Technical Specification for

12 mm capacity 4-Roll Hydraulic double pinch cum pyramid type plate bending machine.
(Supply, Installation, Commissioning and Testing)

Government of India
Department of Atomic Energy
Fabrication Facilities, Accelerator Component Design & Fabrication Section
Raja Ramanna Centre for Advanced Technology,
Indore-452013

INDEX

S. No. Contents Page no

1. Technical Specifications of the machine 3-14

2. MANDATORY INFORMATION ABOUT THE MACHINE 15

3. Annexure – I (Guaranteed technical parameters required) 16-17

4. Annexure – II (MANDATORY TECHNICAL QUESTIONNAIRE) 18-19

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1. CONSTRUCTION: 4-Roll Hydraulic double pinch pyramid type plate Bending machine with
non-programmable PLC & HMI facility, for Pre-bending, Cylindrical Rolling & Cone Rolling.
2. PURPOSE: (Operations/Jobs involved) – Section bending, Pre-Bending, Rolling of pipes,
Cone bending etc.
Work Piece Material -Carbon Steel, Stainless Steel, Aluminum alloy etc.
3. SCOPE OF SUPPLY; Supply, Installation, commissioning and testing of plate bending
machine. Scope of supply also includes
1. Unloading of the machine/equipment on receipt and its movement to the site of
installation.
2. All electrical/mechanical/ hydraulic tools/equipment etc. manual/automatic type,
required for erection and commissioning of the machine shall be brought by the vendor
during erection and commissioning of the machine.
3. Arrangement of all man power, material, material handling equipment during installation
and commissioning of the machine.
(All other relevant points under this clause are also discussed at suitable places in the
tender document)
4. BIDDER’S QUALIFICATION:
a) The quotations are invited and accepted only from reputed Plate Bending machine
manufacturers or their authorized dealers. The bidders should be an ISO 9001-2008 or
equivalent certified company, which have supplied & commissioned at least two Plate
bending machine of same or higher capacity. The OEM shall possess adequate plant and
manufacturing capacity/facilities. Company should provide satisfactory evidence,
acceptable to the Purchaser, to prove that they are licensed manufacturer/ authorized
dealers. OEM should furnish a statement that they have manufactured and supplied 2
nos. of Plate bending machine of similar type during the last 5 years. Bidder’s shall
provide information regarding, Purchaser’s name and address contact details, order
number, date and quantity supplied, comments on their performance, and whether the
supplies were made within the delivery period etc., This information must be enclosed
with the offer. In the absence of the above information, the offer is liable to be rejected.

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b) The OEM/ their authorized dealers should have good presence in India through their
company’s sales and service network in India, This network should be working
continuously from at least last three years.
c) Please note that Purchaser reserves right to evaluate bidder’s fabrication facility, to see
its competence to carry out the work.
5. TECHNICAL SPECIFICATIONS OF THE MACHINE
S.No.
A. Mode of Operation Using Hydraulic motors(With a provision
to operate in both clockwise and counter
clockwise directions)
B. No. of Rollers 4 (Four)
C. Max. Rolling Capacity (Yield strength 300 MPa for 12 mm thick X
2500 mm width or more)
D. Max. Pre-Bending Capacity (Yield strength 300 MPa for 12 mm thick X
1500 mm width or more)
E. Rolling Speed (step less arrangement) ≤ 5 meter/min.
F. Min. Diameter of the shell to be 600 mm or less
rolled
G. No. of Feeding Rollers 2 Nos.
H. Hydraulic Motors Independent Hydraulic Motors for drive
rolls (With suitable transmission for the
specified thickness)

5.1 ROLLERS
A. Material Specification for all Rollers - High tensile grade forged alloy steel
(Hard chrome plated, test certificates for mechanical and chemical properties shall be
required)
B. Roller Hardness - 45 - 62 HRC
C. Roller Movement - By Hydraulic arrangement
(Using high precision excellent quality ball screws bidder shall specify make and accuracy
class of ball screw)
D. All the bottom rolls shall be accurately levelled in the bearing housings with their
longitudinal axis parallel to each other. The top rolls shall be housed in individually
moveable bearing housing.

