HYDRAULIC PULLER FOR BG (1676 mm) 1.0 GENERAL

MFBWP-2019 of 31

TECHNICAL SPECIFICATION OF MOBILE FLASH BUTT WELDING MACHINE WITH HYDRAULIC PULLER FOR BG (1676 mm)

(Specification no. TM/HM/MFBWP/458 of 2019)

1.0 GENERAL

1.1 Alumino - Thermic (AT) welding process is being used presently for repairing of weld/rail

failures in service track and welding of new joints after rail renewal. The service life of AT weld is approximately 50% whereas the service life of Flash Butt welds is approximately same as that of rail in terms of GMT. It is, therefore, desirable to repair such weld/rail failures and welding of new joints on running lines on Indian Railway track by using Flash Butt welding process so as to avoid repeated problem. A fully self-contained Flash Butt Welding Unit mounted on Rail Borne Vehicle and equipped with Hydraulic Puller hereinafter called machine is required to carry out this job.

1.2 The technical specification has been drafted to reflect the performance and quality requirements of the Machine in a neutral manner without bias to any specific manufacturer. Bidders are requested to carefully study the specification and ensure that their equipment fully complies with these specifications. Thereafter, if a bidder feels that his equipment can substantially meet the performance and quality requirements laid down herein but does not fully satisfy a particular item of this specification, he shall mention the deviations, if any, in the statement of deviation from the specifications, giving the details how the functional requirements of this specification are going to be met with.

1.3 The bidder shall specify the model of machine offered and furnish a detailed Technical Description of the same. System/sub-systems and working mechanisms of the machine as per Para ‘4’ and ‘5’ in particular and all the items of the specifications in general shall be described in the “Technical Description” in detail along with the sketches to show the manner in which the requirements of the specifications are accomplished by the offered model of machine.

1.4 Photographs of the type of the machine offered, in working mode shall be enclosed with the offer. These shall also show close-ups of various working assemblies/systems and the full machine. The tenderer shall furnish a compact disc or DVD or USB showing the working of machine in real time under field condition. Tenderer shall also submit the names of countries & Railways where the offered machines are working and where their working at the site can be visited by Indian Railways officials.

2.0 DESCRIPTION

2.1 The machine shall be self-contained and self-propelled vehicle consisting of following

components: A. Carrier Vehicle (Rail Borne)

B. Flash Butt Welding Unit

C. Hydraulic Puller Unit

MFBWP-2019 of 31

2.2 Carrier vehicle shall be fully Rail Borne bogie type vehicle for enclosing necessary crane/manipulator, welding unit and hydraulic puller unit.

2.3 Flash Butt Welding Unit mounted on such carrier vehicle shall be with all necessary requisites/attachments/manipulator etc. for carrying out all operations related to welding of rail joints as per Indian Railway’s Manual for Flash Butt Welding of Rails (Revised January 2012) with up to date Addendum and Corrigendum slips (hereinafter called Flash Butt Welding Manual).

3.0 DIMENSIONAL AND OPERATING REQUIREMENTS

3.1 The self-driven diesel-powered machine shall be heavy duty, robust, reliable and suitable for working and travelling on the Indian Railways Broad Gauge Track (1676 mm gauge). The design and dimensions of the machine components shall be to metric standards and shall comply with provision of Indian Railways Schedule of Dimensions–1676 mm gauge (BG), revised, 2004 with the latest corrigendum and up to date correction slips issued. Quality assurance during manufacturing of the machine shall be according to ISO-9001. The welding standard followed for manufacturing of machine shall conform to ISO: 3834, EN:15085 or any other equivalent standard for welding Railways vehicle and components. The manufacturer shall specify the standard followed and certify that it meets the welding standard mentioned above. The machine shall be suitable for working on straight, transition curved tracks (up to 100) and on turn out on broad gauge (1676 mm) of Indian Railways.

3.2 The profile of the machine longitudinally and in cross section during transfer as self-propelled vehicle on Railway track shall be within the Indian Railways Schedule of Dimensions –1676 mm gauge (BG), Revised, 2004 with latest corrigendum and up to date correction slips. The maximum moving dimensions are shown in Annexure I . The tenderer shall provide sketches of the machine, both in plan and elevation and shall give calculations for moving dimensions on 10° curve to show the extent of lateral shift at the ends, centre and any other relevant cross section to prove that the machine does not cause any infringement while moving on a 10° curve at any cross-section.

3.3 In the past Indian Railways have condoned certain infringements to the Indian Railways Schedule of Dimensions –1676 mm gauge (BG), revised, 2004 of such dimensions as Rigid wheel Base, Length of stocks, Distance apart of bogie centres and maximum height of floor above Rail level in certain track machines after due consideration of their design features vis-à-vis safety and operation requirements of Indian Railways. However, condonation of an infringement in another track machine in the past does not by itself entitle the manufacturer to assume acceptance of the same in other track machines by Indian Railways. Where an infringement to Indian Railways Standard BG schedule of Dimensions (metric)-2004 print is considered necessary by the manufacturer as intrinsic to the design of the machine for meeting the work performance requirements laid down in this specification while meeting the safety and operational requirements of Indian Railways, the condonation of the same may be permitted by Indian Railways. However, only those infringements which are acceptable shall be permitted.

3.4 Adequate clearance shall be allowed so that no component/part infringes the minimum vertical clearance of 102 mm from rail level while traveling on track to condemnation limit of wheel.

MFBWP-2019 of 31

3.5 It shall have a minimum wheel diameter of 914 mm. However, lesser diameter upto 710 mm (new wheel profile) can also be considered, provided it meets the condition as laid down in Para 3.4 and rail wheel contact stresses for 72 UTS are within permissible limit. Forged wheels to Indian Railway Profile shall be provided on the machine. It is desirable that 50 mm margin between new and permitted worn wheel diameter shall be available, but this shall not be less than 20 mm. The worn out wheel diameter (condeming worn out diameter) based on the criteria of rail wheel contact stresses for various maximum axle loads are as under:

Maximum Axle load (tonne) Minimum worn out wheel diameter (mm) 22.82 908 22.00 878 21.50 860 21.00 841 20.32 816 20.00 805 19.50 787 19.00 768 18.50 750 18.00 732 17.50 713

Permitted worn out wheel diameter shall be specified by the manufacturer. The diameter of wheel for assessment of permitted axle load will be the worn out wheel diameter.

