Specifications of 1600MT Extrusion Press

Detailed description/features & functional requirements/specifications

The objectives and broad guidelines laid down in Section 1.0 define end goals of the
system which shall prevail over all subsequent sections. The supplier shall therefore be
guided by these stipulations.

A PLC based 1600MT capacity horizontal hydraulic extrusion press is required for hot
extrusion of Copper, Brass and other non-ferrous metals and alloys. PLC and HMI/SCADA
based control and data acquisition is required for overall control, display and logging of
process parameters, press status, alarms, trends, analysis, report generation and online
diagnosis of the system.

The press shall be supplied with auxiliary handling system of suitable capacity for changing
of extrusion tooling like container, die and stem.

1.0 Functional and Technical Requirements of Extrusion Press

Hot billets shall be extruded in air at temperature up to 850°C and the extruded rod shall be
quenched in the water tank.

1.1 It shall be possible to carry out extrusion in “Direct” as well as “Indirect”

modes. It shall have arrangement for easy change-over from Direct to Indirect
mode and vice-versa.

1.2 The extrusion press shall be of Pre-compressed Column & Pre-Tension Tie-
rod design.

1.3 It shall be possible to carry out extrusion of solid billets of copper, brass and
other non-ferrous materials into rods, solid sections and tubes.

1.4 It shall have infinitely variable extrusion speed up to 60mm/sec with closed
loop speed control.

1.5 It shall be possible to operate the extrusion press in Manual, Adjustment and
Auto-sequence modes.

1.6 The press shall have adjustable tonnage from 100 to 1600MT.

1.7 It shall have hydraulically operated shear slide.

1.8 It shall have hydraulically operated die slide with two die station.

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1.9 The power pack shall be mounted on the top of the main cylinder in order to
reduce the “Foot-Print” within 20m length x 9m width. Clear height of 7m is
available.

1.10 Lubrication system for Container, Main Ram, Die Slide & Die Slide guides
shall be provided.

1.11 It shall have indirect extrusion system with pusher, secondary shear and
column mounted conveying arm.

1.12 It shall have Piercer cylinder and slide housed in Main Ram and crosshead
with the connection for water for internal cooling of piercer.

1.13 It shall have Mandrel (piercer) stroke adjustment device and mandrel
(piercer) stroke limiting device.

1.14 It shall be possible to extrude Billet length up to 350mm

1.15 Maximum weight of the billet will be ~28kg

1.16 It shall be possible to achieve Container temperature of 600oC within 4hrs.

1.17 Containers of bore sizes: 150mm, 100mm and 50mm shall be provided. Apart
from this, it shall be possible to use container sizes: 120mm, 80mm, 75mm &
65mm in this press.

1.18 It shall have PLC with Soft Operator Panel (SCADA) and Hard wired push
button Panel with HMI to display following:

a. Extrusion speed, Stroke of main ram, working tonnage of extrusion,

extrusion pressure, Container clamping pressure, Container
temperature, billet length & discard length etc.
b. Operating status of press, graphical representation of press
movements etc.
1.18.1 Press parameters shall be adjustable from SCADA as well as HMI.
1.18.2 Hard Wired Operator push button panel with HMI shall act as
redundant/ parallel control.

1.19 Soft starter shall be provided for the Main Pumps.

1.20 The Press shall be provided with necessary interlocks for operator safety,
prevent the faulty operations and save the equipment from damage.

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1.21 The vendor shall mention following in the offer along with design basis
calculations:

1.21.1 Container stroke

1.21.2 Container length
1.21.3 Container stripping capacity
1.21.4 Container sealing capacity
1.21.5 Billet upsetting capacity
1.21.6 Shear capacity
1.21.7 Piercer capacity
1.21.8 Container pre-heating power
1.21.9 Nominal oil tank capacity
1.21.10 Main motor capacity
1.21.11 Motor speed & type
1.21.12 Type of pumps
1.21.13 Oil filtration scheme and oil cooling arrangement in their offer.
1.22 The vendor shall include full schematic diagram of the extrusion press in the
technical offer.
1.23 The vendor shall mention the basic design calculations and details of
construction for various components like main cylinder, main ram, auxiliary
cylinders, tie rods & nuts, columns, end frame, moving cross head, guide for
container & stem cross head, container, stem, container heating, foundation
structure & support, power pack.
1.24 The vendor shall also mention the overall size of the extrusion press.
1.25 Scope of Supply
1.25.1 1600MT capacity horizontal hydraulic extrusion press which shall
operate in Manual, Adjustment and Auto-sequence modes. The press
will be utilized for extrusion of solid/pierced billets of copper, brass and
other non-ferrous materials into rods, solid sections and tubes.
1.25.2 The extrusion press shall be supplied along with 150mm, 100mm and
50mm bore container with housing and toolings like stem, die holder
assembly etc. Container housing shall be interchangeable.
1.25.3 The extrusion press shall be supplied along with 25mm dia. extrusion
die (2 nos.) for 150mm bore container, 16mm dia. extrusion die (10

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 nos.) for 100mm bore container and 12mm dia. extrusion die (2 nos.)
for 50mm bore container.
1.25.4 The extrusion press shall be supplied along with suitable Extruded rod
quenching mechanism.
1.25.5 The extrusion shall be supplied along with Suitable Mechanical filter
and Electrostatic filter for Oil filtration.