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 E. There should be provision of suitable arrangement to adjust the roller gap.
6. CONSTRUCTIONAL FEATURES OF THE MACHINE
1. MACHINE FRAME
Main frame of the machine shall be fabricated from Mild steel confirming IS 2062, main
frame structure shall be strong enough to withstand heavy jerks and loading encountered
during rolling operation. The frame will be fabricated by following standard welding practice
as described in relevant standard/code. Complete welded structure shall be stress relieved
before machining, and also accurately machined to obtain the accurate fitment oh housing
bearings etc.
All relevant test certificates of the construction material shall be verified during PDI. These
certificates shall also be submitted with the supply of machine.
2. BEARINGS
The bearings of rollers should be Self-aligning roller bearings and cylindrical roller type. No
bush/ collared bush/ journal bearing should be used.
Preferred make - SKF/FAG
MATERIAL CLAMPING ARRANGEMENT
A. Material clamping action thru hydraulic mechanism
B. Clamping Pressure The clamping pressure shall be adjustable to suit
different material. Suitable pressure indicators shall be
provided.
3. ESSENTIAL ACCESSORIES
Following essential accessories shall be the integral part the basic machine and will be in
standard Scope of supply. (Bidders should take into account this while quoting basic price of
the machine.
1. Hydraulic Overhead Support System (Purpose: To hold thin plates of large diameters)
2. Hydraulic Side Support (Purpose: To avoid re-opening of thin shell)
3. Angle, Section Bending and cone bending facility (Purpose: To roll different types and
size of profiles, Bidder shall give details of the mechanism with submitted offer)

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4. The machine should have provision for mounting of bending dies on the top and side
rolls extended shafts.

4. OPERATION AND CONTROL SYSTEM

A. The Plate bending machine should have provision for Pendent push button control. This
Pendent push button control should be interfaced for all features of the machine.
B. There should be Electronic speed control of all movements of the machine using non
programmable potentiometer thru pendent control box.
C. There should be provision of electronic indication of the position of the lower rolls.
D. There should be provision of Emergency switch for instant stopping of the machine in
case of emergency.
E. Variation in synchronization on rolls shall be less than ≤ 0.5 mm.
F. Machine shall have provision for drop end arrangement at the top roller for easy removal
of rolled shell/pipe.
G. The machine shall have provision of automatic linear speed compensation between top
and bottom roller to achieve the exact internal and external circumferential speed w.r.t
the plate thickness.
5. HYDRAULIC SYSTEM

A. The System should have provision of centralized Hydraulic tank.

B. Preferred make of Hydraulic elements shall be Rexroth / Vickers Sperry / Parker.
C. The machine should have a dedicated Filtration System for the hydraulic oil to be used.
D. There should provision for failure indication of hydraulic system. This indication should
be available at operator’s panel.
E. There should provision for Automatic shut off of hydraulic system (safety interlocking)
F. There should be a provision of efficient hydraulic oil cooling system of suitable capacity
to maintain complete Hydraulic System at a temperature not exceeding 40 deg C
irrespective of the ambient conditions.
G. Bidder shall specify the hydraulic pump capacity (flow / pressure) and hydraulic tank size
etc. along with the offer.

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H. First filling of all type of Oils & Grease etc. shall be in supplier’s scope. Bidder’s shall give
details of Indigenous (Indian) source or Indian equivalent and specifications of oils/
greases which is to be used for smooth and trouble free operation of the machine.
I. There should be provision of Life time lubrication of the parts wherever possible. Other
lubrication points shall be of automatic lubrication type.

