recorded in soft form in a local
database and the software shall have provision to generate reports from
the recorded data. System shall be capable of storing all the above
mentioned data for minimum 2 years.(ii) Suitable Software used in Forging
Industry shall be provided to enter & maintain the history of the job
details.

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9.8 PC and LAPTOP i) Firm has to provide two numbers rugged LAPTOP for fault diagnosis and
specifications maintenance assistance with following SPECIFICATIONS :
a) Laptop (minimum screen size 17 inch) b) Intel i9 /AMD Ryzen9
processor or higher version c) 1 TB SSD (minimum) d) 32 GB RAM
(minimum) with expansion slot

Preloaded original softwares:

a) Latest windows OS (unlimited licensed version)
b) Anti-virus (minimum 3 years validity).
c) PLC programming software(with unlimited license key)
d) HMI programming software with full package (with unlimited license
key)
e) Hydraulic simulation software (with unlimited license key)
f) Forging simulation software (with unlimited license key)
f) PC_ PLC communication cable and required driver software and
hardware(if any)
g) Any other software for full functionality of the LAPTOP.
h) Full backup of PLC, HMI or any other programs used, to be loaded in
the Laptop. These back-up programs also to be provided in a separate
CD/DVD or USB.

• MAKE of LAPTOP : DELL/ HP/ SIEMENS/ LENOVO .

ii) Specification of operator's CONSOLE PC:

a)LED MONITOR of minimum 32” size b) Intel i9 processor or higher
version. c) 1 TB SSD d) 32 GB RAM with expansion slot

Preloaded original software:

a) Latest windows OS(windows 10 or above ) (unlimited licensed version)
b) Anti-virus (minimum 3 years validity).
c) HMI software(with unlimited license key) for proper functioning of
plant.
d) PC_ PLC communication cable and required driver software and
hardware(if any)
e) Any other software for full functionality of PLANT.
9.9 General The firm shall supply 1:1 spare for OPERTOR’S CONSOLE PC and
Requirement communication system with all required pre-loaded License (unlimited)
software and hardware for communication with PLC and other control
system.

* All software packages accompanied by lifetime licenses, supplied by the

firm, must be genuine, original package and sourced directly from the
original equipment manufacturer (OEM) preferably in hardware forms like
CDs, DVDs, or USB sticks. In cases where software licenses are digital (soft
licenses), the licenses must be registered to Executive Director/MSF with
email id ([email protected]) and possess proper certification. This is to ensure
ease of license recovery in the future.
9.10 Maintenance It should provide control system PLC input and output diagnostics,
Diagnostic hydraulic trouble aids and automated calibration and preventative
Systems maintenance test. There shall be provisions to monitor vibration and
temperature of all critical parts. Alarms with indication of probable
remedial measures/ suggestions must be popped up in operator's console
PC, if the monitored values exceed permissible limit.
9.11 PLC-CPU The plant shall have back-up PLC-CPU unit. If the primary CPU fails, the
Redundancy back-up CPU shall take over automatically without disrupting the process.
9.12 INDUSTRY 4.0 There shall be AI tool which shall continuously analyse all the data and
Compatibility forecast a predictive maintenance schedule to reduce downtime of plant.
10.0 ELECTRICAL SYSTEM

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10.1 (i) The materials used for all items of electrical equipments supplied shall
General be new, latest and of reputed make. The equipment supplied shall be
Requirement suitable for operation where continuity of operation is the main
consideration and shall be such as to allow easy access for connecting,
inspection, maintenance and repairs.
(ii) The electrical switch boards shall be metal enclosed, free standing, floor
mounting and compartmentalized, and modular type suitable for indoor
installation.
(iii) All the cables shall be of FRLS type.
(iv) All the safety critical interlocks shall be hard wired.
(v) The firm have to specify the total connected load (in KWs / Amps)
required for smooth functioning of Press, manipulator and its associated
equipments.
(vi) Voltage stabiliser & Isolation Transformer of suitable capacity to be
provided.
(vii) To avoid ingress of dust and moisture inside the control cabinet (made
of steel sheet of minimum 3 mm thickness), Panels must have minimum IP-
55 level protection.
(viii) All Motors must have degree of protection corresponding to
minimum IP-55 and must be of IE3 (minimum) efficiency.
10.2 Codes & (i) The equipment shall comply with the requirements of latest revision of
Standards relevant IS/ IEC. The equipment shall also conform to the provisions of
Central Electric Authority (CEA) Regulations and other statutory
regulations currently in force in West Bengal.
(ii) All equipment & accessories, harmonics limit, ferruling, documentation,
symbols & drawings etc. shall be in line with relevant IS/IEC standards. All
equipment supplied shall be type tested as per relevant IS/IEC.
10.3 Electric Power (i) Single point High Voltage (6.6KV+/- 10% volts , 50 Hz +/- 3%, 3phase)
Supply and Single point Low voltage (415 V +/- 10% volts , 50 Hz +/- 3%, 3phase
with Neutral) power supply shall be made available at the substation
(approximately 150 meter away from the location of the Press) for the
purpose of main load of the Press. Suitable distribution of power supply, its
protection and metering devices and the electrical equipment beyond this
point i.e. cable and cable laying, circuit breakers/switches, transformers (if
required), switch-boards, instrumentation, inter connecting cables and any
equipment of special nature for control and other electrical equipments
shall be provided by the Tenderer. All electrical equipments/ items shall be
of IS/ IEC standards.
(ii) 24 Volt DC. to be used for control circuit. Arrangement to step down
the voltage from 415 ± 5% volts, 3 phase, 3 wire, 50 Hz to 24 Volt DC to be
incorporated in the electrical equipment to be supplied by Firm.
(iii) Supply for special sockets for utilities at Panel room, control room &
inside the panel shall be arranged through a suitable transformer to be
included in the supply of electrical equipment. Also a dedicated power
supply system ( battery backup/UPS) of suitable capacity should have to
provide by the firm to operate the HMI, PLC and all the controls in case of
total power failure.
(iv) The firm shall indicate in the technical bid, the maximum power
requirement for entire Plant (with break up for Forge Press, Manipulator
and accessories).
(v) Suitable earthing system including earth pits and earth conductors to
be provided to all equipments of the plant as per IS/ IEC standard and IE
rules.
10.4 Short Circuit Short circuit level for 6.6KV HT supply is 250 MVA (max.) in the scope of
Levels supply, firm have to design and supply all the electrical equipment for 6.6
KV HT and supplier has to specify corresponding short circuit levels also.
11.0 LUBRICATION SYSTEM