1.25.6 The extrusion press shall be supplied along with Suitable Auxiliary
handling system for changing of extrusion tooling like container, die
and stem used in the press.

1.25.7 The extrusion press shall be supplied along with required quantity of
Hydraulic Oil.

1.25.8 PLC with Soft Operator Panel (SCADA with IPC) and Hard wired push
button Panel with HMI shall be provided for control of Extrusion Press,
display and logging of essential process parameters, press status,
graphical representation of the press movements, alarms, trends,
analysis, data logging, report generation and online diagnosis of the
system.

2.0 Control Description

2.1 Control Modes: The Extrusion Press shall be able to operate in Manual,
Adjustment & Auto-sequence modes.
2.1.1 Adjustment Mode: In Adjustment Mode the operator shall have the
accessibility to operate the machine in full manual control for any
individual operation. This mode is required for maintenance, tool
change and alignment work purpose. All the Press movements shall
be at low speed by continuous push of button by operator. All safety
interlocks must be active.
2.1.2 Manual Mode: In manual mode, the control of all the individual Press
operation must be possible through push buttons on Hardwired
operator panel or Soft operator panel, though data logging must
continue. All the Press movements shall be at set speed until their
limit positions is reached by a single push of button by operator. All
safety interlocks must be active.
2.1.3 Auto-sequence Mode: In auto-sequence mode, the operation shall

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 be possible as per the programmed sequence by a single push of a
button either on Hardwired operator panel or Soft operator panel. All
the Press movements shall be at normal programmed speed following
the programmed sequence. All the interlocks (safety and otherwise)
must be active. During the auto-sequence mode, it shall be feasible to
change the Press parameters. “Optional Container Cleaning cycle”
and “Burp-cycle enabling provision” shall be present to include the
Container Cleaning cycle and/or Burp-cycle in the sequence.
2.1.4 Following programmed sequences are required:
2.1.4.1 Homing cycle: An auto-homing cycle must be provided for
automatic initialization of the Press components to 'Home-
position' with the press of single button.
2.1.4.2 Idle cycle: An Idle cycle must be provided for testing of
press movements without loading any material to be
extruded.
2.1.4.3 Extrusion cycle: An auto-Extrusion cycle starting from the
Press Home-position must be provided with the press of a
single button.
2.2 Operator Control Panel Modes

All the above three control modes viz. Adjustment, Manual or Auto-sequence mode
must be possible through Hard Wired Operator Panel and Soft Operator Panel
independent of each other. Mode changeover in either direction shall be bump less.

2.2.1 Hard Wired Operator Panel with HMI

In Hard Wired Operator Panel with HMI, the control of the Press operations must be
possible through Hardwired operator Panel, independent of the Soft Operator Panel,
though data logging must continue. The main-ram pressure, position/ travel length
and speed, container pressure, position and temperature, all other indications like
home position indicator, container in lock position, main-ram in retract position,
shear position indicator, billet loader position indicator which are needed for
complete operation of Press shall be available to the operator on HMI for control of
operation. It shall be possible to adjust the operating parameters of the press like
Upset Pressure, Seal Pressure, Pressure limit, Begin Pressure, Main-Ram speed
control, discard length, etc. through precision multi-turn potentiometer or HMI.

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 2.2.2 Soft Operator Panel

In Soft Operator Panel, the operation shall be possible through SCADA screens on
IPC. It must be possible to control all the individual operation of the Press through
soft buttons. It shall be possible to change set point, tuning constant, operating
parameters, control mode with required security levels. Detail requirements are as
given in section 2.4 of this specification.

2.3 PLC Control requirement

2.3.1 Controller requirement

The control system shall be a PLC based control system. It shall permit data
acquisition, logging and control functions to be performed and the capability to
monitor and control. The system shall be sufficiently flexible so that it can be
configured to a wide range of process requirements without changes in the
hardware.

The PLC based control system shall be based on Open architecture. The open
capabilities shall also allow third party software (such as operator interface,
optimization software or expert systems) to be an integral part of the systems when
purchaser intends to procure them. The programming language used for writing
application software shall be as per IEC-61131-3. PLC shall support the Fail-safe
operation of the Press.

2.3.2 Input/output interface requirement

All the input output modules shall be mounted in a single /multi rack system
connected to a common communication highway/backplane. The system shall
support the following type of input and output signals.

