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| 1 | WAREHOUSE SYSTEM |
| 2 | Design, Procurement, Supply, Installation, Erection and Commisioning of Warehouse AS/RS Detailed Design and Engineering, Procurement, Supply, Installation, Erection and Commissioning including preparation and submission of documents (General Arrangement, detail drawings, as- built drawings, calculations, etc.,) providing necessary accessories,spares, special tools & tackles, testing, calibration, painting etc. as per drawings, technical specifications and applicable codes and standards. The scope shall include complete ASRS racking system, Automated Cranes, associated aisle equipment including power bus bar / flexible cable, top rail, bottom rail, conveyor systems for pallets loading / unloading, suitable stacker cranes in required quantities for each ASRS, telescopic fork, suitable scanning devices, printer, display screen on forklift/ Pallet trolleys/ stackers, etc., and other gadgets suitable transfer vehicles or cars in required quantities, all necessary controls, PLC, IT hardware & software for Automation, supply, fabrication & installation as per drawings and specification shall also be in the scope of bidder. Painting (external surface, support structure etc.) of ASRS shall be carried out as per the approved painting procedure.Scope also includes successful interfacing / integration of WMS system with ERP system (SAP) for seamless integration and real-time exchange of inventory data for all Raw materials (including low flash raw materials),Packagiing materials and Finished products including reconciliations at end of each day and generation of reports as required.Main incoming power to one number main control panel of each ASRS system shall be provided by IOCL and scope of work of vendor includes cable termination to the panel. Vendor should provide cable and further connection in case the requirement is there for more than one panel for said ASRS system. Moisture free Air (Process and Instrumentation) supply shall be provided by IOCL to the ASRS system at one tie-in point each and further air connection required for ASRS systemshall be in the scope of vendor.Vendor scope also includes supply and fixing of foundation bolts & grouting (as required) for all equipments in warehouses, wherever required.Vendor\"s Scope also includes provision of a Office and Server room with furniture for these rooms (including UPS of adequate rating). Only Main electrical connections to the Main Electrical Power distribution panel and LAN network shall be provided by client at 1 point for each warehouse. UPS back-up for WMS Server and PLC operation shall be provided by EPC Contractor. Any modifications in the ERP software (SAP) to complete the integration with WMS shall be in the scope of the IOCL.Optionally the WMS can be integrated with the existing ERP system through’ selective online data transaction. |
| 3 | Raw Material AS/RS for approximate dimensions 27.5 m wide x 45 m length x 12 m height conforming to FEM standards 9.311, 9.831, 9.851 & 9.881. and having storage capacity of 2500 PALLETS;Mechanical Contractor shall engage with reputed ASRS suppliers to optimize following warehouse storage type / details such as, (i) single deep vs double deep system, (ii) dedicated automated linear stacker crane for each aisles vs combination of automated linear stacker crane with transfer car options. Optimisation shall be based on operation cycles specified in the attached reference documents for ASRS. Storage Racks shall be designed for Pallet sizes of 1200 mm x 1200mm x 200mm height steel pallets of suitable design arranged in 6 tiers; Each loaded pallet outer dimensions are considered as 1200mm x 1200mm x 1300mm and loaded pallet weight is considered as 1150 kgs UDL (including self weight of the Pallet).Vendors to validate these design considerations. The proposed system shall be suitable for storage of 240 SKUs. Operations involved are RECEIVING, REGISTERING, STORAGE, PICKING AND ISSUANCE TO PROCESS PLANT FOR PROCESSING.The proposed system shall be fully integrated with infeed/outfeed conveyors with shuttle car for storage & retrieval of the material. Following is the functional design requirements :a) Material will be received in Drums or Bags (in case of Powders) from Suppliers.The same shall be palletized (after QC clearance) on Pallets of 1200mm x 1200mm x 200 ht Steel pallets as per the pre-defined configuration.Once the material is loaded on the pallet, tertiaryQR code will be generated and pasted on the pallet.The Palletized load isfed to the AS/RS on GF. Hand held terminal will be used to link the tertiary QR code and pallet QR code.Then the pallets will be loaded on the input conveyor. The pallet will go through the profile check where the profile of the pallet (width, depth, Height) will be checked and QR code of the pallet will be scanned to verify the correctness. AS/RS