3.6 When travelling on track, it shall be capable of negotiating curves up to 10° curvature (175 m radius), super elevation up to 185 mm and gradients up to 3%.

3.7 The rail wheel profile shall be as per Indian Railways Standard “WORN WHEEL PROFILE’ provided in Annexure-II .

3.8 Wheels shall be conforming to Indian Railways Standard R-19/93 or European Standard EN13262 or any other equivalent standard (for product requirement) and design shall duly conform to European Standard EN 13979 or other equivalent standard. The supplier shall submit detailed design calculation along with material parameters at the time of supply of the machine.

3.9 The non-powered axles shall be conforming to Indian Railways Standard R-16/95 or European Standard EN 13261(EA1N) or any other equivalent standard. The supplier shall submit detailed design calculation along with material parameters at the time of supply of the machine.

3.10 The powered axles shall be conforming to Indian Railways Standard R-43/92 or

European Standard EN 13261(EA4T) or any other equivalent standard (for product requirement). The design shall conform to EN: 13104 or any other equivalent standard. The supplier shall submit detailed design calculation along with material parameters at the time of supply of the machine.

3.11 Wherever applicable axle load shall be lesser than 20.32 t with minimum axle spacing of 1.83 m. Load per metre shall not exceed 7.67 t. Axle loads up to 22.82 t and lower axle spacing may be permitted provided the load combinations do not cause excessive

MFBWP-2019 of 31

stresses in the tracks & bridges of IR. Stresses in the tracks & bridges shall be calculated by IR/RDSO based on design data submitted by the firm as per (Annexure-

VI/A), and decision of IR/RDSO shall be final in this regard.

3.12 It shall be capable of continuous operation during the varying atmospheric and climatic conditions prevailing throughout the year in India. The range of climatic conditions is as follows: -

a. Ambient temperature : -50 to 550C b. Altitude: : Sea level to 1800 m above mean sea level c. Humidity: : Up to 100% d. Rail temperature: (-) 10° C to (+) 75° C.

All the system components on the machine, which are vulnerable to moisture ingress and adversely affected during rains, shall be covered by roof or suitable arrangement so that the machine is able to work continuously even during rains.

3.13 During transfer from one station to another in self propelled mode, it shall be capable of traveling on its own speed at minimum 80 kmph in both directions. During towing of the machine by another locomotive or by attaching to another load, neutral position of gears shall be sufficient and speed shall not be less than 100 kmph. No opening of cordon shaft etc. shall be required for safe movement. It shall be able to negotiate sharpest gradient up to 1 in 33 prevailing on Indian Railways.

3.14 It shall be capable of working and moving on railway track without requiring power block in electrified sections. On Indian Railways, 25 KV or 2X25 KV AC supply is used for traction through an overhead wire at 5500 mm above rail level. On bridges and tunnels, the height is restricted to 4800 mm.

3.15 While working and moving on multiple railway line sections, it shall not infringe the adjoining track and it shall be possible to permit trains at full speed on that track. During on-tracking/off-tracking, there shall be no infringement with the adjacent railway tracks at level crossing. Minimum spacing of track is 4265 mm. The machine or its any part shall not infringe adjoining track as per Schedule of Dimensions of Indian Railways during traveling or its welding operation including opening and closing of the work.

4.0 WORKING MECHANISM AND FUNCTIONAL REQUIREMENTS :

4.1 It shall be possible to start welding by the machine at site within five minutes of its arrival including fixing of out-riggers etc. wherever required. The time required in complete welding operation from start to finish including clamping and aligning rail ends, matching rail ends through power adjustment, welding cycle, stripping of upset, unclamping (excluding the time taken for post weld heat treatment wherever required and all rail/track related preparatory works) shall not be more than 3 minutes.

4.2 The machine shall be provided with suitable device for measurement of rail stresses and determination of stress free temperature of LWR/CWR. The device shall conform to RDSO specification of Equipment/System for Measurement of Rail Stresses and Determination of Stress Free Temperature of LWR/CWR approved by Railway Board vide letter no. 2010/CE-II/TK/3 Scanner dated 19.02.2014.

MFBWP-2019 of 31

4.3 The machine shall be designed to weld rails of various sections and metallurgies specified in Indian Railway’s Standard Specification for Flat Bottom Rails (IRS-T-12-2009) with up to date Addendum and Corrigendum slips (hereinafter called Specification of Rails) viz. 60/52Kg of grades 880 (C-Mn, Cu-Mo, Ni-Cr-Cu, Niobium, Vanadium) and 1080 (HH, Cr), continuously to form LWR/CWR in-situ or on cess or long rail panels in depot. Plant would also be capable of welding of 60/68 Kg/m rails having mechanical & chemical properties of R350HT of BS EN 13674-1:2011+A1:2017.

4.4 The welding unit shall have a trimming arrangement as an integral part of the unit so that

it can trim the excess upset immediately after welding. The weld shall be in compression during trimming and removal of excess upset. The trimmer shall have the capability to trim excess hot upset metal all-round the rail section in such a way that minimum grinding is required to achieve final finished profile at weld as prescribed in Flash Butt Welding Manual-2012 with latest amendment.

4.5 It shall be dual purpose unit that can be locked to do normal welding and also shall have

the capability of getting auto extended & using an integral rail pulling arrangement to do long closure welding up to 380 mm of traction & 150 t minimum traction force.

4.6 The unit shall be capable of exerting a pulling force of minimum 160 t. 4.7 The operation of hydraulic puller unit shall be independent of welding unit. 4.8 The unit shall be able to execute on track welding to repair rail gap with/without use of a

hydraulic rail pulling arrangement as per site requirement. Hydraulic rail pulling arrangement shall be integral part of the welding unit and shall not be provided separately.

4.9 Hydraulic rail pulling arrangement shall be capable of generating adequate pulling force

for doing in-situ welding in existing LWR/CWR tracks at required temperature as per the provisions of ‘Manual of Instructions on Long Welded Rails-1996’ for Indian Railways with up to date Addendum and Corrigendum Slips.