2.3.2.1 Separate card shall be provided for digital and analog

Inputs/Outputs.
2.3.2.2 The I/O card shall be configurable to fail-safe condition in
case of failure of CPU card.
2.3.2.3 I/O card shall have LED indication for healthiness of the card
as well as its health of communication with the controller.
2.3.2.4 The I/O card rack shall not be loaded for more than 80
percent capacity and each I/O card must have 10% spare
I/O points.

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 2.3.2.5 Barriers Isolators: All types of I/O’s shall be provided with
suitable active barriers/isolators. All the digital inputs shall be
potential free contacts.
2.3.2.6 Fuse: Each line carrying current in ampere range should
have fuse in live as well as return arm.
2.3.2.7 Resolution & Accuracy: For Analog input/output cards,
conversion resolution of 13 bit or better and accuracy shall
be better than 0.1% of full range.
2.3.3 Spare Capacity and Expansion Capability

The PLC system shall have the following minimum spare capacity and expansion
capability.

2.3.3.1 PLC I/O racks shall have an additional 20% spare rack
space, without installed modules. These spaces shall be
capable for installing any type of modules of any mix.
2.3.3.2 The system design shall include the capability for at least
20% future hardware expansion, which shall be achieved by
addition of modules, without modifying or replacing existing
modules, communications cables or system operating
software.
2.3.3.3 Each installed communication system shall have 25% node
expansion capability for future development and still be
capable of meeting the requirements of this specification.
2.3.3.4 Licensed PLC and SCADA development software shall be
provided for expansion purpose along with runtime and
development licenses.
2.3.3.5 Any special cables, connectors or interfaces required for
online diagnosis/monitoring of PLC shall also be provided for
maintenance, troubleshooting and future up gradation.
2.3.4 Protection & safety interlocks

All necessary protections and safety interlocks shall be incorporated for safe
operation of the Press against unsafe operation, over voltage, over current, phase
failure, short circuit, open circuit and interlocks for panel doors, temperature,
pressure etc. The Press shall be provided with interlocks for operator safety, prevent
the faulty operations and save the equipment from damage.

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Fail Safe Operation
The design of the PLC system shall adhere to the principle of fail safe operation i.e.
under no circumstances the safety of the personnel/equipment should be
jeopardized while at the same time the system shall prevent occurrence of false
trips. In case of failure, Press shall set itself to a predetermined safe state.

2.4 SCADA requirements

2.4.1 Soft Operator Panel

The Operator Panel shall perform broadly, but not limited to following
functions:

2.4.1.1 Remote control of the Press operation by means of

providing soft operator panel with operation in Adjustment,
Manual or Auto-sequence mode.
2.4.1.2 It shall have all mimic for the system and control through
mimic shall be possible under password control.
2.4.1.3 It shall have facility to provide guidance to operator on
various system failures and malfunctions etc. and shall also
help to find out the root cause of the problem.
2.4.1.4 All type of display, but not limited to, namely dynamic
display, trend display, alarm display, alarm summary
display, system alarm display, graphic display, press mimic
display etc shall be made available by Soft Operator Panel
for the operator with current data and if required with history
data.
2.4.1.5 Operator shall be able to change set points and switch
on/off the system remotely.
2.4.1.6 The Operator Panel shall be latest version of Fan-less Dust-
tight Industrial grade IPC system complete with at least 19“
TFT-LCD Touch Panel with latest configuration.
2.4.1.7 The SCADA software shall enable the operator to view the
entire system in operation. It shall provide features like data
logging, alarm handling, historical data, etc. The design
should be such that operator can quickly review the system
at different display levels like overview of entire press,
subsystem wise display etc. They shall provide colour