6. ELECTRICAL
A. All electrical & electronic control cabinets & panels should be dust and vermin proof.
B. The main drive shall be with an electric motor and an integrated distribution gearbox.
C. Electro-mechanical braking system shall be provided in the drive for stopping of rollers.
D. All electrical components in the cabinet should be mounted on suitable DIN Rail.
E. The machine shall have provision to change the direction of the main drive so that it is
possible to reverse the movement of the plate to be rolled.
F. All electrical and electronic panels including operator's panel should be provided with
sufficient illumination and power receptacles of 220Volts, 5/15 Amp AC. All
adapters/receptacles should have compatibility with Indian equivalents.
G. Motors shall conform to IEC or Indian Standards.
H. All cables and cable trays required for the installation of the machine should be included
in the offer. Preferred make of cables-Lapp/Finolex/Havells/Polycab/Igus conforming to
IS/IEC standard
I. Vendor should ensure for proper earthing for the machine and its peripherals. Two run
bare copper wire/strip shall be run with power cable and be connected to power panels
as per IS standards.
J. Tropicalisation: All electrical / electronic equipment shall be tropicalized
K. The electrical components used shall be from reputed international makes and shall be
accordance with DIN/IEC Standard.
Preferred make - Siemens / Telemechanique / Merlin Gerin / GE/ ABB/L&T/Schneider
7. CONTROLS

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A. All operational functions of the machine shall be non-programmable PLC with HMI
facility (HMI Screen approximately 8” in size) controlled from a centralized ergonomically
designed control panel through push buttons and selector switches. The location of the
control panel shall be such that the operation can be seen by the operator.
B. The controls shall necessarily include the following functions:
i. Direction of feed/motor
ii. Braking of main drive
iii. Overload relays.
iv. Limit switches.
v. Electric interlocks.
vi. Independent fuses.
vii. Stop push button.
viii. Forward/reverse Push button.
ix. Up & Down Push Buttons.
x. Digital electronic type roll positioning indicator.
(Details of controls shall be furnished in the bid)
8. OTHER FEATURES OF THE MACHINE
A. Cone rolling facility: The machine shall have provision of continuous cone rolling facility.
B. Shell Removal shall be through Hydraulic operated over hung support of top roll and
other end of the roller journal swing by hydraulic.
C. Peripheral speed compensation: Shall be automatic by hydraulic system.
D. Digital Readout: Electronic digital display shall be provided on the operator’s panel to
indicate all moving roller positions.
E. The digital readout resolution shall be +/-0.1mm.
F. Timer controlled Lubricating system shall be provided in the machine.
G. Preferably provision of Arch meter to measure shell’s external radius.
H. Pre-Bending shall be done in the same machine with minimum flatness.
I. Hydraulic, Pneumatic & oil piping should be preferably metallic except places where
flexible piping are essential.

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J. All the pipes required for the same shall be included in the standard scope of the
machine.
9. SAFETY ARRANGEMENTS
The machine design shall ensure safety of the machine and operator at all times. The
machine shall necessarily have, but not be limited to, the following safety features:
1. Machine should have adequate and reliable safety interlocks / devices to avoid damage
to the machine, work piece and the operator due to the malfunctioning or mistakes.
2. Overload protection for load exceeding 100% of normal load.
3. All the pipes, cables etc. on the machine should be well supported and protected.
These should not create any hindrance to machine operator's movement for effective
use of machine.
4. All the rotating parts used on machine should be statically & dynamically balanced to
avoid undue vibrations.
5. All control panels/electrical items shall have IP54 protection.
6. Mushroom type emergency stop switches to bring all operations to a halt. These
switches shall override all other controls. These stop switches shall be provided at all
suitable locations including each pillar and control panel (Details of the locations of
Emergency Switches shall be furnished in the bid all emergency switches should be as per
international norms)
7. Oil & water pipe lines should not run with electrical cable in the same tray / trench.
8. Necessary protection shall be provided in the Hydraulic power pack to prevent from
over loading.
9. In case of power failure, the machine shall stop instantaneously and shall not start
automatically when power supply is restored. The machine shall restart only after it is
manually reset to its initial start-up position.
All safety features provided in the machine shall be explained in detail in the bid.
10. ENVIRONMENTAL PERFORMANCE OF THE MACHINE
The Machine shall conform to following factors related to environment