4.10 The welding process must be capable of welding new/ released but serviceable rails of

various sections and metallurgies given in Specification of Rails. Suitability of rails is prescribed in the Manual for Flash Butt Welding of Rails-2012. Total rail usage per weld shall be within 30 mm.

4.11 Quality of weld produced by the machine shall meet the various test standards and

geometrical tolerances specified in Flash Butt Welding Manual-2012 with latest amendment.

4.12 Welding parameters will depend on section and metallurgy of rail to be welded. These

shall be specified by the manufacturer of welding plants which shall be standardized in accordance to Para 5.6 of Flash Butt Welding-2012 with latest amendment in presence of RDSO officials after commissioning of machine and before adoption for production of regular welds. Common welding parameters are as below :

a) Welding current (primary, amps) b) Primary voltage (volts) c) Clamping pressure Kg/cm2

MFBWP-2019 of 31

d) Butting pressure Kg/cm2 e) No. of pre-heats f) Pre-heating time on……………..Off…… g) Burn off time (sec.) h) Flashing time (sec.) i) Upset length i.e. rail usage per weld (mm)

The machine shall have the arrangement for displaying all the welding parameters including alignment (preferably). These parameters shall be automatically stored in the system in reproducible electronic and hard forms in a manner such that each welded joint has a unique identity. The recommended butting pressure for different types of rails being used in Indian Railways is as under:

• 72 UTS rails- 5 Kg/mm2 on cross sectional area of rail. • 90 UTS & Head Hardened rails- 6 Kg/mm2 on cross sectional area of rail. • 110 UTS rails- 7 Kg/mm2 on cross sectional area of rail.

4.13 72 UTS and 90 UTS rails do not require any special post weld heat treatment.

However, alloy steel rails of 110 UTS and head hardened rails need post weld heat treatment to ensure variation in hardness within acceptable limits in heat affected zone. Therefore, machine shall have a computer controlled, temperature controlled cooling process (based upon measurement of actual temperature) with post weld heat treatment arrangements like quenching etc. for welding of 1080 HH and 1080 Cr alloy rails.

4.14 The machine shall have the provision that parameter once fixed in machine by Railway/Authorized person cannot be modified by the operator. Once rails clamped and ready for welding, the operator shall have nothing to do after weld cycle starts except wait for the weld to complete and the software shall facilitate auto-incorporation of the date and timing of welding from computer memory and this data shall be un-editable.

4.15 The unit shall be able to align the running surfaces of two rails at interface avoiding any step defect as per the provisions of Flash Butt Welding Manual-2012 with latest amendment.

4.16 The machine shall be controlled by a PLC of latest version of a reputed

manufacturer which monitors all the vital parameters of the process such as Voltage, Current, Displacement, Pressure, Time intervals, Velocity and Duration of flashing etc. The parameters are also recorded and displayed on a Weld Data Recorder as required. The PLC shall also have a self diagnostic arrangement. If the rail weld does not meet the preset values, suitable error indication shall be shown whether the weld joint is “Good” or “Bad” and the operation shall stop automatically.

5.0 FLASH BUTT WELDING WITH HYDRAULIC PULLER UNIT

5.1 The machine shall be container type self propelled vehicle. The container shall enclose a Flash Butt Welding unit, hydraulic puller unit and a crane/manipulator mounted and fixed on the vehicle for performing pulling of rails in course of de-stressing and Flash Butt Welding of rail joints both on track, at depot and on cess. The machine shall be fitted with suitable numbers of outriggers for supporting the machine during operation of the manipulator/crane.

MFBWP-2019 of 31

5.2 The hydraulic puller unit shall be assembled with the welding unit in such a manner that

it can be operated independently of welding machine, allowing the hydraulic puller to remain in place while moving the welding machine to other location. It shall exert required pulling force for pulling the rails for welding, for flashing and for upsetting during welding process.

5.3 The hydraulic puller shall be able to exert minimum 160 t of pulling force and effective

stroke length of pulling cylinders shall not be less than 360 mm. The hydraulic puller shall be so designed that it can pull the rails to that extent which is required for de-stressing of the rail. The hydraulic puller shall also be able to easily and precisely perform the alignment of the rails during course of welding.

5.4 The welding unit of machine shall be fixed on a manipulator/crane which shall be

mounted on the rear/front of the machine and shall be secured to the vehicle frame. It shall have sufficient out stretch for welding of rails on track and also it shall be capable of rotating sufficiently in both directions so as to also weld the rails placed on cess at minimum 3 m away from centre of track. If required, support from hydraulically operated out-riggers fixed on the machine may be provided for stability of the machine during welding on cess. These out-riggers shall be operated from the main control panel as well as from a remote/portable control panel wherever provided.

5.5 The machine shall be so designed that the welding head along with its rail clamping

device, rail pulling device, rail aligning device, rail lifting device, weld trimming device and their components with necessary control panels and other arrangements shall be out stretchable from the container for welding work and can be retreating back into the container after completion of welding. The complete operation of out stretching, retreating and rotation of units shall be hydraulically controlled.

5.6 There shall be a system for measurement of rail temperature at the time of welding, uniform cooling arrangement, recording of rail alignment, software for evaluation of each welding process and display of current (Amp), Force applied and Voltage etc.

5.7 The welding operation shall be such that there is no infringement to over head electric equipment during welding head maneuvering/extension/shortening and there is no infringement to the Indian Railways Schedule of Dimensions–1676mm gauge (BG), Revised, 2004 with up to date Addendum and Corrigendum slips.

5.8 The system shall be fitted with an emergency backup arrangement to windup the welding unit with hydraulic puller and retract them into the container in all respect for cancellation of traffic block in the shortest possible time say 10 minutes.

5.9 All hydraulic hoses shall either be fire proof or contained in fire proof sleeves.

5.10 All components of Flash Butt Welding units shall be housed in a self-contained enclosure, lined and insulated with fire retarding sound proof material and automatic fire protection system in the engine compartment. It shall be suitable to be used for depot welding, on-track welding (weld renewal/replacing fractures/cess welding) and cess welding at construction sites.

5.11 The Flash Butt Welding Unit shall be of reputed make with proven credential.

MFBWP-2019 of 31

5.12 The welding head shall be adequately designed so that it does not get heated up during continuous welding. A proper system shall be provided for cooling of welding head.