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 graphic, control, display and alarm functions.
2.4.1.8 There shall be permanent area on every page providing
immediate alarm indication of abnormal Press condition.
Each display shall always provide the Time of day in hours
and minutes; Date by day, month, and year.
2.4.1.9 The operator shall be informed about a trip situation by a
warning sound and the first up alarm shall flash on screen.
2.4.1.10 Security for modifying system parameter shall be through
login and password.
2.4.2 Dynamics Graphic Displays / Monitoring and Control
2.4.2.1 The graphics shall be built by the vendor on the basis of
system design.
2.4.2.2 These graphic displays shall be able to show graphically the
process, equipment, and relevant instrumentation. The
following information shall be available from these displays:
2.4.2.2.1 Measured value of each analog variable (container
temperature, pressure values, billet length, position
values of press and container, etc.)
2.4.2.2.2 Press status display (cycle type, control mode,
working mode, etc.)
2.4.2.2.3 Status of pumps, valves, heating coil etc.
2.4.2.2.4 Alarm for analog or digital variables
2.4.2.2.5 Number of extruded billets against total to be
extruded, etc.
2.4.2.3 Graphic displays shall be interactive type through which it
shall be possible to control the process. Following actions
shall be possible from the display:
2.4.2.3.1 Setting of extrusion parameters
2.4.2.3.2 Selection of working mode (Direct/ Indirect Mode)
2.4.2.3.3 Selection of extrusion cycle (Normal, Burp-cycle, Idle-
cycle)
2.4.2.3.4 Increase / decrease set points (container
temperature, ram speed, discard length)
2.4.2.3.5 Change control mode
2.4.2.3.6 Change tuning parameters
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 2.4.2.3.7 Change limits on set point & output
2.4.2.3.8 Change alarm set point
2.4.2.4 Graphical representation of the Press movements
2.4.2.5 Real time dynamic updating shall be possible for data
variables in each display. Dynamic updating shall include
changing symbols (such as closed valve position open valve
position, Status of pumps), change in colour, and change in
values.
2.4.2.6 The current values of process variables with engineering
units shall be displayed in the objects.
2.4.2.7 Abnormal conditions shall also be displayed in the graphics.
Number of graphic pages available should not be a limitation
to adequately display the complete process.
2.4.2.8 Set point validation check- if Set point or parameter entered
is irrational value or beyond the specified limit then system
shall have facility to warn the operator.
2.4.2.9 The system shall provide a screen update time not
exceeding 0.2 sec.
2.4.3 Alarm Display and Alarm History
2.4.3.1 Alarm display shall be available to inform the operator of
important process abnormalities.
2.4.3.2 The operator console shall have the facility to set the alarm
limits (such as low, very low, high, very high) for all the
process variables as well as set point, output and deviation
on the variables.
2.4.3.3 Alarm information such as Date & Time, Alarm explanation,
Alarm status (active & not noticed, active & noticed,
deactivated alarm).
2.4.3.4 All the alarms shall be accompanied by audio/visual
annunciation till the same is acknowledged and a flashing
light shall indicate the group in which the alarm has
occurred. This will be visible on the display irrespective of
the current display.

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 2.4.3.5 It shall be possible to selectively mute any alarm from
Operator panel. The alarm condition shall indicate the
point(s) in alarm by flashing red.
2.4.3.6 When the alarm is acknowledged, the flashing display shall
become steady. The display shall return to normal when an
acknowledged alarm condition returns to normal only after
operator’s intervention.
2.4.3.7 Alarm Summary Display should provide the operator with a
summary of alarms in an operator Panel in an order of
occurrence.
2.4.3.8 Chronological Alarm Sequence Summary should display the
list with Date and Time of alarm.
2.4.3.9 Alarm History must be maintained and it shall be possible to
store the event log for the last 7 days on a mass storage
device.
2.4.4 System Alarm

System shall have capability of on-line self-diagnosis. There shall be

extensive self-diagnosis to monitor healthiness of all the
cards/modules/communication links/equipments/heaters/system etc. Healthy
indication shall be provided on card as well as on the operator panel. Any
abnormal conditions in subsystems shall be displayed as system alarm
message on operator console irrespective of the display selected.

2.4.5 Trend Display

2.4.5.1 The system shall have the features of both real-time trend
and historical trend display at the console which shall also
be available on a mass storage device.
2.4.5.2 The simultaneous trending of at least four (4) selected
variables (including but not limited to main-ram pressure,
main-ram speed, container temperature and container
pressure) shall be possible on the display with selectable
scales and colours, per trend, and with selectable sampling
rates (min. 0.01 sec per sample or better).
2.4.5.3 The real-time trend shall have a scan time preferably less
than 0.1 sec and the display time frame shall be user

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 definable from 0.5 minute to 8 hours. Sampling rate shall be
selectable.
2.4.5.4 The historical trend values are to be stored on mass storage
device automatically without any user intervention for at least
30 days with maximum scan time of 0.1 sec and this data
shall be available on demand on the operator console.
2.4.5.5 Trend display shall indicate value & time on cursor
movement.
2.4.5.6 Magnification up to 10 times of part of the plot shall be
possible.
2.4.6 Data Logging

Data logging shall be done in hardwired operator panel and soft operator
panel mode, in both manual and auto-sequence cycle. All logs shall be
displayable on the Operator Panel.

2.4.6.1 All the set points and measured process variables must be
logged on the non-volatile memory for data storage along with
the batch information. It must be capable to display the data
being collected in real time on the Operator Panel. The sample
must be collected with an appropriate sample time for every
extrusion cycle run with appropriate record length.
2.4.6.2 Event History: On demand, a chronological record of events
(e.g. operator action, set point changes, alarms etc) shall be
displayed on the screen. The pages of the log shall be scrolled
and the log capable of being stopped at any time. It shall be
absolutely impossible for the operator to erase any part of the
event log.
2.4.6.3 Database Management
2.4.6.3.1 The historical database shall be designed to store at
least one-month data of critical variables on hourly
basis, as well as other standard data elements. It
shall be possible to retrieve the data in the form of
reports / files as defined by the user.

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 2.4.6.3.2 The operational data-base shall provide for retaining
data for Alarm/event logging: 30 days or more and
Process log: 30 days or more.
2.4.7 Report Generation

Following reports are required on demand as well as automatically.