Page 10 of 24
11.1 Requirements The Press, Manipulators and its accesories shall have Automatic
and Directives centralized Lubrication system.
for Lubrication As far as possible lubrication system to deliver lubricant to all parts of the
Systems machine requiring lubrication shall be automatic alongwith the following
arrangement :
a) Lubrication system should automatically switch on with switching on of
the Plant.
b) Press should start only if the system has adequate lubricant pressure.
c) If pressure drops during operation, a warning light signal/message on
monitor shall appear.
d) Lubrication system should be total with coverage to all points needing
lubrication.
Wherever manual lubrication is retained as inescapable, a lubrication chart
fixed on the machine body shall clearly indicate the same. These charts
shall furnish the following information about lubrication.
i. Points of application.
ii. Service intervals.
iii. Type of lubricants.
iv. Quantity per filling.
v. Viscosity.
vi. Important cautions if any.
12.0 ACCESSORIES & TOOLING
12.1 POP-UP TURN The Plant shall have in built system for receiving the input/output material
TABLE and proper loading into the manipulator. The material will be shifted from
furnace to pop up turn table using EOT crane. It shall have all types of
required motion (up, down and rotation in both direction) using joystick at
operator's desk so that material can be easily loaded into manipulator. It
shall be placed both sides of the press for each manipulator i.e. two
number pop-up turn table is required. It shall be able to handle all types of
input and output material as mentioned in Clause No. - 4.4 to 4.6. Each of
the pop up turn table shall have 15 MT (minimum) lifting capacity. It shall
be located at suitable location along the manipulator track to handle job
length upto 12 m.
12.2 DIE MAGAZINE Die magazine shall be designed to provide selection of the dies from
operators desk.
Die magazine shall have capability to hold five number of Dies along with
one empty slot.
Die magazine system shall be complete with fixing/ holding accessories.
12.3 DIES AND DIE The firm shall have the following dies included in the supply. All dies must
HOLDER be designed to cater all types of material size as input and output
mentioned through out the specification.
(a) One set of Flat Dies (consisting of 1 Lower Flat Dies with Die holder and
1 Upper Flat Dies with Die holder).
(b) Two set of V-dies (each set consisting of 1 Lower V-dies with Die holder
and 1 Upper V-dies with Die holder) .
(c) One Bottom Knife/Cutting Die with One Bottom Knife/Cutting Die
holder.
(d) One Bottom Upsetting Die and One Top Upsetting Die with Die Holder
for each Die.
(e) One spare lower and upper die holder is also required.

All dies shall be provided with necessary fixing/holding accessories. The

firm shall provide necessary specification and drawing of each die and
holder at least one year in advance before commissioning of the plant.
Apart from above if any other die's required for successful commissioning
of the plant shall be provided by the firm.
12.4 VENTILATION Adequate capacity Ventilation system for the hydraulic pump station for
AND AIR- Press operation shall be in the firm's scope. The control Room of Press
shall be provided with split type Air conditioning system of minimum 10
Page 11 of 24
 CONDITIONING Ton capacity (minimum 5 units of 2 Ton Capacity each). PLC panel and
SYSTEM (VAC) Drive panel should be preferably located in Control room/ adjoining room
with air conditioning.
12.5 COOLING Design ,Supply, erection and commissioning of adequate capacity cooling
WATER SYSTEM water system with soft water for cooling of hydraulic oil/fluid of Press,
WITH SOFT Manipulators and other accessories shall be in firm's scope. This includes
WATER civil construction of pump house, sump, Cold water pumps with inline
standby pump, Hot water pumps with inline standby pump for circulating
the hot water of sump to cooling tower, cooling tower, pipelines, control
panel, etc. There shall be provision of draining out of water from the sump
for the purpose of cleaning and maintenance. The space for construction
of cooling water system will be provided within 50 m from the battery limit
of proposed site for Press. Suitable number of ceiling/ wall mounted fans
to be provided inside pump house and proper illumination to be provided
inside as well as surrounding of Pump house.The firm shall provide the
ratings of various components of this system along with the basis
calculation before the final commissioning of plant.
12.6 COMPRESSED No compressed air supply will be provided by MSF for any operation of the
AIR plant. Therefore, supply of Dedicated compressor unit for plant operation
shall be in firm's scope (if any). Suitable size of compressor room to be
provided for housing of the compressor system. Suitable number of
ceiling/ wall mounted fans to be provided in compressor room.
12.7 DIMENSION & (i) The press shall have capability to measure the straightness of long
STRAIGHTNESS forged stepped round products of length up to 12000mm along the
MEASUREMENT centreline of the job.
SYSTEM (ii) Suitable system to be provided for both length and diametrical
measurement for each step of the job.
(iii) The measurement system shall be Non-contact type. There shall be a
display system for the above measurement at operator's desk.
(iv) There shall be display of difference of between set value and actual
value achieved in job dimension.

Firm to provide technical details of the dimension and straightness

measurement system with technical bid.
12.8 MILL SCALE The firm shall provide a mechanical cleaning device integrated with the
CLEANING press to automatically clean mill scales (generated during forging
operation) from the surface of flat bottom die. This device will be operated
from the Control Room.

Firm to provide technical details of the mill scale cleaning with technical
bid.
12.9 CCTV The firm shall provide high resolution CCTV camera system for monitoring
MONITORING of complete plant (Press, Manipulator, control room, pump room, panel
room, etc.) from the control room. This shall also include two wireless
CCTV cameras, one on each Manipulator to get clear view of the job for
ensuring correct placement/alignment on the die. Two nos. separate
display unit of 55" to be provided for CCTV monitoring (one for control
room and another in office).
12.10 TOOL & The firm shall provide following tool & tackles for operation and
TACKLES maintenance:
(a) Set of special tools required for Press & Manipulator - 2 sets.
(b) Tools & Tackles, wrenches/spanners etc. required for setting of forging
tools, jaws and dies : 2 sets.
(c) Full service tools, Mechanical Torque Wrench, Hydraulic Torque
Wrench, Hydraulic bolt tensioner, Torque Chart etc. required for
maintenance of complete plant: 2 sets.
(d) Tool kit for electrical & electronics maintenance.
Apart from toolkit mentioned above following special tools for electrical
maintenance to be provided:
Page 12 of 24
 i) Wire crimper cum stripper - 2 nos.
ii) DC clamp meter to measure DC current in 24 V DC circuit- 2 nos.
iii) AC true RMS clamp meter- 2 nos.
iv) Multimeters for resistance, inductance and capacitance measurement-
2 nos.