5.13 Engine of adequate capacity for meeting the Flash Butt Welding requirement shall be separately provided for welding operation. High-speed diesel oil conforming to Indian Standard Specification shall be normally used.

5.14 Unit shall be equipped with quick change electrode inserts for various rail sections mentioned in Specification of Rails. Unit shall also be equipped with compressed air pistol to ensure that electrical contacts i.e. copper/melloroy electrodes in the welding machine are free from loose oxides and other foreign matters so that no arcing takes place at the contact points on the rail. The welding system shall have self-diagnostic software to allow easy maintenance and repair.

5.15 Unit shall be able to meet with the welding requirements under the atmospheric and climatic conditions mentioned in 3.12 above.

5.16 The clamping unit shall be capable of applying a load suitable for different section of rails

i.e. 68 kg/m. Multiple clamps to be provided for holding the rails to prevent slippage during butting operation and to prevent abnormal indention of the rails. The bidder shall specify the details of clamping cylinders and ratio of clamping and forging force.

5.17 Forging unit shall be of air/oil intensified type capable of applying forging force suitable

for welding rails up to 68 kg/m. The rams of forging unit shall be so placed so as ensure equal distribution of the forging load across the interfaces. The control includes a servo system, which shall be controlled by the PLC for fine control on the velocity of flashing. The forging action, which has to be as fast as possible, shall be accomplished with the help of a gas charged accumulator. The accumulator system must be connected to filled/charged Nitrogen cylinder with required pressure gauge and other necessary fixture. If any deficiency of nitrogen gas is observed in accumulator, then it must be easily recouped by nitrogen cylinder. The unit shall be capable of delivering suitable force for welding 68 kg/m rails with UTS of 130 kg/mm2. In view of the heavy force involved, certain interlocks shall be incorporated in the system. The weld initiation shall not be done without clamping. Similarly, the machine shall not retract after welding unless de-clamped. This is to avoid application of tensile force on the still plastic joint inadvertently after welding.

5.18 Welding electrodes are to be of copper alloy with high abrasion with relatively good conductivity and water cooled with quick release facilities for maintenance and replacement. Metallurgical composition of copper alloy electrodes to be specified to take care of replacement of electrodes in case manufacturers do not support servicing of FBW unit after certain period. Suitable welding electrodes shall be provided for the rail sections up to 68 kg/m to be welded. Arrangement shall be provided to blow off scale and flash from the electrodes. Electrodes supplied with machine shall be the part of welding machine. The codal life of the electrodes in terms of number of welds shall not less than 25000. The number of spare electrodes supplied with the machine shall be two sets. The electrode holders shall have a provision for vertical horizontal adjustment to compensate the wear up to 25 mm.

MFBWP-2019 of 31

The equipment to cool the water circulated in electrode shall be included with the machine.

5.19 Flash Butt Welding Machine shall be equipped with automatic rail ends alignment facility. Rail alignment (lateral and vertical) and de-twist facility should be incorporated in the fixed and moving heads of the machine for execution of the weld in perfect geometric alignment fully automatically over a length of 1 m. There should be no need of any manual adjustment while welding the new rails. Arrangement through sensors which reads and records maximum mismatch in alignment between gauge faces should be provided. Automatic selection of gauge face should be possible. The aligning force and de-twisting force shall be sufficient for maximum rail section to be welded. Visual display should be available for correct alignment. Automatic rail alignment setup should be capable to perform alignment as per stipulations of Manual for Flash Butt Welding of Rails-2012. There should be provision of manual adjustment in case cross section of two rail ends being welded have major mismatch of rail ends. Adequate lighting arrangement should be available inside the machine to enable visual check of alignment and matching of rail ends.

5.20 Computer based Weld Data Recording and Monitoring Equipment should be capable to give an immediate read out which in comparison with pre-fed master data and should automatically identify any inconsistency in welding machine operation. Automatic microprocessors weld control recorder shall be provided to record data pertaining to each weld such as voltage, current, upset pressure and total welding time and temperature of cooling water and servo oil. It shall be of the digital print out type in which the various values are printed in one colour (say blue) when they are within limits. Otherwise these are printed in other colour (say red).

6.0 DIESEL ENGINE:

6.1 The machine shall be powered by diesel engine(s) preferably indigenous with proven record of service in tropical countries with wide service network in India. Robust construction and low maintenance cost are of particular importance. Separate diesel engine of adequate capacity shall be used for the purpose of welding and allied works. Adequate allowance shall be made for de-rating of diesel engine under the most adverse climatic conditions mentioned in this specification elsewhere.

6.2 High speed diesel oil to Indian Standard Specification shall be normally used. A minimum fuel capacity sufficient for continuous operation for 8 hours but not 1400 liters shall be provided.

6.3 Sight glass type fuel measuring gauge preferably of full height shall be provided on the

fuel tank.

6.4 For starting the engine, storage batteries of well known indigenous make with wide service network in India shall be provided. The engine shall normally be push/pull button start type or key type.

MFBWP-2019 of 31

6.5 Since the engine has to work outdoor under extreme dusty conditions, the air intake system shall be designed suitably so as not to allow dust through air intake system.

6.6 There is a likelihood of dust deposition over the engine body and surrounding area over

the lubricants spill-over. These locations shall be easy to accessible for daily cleaning and routine maintenance. In case, air cooled engines are proposed by the supplier, maintenance equipment for cleaning and maintenance of the air cooling fins shall be provided by the supplier along with the machine.

6.7 The engine parameter monitoring gauges like temperature, rpm, and lubricant oil

pressure shall be direct reading type mounted on the engine backed up by electrical/mechanical gauges in the operator’s cabin showing the absolute readings along with safe limits suitably coloured. There shall be audio visual warning (safety mechanism) to the operators in case of any of these parameters exceeding the safe limit and engine will shuts down automatically.

6.8 Suitable and rugged mechanism shall be provided to start the prime mover at no

load/minimum load and gradual loading after the start of the prime mover. A fail safe clutch mechanism, if required, may be provided to meet this requirement. The engine power take off shall be coupled to the main gearbox through a flexible coupling/cardon shaft (propeller shaft). The engine shall be mounted on suitable Anti Vibration mountings.