2.4.7.1 Shift/Daily/Monthly reports of different process variables.

2.4.7.2 System diagnostic reports in case of failure of any module /
component of the system both current and historical.
2.4.7.3 Log of operator initiated actions, on demand.
2.4.7.4 Alarm and trip review reports
2.4.8 On-Line Help and Diagnosis
2.4.8.1 An on-line help facility shall be provided at the SCADA and
HMI, which shall provide the user information about the
System configuration and details, Maintenance
manuals/procedures including fault manual and Operation
manual
2.4.8.2 System shall have its own documentation so that engineers
may not carry manuals to rectify the fault.
2.4.8.3 The status of all the digital and analog inputs/outputs must
be made available for online diagnosis of faults. With option
of viewing it as Group as per mode/cycle of operation and
all the digital and analog inputs/outputs
2.4.8.4 Conditions and interlocks for each cycle phase
2.4.8.5 Valves to be activated for each movement
2.4.8.6 Container alignment real values against reference values
during container alignment process.
2.4.8.7 Real time values of the following, but not limited to it shall be
available
2.4.8.7.1 real time monitoring of main pumps
2.4.8.7.2 real time position values of press and container
2.4.8.7.3 real time status of proximity switches
2.4.8.7.4 real time status of pressures
2.4.8.7.5 missing conditions to start next cycle phase
2.4.8.7.6 real time commanded valves and actuators

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 2.5 Panels framework requirement

Panel’s framework shall be provided and standardized in accordance to the following:

2.5.1 Panel should be MS powder coated enclosure to house all the

components.
2.5.2 Self-standing type, min. 1.8 mm thick cold rolled steel plates, with
channel base.
2.5.3 Supply Cables entry - From the bottom. Control cable can suitably
routed. Additional blank holes properly sealed during delivery for
passing cable for interfacing with additional PLC modules and data
acquisition system is required.
2.5.4 Cabinet access - From rear & from front with locked doors complete
with keys.
2.5.5 Copper grounding bars. As a minimum, safety grounding and signal
grounding shall be provided with a grounding strip.
2.5.6 Terminals shall be mounted on DIN 46227/1 standard rail.
2.5.7 Cables fixing through cable glands and Shielded cables should be
used for all control wiring jobs.
2.5.8 Proper Ventilation of the cabinet is required to maintain the cabinet
body below 30°C.
2.5.9 Internal Light: CFL bulbs/LED light or equivalent complete with switch.
Illumination of minimum 300 lux inside panel is required, interlocked
with door limit switch.
2.5.10 Incoming and outgoing cables/wires from and to the cabinets shall
terminate at terminals in the cabinets. All these internal wiring,
termination and interconnection between cabinets, system cabinets
and panels shall be executed by Vendor.
2.5.11 Cable ducts – Dedicated and separate for power, signal and non-
signals. Cable ducts shall be provided with ~20% empty space.
2.5.12 Min. of 4 nos. of lifting eye bolts for handling are required for each
cabinet
2.5.13 Power supply packs shall be positioned so as not to generate
electromagnetic interference in the electronic component.
2.5.14 There shall not be any adverse effect in the system functioning due to
R.F. interference from R.F source being used in the vicinity / factory

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 premises.
2.5.15 All I/O circuit shall be isolated from logic signal processing circuit by
means of galvanic / opto electronic coupled devices.
2.5.16 Isolation from common over voltage peak shall be at least 1500 V rms.
2.5.17 All I/O circuits shall be designed so that accidental application of a
voltage of 500 V AC / DC at their terminals causes no damage to the
system and any damage should be limited to that module only.
2.5.18 The output circuits shall be fitted with overload protection against
inductive loads, over currents and reverse polarity and short circuit.
2.5.19 The cabinet shall be supplied complete with all the materials and
accessories for wiring with fixing brackets and cable clamps for
customers in/out cables also.
2.5.20 The panels shall be well sealed against dust IP51 as per IEC 529 for
indoor applications.
2.5.21 Conductors shall be marked at each end. All electrical cables shall be
identified by cable markers on terminal boards and at the panel
mounted instruments.
2.5.22 The relays shall be installed so that they are insensitive to vibrations
and mechanical shock.
2.5.23 Suitable digital meters shall be provided at input for measurement of
input current, input voltage, frequency, power, energy, etc.
2.5.24 Indicator lamp for 3-phase supply.
2.5.25 Emergency pushbutton shall be provided at convenient location on the
panel.
3.0 Approval

The Supplier shall submit all relevant electrical /mechanical detailed drawings, circuit
diagrams, design basis, etc. for approval before starting of development work &
commencement of the fabrication job.