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(a) Maximum noise level shall be 85 dB (A) at normal load condition, 1 meter away from the
machine with correction factor for back ground noise, if necessary.
(b) If any safety / environmental protection enclosure is required it should be built in the
machine by the vendor.
(c) Paint of the machine should be oil / coolant resistant and should not peel off and mix up
with coolant.
11. LEVELING & ANCHORING SYSTEM

1. Complete anchoring system including foundation bolts, anchoring materials, fixtures,

levelling shoes etc. shall be supplied.
7. TOOLS REQUIRED FOR OPERATION & MAINTENANCE OF MACHINE

1. Necessary tools like Torque Wrench, Spanners, Keys, grease guns etc. for operation and
maintenance of the machine shall be supplied with the machine. List of such tools should
be submitted with offer.
8. SPARES

The bidder should provide, Itemized breakup of mechanical, hydraulic, electrical and
electronic spares used on the machine in sufficient quantity as per recommendation of
Vendor for 2 years of trouble free operation on three shifts continuous running basis. (Price of
the spares will be used as reference for buying these items, in future if required price of
spares will not be considered for cost comparison)
a) Mechanical & Hydraulic Spares: All types of Pumps, Valves, Pressure Switches, Transducers,
Flow Switches, Filters, Seals, O-rings, Hydraulic Hoses etc.
b) Electrical /Electronic : All types of Relays, Contactors, Proximity Switches, Push Buttons,
Indicating Lamps, Semiconductor Fuses, Special Fuses, Circuit Breakers, Main Power Switch,
Operator's panel with Display Unit, I/O Cards for PLC, Motors for Feed Drives, Power Module
& Control Cards for Main Drive as well as Feed Drives etc.
c) Vendor to confirm that complete list of spares for machine and accessories, along with
specification / type / model, and name & address of the spare supplier shall be furnished
along with documentation of the supplied machine.

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Bidder should confirm that, all types of spares for the machine and accessories should be
available for at least five years after supply of the machine. If machine or control is likely to
become obsolete in this period, the vendor should inform RRCAT sufficiently in advance and
provide drawings of parts / details of spares & suppliers to enable RRCAT to procure these in
advance, if required.

9. COLOR OF MACHINE
All surfaces of the machine shall be cleaned so as to be free of rust except mechanical
mating surfaces, and then painted with two coat of red oxide and zinc chromate primer as
per IS: 2074. The painted surfaces of bought out items need not be disturbed. The machine
and its accessories shall be painted in Apple green color no. 281 of IS-5.
10. DOCUMENTATION
Three sets of following documents (Hard copies) in English language should be supplied
along with the machine.
Detailed Maintenance manual of machine with all drawings of machine assemblies/sub-
assemblies/parts including Electrical / Pneumatic/ Coolant / Hydraulic circuit diagrams. All
Assembly/ Sub Assembly Drawings shall be supplied along with the part list. Manufacturing
drawings for all rollers, sleeves, fixtures etc. Catalogues, O&M Manuals of all bought out
items including drawings, wherever applicable. Detailed specification of all rubber items and
hydraulic/lube fittings. Complete Master List of parts used in the machine along with
suppliers contact details shall be submitted by the vendor.
One additional set of all above documents on CD ROM wherever possible.
11. TRAINING
RRCAT operation/maintenance persons shall be trained at RRCAT site for three days.
(a) Electrical, Electronic maintenance for machine & other supplied equipment.
(b) Mechanical & Hydraulic maintenance of the machine & other supplied equipment.
(c) Operation of the machine & other supplied equipment.
12. TESTING STANDARD AND PROCEDURE