instructs the Stacker crane to pick the pallet from the conveyor and store in the pre- defined location in the system As soon as the Pallet is stored,the inventory is updated in the system.Estimated Peak number of Pallets IN/ hr = 40 pallets /hrb) Materials will be issued for production on the 1st floor (7.0 M level). For retrieval of pallets, the command will be given in the computer terminal. The system will automatically select the required pallets either on FIFO or FEFO basis and command the stacker crane to retrieve the same pallet. The stacker crane shall bring the pallet from AS/RS and keep it on the output conveyor. As the pallet is retrieved from AS/RS, the inventory gets updated in the system.Estimated Peak number of Pallets OUT/ hr = 30 pallets /hrc)In addition to the above,AS/RS will also receive RETURN of Part Pallets from the system.Estimated Peak number of Part Pallets RETURNED to the system are 8nos. d_ In addition to the above,AS/RS will also receive EMPTY pallet stacks from the Plant.Estimated Peak number of RETURN PALLET stacks are 6nos.Thus the total Peak THROUGHPUT for the AS/RS system = 84 pallets/hrVendor design to also consider the requirement for provision of In-rack sprinkler for the Storage racks – in accordance with guidelines of NBC / NFPA and accordingly suitable free-board space shall be considered during finalization of rack-to-rack vertical spacing. In-rack sprinklers will be provided by FF contractor.Suitable Stretch wrapping or Strapping provision shall be included in the scope of Vendor for Loaded pallets carrying Cartons or packaging materials etc. suitably to avoid any fall of items during handling, before sending to the ASRS.Contractor to include RFID / QR coding provision for integration with Track-N-Trace system, MDE for Additive Raw Material pallet identification. |
| 4 | Packaging Material AS/RS for approximate dimensions 13.8 m wide x 58 m length x 12 m height conforming to FEM standards 9.311, 9.831, 9.851 & 9.881. andwith capacity of 1500 PALLETS; Mechanical Contractor shall engage with reputed ASRS suppliers to optimize following warehouse storage type / details such as, (i) single deep vs double deep system, (ii) dedicated automated linear stacker crane for each aisles vs combination of automated linear stacker crane with transfer car options. Optimisation shall be based on operation cycles specified in the attached reference documents for ASRS. Storage Racks shall be designed for Pallet sizes of 1200 mm x 1200mm x 200mm height steel pallets of suitable design arranged in 6 tiers; Each loaded pallet outer dimensions are considered as 1200mm x 1200mm x 1300mm and loaded pallet weight is considered as 1150 kgs UDL (including self weight of the Pallet).Vendors to validate these design considerations. Operations involved are RECEIVING, REGISTERING, STORAGE, PICKING AND ISSUANCE TO PROCESS PLANT FOR FILLILNG & PACKAGING.The proposed system shall be fully integrated with infeed/outfeed conveyors with shuttle car for storage & retrieval of the material. Following is the functional design requirements :a) Material will be received in Stacks, Polybags, pallets from Suppliers.The same shall be palletized (after QC clearance) on Pallets of 1200mm x 1200mm x 200 ht Steel pallets as per the pre- defined configuration.Once the material is loaded on the pallet, tertiaryQR code will be generated and pasted on the pallet.The Palletized load isfed to the AS/RS on GF. Hand held terminal will be used to link the tertiary QR code and pallet QR code.Then the pallets will be loaded on the input conveyor. The pallet will go through the profile check where the profile of the pallet (width, depth, Height) will be checked and QR code of the pallet will be scanned to verify the correctness. AS/RS instructs the Stacker crane to pick the pallet from the conveyor and store in the pre- defined location in the system As soon as the Pallet is stored,the inventory is updated in the system.Estimated Peak number of Pallets IN/ hr = 34 pallets /hrb) Materials will be issued for production on the 1st floor (7.0 M level) or on the GF (0.6M Level). Whereas empty small can containers, Grease Cans and Caps etc. will be issued on FF,Buckets, Cartons etc. will be required on GF.For retrieval of pallets, the command will be given in the computer terminal. The system will automatically select the required pallets either on FIFO or FEFO basis and command the stacker crane to retrieve the same pallet. The stacker crane shall bring the pallet from AS/RS and keep it on the output conveyor. As the pallet is retrieved from AS/RS, the inventory gets updated in the system.Estimated Peak number of Pallets OUT/ hr = 48 pallets /hrThus the total Peak THROUGHPUT for the AS/RS system = 82 pallets/hrVendor design to also consider the requirement for provision of In-rack sprinkler for the Storage racks – in accordance with guidelines of NBC / NFPA and accordingly suitable free-board space shall be considered during finalization of rack-to-rack vertical spacing. In-rack sprinklers shall be provided by FF contractor.Suitable Stretch wrapping or Strapping provision shall be included in the scope of Vendor for Loaded pallets carrying Cartons or packaging materials etc. suitably to avoid any fall of items during handling, before sending to the ASRS. Contractor to include RFID system, MDE & stretch wrapping for Packaging Material pallet identification. |