Following documents are required to be submitted for purchaser’s approval before taking
up material procurement and fabrication:

3.1 Mechanical

3.1.1 Lay out of Extrusion Press with major dimensions

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 3.1.2 Design report & design drawings for all the sub-systems

3.1.3 Lay out of Hydraulic system with major interconnects

3.1.4 Manufacturing process schedule

3.1.5 Quality Assurance Plan (QAP)

3.1.6 Quality Control Procedure (QCP)

3.1.7 Acceptance Test Plan (ATP)

3.2 Electrical

3.2.1 All design details, Schematic diagrams, circuit diagrams along with
functional details shall be provided.

3.2.2 Calculations for Power consumption requirements and expected heat

dissipation, selection of heating element and temperature sensors
shall be provided.

3.2.3 List of materials giving type, number and make of all components used
shall be provided.

3.2.4 Testing schedule and details of all the test to be carried out shall be
provided.

3.3 Control and Instrumentation

3.3.1 Design of PLC logic and software programming

3.3.2 Design of SCADA/HMI screens

3.3.3 Design of the Hydraulic System control and measurement

3.3.4 Measurement and Instrumentation of the Press

3.3.5 Overall control (PID) of heating system of the Container and main ram
speed.

4.0 Services available

4.1 Electrical : 415V, 3-phase, 50Hz & 230V,1-phase, 50Hz are available.
4.2 Compressed air at 6 kg/cm2 is available.
4.3 Cooling water at 2 kg/cm2 is available.
4.4 Vendor shall mention the Electrical power requirement, voltage, current,

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 connection method, line size etc.
4.5 Vendor shall also mention the other services required for the operation of
press like compressed air requirement, cooling water requirement etc.
4.6 Vendor shall inform the services requirements in advanced for appropriate
arrangement to be made by purchaser.

5.0 Acceptance Test

In addition to the vendor’s standard test procedures, a factory acceptance test (FAT)
shall be performed in purchaser’s presence at the vendor’s works. The FAT is intended to
fully demonstrate that the Extrusion Press have been made correctly and completely in
accordance with all manufacturing, assembly and software configurations and that the
system performance is as per the specifications.

The test shall include:

5.1 Mechanical built and finish quality inspection

5.2 Operation of all peripherals.

5.3 Complete functional check to demonstrate that the system operates in a

manner as defined in this specification and relevant documents, based on all
equipment of the system connected together, input/ outputs fully simulated.

5.4 Dry run or ideal run (without loading of material) in all possible modes of
operation must be done to validate the operation/function of the system at the
vendor’s factory to the satisfaction of the purchaser.

5.5 Hardware & Software functional testing, including the run test of the entire
configuration, their normal operating modes(in Adjustment, Manual and Auto-
sequence modes) and performs all potential operations through the operator
interfaces.

5.6 System inspection including inspection of all major components and module
interconnection.

5.7 System start up, power up, system reload, trip testing shall be carried out.

5.8 Process interface testing including calibration of Pressure, Temperature, Ram

travel measurement, Power, frequency, voltages and currents inputs point by
point analog and discrete input and output tests, interface tests for
transmitters and signal drift correction test.

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5.9 Interlocks logic function testing, startup and shutdown routines testing.

5.10 Operator interface checking including testing of digital displays, Emergency

Push button, Potentiometer, Selector switch, Push buttons and indication
lamps.

5.11 Hardware and Software must be thoroughly virus scanned for Viruses like
Stuxnet, Flame, Duqu, etc.

5.12 The supplier shall provide all the necessary test equipment & instruments
required for the performance testing of the entire Extrusion Press at the
supplier’s works, before its dispatch.

5.13 Three sets of following approved documents shall be made available to the
inspector visiting vendor’s shop for pre dispatch clearance of the complete
assembly:

5.13.1 As built drawing of all the sub –system of the complete assembly

5.13.2 Design report

5.13.3 QA/QC report

5.13.4 Performance test report

5.13.5 Calibration reports of all instruments/sensors/transducers

5.13.6 Detailed electrical / electronic circuit diagrams

5.13.7 Operator’s manual for day to day operation and troubleshooting

5.13.8 Instruction manual for future servicing work

5.14 The On-Site acceptance test (On-SAT) will be conducted after system
installation on site and is intended to assure that no damage occurred to the
system during shipment, that the system is correctly installed and that the
system requirements are satisfied when connected to “live” field
inputs/outputs. Actual testing of the complete system with actual load or
equivalent operation/function must be done to validate the system at the
purchaser’s site. At least 10 actual successful runs (5 in auto mode and 5 in
manual mode) of the Extrusion Press shall be done to validate the entire
system operation to the satisfaction of the purchaser.

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6.0 General Scope of Work

The Scope includes all the items covered in this specification. The scope of work also
includes any other items required to meet the performance or statutory requirements.

Following gives some major activities covered under the scope of work.

6.1 Mechanical

6.1.1 To prepare the final design reports and design drawings for all sub-
systems.

6.1.2 Hydraulic System design which includes pressure calculation and

pump selection criterion.

6.1.3 To prepare fabrication drawings based on the approved design

drawings and design report.