12.11 MATERIAL Firm shall provide necessary material handling facilities for maintenance
HANDLING work inside Hydraulic pump room, Compressor room, Cooling water
FACILITY FOR system plant and HT motor room.
MAINTENANCE
13.0 PREFFERED MAKE
13.1 PREFFERED All Mechanical & Hydraulic items, Electrical & Electronic Instruments,
MAKE Control Equipments/parts or any other special items should be of reputed
make as per National or International Standard preferably as indicated
below:
13.2 Hydraulic Pump REXROTH / PARKER / OIL GEAR TOWLER / WEPUKO / ALWEILER
13.3 Hydraulic Motor REXROTH / POCLAIN HYDRAULICS/KRACHT/PARKER
13.4 Hydraulic Valve REXROTH / PARKER / OIL GEAR TOWLER / WEPUKO / EATON
13.5 Accumulator HYDAC / BOSCH REXROTH / OLAER/HAWE
13.6 Hydraulic Filters HYDAC / REXROTH / PARKER / INTERNORMEN / DDS /CENLUB
13.7 Hydraulic Hoses GATTS / AEROQUIP / MARKWEL / HYDROKRIMP A.C. / INSAP / PARKER
& Hose /K.B. ENGINEERS / FENNER / MINIMESS / HYDROTECHNIK
Assembly
13.8 Pressure Guages WIKA / STAUFF / SWITZER / PRICOL / WAREE / PRECISION INSTRUMENTS /
HYDRA / ODIN /MANOMETER / MICRO / HYDAC / IFM / VDO / STAUFF /
HYDROTECHNIK / IFM
13.9 Hydraulic REXROTH / PARKER / VICKERS / OEM MAKE
Cylinders
13.10 Hydraulic Level REXROTH /LEVCON /STAUFF / VICKERS /KUEBLER / TECHTROL / KRONE-
Indicator MARSHAL/ BALLUFF/ SIEMENS/ IFM/ HYDAC
13.11 Hydraulic Level LEVCON / STAUFF / DR. TIEFENBACH / SRIDHAN/DWYER/ BALLUFF/
Switch SIEMENS/ IFM/ HYDAC
13.12 Hydraulic ROTEX / LOVEJOY / HICLIFF / CONCORD / WELLMAN GBM / ALLIANCE /
Coupling GBM /ALLIANCE / NEW ALLENBARY WORKS / FENNER/SKF
13.13 Heat Exchanger ALFA LAVAL / INDSWEP / G.E.A / TRANTER/OLAER
13.14 Hydraulic Oil SWITZER / WIKA / STAUFF/ BALLUFF/ SIEMENS/ IFM/ HYDAC
Temperature
Indicator
13.15 Oil Seals PARKER / SPARE AGE / SKF / ECONOMOUS / MERKEL/ STAUFF
13.16 Bearings SKF / FAG
13.17 Voltage NEEL / SIEMENS / ABB.
Stabiliser /
Isolation
Transformer
13.18 Proximity AG SYSTEMS / SCHNEIDER / TECHNIC UCHNER / SIEMENS / BCH / PEPPERL
Switches / Limit & FUCHS / IFM / ALLEN BRADLEY / IFM / TURCK / BALLUF / JAI BALAJI
switch
13.19 PLC Latest version of SIEMENS (S7/1200 or S7/1500) / ROCKWELL
AUTOMATION / ABB / L&T
13.20 Contactors SIEMENS / SCHNEIDER / L&T / GE / ALSTOM / HPL / C & S / ABB

Page 13 of 24
13.21 Power & GLOSTER / NICCO / FINOLEX / UNIVERSAL / LAPP / HELU / INCAB /
Control Cable - HAVELLS / RR KABEL / POLYCAB/ SIEMENS
Stranded
Copper
13.22 Pressure Switch HYDAC / SIEMENS / IFM / BALLUF
13.23 Switch Gears L&T / SIEMENS / ABB / SCHNEIDER
13.24 Motors SIEMENS / FANUC / CONTROL TECHNIQUES (EMERSON) /ABB / CGL /
MARATHON (ALSTOM) / HITACHI / ALLEN BRADLEY / GE
13.25 Timers SIEMENS / CUTLER HAMMER / L&T / BCH / SCHNEIDER
13.26 HRC Fuse and ENGLISH ELECTRIC / SIEMENS / L&T / AREVA / ABB / GE POWER /
Fuse Carrier SCHNEIDER / COPPER BUSSMAN / MERSEN
13.27 HMI–PC IBM / HP / DELL / ADVANTEC
(Induistrial
Grade with
TFT/LED)
13.28 HMI Software SIEMENS (WIN CC) / ABB
(3rd Party)
13.29 Encoder PEPPERL & FUCHS / ROCKWELL / HUBNER / SIEMENS / FANUC / KUBLER /
BALLUF/ SICK
13.30 MCCB & MPCB SIEMENS / GE POWER / L&T / ABB / SCHNEIDER
13.31 VVVF Drive SIEMENS / ABB / GE POWER / SCHNEIDER / YASKAWA
13.32 UPS SIEMENS / EMERSON / KEC / DB / NUMERIC
13.33 Energy Meter, AEPL / HPL / CONSERV / MECO / SECURE/ FLUKE / RISHABH
Voltmeter,
Ammeter,
Multimeter
13.34 Oil & Grease CENLUB / REXROTH / LINCOLN HELIOS / DELIMON / PRAKASH LUBRIQUIP /
Lubrication AFMC
System
13.35 Pneumatic FESTO / NUCON / ROSS / MARTONAIR DANCAL / SMC / JANATICS / VELJAN
System / ROSS / PARKER / MORGAN / EFFBE / STASTO / BOSCH
13.36 Fire Alarm Panel NOTIFIER / EDWARD / CERBERUS AND UL / FM APPROVED / DAKASH /
(Intelligent HONEYWELL
Addressable)
14.0 BATTERY LIMIT
14.1 GENERAL (i) The Firm's battery limit is the proposed site shown in the Layout
REQUIREMENT drawing given in Annexure-A. Supply of complete equipment, accessories /
auxiliaries shall be located within the battery limit for satisfactory
performance of all functions as specified in this document. The space for
construction of cooling water system and compressor room will be
provided within 50 m from the battery limit of proposed site for Press.
(ii) Make-up raw water for Cooling Water system will be supplied by MSF
through Overhead Tank. The provided raw water may contain dust,
carbonates/ sulphates of hard water etc. The firm may design the system
considering these contaminations.
15.0 PROTECTION