6.9 The tenderer shall furnish the information regarding make and model of the engine

proposed to be used and details of agency which will provide after sales service support and availability of spares in India, details of diesel engine and its controls to assess its conformity with the engines already operating on track machines on Indian Railways. If the machine design incorporates an engine, not already operating with the purchaser, the model of the engine is liable for change as per the technical requirements and the maintenance logistics with the purchaser after technical negotiations with the supplier. Nothing extra shall be payable on this account.

6.10 The engine shall have Electronic Control Module (ECM) or similar arrangement for

taking out operating parameters on real time basis such as RPM, load, fuel consumption, temperature, pressure and diagnostic data as well as trip and historical data. These data shall be displayed and stored on a computer and monitoring system. It shall also be possible to transfer these data on USB device through the computer based control.

6.11 In order to adhere to pollution control norms, the diesel engine shall be electronically

controlled emmissionized engine with minimum compliance of tier 2 stage.

6.12 The engine shall be enclosed in a weather protective, sound and dust resistant enclosure to minimize engine noise and to prevent oozing out of oil spills etc. from engine area to the adjacent machine components, hoses, electrical cables fittings as a protection against fire. All doors on the enclosure shall be strategically located in areas as to allow ease of maintenance of the engine and allow good access to and visibility of instruments, controls, engine gauges, etc. Sufficient louvers shall be provided to allow the total engine cooling air requirements used in this application.

7.0 DRIVING MECHANISM

MFBWP-2019 of 31

7.1 The machine shall be provided with an efficient traction drive system for traction during the operation. The machine’s driving system shall be through hydro dynamically coupled power/transmission with shift arrangement capable of achieving full speeds in travel mode in both the directions. The system shall be so designed that all the driving wheels work in synchronization and there is no slippage/skidding of the wheels during the work drive. The driving mechanism for travel drive shall be rugged to perform satisfactorily during the life cycle of the machine.

7.2 Suitable differential systems may be provided between coupled wheels on the same bogie.

7.3 Suitable flow divider/throttling arrangement may be provided to equalize the tractive

effort amongst different bogies.

7.4 The supplier shall provide the necessary technical details including circuit diagrams and detailed specifications of all electronic/electrical, hydraulic & pneumatic parts to confirm the above requirements.

7.5 Adequate gauges to monitor driving performance of machine shall be provided in driving

cabin near operator’s seat and solenoid valves shall be provided near linkage assembly for indication, flow control and carrying out necessary adjustment in the field.

7.6 To the extent possible hydraulic and pneumatic component/assembly shall be fixed at

suitable location preferably on the side frame of the machine so as to avoid the need of going on top of the machine for day-today maintenance schedules.

7.7 The pneumatic circuit shall be provided with air dryer and air lubricator for the smooth

working of pneumatic components.

7.8 The machine shall be equipped with adequate safety circuit such that if any unit/part which may endanger the safety if unlocked or not retracted properly, the machine shall not move during run drive. The indication of locking and unlocking of all units shall display in the cabin.

7.9 Onboard system for online filtration and monitoring the quality of hydraulic oil in hydraulic circuit shall be provided. The gauge shall clearly indicate that the hydraulic oil is contaminated beyond the permissible limits and requires immediate replacement.

8.0 COOLING SYSTEM 8.1 The cooling system shall be efficient and designed for a maximum ambient temperature

of 55°C. Supplier shall note that the machine shall be working under extreme dusty conditions and the cooling mechanism shall be maintainable under these conditions.

8.2 Adequate heat transfer arrangement for the hydraulic system shall be designed and

provided so that under extreme heat conditions as mentioned in Para 3.12 above, the system oil temperature does not go beyond the range specified by the supplier.

9.0 BRAKES

9.1 The machine shall be fitted with the compressed air brake system which shall apply

brakes equally on all wheels and provision shall be made to connect air brake system of

MFBWP-2019 of 31

the machine to that of coach/wagon, if hauled. Fail safe braking mechanism system shall be provided so that in case of any failure of brake there shall be arrangement of automatic application of brake. The pneumatic parking brake shall also be spring loaded so that in case of drop in pneumatic pressure below certain value the brake will be applied automatically. The brakes shall be protected from ingress of water, grease, oil or other substances which may have an adverse effect on them. The brake shoe lining shall be suitable for high ambient temperature of 55°C. The force required for operating the brake shall not exceed 10 kg at the handle while applying by hand and 20 kg on the pedal, when applied by foot. Mechanical brakes shall also be provided in addition for use as parking.

9.2 Machine shall be equipped with suitable arrangement of braking so that while attached in

train formation as last vehicle, machine can be braked by traction vehicle having compressed air braking system. In addition the machine shall be equipped with suitable air brake system in the driving cabins so that the attached wagon or coach while being hauled by the machine can be braked.

9.3 There shall be provision of emergency brake application using the compressed air in the

machine either travelling alone or coupled with the coach/wagons, in addition to the normal braking system of the machine. The emergency braking distance (EBD) of the machine on the Indian Railways track at the maximum designed speed on a level track shall not be more than 600 m. In this regard the firm shall submit design calculation for the braking effort and EBD at the maximum design speed of the machine on level track and at falling gradient of 1 in 33. The brake design details are to be submitted as per Annexure-III .

9.4 Clearly visible brake lights shall be provided at both the ends of the machine, which will

be automatically operated when brake is applied and switched off when brake is released. This will be required to alert the operator of machine following this machine when the machines are working in groups.

10.0 HORN, HOOTER AND SAFETY SWITCHES

10.1 The machine shall be provided with dual tone (low tone & high tone) electric/pneumatic horns facing outwards at each end of the machine at suitable locations for use during travelling to warn the workmen of any impending danger. Control shall be provided in close proximity to the driver permitting the driver to operate either horn individually or both horns simultaneously. The horns shall be distinctly audible from a distance of at-least 400 m from the machine and shall produce sound of 120-125 dB at a distance of 5 m from horn (source of sound). The higher tone horn shall have fundamental frequency of 370 ±15 hertz. These horns shall be operated by means of push buttons provided in the cabins.