6.1.4 Preparation and submission for approval of

6.1.4.1 Manufacture procedure Specification (MPS)

6.1.4.2 Manufacture process Schedule

6.1.4.3 Quality Assurance Plan (QAP)

6.1.4.4 Quality Control procedure (QCP)

6.1.4.5 Acceptance Test Plan (ATP)

6.1.4.6 Preparation of Bill of materials

6.1.5 Purchase, procurement, testing and identification of material as per bill

of materials and material specifications.

6.1.6 Stage wise inspection as per the approved QAP & QCP.

6.2 Electrical

Preparation and submission for approval of

6.2.1 Electrical drawings of the various subsystems

6.2.2 Calculation of Power consumption by each sub-system

6.2.3 Purchase specification for bought out items

6.2.4 QA Plan / testing procedure

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 6.3 Design of control and Instrumentation

Complete design of control and instrumentation shall include but not be limited to the
following:

6.3.1 Design and development of PLC logic and software programming

6.3.2 Design and development of SCADA screens

6.3.3 Hydraulic System control and measurement

6.3.4 Instrumentation System control and measurement

6.3.5 Overall control of Container heating control (PID) and main ram speed.

6.4 General

6.4.1 Component performance testing as per the ATP.

6.4.2 Performance testing of the assembly as per ATP.

6.4.3 Modifications, if any, required for satisfactory performance.

6.4.4 Preparation of as built drawings and revised design reports.

6.4.5 Disassembly of the system, packing and forwarding to BARC site.

6.4.6 Connection of the main oil tank to the electrostatic filter.

6.4.7 Installation of power cable from distribution box to panel and their
termination.

6.4.8 Supply and Installation of the auxiliary handling system.

7.0 General Requirements

7.1 Installation, Testing & Commissioning

7.1.1 Vendor shall offer the services of the installation team, which shall
carry out installation, testing and commissioning of the Extrusion Press
at user's site at Mumbai.

7.1.2 All technical personnel deputed on site by vendor shall be fully

conversant with the supplied system and offered software package.

7.1.3 Vendor shall mention the heaviest part/components to be installed and

vendor shall arrange for movement of such part/components to
installation site.

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 7.1.4 Vendor’s responsibility at site shall include all activities necessary to
complete the job as per specifications including following:

7.1.4.1 Installation of the Extrusion Press and Electrical & Control

panel on the site.

7.1.4.2 Cabling of all power/ signal & system cables with the
instruments, sensors, actuators, etc.

7.1.4.3 Safety /Electronic /Barrier earthing of all panels to the

nearest earth point.

7.1.4.4 Mounting of all hardwire instruments in the cabinet.

7.1.4.5 Powering up the system, loading the system configuration

carrying out internal loop checks.

7.1.4.6 Control loop checking simulating with field instruments.

7.1.4.7 Commissioning and on-line debugging of the system

7.1.4.8 Performance of final acceptance test

7.1.4.9 Submission of “AS BUILT” drawings.

7.1.4.10 All skilled / non-skilled manpower required for above

complete job are in the scope of vendor.

7.2 Training

Training for four persons shall cover complete education of all aspects of the system.
The duration of training must be specified for each training categories.

The training module shall be divided to impart the following categories:

7.2.1 System feature: The training shall cover various mechanical,

hydraulic, electrical, control, hardware and software feature of the
system, system configuration, making of logic and its implementation,
modification to be carried out, etc.

7.2.2 Maintenance feature: This shall cover all aspects of the trouble
shooting and maintenance of various parts / units of the system up to
the module / component level. This shall also include training on
replacement and alignment of tools, die, container, and all other

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 hydraulic, electrical and electronics components. This shall also
include software diagnostic using SCADA, HMI and PLC.

7.2.3 Operational feature: This shall cover all aspects of the operation of
the system, setting system parameters, setting operation set points,
various other features etc.

7.2.4 A detailed training on PLC & SCADA software package used must be
provided in order to carry out future software modifications and
integration of existing system with the Press.

7.3 Documentation

The supplier shall submit documents and manuals, in English, which shall be
comprehensive and provide sufficient information for efficient operation, maintenance and
use of the system. These manuals shall provide the functional description of the equipment
operating & maintenance instructions, precautions, preventive maintenance guidelines,
trouble shooting charts. etc., relevant circuit diagrams/drawings, recommended list of
spares, etc. make and models of the items like PLC, IPC, SCADA, relays, hydraulic valves,
solenoid valves, servo/proportional valves, temperature controllers, heater elements,
contactors, meters etc. along with catalogues with specifications for all bought-out items.

The manual must include, but not be limited to, the following:

7.3.1 Configuration details in hierarchical fashion.

7.3.2 Bill of material from system level up to component & card level and
bought out items.

7.3.3 Standard dimensional drawings for cabinets, operator console,

auxiliary part etc.

7.3.4 Power consumption requirements and calculations and expected heat

dissipation.