Page 14 of 24
15.1 GENERAL i) The design shall be compliant to national/ international norms for safety
REQUIREMENTS regarding operating and maintenance personnel. The safety features shall
cover not only the elements of the forging press, but also the
manipulators, covers, guards, cross-covers, stairways, access ladders,
platforms, hand rails, etc which are necessary for safe operation of the
plant.
ii)High pressure pipes & joints exposed or near to hot working area should
be suitably encased in light metal sheet covers to prevent hydraulic fluid
from falling directly on the hot job, but allow easy maintenance.
ii)All ventilation openings shall have suitable screen protection. When
screens are provided on top of the equipment, means shall be provided to
protect these from falling objects. Special care shall be taken to protect
enclosed electrical equipment from entry of any creeping reptiles which
may create electrical short-circuit inside the live equipment.
iii) All electrical and electronic equipments shall be housed in totally sealed
enclosures/panels.
v) All electrical panels shall have interlocking devices to ensure that panels
doors can be opened only after switching off the incoming supply.
vi) All Panels must have minimum IP55 level protection.
vii) All incoming and outgoing cables from the control panel shall be
connected to the control through dust proof openings fitted with
glands/ferrules to prevent ingress of dust and insects.
viii) All equipments/parts shall be suitably protected against damages due
to corrosion, rusting etc., in the prevailing conditions at site.
ix) For easy maintenance at heights anywhere in the plant , proper
ladders and platforms to be fitted by the firm at appropriate places.
15.2 ADDITIONAL (i) The Press and Manipulators shall have safety device to prevent
SAFETY overload.
FEATURES (ii) The hydraulic system shall have the standard safety features to avoid
any accident in case of any emergency/ power failure.
(iii) The Press shall meet the requirements of all latest codes and
applicable standards including electrical, fire and safety standards.
(iv) Safety of the Press shall be ensured during power interruption or in
case of emergency stop, in all modes of operation: integrated, automatic,
manual & maintenance.
15.3 FIRE DETECTION Suitable Fire Detection and Protection (Suppression) System shall be
& SUPPRESSION provided at appropriate places of the Plant.
SYSTEM
16.0 POLLUTION CONTROL
16.1 REQUIREMENTS (i) The noise level caused by the entire system in normal operating
FOR POLLUTION condition shall not exceed the permissible limit as per national/
CONTROL international standards and shall also comply the norms of West Bengal
Pollution Control Board (WBPCB) as applicable. Suitable Accoustic
measures shall be provided at the source to comply the norms.
(ii) Wherever applicable, the discharge/ effluents of the plant shall comply
the applicable norms of WBPCB. Suitable system/ sub-systems shall be
provided to comply the same. The details of discharged effluents of the
plant (if any) with parameters shall be informed to the purchaser.
17.0 CIVIL CONSTRUCTION WORKS

Page 15 of 24
17.1 CIVIL WORKS (i) As the Scope of Supply is a Turn-key project, tenderer shall be required
to undertake entire civil work required for erection of Press, Manipulators
& their all associated equipments and services.

(ii) Civil works shall include:

(a) Foundation for Press, Manipulators and Accessories. Foundation
design shall be done considering the high ground water level at the
proposed site.
(b) Rooms to accommodate hydraulic and electrical equipments,
compressor and other associated accessories of Forging Press.
(c) Control Room.
(d) Pump house for Cooling water system.

(iii) Detailed construction/civil works drawings shall be prepared and

supplied by the Firm for the approval of the layout in the event of
placement of order.
Note: All the civil construction works shall be bone-dry and free from any
type of seepage. The bidders are advised to visit the site to access the
actual site conditions for the same on any working day of the factory
before submitting their bid.
17.2 CIVIL WORKS (i) The firm shall undertake detailed design of the above mentioned Civil
DESIGN construction works and also the Pumping units, Cooling Water System,
Independent Compressed Air System, accessories and allied system which
are essential for completeness of the Plant and its successful
commissioning.
(ii) Detailed instructions which are not indicated herein shall be as per the
latest standards, codes and recommendations of the Bureau of Indian
Standards (BIS) specifications. In the absence of suitable IS specification
and codes of practices, other recognized international standards and codes
such as of International Standards’ Organization (ISO), British Standards
Institution (BSI), Deutsche Industries Norm (DIN), American International
Standards Institution (AISI), etc. to be complied.
17.3 HANDING OVER (i) The site shall be handed over to the Supplier as per mutually agreed
OF SITE activity chart for execution of work, so that the Supplier can complete the
entire Civil Foundation Works before receipt of machine/equipment to
avoid any delay in installation of plant.
(ii) The Press & manipulators and their associated equipments are to be
housed in the existing New Gun Forge shop (indicative layout as Annexure-
A), if any concrete structure/obstacle is found on the site during
excavation for civil work, the demolition of same shall be in firm's scope.
(iii)The debris & demolished material if any generated during demolition
and excavation of civil foundation are required to be cleared and shifted by
the firm to designated place within 1 km.
17.4 CONTROL The Control room shall be equipped with proper Lighting, interior
ROOM decoration, Safety Features, Emergency Exit other than Main Entrance,
Control Desk for operator and Desk for other Diagnosis and Display system.
The side of Control Room facing towards Press should be covered with
double layer of toughned & heat resistant glass and Control room shall be
designed & constructed in such way that operator should have proper
visibility of Press & both the Manipulators simultaneously from the control
desk.

