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| 1 | LABOUR: Labour involved in performing all activities A to I of scope of work enclosed. |
| 2 | MATERIAL (Initial spares): Mechanical |
| 3 | All slide ways / guide ways of machine bed longitudinal, cross slide and saddle have to be ground and blue-matched with mating parts to obtain final alignment. Scraping of all sliding parts, gibs etc. Final alignment scraping. Pasting of Turcite-B anti-friction bearing material on all slides, wherever required. |
| 4 | Replacement of all worn out gears (Spur, Helical, Spiral and Bevel) other parts in machine head stock and carriage movement with new ones to I.S. standards and specified quality materials complying with the original manufacturer’s specified tolerances. |
| 5 | Replacement of all bearings existing in the machine as per HMT, list includes main spindle bearings also irrespective of their size and present condition |
| 6 | Tailstock mechanism to be serviced and any damaged parts to be replaced with new. |
| 7 | TOOL TURRET:Model- BTP -125 Make - Pragathi Tool Turret.No of tools - 8 (Eight)Weight of the Tool disc and tooling - 160 kgRepeat Positioning Accuracy-±2\"degIdexing Accuracy- ±6\"deg New Pragathi tool turret installation and interfacing tool changing operation with the new CNC controller. |
| 8 | Telescopic covers to be repaired, if required should be replaced |
| 9 | Hydraulic power pack to be replaced (Rexroth make) with new system including hoses.All solenoid valves, pressure switches are to be replaced with new parts. |
| 10 | X-axis ball screw, end support bearings, X-axis gear box, flanges, brackets, timer pulley, timer belt, sheet metal covers, seals, spacers etc. Length of the ball screw for X Axis 1500 mm |
| 11 | Z-axis ball screw, end support bearings, Z-axis gear box, flanges, brackets, timer pulley, timer belt, sheet metal covers, seals, spacers etc.Length of the ball screw for Z Axis 6300 mm |
| 12 | Cable drag chain with accessories for Z-axis. |
| 13 | Lubrication system to be replaced with new system including hoses.Centralised lubrication system with accessories for the axes and spindle. |
| 14 | Coolant system including hoses to be replaced with new |
| 15 | PAINTING-Painting should be carried out according to the HMT new machine standard procedure for painting including cleaning and removing old paint, applying metal primer putty etc. Good finish should be ensured. Overall, Machine aesthetic view should be taken care of. |
| 16 | Others like brackets and couplings for mounting feed motors, spindle motor, encoders, and protective guards. Painting material,handles& levers, nickel plating of levers & handles. Documentation. etc., any other material required for machine Reconditioning & retrofitting |
| 17 | MATERIAL (Initial spares): Electrical and Electronics |
| 18 | Type: 6FC5370-5AA40-0AA0, CNC-HARDWARE PPU 271.4 (or latest successor with same or more features) with relevant keyboard, system software, hardware & accessories.The following additional features are also required for the supplied CNC system. a) Bidirectional compensation software option b) Network drive management via Ethernet option. c) Access My Machine / OPC UA optionSiemens make MCP 6FC5303-0AF22-0AA1, Siemens make Mini HHU (6FX2007-1AD03)to be provided for axis movement. PLC (integral with CNC) with minimum 72 inputs and 48 outputsPLC I/O Module PP 72/48D PN Type: 6FC5311-0AA00-0AA0, Make : SiemensOne set of additional drives and cables spares as mentioned in clause B-12 in specification. |
| 19 | Suitable motors of Siemens make 1FK7/ 1FT7 with Key way is to be provided. For feed axes.Vendor should take approval from BHEL while choosing the motors.External feedback encoder (Siemens /Heidenhain) for spindle axis is to be interfaced for getting actual RPM. The following external measuring encoders shall be supplied, installed & commissioned on the machineSpindle - axis: Incremental Encoder with 1-V-Sinus 1024PPR, Type:6FX2001-3CB02, Make: Siemens X & Z - axis: Incremental Encoder with 1-V-Sinus 2500PPR, Type:6FX2001-3CC50, Make: Siemens |
| 20 | Operator pendent & Electrical Panel cooling AC system is to be provided with displaying existing temperature & Set point temperature. One spare ac system also to be supplied, The over temperature alarm input interfaced to PLC to generate warning message. 2 No’s four-core signal cable to be provided from PPU to Electrical drive panel to meet future requirements. |
| 21 | Operator pendent layout drawing is to be submitted( to know the Operator Push buttons & Switches placement).The following push buttons like Chuck OD/ID clamping ,Quill Forward , Quill retract ,Turret index , Emergency override, Control ON with light , Coolant ON/OFF .Complete 3 sets of Electrical drawings, PLC logic soft copy & hard copy with comments are to be provided. |
| 22 | Siemens Make Energy meter PAC5200 with Ethernet port facility should be provided on main electrical control panel door to indicate and record total consumption of electric power for the machine including auxiliary systems. Scope should include necessary current transformers & relevant accessories.Vendor shall get approval from BHEL with respect to Make & Model of Digital Energy Meter before procurement of the same. The vendor has to demonstrate features like Total energy consumption, Trends in Voltage, Current & PF and energy. The vendor has to supply necessary software & Communication cables. |
| 23 | One spare Turret encoder to be supplied for trouble free operation. |
| 24 | a) All fuses and overload relays to be replaced with Siemens make motor protection circuit breakers. Necessary modification to be done in the circuit.b) Replacement of all limit switches, limit dogs, mercury float switch, rotary switch, PVC conduits etc. with new ones of Euchner/ Balluf /Teknic or reputed make.c) All switchgear items like MCBs, contactors, control relays, switches, push buttons shall be of SIEMENS make only.Terminal blocks of make WAGO/reputed make.d) Indication lamps wherever required to be provided (Siemens make).Tower lamp to be placed on machine.Indicating instruments shall be replaced with new ones of reputed make.e) Two industrial grade LAN cables to be laid from Electrical panel to operator pendent for Network connectivity. |
| 25 | Servo stabilizer of suitable capacity is to be provided (with safety enclosure) for entire machine covering complete electrics (CNC, PLC, drives, motors and other electrical Devices). This should be installed outside the control panel.Make: Reputed Indian make. To be furnished with test certificate. Catalogs and trouble shooting manuals are to be provided. |
| 26 | Laser calibration of X&Z axis shall be carried out. Calibration equipment in contractor’s scope. Details as below: (Laser calibration equipment in contractor’s scope) Checking of positional accuracies and repeatability as per VDI/DGQ 3441 latest version by Linear method.i)Positional accuracy X-axis0.020(over full length of X-traverse) Z-axis 0.020 (over full length)ii)Repeatability X-axis0.010 (per meter) Z-axis0.010 (per meter) |