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1) The machine shall be tested for its geometrical accuracies as per IS code 14878: 2000
reaffirmed in 2006 (IS code for testing of plate bending machine) or suitable international
standard. Here the relevant portion from this document, applicable to 4 roller bending
will be utilized. These tests shall be carried out during PDI of the machine.
2) The bidder shall also submit a copy of the quality assurance plan being followed at the
Manufacturer’s works for ensuring quality of the product offered. There will be stage
(during manufacturing) and final inspection of the machine, hold points and stage
inspection plan will be decided according to this QA plan submitted by the manufacturer.
3) All the accuracies as per standard shall be demonstrated to RRCAT engineers during pre-
dispatch inspection at Suppliers works and during Erection & Commissioning at RRCAT
Works.
13. ERECTION & COMMISSIONING
1. Supplier to take full responsibility for carrying out the erection, start up, testing of
machine, it’s control & all types of other supplied equipment, machining of test pieces
etc. Service requirement like power, air & water shall be provided by RRCAT at only one
point to be indicated by supplier in their foundation/layout drawings. Other
requirements like crane and helping personnel shall also be provided by RRCAT. Details
of these requirements should be informed by vendor in advance.
2. 415V + 10% / -10%, 50HZ +/-3 HZ, 3 Phase AC (3 wire system without neutral) power
Supply Voltage will be provided by RRCAT at a single point near the machine, as per
layout recommended by Vendor. All types of cables, connections, circuit breakers etc.
required for connecting RRCAT's power supply point to different parts of the
machine/control cabinets, shall be the responsibility of vendor. Requirement of
grounding/earthing with required material details is to be informed by vendor well in
advance so that same could be incorporated during construction of foundation.
3. Successful proving of RRCAT machine, shall be considered as part of commissioning. All
tests, as mentioned at (Machine Acceptance) shall form part of the commissioning
activity. Tools, Tackles, instruments and other necessary equipment required to carry out
all above activities shall be brought/arranged by the supplier. Commissioning spares,

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 required for commissioning of the machine within stipulated time, shall be brought by
the supplier on returnable basis. All Cover Plates with painting required for the machine
and its peripherals including pits, cable tray etc. if any, shall be supplied and installed by
the vendor. Portion, if any, of the machine, accessories and other supplied items where
paint has rubbed off or peeled during transit or erection should be repainted and merged
with the original surrounding paint by the vendor. For this purpose, the vendor should
supply sufficient quantity of touch-up paint of various colours of paint used.
4. Schedule of Erection and Commissioning shall be submitted with the offer.
5. Duration of erection and commissioning, terms & conditions for E&C should be furnished
in detail, separately by vendor along with offer.
14. MACHINE ACCEPTANCE
Tests/Activities which shall be carried out at supplier’s works during pre-dispatch
inspection.
1. To demonstrate the rolling/bending capacity of the machine, a pipe will be fabricated (as
per drawing no. RRCAT/FF/ACDFS/VKB/01/2016) in austenitic stainless steel grade
304/304L material. This pipe will be rolled on the offered machine, the pipe will be
inspected for the permissible tolerances specified in the drawing. Raw material, tool
tackles, consumables etc. required for this purpose, shall be arranged by the
manufacturer during PDI of the machine.
2. Demonstration of all features of the machine, control system & accessories.
3. All expenditure against the arrangement of material tools, fixture etc. needed for
rolling/bending of the test piece, during pre-dispatch will be borne by the supplier.
Tests/Activities which shall be carried out at RRCAT after successful installation of the
machine.
1. Full load test to demonstrate the maximum power, rolling/bending capacity and Cone
Rolling using RRCAT raw material.
2. Demonstration of all features of the machine, control system & accessories to the
satisfaction of RRCAT for efficient and effective use of the machine.

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3. Training of RRCAT machine operators in operation of complete machine & accessories
etc. by the supplier's experts / engineers during their stay at RRCAT.
4. Demonstration by actual use of all supplied attachments and accessories to their full
capacity.
15. PACKING
Sea worthy & rigid packing for all items of complete machine, all Accessories and other
supplied items to avoid any damage/loss in transit. When machine is dispatched in
containers, all small loose items shall be suitably packed in boxes. The container shall be of
top opening type and packing list shall be furnished container wise with weight.