Page 16 of 24
17.5 GENERAL (i) The tenderer shall inspect the site for Civil Foundation Works and shall
REQUIREMENT satisfy himself of site conditions and collect himself any other information
which he may require before submitting their offer. If required, the
tenderer may also carry out Soil Testing at proposed site of their own
before submitting their offer.(ii) All necessary Materials, Tools & Tackles
and manpower, required for execution of Civil Foundation & Structural
Works, shall be in the scope of the firm.(iii) All the pits, trenches and
channels for Press, Manipulators, accessories and auxiliaries should be
leak/seepage proof to avoid the accumulation of seepage water. The firm
shall make it by pressure grouting or any advance techniques to make it
seepage proof for whole life of press. (iv) There shall be provision for the
collection of spilled water, oil, slurry etc. in the foundation pits and slurry
pumps are to be provided at least at two places in the foundation pits.
Suitable size delivery pipeline for discharging the above from pit upto the
discharge point (approx. 30 m) shall be provided. The pumps shall work
automatically with level sensors. (v) All trenches, pits, pockets etc. should
be properly covered with Steel Chequered Plates of suitable size (not less
than 10 mm thick).
18.0 ILLUMINATION
18.1 GENERAL Proper lighting of control room, electrical room, pump rooms, compressor
REQUIREMENT room, cooling water pump house, sump and cooling tower area, etc. shall
be in the scope of supplier. Spot lighting near Forging Press shall be
provided.
19.0 PAINTING
19.1 GENERAL (i) Painting of the Machinery, structures, control room, electrical room, etc.
REQUIREMENT shall be in the Scope of supplier.
(ii) All the electrical equipments shall be painted as per national/
international code of practice.
20.0 SHIPMENT
20.1 GENERAL The units shall be disassembled into major components suitable for
REQUIREMENT shipment and shall be properly packed to provide adequate protection
during shipment. All assemblies shall be properly match marked for site
erection.
All machined and bearing surfaces shall be protected against rust.
21.0 IDENTIFICATION PLATE
21.1 GENERAL Each equipment shall have an identification plate giving salient equipment
REQUIREMENT data, make, year of manufacture, equipment number etc.
All words and directions, indication plates and instruction plates shall be in
the English Language engraved, embossed or stamped in plain, bold face
easily read letters with contrasting finish.
22.0 INSPECTION & TESTING
22.1 PRECONDITION Before inviting MSF for Pre-despatch Inspection (PDI), the firm shall
FOR PRE- complete all necessary Civil Foundation & related Works enabling erection
DESPATCH & commissioning of the plant without any delay.
INSPECTION Place of PDI : In case of PDI in foreign country, firm will arrange PDI at
single location for all the materials. Similarly for all indigenous supply the
location of PDI shall be at one place only.

Page 17 of 24
22.2 PRE-DESPATCH The following Inspection Clause will form part of the Contract placed on
INSPECTION successful Bidder :(a) After placement of Supply Order, the Quality
(PDI) Assurance Plan (QAP) shall be prepared as per Inspection & Testing
Procedure laid down in relevant IS or other International Standards
considering Technical Specification of MSF Tender Enquiry & offer of the
Firm and to be submitted by the firm to the Purchaser for scrutiny &
approval, well in advance prior to Pre-despatch Inspection (PDI) call. The
approved QAP shall be the governing parameter for all sorts of tests and
inspections.(b) Based on the approved QAP parameters and
responsibilities, the Supplier shall carry out all necessary tests for material
and quality of manufacture. All such relevant test & inspection certificates
shall fulfill the QAP requirements and shall be submitted by the Supplier
before Pre-despatch Inspection (PDI) for scrutiny and reference for
undertaking the Pre-despatch Inspection by the representatives of
Purchaser at the Supplier’s Premises. Also one copy of all test certificates
including that of bought out items shall be mailed to MSF one month prior
to PDI.The following shall be checked during PDI.Press: (i) Verification of
bill of material as per approved QAP.(ii) Verification of parameters of all
Pumps & Motors as per Standard charts with manufacturer's test
certificates.(iii) Physical Verification of all items and Checking of Test
Certificates of Bought-out items.(iv) Modelling with 3D simulation of
complete plant as per MSF site layout .(v) Dimentional check up of major
critical item as per QAP.(vi) Functioning of straightens measurement
system.(vii) Functioning of Dimension measuring device.(viii) Functioning
of Mill scale cleaning system.(ix) All electrical Control cabinets with wiring
and components.MANIPULATORS:(i) Demonstration of physical functions
of all parameters of Manipulator mentioned in clause 7.1 to 7.5.(ii)
Verification of bill of material as per approved QAP.(ii) Verification of
parameters of all Pumps & Motors as per Standard charts with
manufacturer's test certificates.(iii) Physical Verification of all items and
Checking of Test Certificates of Bought-out items.(iv) Dimentional check up
of major critical item as per QAP.
22.3 PDI INTIMATION The Supplier shall intimate the Buyer in writing at least One (1) month (for
Indigenous Supply) or Four (4) months (for Foreign Supply) prior to the
scheduled date of Pre-despatch Inspection. Pre-despatch Inspection shall
be carried out by the authorized representatives of the Executive
Director/MSF at the Supplier’s/Sub-supplier’s premises on receipt of
inspection call from the Supplier. During Pre-despatch Inspection, the
equipments shall be thoroughly inspected as per QAP parameters and the
technical parameters depicted in the Supply Order.
22.4 Pre-Despatch (i) In case of F.O.B. Supply, as the PDI to be conducted for one (1) time
Inspection : only, PDI call to be offered only after absolute readyness of all items
F.O.B. Supply confirming all requirements as per T.E. & S.O. specification. During the
period of PDI in Foreign Country, a operational & maintenance training
also to be conducted by the Supplier of their offered machine to the
Purchaser's Personnel (min. 6 persons), who will be authorised to carry out
PDI at firm's premises. As such, the Firm should clearly specifiy the period
of PDI including Training at their premises. Normally, the period of PDI
with Training should be maximum for 2 working weeks at Supplier's/Sub-
supplier's country.
(ii) The Buyer (MSF) reserves the right not to attend the PDI or to request
for postponement of the beginning of the PDI by a maximum of one month
from the date fixed for such PDI in order to allow his representative(s) to
attend such tests, in which cases he shall inform in writing the Seller within
15 days before the date of the beginning of the PDI. If the Buyer request
for such postponement, liquidated damages, if any, shall not apply. In case
the Buyer informs the Seller within the period mentioned herein above
that he cannot attend the PDI or in case the Buyer does not come at the
postponed date requested by him for performance of the PDI as
Page 18 of 24
 mentioned above, the Seller shall be entitled to carry out said tests alone
as scheduled. The Certificate of Conformity and the Acceptance Test
Report will be signed by the Seller’s QA representative alone and such
documents bearing the sole signature of the Seller’s QA representative
shall have the same value and effect as if they have been signed by both
the parties. In case Buyer does not elect to attend the PDI, the Buyer shall
intimate the Seller in writing that it does not wish to attend the PDI.