10.2 Adequate numbers of safety stop switches shall be provided all around so that in case of

any danger to worker as well as hitting of any obstructions like OHE/signal post etc by any part of the crane/manipulator, so that the operator can be warned or the machine can be stopped immediately.

10.3 Safety equipment like jack, pullers, terfor and other such equipments specific to the

machine for restoring failed units of the machine during working shall be provided on the machine.

MFBWP-2019 of 31

10.4 The machine shall be provided with emergency backup system to wind up the machine in the event of failure of prime mover or power transmission system of the machine. The emergency backup system shall be able to be operated manually also.

10.5 Pneumatically/electrically operated hooters capable of producing intensity of sound

between 105-110 dB at a distance of 5 m (when measured in still air in a closed room) and variation in intensity of sound shall not be more than 5 dB. The hooter shall be provided facing outwards at each end of the machine at suitable locations, operated by means of push buttons provided in the cabins to warn the staff working on/around the machine about approaching train on adjoining track. Additionally switches for such pneumatic hooter shall be provided in the machine frame and near the both side exit gates so that it can be operated by staff present at work site near the machine. The hooter shall also be operated by remote switch at a distance of at least 300 m from the hooter.

10.6 In addition, separate electric horns with push bottom type switches shall be provided at

suitable locations in all cabin(s) and on machine body for communication between the machine staff about infringement/malfunctioning or any other trouble.

10.7 The machine shall be equipped with all safety features commensurate with good

engineering practice and Railways standards as expected. The machine shall disable and indicate in case of system failure. Safe interlocks shall be provided to prevent faulty operation. Indicate the safety features provided in the machine. Following safety features in addition to other standard safety features shall be provided on the machine:

i. A detailed list of all alarms/indications provided on machine.

ii. All the pipes, cables etc. on the machine shall be well supported and protected.

These shall not create any hindrance to machine operator’s movement for effective use of machine.

iii. Machine shall have adequate and reliable safety interlocks/devices to avoid

damage to the machine, work piece and the operator due the malfunctioning or mistakes.

iv. Machine functions shall be continuously monitored and alarm/warning indications. v. Through lights/alarm number with messages (on the display and operator panels)

shall be available. vi. All the rotating parts used on machine shall be statically & dynamically balanced to

avoid undue vibrations suitably guarded.

vii. Protective Guard is to be provided to prevent splashing on the operator while welding.

11.0 HOOKS AND BUFFERS 11.1 The machine shall be fitted with transition coupling as per specification no.

RDSO/2009/CG-22 with latest revision along with side buffers to RDSO drawing no. RDSO/SK-98145 with latest alteration on both ends for coupling it with coach or other

MFBWP-2019 of 31

vehicles and for attachment with coach, locomotives and wagon while running in train formation as last vehicle.

12.0 HEAD LIGHT, FLASHER LIGHT, MARKER LIGHT AND OT HER LIGHTING

ARRANGEMENTS 12.1 The electrical equipment to be provided shall conform to relevant standard specifications

and shall be suitable for Indian climatic conditions. The machine shall be equipped with twin beam LED headlight assembly conforming to RDSO specification no. RDSO/2017/EL/SPEC/0134 (Rev-0) with latest amendment to ensuring a light intensity of 3.2 lux at ground level at track centre at a distance of 305 m away on a clear dark night, at each end and with two front and rear parking lights, which can be switched to red or white according to the direction of the travel. Powerful swivelling floodlights shall also be provided to illuminate the working area sufficiently bright for efficient working during night. In addition minimum eight power point locations (24 volt DC/15 amp socket) shall be provided on outside frame of the machine two in front, two in rear and two on both sides for providing lighting arrangements during night working. Specification for DC-DC converter for electric loco/diesel electric loco no. ELRS/SPEC/DC-DC converter/0021, (rev-1, Sept’2004 or latest).

12.2 The amber colour LED based flasher lights producing not less than 500 lux at 1 m and 55

lux at 3 m in line measurement in axial direction from flasher light to RDSO Spec No. ELRS/SPEC/LFL/0017 (Rev-1) of Sept-2004 or latest shall be provided at both ends in the machine at both ends to give indication to the train arriving on other line about any impending danger.

12.3 The Mobile Flash Butt Welding Plant shall be provided with Marker light to RDSO

specification no. ELRS/SPEC/PR/0022, (Rev-1) October’2004 or latest.

13.0 CHASSIS AND UNDER FRAME 13.1 The chassis shall be fabricated from standard welded steel sections and of steel sheets,

so as to permit transportation of the machine in train formation without endangering safety of the train. The under-frame shall be constructed with rolled steel section and/or plates shall be designed to withstand a horizontal squeeze load of 102 t at CBC rear stops or 51 t at each buffing point without any permanent distortion. The under-frame shall be sufficiently robust for safe travel of the machine in train formation and not necessarily as the last vehicle.

14.0 SUSPENSION SYSTEM 14.1 The suspension system shall be preferably of two-stage type with suitable spring and

damping arrangement. Spring for primary and secondary suspension shall be designed to cater for actual service conditions. Effective measure shall be adopted to minimize the weight transfer while starting, stopping and during runs.

15.0 TOOLS AND INSTRUCTIONS MANUALS:

15.1 Each Machine shall be supplied with a complete kit of tools required by the operator in emergency and for normal working of the machine. The list of tools to be provided shall also include all tools necessary for maintenance and repair of the entire Machine

MFBWP-2019 of 31

including specialized equipment. All special tools shall be listed and catalogued illustrating the method of application.

15.2 Detailed operating, maintenance, service manual, user manual indicating capabilities of

machine and major assembly/component overhauling manuals shall be specifically prepared in English language and four hard & soft copies of these shall be supplied with each machine.

15.3 As a part of service manual, the manufacturer shall also supply circuit diagram in hard

and soft copies of electrical, hydraulic, pneumatic and electronic circuits used on the machine. Troubleshooting diagram/table shall also be supplied. In additions, the manufacturer shall provide dimension drawings with material description of items like rubber seals, washers, springs, bushes, metallic pins etc. Performance specification/working parameters and standard part numbers with supplier name of items like hydraulic pumps-motors and such other bought out components/assemblies shall be furnished by the tenderer. This shall be in English language and four copies of these shall be supplied with each Machine.