7.3.5 Calculations for selection of Hydraulic system, valves and Pumps, etc.

7.3.6 Schematic drawings for grounding systems.

7.3.7 Cable schedule / Loop drawings / ladder drawings for logic etc.

7.3.8 Maintenance and service manuals for the system and peripherals
along with troubleshooting chart.

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 7.3.9 Technical document for hardware and software products to be
supplied.

7.3.10 Software operation manuals.

7.3.11 Software configuration manual and list of configured parameters.

7.3.12 As built drawings for I/O details / loop drawings / Ladder logic /Hook-
Up drawings Cable schedule etc.

7.3.13 Number of cabinets and drawings along with weight

7.3.14 Operator panel layout with dimensions

7.3.15 Sensibility to Radio Frequency Interference (RFI)

7.3.16 Type of special cable, if any.

7.3.17 Supplier’s technical standard documentation for hardware and

software products included in the offer.

7.3.18 Description of the function of each program. This shall include the
logic configuration requirements, constraints, subprograms used and
special characteristics.

7.3.19 Input and output details of each program.

7.3.20 Dimensional drawings of all equipment

7.3.21 Layout of all cabinets with positions of components and drawings of

termination references.

7.3.22 Earthing drawings with termination references

7.3.23 Maintenance and service manual along with circuit details with test
point voltages details for the system, sub -systems and individual units
up to component level.

7.3.24 Softwares along with development and run time license.

7.3.25 Documentation of all application and configuration software.

7.3.26 All the above documents shall be supplied in 3 sets.

7.4 Support Services

7.4.1 Support Capability

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 7.4.1.1 If restoration is likely to take a long time (more than one
week), the defective control card / module shall be replaced
immediately, for uninterrupted operation.

7.4.1.2 The supplier shall indicate the organization, manpower and

other resources of customer support division.

7.4.1.3 The supplier shall produce documentary evidence of support

from the principal for a period of 5 years. The address of the
principal may also be mentioned.

7.4.1.4 List of customers along with the name, address and

contact details to whom similar or higher capacity
extrusion press has been supplied in the last five years
shall be provided along with the quotation. Supplier
shall submit the performance certificates of the supplied
working extrusion press along with the offer. Quotation
will not be considered if this information is not provided.

7.4.2 Spares availability and Personnel Support Services

7.4.2.1 The vendor shall ensure stocking of spares within the

country and the same shall be made available on demand
within a period of 120 hours except for manufactured parts.

7.4.2.2 The supplier shall further ensure the availability of all spares
for at least 5 years from the date of acceptance of the
system. The supplier shall furnish a certificate to this effect
from their principal.

7.4.2.3 The vendor shall make available whenever necessary, the

services of the specialists at purchaser site within 48 hrs
from the time of communication, telephonic or otherwise.

7.4.2.4 Any developments arising out of shortcomings of the

systems in performing its designed task shall be carried out
by the vendor at purchaser's site including hardware and
deputation of vendor's engineer to site.

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 7.5 Technology and Obsolescence

The Extrusion Press to be supplied shall incorporate advance state-of-the-art technology

that shall guarantee freedom from obsolescence at least for 10 years. All the components,
PLC, SCADA, PID controllers, etc. to be offered shall be the latest in the product range of
the principal of the supplier. The vendor shall certify that the product offered is the latest
and proven in their product family and all the cards supplied along with the system are of
Industrial Grade. Any impending product launch shall also be indicated in the bid, along
with features for up gradation compatibility.

7.6 Maintainability Requirement

7.6.1 Proven Products: Vendor shall use proven and widely used
components and products of well established manufactures.

7.6.2 Modular: System will be modular type in design so that identification

and replacement of faulty modules will be easy and quick.

7.6.3 Trouble shooting aids: Detailed guide for Troubleshooting procedures

and tips must be provided.

7.6.4 Fault Indications: In order to achieve low time to repair, indicators for
failed component/module/unit/system be made available in the system.

7.6.5 Maintenance tools: The supplier shall provide maintenance tools such
as Field Laptop with all licensed development software loaded, special
purpose cables, diagnostics software, any other tools/instruments
required for diagnostics. Source code for Ladder program and
SCADA/HMI shall be supplied for incorporating future modification in
the press.

7.6.6 Calibration tools: The supplier shall provide Calibration tools for all
instruments such as Pressure Calibrator, Temperature Calibrator,
Multifunction Electrical Signal Calibrator (4-20mA, 0-10V, etc) and any
other tools/instruments required for recalibration of the installed
instruments. All Calibrators shall be traceable to NABL accredited Lab.

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8.0 Quotation Format

8.1 If any parts of the system are to be sub-contracted, sub-vendor details to be

submitted.

8.2 Details, relevant technical literatures/brochures, Catalogues shall be provided

for the model offered.

8.3 Instruction Manuals for all bought out items shall be provided.

8.4 There is no free issue of material or components.

8.5 Any import of material/equipment will be arranged by the vendor alone and
shall not be referred to the purchaser for end use certification.

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