22.5 GENERAL (i) In case Buyer (MSF) does not elect to attend the PDI or where function
CONDITIONS PDI is not possible, The Executive Director/MSF reserves the right to issue
FOR PDI waiver of Pre-despatch Inspection, if considered necessary against
Supplier’s specific request for the same alongwith all relevant documents
like Manufacturer's Test Certificates, Guarantee-Warranty Certificates
etc.(ii) The Seller shall provide all reasonable facilities, access and
assistance to the Buyer’s (MSF) Representative for safety and convenience
in the performance of their duties in the Seller’s country.(iii) All costs
associated with the stay of the Buyer’s (MSF) Representative(s) in the
country where the PDI is to be carried out, including travel expenses,
boarding and lodging, accommodation, fooding, shall be borne by the
Buyer (MSF).(iv) In case, if the item is not accepted in 1st PDI, subsequent
PDI may be carried out for the same and entire expenses of subsequent
PDI of the Buyer (i.e. expences towards travel , boarding and lodging,
accommodation, fooding of MSF representatives) will be borne by the
Supplier.(v) Upon successful completion of PDI, the representives of Seller
and Buyer will sign and issue a Certificate of Conformity and Despatch
Clearance Certificate / Shipping Clearance Certificate. Based on the
Despatch Clearance Certificate / Shipping Clearance Certificate , the
ordered items shall be despatched by the Supplier to MSF, Ishapore
alongwith all relevant documents and packing list. In case of F.O.B. Supply,
the entire consignment has to be supplied (on F.O.B. basis) at a time from
the seaport of the country of origin. Part Supply is not acceptable.
22.6 JOINT On receipt of the items at MSF, Ishapore in good condition and based on
INSPECTION the request of the Supplier, a Joint Inspection of all the supplied items shall
be carried out by the representatives of Purchaser (MSF) and Supplier to
check and ensure the correctness of the stores received. Packages/loose
items, found in damaged condition or despatch in incorrect condition
during the aforesaid joint Inspection at MSF, Ishapore shall be
replaced/made good by the Supplier without any financial repercussion,
whatsoever may be, to the purchaser’s account. The cost of lifting the
items, to be replaced/made good, shall be borne by the Supplier.
22.7 INSPECTION & The Purchaser (MSF) reserves the right to accept or reject any of the
TESTING supplied items or the total supply, if found not conforming to the
Contract/Order specification during testing and inspection at any stage.
23.0 ERECTION & COMMISSIONING
23.1 ERECTION & Erection & Commissioning of 3000 Ton Forging Press, Manipulators along
COMMISSIONIN with all accessories shall be carried out by the firm with all the supplied
G items and to be completed within Ten (10) months from the date of
receipt of last consignment at site. The supplier will also submit the
Erection & Commissioning Schedule activity-wise with Time-frame starting
from receipt of machine at site to handing over of equipment in the form
of BAR CHART after the placement of supply order.
23.2 ERECTION & Necessary Tools & Tackles and Manpower required for successful erection
COMMISSIONIN & commissioning of the machine, should be arranged by the Supplier at his
G own cost and risk. First filling of all consumables like Hydraulic fluid,
Grease, Gearbox Oil, Lubrication Oil etc. and Commissioning Spares to be

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 provided by the Supplier at his own cost for successful commissioning of
the equipment.

23.3 ERECTION & The items supplied shall be stored in the covered or uncovered store house
COMMISSIONIN nearer to the site of erection at MSF, to be provided by the Purchaser.
G However, custody of the store will be the responsibility of the Supplier till
hand over the machine to the Purchaser after Final Acceptance. For the
purpose of execution of erection, the Supplier shall have to draw the items
from the store, provided to them and shall bring the same to the erection
site by own transport & risk.
24.0 PERFORMANCE GUARANTEE TEST
24.1 FINAL On completion of successful erection & commissioning of the plant
INSPECTION alongwith accessories & peripheral equipments, final Inspection of all the
supplied items shall be carried out jointly by the Supplier and Purchaser for
checking correctness and completion of the supply in accordance with the
Supply Order stipulations. The machine shall be put under trial run with no
load and load for commissioning. The machine will be put to load trial run
and observed in respect of the Performance Guarantee Parameters (clause
24.4).
24.2 PERFORMANCE The Supplier shall provide guarantee of all the materials supplied by him.
GUARANTEE The guarantee shall generally cover performance of all individual items/
major assembly/ sub-assembly and systems of all Mechanical / Hydraulic /
Pneumatic / Electrical / Electronic in respect of rating and output as per
OEM certificates.
24.3 PRE- Before start of final performance trial, the plant shall be put under various
PERFORMANCE tests for checking and setting of various press and manuipulator
GUARANTEE parameters with/without hot material. For this purpose, Five types of
TRIAL ingot/ slug (two nos. from each type) as per Annexure-B shall be provided
for checking and setting press & manipulator parameters. If required, extra
input material ingot/slug required during hot trial shall be provided on
payment basis as rate mentioned in Annexure-B against each item.
24.4 PERFORMANCE During final acceptance test, the machine will normally put under various
GUARANTEE tests upto one (1) month (8 hrs. per shift x 3 shifts per day). After
TEST successful Pre-PG trial , the complete press and manipulator system shall
be subjected to performance trial for the items mentioned in Annexure-B.
During PG test, all the performance parameters related to press,
manipulator and instrumentation control mentioned throughout the
specification shall be proved. Firm shall also demonstrate all forging
operation mentioned in clause no. 4.1 . Necessary input material required
for above operation shall be provided by MSF. Forging operation for
different components from the given Annexure-B shall be completed with
maximum permissible downtime of 5% per day during PG trial in different
types of press and manipulator operation mode as per Clause No. - 8.2.
Apart from this, following parameters shall be monitored.
(i) Proving of Normal working capacity of 3000 Ton & upsetting force of
3300 Ton. Firm shall arrange necessary measuring instrument like load cell,
etc. at their own cost to prove the Press capacity.
(ii)Functioning of Press, Manipulators and all its associated auxiliaries
equipments in respect of all parameters mentioned throughout the
detailed specification.
(iii) Dimensional Accuracy of the component after Forging Operation.
(iv) Performance of Lubrication System.
(v) Function of limit switches, Relays, Contactors, Valves etc.
(vi) All Safety System.
(vii) Overall performance of the Press.
(viii) Forging of various forging sizes range as mentioned in Clause No. -
4.4, 4.5, 4.6
(ix) Forging of stock as per clause no. 4.7
(x) Forging Speed at 3000 Ton Force as per clause 6.11.
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 (xi) No of strokes as per clause 6.12-6.14
(xii) Manipulator Carrying Capacity and Load Moment as per clause no. 7.1.
(xiii) Manipulator motions as per clause 7.3 to 7.5.
(xiv) Press and manipulator operation in manual, auto and integration
mode.
(xv) Variable Press Speed and Variable Force Feature.
(xvi) Straightness Measurement System.