16. GUARANTEE
24 months from the date of acceptance of the machine at RRCAT works.

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17. MANDATORY INFORMATION REQUIRED TO BE SUBMITTED WITH THE OFFER
Bidder should submit the following mandatory information along with the offer
1. Machine Model No., make, Type etc.
2. Total connected load (kVA)
3. Power rating of main motor.
4. Power ratings of other auxiliary motors.
5. Floor area required (Length, Width, and Height) for complete machine & accessories.
6. Total weight of the machine
7. Weight of heaviest part of machine
8. Weight of the heaviest assembly / sub-assembly of the Machine.
9. Dimensions of largest part/ sub-assembly/ assembly of the machine.
10. Vendor to submit, reference list of customers where similar machines have been
supplied mentioning broad specifications of the supplied machine i.e. Model, Rolling
Capacity, Load Capacity, Main Drive Rating etc. along with offer
11. Detailed catalogues, sketch/photographs of the m/c and accessories/ attachments
should also be submitted with the offer.
12. Cone Angle & Minimum ID of the rolled Cone for maximum and minimum thickness
capacity (Bidder shall give information regarding The maximum cone angle and minimum
inside diameter of the cone to be rolled with submitted offer)

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 ANNEXURE -1
GUARANTEED TECHNICAL PARAMETERS REQUIRED

S. No. Parameters required Values Bidder’s Deviation

response

TECHNICAL SPECIFICATIONS

1. Mode of Operation Using Hydraulic motors

2. No. of Rolls 4 (Four)

3. Max. Rolling Capacity (Yield strength 300 MPa for

12 mm thick X 2500 mm
width or more)

4. Max. Pre-Bending (Yield strength 300 MPa for

Capacity
12 mm thick X 1500 mm
width or more)

5. Rolling Speed (with step less than 5 meter/min.

less arrangement)

9. No. of Feeding Rolls 2 (Top & Bottom Clamping

Rolls)

10. No. of Hydraulic Motors 2 (Independent Hydraulic

Motors for both rolls)

ROLLERS

11. Material Specification for High Tensile Forged Steel

all Rolls

12. Roller Hardness (Depth of 45 - 62 HRC.

hardness to be specified
by the Vendor)

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 13. All the rollers shall be Bidder to confirm
induction hardened and
ground

14. Roller Movement By Hydraulic arrangement

MATERIAL CLAMPING ARRANGEMENT

15. Material clamping action By Hydraulic arrangement

16. Clamping Pressure The clamping pressure shall

be adjustable to suit different
material. Suitable pressure
indicators shall be provided.
ESSENTIAL ACCESSORIES

17. Essential accessories shall Bidder to confirm

be the integral part the
basic machine as specified
under ESSENTIAL
ACCESSORIES clause.

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 ANNEXURE -2
MANDATORY TECHNICAL QUESTIONNAIRE
(TO BE FILLED IN BY THE BIDDER & SUBMITTED ALONGWITH THE OFFER)

Instruction-1 Table A.1 and Table A.2: The rightmost column should be filled in by the Bidder.
Instruction-2 Failure to submit a fully completed, duly signed and stamped questionnaire will
result in the rejection of the offer.
Instruction-3 Wherever, the response is Yes/No, please strike out the inapplicable response.
Table-A.1: General Information

Bidder’s Qualification

A.1.1. Name of the fabricator/manufacturer

Contact details of the manufacturer

A.1.2.
(Give full address, email, phone and fax numbers.)

Do you have ISO 9001-2008 certification as

A.1.3. Yes/No
mentioned in specification

A.1.4. Validity of ISO certificate

Do you have in house, manufacturing facility of

suitable capacity for the manufacturing of the
A.1.5. Yes/No
specified plate bending machine (please provide
support documents for the same)

Do you have at least five years of experience in the

A.1.6. field of manufacturing of plate bending machine Yes/No
(Please provide support documents for the same)

Delivery period

……….months after
A.1.7. Delivery Period
confirmed order.

Do you certify that you will be able to supply the

A.1.8. machine within the delivery period mentioned in Yes/No
your offer?

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 Table-A.2: Technical Information

S.No Question
Response
.
Do you have sufficient know how and awareness
A.2.1. about the packaging and handling of machine during
transportation of the machine.
Do you have suitable machining and welding facility
Yes/No
A.2.2. to carry out manufacturing work for plate bending
machine, as specified in the specifications?

Signature:
Name of Authorized Signatory:
Stamp of the bidding firm:

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