15.4 While offering the Machine for first inspection, the supplier shall submit one copy of

complete technical literature in English language including operation, service and field maintenance manuals/instructions, spare catalogue and complete electric/electrical, hydraulic and pneumatic circuit diagrams, troubleshooting charts, component drawings/description and other relevant technical details as reference documents for the inspecting officer.

15.5 The firm shall provide detail technical drawings and specifications of wheels and axles used in a machine. The above details shall be provided in four sets.

15.6 One additional set of all the manuals and diagrams/drawings in hard and soft copies prepared in English language shall also be sent each to the Principal/IRTMTC, Allahabad, Track Directorate and TMM Directorate of RDSO, Lucknow, Track Machine Directorate of Railway Board and Director/IRICEN, Pune along with supply of first machine of similar group. In case there is any subsequent amendment in any document based on field performance, the amendment/ amended documents shall also be sent to above mentioned authorities.

16.0 SPARE PARTS

16.1 The expected life of the components/spare parts shall be advised along with their condemning limits. The machines shall be supplied with necessary spare parts for the operation and maintenance of the machine for a period of two years, i.e., working for about 2000 hours. The spare parts required shall be detailed in a separate list indicating description, part number, quantity and whether imported or indigenous.

16.2 The manufacturer shall be responsible for the subsequent availability of spare parts to

ensure trouble free service for the life of the machine (20 years). It is preferred that the spares shall be stored in India and will be available at short notice say maximum within a month.

MFBWP-2019 of 31

16.3 For indigenous parts and bought out components and assemblies, the source (original equipment manufacturer’s reference and part no.) and other relevant technical details shall be supplied while offering the first machine for inspection.

17.0 OPTIONAL EQUIPMENT 17.1 Tenderer is expected to quote for optional equipment if any separately for each item

giving the advantages/functions of such optional equipment. Tenderer shall also indicate whether such equipment is already in use on machine elsewhere indicating the user Railways system.

18.0 MAKER’S TEST CERTIFICATE 18.1 Copies of maker’s certificate guaranteeing the performance of the machines shall be

supplied in duplicate along with the delivery of each machine.

19.0 WARRANTY CLAUSE:

In addition to the special conditions of contract dealing with warranty, the following will apply.

Should any design modification be made in any part of the equipment offered, the period of warranty (24 months) would commence from the date of the modified part is commissioned in service for the purpose of that part and those parts which may get damaged due to defects in the new replaced part, the cost of such modification shall be borne by the supplier.

20.0 INSPECTION OF THE MACHINE:

20.1 While inspecting the machine before dispatch from the supplier’s premises, the inspecting officer shall verify the conformity of the machine with respect to individual specification as above. The conformity/non- conformity with respect to each item shall be jointly recorded before issue of the Inspection certificate and approval for dispatch of the machine as per Annexure - IV enclosed.

20.2 Following arrangements shall be made by the supplier/Manufacturer at the inspection premises for carrying out inspection of the machine by inspecting officials:

• Machine to be stabled on straight & level BG track. The length of the track shall

be at least 10 m more than buffer to buffer length of machine.

• In order to check Maximum Moving dimensions in cross section, a Sturdy frame of IR Max Moving Dimensions shall be provided by the manufacturer and passed over the machine holding it perpendicular to track, centre aligned with track centre. Adequate arrangements shall be made to the satisfaction of inspecting official.

20.3 The following documents shall be provided to the Inspecting Officer at least 30 days in advance of the date of inspection.

MFBWP-2019 of 31

i) One copy of complete technical literature mentioned in Para-15, in English language, including operation, service and field maintenance manuals/instructions and complete electrical, hydraulic and pneumatic circuit diagrams, trouble shooting charts, component drawings/description and other relevant technical details as a reference documents for the inspecting officer.

ii) Cross section of the machine super imposed on Indian Railways maximum moving dimensions envelope shall be provided to Inspecting Officer in advance.

iii) Clause by clause comments of the manufacturer on this specification to be sent to Inspecting Officer (IO) in advance for his review. Comments shall state manufacturer’s conformity/compliance of each of the requirement stated in each clause, elaborating wherever necessary the details/manner in which the requirement has been complied. The pro-forma for the clause-wise comments is given below:

iv) Manufacturer’s Internal Quality Inspection Report (IO) of the machine.

v) Manufacturer’s quality certificate and/or test reports for bought out assemblies/sub-assemblies shall be provided to IO, containing serial number wherever applicable.

vi) Draft Inspection Report shall be prepared by the manufacturer, containing all annexure mentioned at Para 20.4.

vii) Details of arrangements made for checking maximum moving dimensions for his approval.

Supplier will incorporate amendments/further clarification in the above documents to the satisfaction of the Inspecting Officer keeping in view the Inspecting Officer’s comments, if any.

20.4 List of documents to be annexed in the draft Inspection Report shall include: i. Maker’s Test Certificate. ii. Manufacturer’s Internal Quality Inspection Report. iii. Quality Certificates of Bought out assemblies/sub-assemblies. iv. Cross section of the machine super imposed on the IR MMD. v. Vogel’s diagram. vi. List of spare parts to be dispatched along with the machine. vii. List of tools to be dispatched along with the machine. viii. List of Manuals, Drawings, Spare Parts Catalogues, etc. to be dispatched along with

the machine, duly indicating the number of sets of each. The above documents shall form part of final inspection report.

21.0 SERVICE ENGINEERS AND OPERATIONAL BASE IN INDI A:

Clause No. Clause Comments of Supplier/manufacturer

Comments of Inspecting Officer

MFBWP-2019 of 31

21.1 The supplier, after supply of machine shall establish a permanent operational base in India for providing necessary technical support in terms of the maintenance and shall also provide assistance and logistics support concerning problem within and beyond the warranty period.

21.2 The contractor shall provide at his own expense the services of competent engineers during the warranty period for warranty related issues and for future product support. The service engineers shall be available for the commissioning of the Machine for regular service and for training of the operating, repairing and maintenance staff of the machine. Machine shall be inspected by OEM or his authorized representative at an interval of two years or execution of 20,000 joints whichever is earlier to conduct technical audit of its health. The engineers shall also advise the railways on appropriate maintenance, testing, operating, repair and staff training facilities that are necessary for the efficient performance of the Machine.