24.5 FINAL Based on the satisfactory performance of machine/equipment along with

ACCEPTANCE Accessories & Ancillaries during Performance Guarantee Tests, final
acceptance of the same shall be considered & the machine shall be taken
over by MSF for regular production purpose. Final Acceptance Certificate
will be issued by the Purchaser as soon as the plant passes the
Performance Guarantee test as per Clause 24.4 & satisfies all contractual
conditions .
25.0 DOCUMENTATION
25.1 DOCUMENTATI Operating & Manitenance Manual comprising details of operation of
ON Machine/ Equipment, all requisite mechanical & electrical drawings &
diagrams, details of mechanical/lubrication parts, detailed Trouble
Shooting, Preventive Maintenance Schedule, List of Wear & Tear Parts with
details specification & contact details of probable suppliers etc. --- 3 Hard
Copies & 1 Soft Copy.
These shall be in English Language and one copy of each of these
documents shall be sent along with the plant. All manuals, Drawings,
Diagrams shall be in hard copy as well as soft format.
(a) Complete Instructions/Operation Manual.
(b) Detail Maintenance Manual for mechanical maintenance of the press,
its auxiliaries and hydraulic system and electrical maintenance of all
electrical equipments, controls, instruments with complete circuit
diagrams.
(c) Spare parts list for all major mechanical, Hydraulics, Electrical &
Electronics. The detailed specification and drawings of all the critical spares
to be supplied along with the material.
(d) Trouble shooting charts & Preventive Maintenance Schedule.
(e) Dimensional design diagrams/drawings for all vital spares.
(f) Assembly Drawing (Mechanical) of press and manipulator & pumps.
(g) Detail individual Part Drawing of press, manipulator, pumps and
accessories.
(h) Details drawing of Pipe and pipe fittings including layout.
(i) Details of any special material used in construction of civil foundation.
(j) Bill of material of complete plant with specification.
(k) Drawing of Wear & Tear Parts like packing, seals, rings etc.
(l) Detail drawing of Civil Foundation of the Press.
(m) FEM Analysis result to be submitted. Purchaser (MSF) reserves the
right to verify the FEM Result with International Standard. If any item fails

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 to meet the International Standards, the same has to be replaced with a
new one complying International Standards.
(n) Safety instruction of complete plant regarding operation and
maintenance with Do’s and Don’ts.
(o) Upsetting force calculation sheet to be provided in soft and hard copy.
(p) The firm shall submit Bill of Material and documents indicating detailed
specification (like nomenclature, ratings, make, country of origin,etc.) of
bought out materials/items to the Buyer for ease of procurement and
spare parts management.
(q) Specifications of all critical items like Main Pumps, Motors shall be
furnished by the firm.
(r) The firm shall submit electrical and control drawings, cable schedule
and routing drawings, Earthing design and layout drawings, maintenance
manual, Planned Preventive Maintenance (PPM) schedules etc., required
before final commissioning of the plant.
(s) Test Certificate/Guarantee/ Warranty Certificate for bought out items
from OEM should be provided.
(t) Complete datasheet & Torque-speed curve of all electric motors.

26.0 APPROVAL OF DRAWING

26.1 APPROVAL OF (i) General Arrangement & other relevant drawings like Civil Foundation,
DRAWING Electrical Circuit Diagram, Hydraulic Circuit Diagram etc. to be submitted to
MSF by the supplier within six months from the date of Supply Order for
necessary approval.
(ii) Approval with or without comments shall be accorded by MSF within
Three (3) weeks from the date of receipt of the same at MSF, Ishapore.
Addition/Alteration/deletion on any point, whatsoever, shall be mutually
settled between the Purchaser and Supplier prior to final approval of
drawing.
27.0 TRAINING
27.1 TRAINING (a) Training shall be imparted to the Purchaser’s personnel by the Supplier
at their premises (max. 6 persons during PDI) and also at MSF site (max. 15
persons at MSF during Erection & Commissioning of the plant) in the
disciplines of :-
i) Operational training for production.
ii) Electrical and Electronic maintenance.
iii) Hydraulic and Mechanical maintenance.
(b) The firm should clearly specify the schedule of training, to be carried
out alongwith PDI of F.O.B. Supply (not more than 2 working weeks). The
firm should also specify the period and location, if any training is to be
conducted at the premises of sub-suppliers or past customers.
(c) All travel expenses as well as the expenses of stay (boarding, lodging &
out of pocket expenses) for training at firm’s premises will be borne by the
Purchaser.
27.2 TRAINING Both Theoretical & Practical Training shall be imparted by the Supplier for
the Purchaser’s representatives to obtain sufficient knowledge and abilities
needed to operate and maintain at the level of capacity, quality and
efficiency required to run the plant smoothly. Detail programme for such
training shall be indicated to the Purchaser in Due course.