| 5 | Finished Product AS/RS for approximate dimensions 34.4 m wide x 62.8 m length x 12 m height confirming to FEM standards 9.311, 9.831, 9.851 & 9.881.and shall be with capacity of 4500 PALLETS;Mechanical Contractor shall engage with reputed ASRS suppliers to optimize following warehouse storage type / details such as, (i) single deep vs double deep system, (ii) dedicated automated linear stacker crane for each aisles vs combination of automated linear stacker crane with transfer car options. Optimisation shall be based on operation cycles specified in the attached reference documents for ASRS. Storage Racks shall be designed for Pallet sizes of 1200 mm x 1200mm x 200mm height steel pallets of suitable design arranged in 6 tiers; Each loaded pallet outer dimensions are considered as 1200mm x 1200mm x 1300mm and loaded pallet weight is considered as 1150 kgs UDL (including self weight of the Pallet).Vendors to validate these design considerations. The proposed system shall be suitable for storage of 550 SKUs. Operations involved are RECEIVING PACKED PRODUCTS FROM FILLING PLANT, REGISTERING, STORAGE, PICKING AND ISSUANCE TO DISPATCH.The proposed system shall be fully integrated with infeed/outfeed conveyors with shuttle car for storage & retrieval of the material. Following is the functional design requirements :a) Material will be received on Palletsfrom Filling Section,of size 1200mm x 1200mm x 200 ht Steel pallets as per the pre-defined configuration.Tthe material is loaded on the pallet, tertiaryQR code will be generated and pasted on the pallet.The Palletized load isfed to the AS/RS on GF. Hand held terminal will be used to link the tertiary QR code and pallet QR code.Then the pallets will be loaded on the input conveyor. The pallet will go through the profile check where the profile of the pallet (width, depth, Height) will be checked and QR code of the pallet will be scanned to verify the correctness. AS/RS instructs the Stacker crane to pick the pallet from the conveyor and store in the pre-defined location in the system As soon as the Pallet is stored,the inventory is updated in the system. |
| 6 | Estimated Peak number of Pallets IN/ hr = 137 pallets /hrb) Materials will be issued for Truck Loading at the Packed Truck loading gantry on the GF (0.6M) Level . For retrieval of pallets, the command will be given in the computer terminal. The system will automatically select the required pallets either on FIFO or FEFO basis and command the stacker crane to retrieve the same pallet. The stacker crane shall bring the pallet from AS/RS and keep it on the output conveyor. As the pallet is retrieved from AS/RS, the inventory gets updated in the system.Estimated Peak number of Pallets OUT/ hr = 114 pallets /hrThus the total Peak THROUGHPUT for the AS/RS system = 251 pallets/hrVendor design to also consider the requirement for provision of In-rack sprinkler for the Storage racks – in accordance with guidelines of NBC / NFPA and accordingly suitable free-board space shall be considered during finalization of rack-to-rack vertical spacing. In-rack sprinklers will be provided by FF contractor. |
| 7 | Design, Procurement, Supply, Installation, Erection and Commisioning of Random Access Storage Rack Warehouse for Low Flash Raw MaterialRandom Access Storage Rack Warehouse for approximate dimensions 14 m wide x 35 m length x 4 m height conforming to FEM standards 10.2.02, 10.3.01, BS EN 15512 & SEMA Practices. 150 PALLETS.Detailed Design and Engineering, Procurement, Supply, Installation and Erection including preparation and submission of documents (General Arrangement, detail drawings, as-built drawings,calculations, etc.,) providing necessary accessories,special tools, testing,calibration, painting etc. as perdrawings , technical specifications and applicable codes and standards. The scope shall include complete Random Access Rack Warehouse, associated aisle equipment for pallets loading / unloading/ transfer, supply, fabrication & installation as per drawings and specification shall also be in the scope of bidder. Painting (external surface, support structure etc.) shall be carried out as per the approved painting procedure |
| 8 | \"NOTE:-THE ABOVE RATE SHALL BE INCLUSIVE OF ALL TAXES & DUTIES, ROYALTIES, CESS, ENVIORMENTAL & POLLUTION, FITNESS & SAFETY CLEARANCE CHARGES (IF ANY), OR ANY OTHER INCIDENTAL CHARGES ETC BUT EXCLUDING GST.\" |