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27.3 TRAINING During installation and commissioning of the Forging Plant with
Accessories & Ancillaries, MSF designated operating and maintenance
personnel (max. 15 persons at MSF during Erection & Commissioning of
the plant) shall be trained and acquainted with the operation and
maintenance of the equipment during the work’s progress. Such training
shall be provided by the firm’s project & commissioning engineers and may
include :
i) Witnessing of installation of the Forging Plant and the various sub-
assemblies and explaining their features and the required maintenance
procedures.
ii) Witnessing of interconnecting piping and wiring to familiarize
maintenance people with pipe and cable runs.
iii) Cold testing of the entire equipment including short circuit tests.
iv) Final maintenance training on the erected plant.
v) Hot Trial of the Forging Press by running test forging operation.

In addition to the above training program and if necessary, the Supplier

shall make arrangements for training of MSF maintenance personnel prior
to commencement of Plant installation on the programmable logic
controller system by the PLC-manufacturer.
27.4 TRAINING Training on mechanical & hydraulic system, comprising :
(a) Schematic diagrams of Hydraulic system.
(b) Fault diagnosis in hydraulic and mechanical system.
(c) Lay-out and foundation drawings
(d) Subassembly drawings
(e) Mechanical and Hydraulic maintenance.
27.5 TRAINING Training on electrical system, comprising :
(a) Cabinet drawings
(b) Panel drawings
(c) Schematic diagrams
(d) Circuit diagrams
(e) Wiring diagrams
(f) Detail understanding of Programmable logic controller (PLC) &
HMI programs including Program uploading, downloading, editing and
detail about communication network, etc.
(g) Hardware
(h) Software (comments on the program)
(i) Practical exercises with the system at Press site
(j) Position indicator
(k) Load cell digitizer
(l) Emergency power supply
(n) Electrical maintenance
28.0 PURCHASER’S RESPONSIBILITY
28.1 UTILITIES The Purchaser shall provide utilities (LT Power and water) required for
erection of the plant within 100 m of the battery limit of proposed site. All
other inter-connecting lines or items shall be within the scope of supply of
the Supplier. The Purchaser shall assist the Supplier by providing EOT
Crane (Two Cranes of capacity 10 and 30 Ton) as per availability for loading
and unloading of items. However firm may arrange their own facility for
handling and shifting of material.
28.2 GENERAL (i) The purchaser will provide, free of charge, One Site Office for Supplier’s
FACILITIES Personnel and for keeping their tools & tackles required for installation of
the equipment.
(ii) The purchaser will provide necessary accommodation, subject to
availability of the same, to the supplier’s personnel during installation of
the equipment on chargeable basis at the rate prevailing at the time of
execution of work.
29.0 SPARES SUPPORT

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29.1 SPARES The firm shall ensure availability of spare parts and maintenance support
SUPPORT services for the offered equipment at least for 10 years from the date of
commissioning.
30.0 COMPREHENSIVE SERVICE SUPPORT [Optional for accepting by the Buyer]
30.1 COMPREHENSIV The rate of Comprehensive Service Support (after expiry of scheduled
E SERVICE Warranty Period) for the complete Press, Manipulators & all Accessories
SUPPORT (Electrical, Electronics, Mechanical, Hydraulic etc.) should be offered by the
[Optional for firm mandatorily and to be submitted in a separate sealed envelope
accepting by the indicating "Price of Service Support for Forging Press for 5 Years" and
Buyer] "Tender Enquiry No., Tender Opening Date & Time". The rate of such
Service Support should be quoted for 5 years after expiry of normal
Warranty Period.
Any Spares required during Comprehensive Service of 5 years should be
provided by the Supplier at their own cost & risk.
The firm should quote lumpsum price for 5 years Comprehensive Service
Support considering all charges like Price of Spares/items required, charges
for Services, all types of Freight (Ocean & Inland Freight), all Taxes & Duties
(like Excise Duty, CST/VAT, Service Tax, Customs Duty etc.) both for Foreign
& Indigenous Suppliers.
The rate of Comprehensive Service Support will not be considered for
ranking purpose for determining the status of Lowest successful bidder for
award of the contract and also the Purchaser (MSF) should have the right
to accept/reject the offer of Comprehensive Service Support. If required a
separate action may be initiated based on the Comprehensive Service
Support offer.
31.0 GENERAL CONDITIONS
31.1 GENERAL The tenderer shall study this technical specification for each item, the total
CONDITIONS system and technical data, other details etc. as incorporated herein and
satisfy himself thoroughly regarding the efficiency and work ability of the
equipment/ machine to be supplied and shall be able to bear full
responsibility for the guaranteed operation in respect of duty,
performance, protection and safety of men & machine and smooth reliable
working. In case, the tenderer reveals in his opinion that any item is
unsuitable or irrelevant, he shall indicate the same with justifications and
quote alternative proposal on the basis of the design he considered
suitable and capable of meeting the required operating and duty demands.
However, such alternatives shall be subjected to the approval of the
purchaser.
31.2 GENERAL The items not covered in this specification but considered necessary for
CONDITIONS completeness of the plant/machine/ equipment, shall be quoted by the
tenderer in their offer.
31.3 GENERAL For items of equipment such as hydraulic/pneumatic cylinders, feeders,
CONDITIONS screens, motors, drives, gear boxes, instruments, controls, valves, switch-
gear etc., the number of different sizes and types shall be standardized as
far as possible and shall be oriented towards maximizing
interchangeability. All like parts on the equipment or on the duplicate
equipment, are to be made interchangeable. Wherever interchangeability
is not possible, Supplier shall list those parts. For such parts & parts which
are interchangeable, Supplier has to mention details of critical equipments
& spares and also to provide documentary support for design,
maintenance along with specific references of availability.
31.4 GENERAL All working parts, in so far as possible, are to be arranged for convenient
CONDITIONS operation, inspection, lubrication and ease of replacement with minimum
downtime.
Note:‐ Bidder shall download the technical specification and upload the signed & stamped copy of same after
filling the “Bidders Compliance” column

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