21.3 Trained Service Engineers shall be available in India for ensuring quick repair in case of breakdown of the Machine.

21.4 During the warranty period of the machine, the supplier must ensure trouble free

availability of the machine in good working condition for at least 90% of the time and accordingly they must ensure availability of spares and services of competent service engineers and prompt disposal of complaint of user railways.

22.0 SPEED CERTIFICATE: 22.1 PROVISIONAL SPEED CERTIFICATE

Whenever a new rolling stock is introduced in Indian Railways, a provisional speed certificate is issued by RDSO based on certain design parameters of the vehicle. The firm shall submit design data as per Annexure-VI/B . Final speed clearance of the vehicle is given after conducting detailed oscillation trial of the vehicle, which is a time taking process. Therefore, issue of provisional speed certificate for the vehicle becomes a necessity and based on the same, the approval of running of the vehicle on Indian Railway track is taken from commissioner of Railway Safety. For issue of provisional speed certificate, the following actions are required to be taken by the suppliers:

A. Current suppliers, whose models are approved: The supplier shall give details of the model, year of introduction in Indian Railway, details of speed certificate issued etc. The supplier shall certify that no change has taken place in the model being offered with respect to design of under carriage i.e. suspension system/arrangement, wheel & axle assembly, bogie, braking arrangement, loading pattern of the vehicle etc. and the distribution of axle loads, lateral forces, un-sprung mass and braking force coming on rails is the same. If, there is any change in above respect, the action shall be taken as detailed in para (b) below:

B. Current suppliers, whose models are new and not app roved: As soon as the supplier completes the design of the machine as per Specifications, the technical details as per Annexure (VI/A & VI/B ) shall be supplied for processing of

MFBWP-2019 of 31

provisional speed certificate for the machine so that it can be permitted to move on track. More technical details (other than mentioned in Annexure (VI/A & VI/B) ) can be asked as required for issue of provisional speed certificate for the machine. The firm will also submit the technical details as per pro-forma placed at Annexure-V for NUCARS or similar track vehicle dynamic simulation report. The simulation charge, if done by Indian Railways, shall be borne by supplier.

C. New suppliers, whose models are new: The technical details shall be supplied as detailed in Para (b) above.

22.2 Final Speed Certificate:

Final speed certificate of the vehicle shall be given after conducting detailed oscillation trials of the machine For this purpose railway shall conduct running speed tests on the Indian Railways main line track on one of the machines supplied to them preferably with in warranty, in accordance with procedure outlined in Annexure- VII with the machine running up to speed 10% higher than the maximum speed mentioned in Para 3.13 above.

23.0 ACCEPTANCE TEST:

Apart from verification of the various items of specification covered above, the following tests shall be carried out by the supplier in India in the presence of purchaser’s representative at the time of commissioning of the Machine. (i) Dimensional check of machine loading gauge, i.e. maximum moving dimensions,

clearances, length of machine, bogie distance etc.

(ii) Testing for negotiability on 1 in 8 ½ turnouts.

(iii) Testing of out stretch and rotation of the manipulator as per requirement in the Para 5.4.

(iv) Testing of Flash Butt Welding Unit.

25 test welds each in 60 Kg/90 UTS and 52 Kg/90 UTS rail sections will be made both in cess and in depot (Total 4X25=100). In addition, 10 test welds in 52 Kg/60 Kg 90 UTS rail section will be made in running track using pulling & traction facility of the machine. Welding parameters for acceptance test are to be decided by manufacturers/ suppliers of the machine.

a) Not more than one test weld of each type i.e. 60 Kg/90 UTS, 52 Kg/90 UTS rail sections

made in cess and in depot and 52 kg/60kg, 90 UTS made in running track using pulling and traction facility of machine shall fail in visual inspection, weld trimming and upset examination, step across the weld examination, dimensional check and ultrasonic testing as per the provisions of Flash Butt Welding Manual-2012 with latest amendment.

In case the failure is more than above specified limit, one more set of equal no. of similar type of test welds which have failed, will be executed and tested for above mentioned parameters. None of the test welds shall fail in the re-test conducted for above

MFBWP-2019 of 31

mentioned parameters or else the machine will be said to have failed to meet the specification and the machine will not be accepted.

b) If the test weld have passed the criteria mentioned in the Para (a) above, 04 test welds

of each type i.e. 60 Kg/90 UTS, 52 Kg/90 UTS rail section made in cess and in depot and 02 test welds in 52 Kg/60 Kg 90 UTS made on running track shall be randomly selected for conducting hardness testing, transverse load testing, macro and micro examination as per the provisions of Flash Butt Welding Manual -2012 with latest amendment. None of these test welds shall fail in the above tests. In case of any failure, another set of four similar type of test welds which have failed, shall be randomly selected from the above prepared welds and the test shall be repeated. None of the welds shall fail in the re-test so conducted. In case of any failure, the machine will be said to have failed to meet the specification and the machine will not be accepted.

c) At the time of preparing the test welds, 10 welds made in cess and 04 welds made on

running track will be considered for measuring the output of the offered machine. Average time required in complete welding operation from start to finish including trimming for one rail joint prepared in all respect excluding post weld heat treatment wherever required and rail/track related preparatory works, shall not be more than 3 minutes.

d) At the time of preparation of test welds on running track, the traction and pulling capacity

of the machine shall be verified and shall meet the provision of Para 4.5 of this specification.

The machine shall be commissioned after pre-commissioning test within 90 days of its arrival at the final consignee end.

24.0 Should any modification be found necessary as a result of the tests, these shall be carried out once by the supplier at his own expense after which the modified machine shall again be subjected to relevant tests mentioned in this specification for confirmation and acceptance of the machine, failing which the offered machine under consideration shall be rejected.

25.0 MARKING & COLOUR OF MACHINE:

25.1 The machine body shall be painted in golden yellow colour (Colour code to be ISC: 356)

conforming to RDSO specification No M & C/PCN/109/88 (with latest amendment) to minimum DFT of 80 mm.

25.2 Following shall be written on the machine at appropriate location: (i) Indian Railways logo of height between 300 mm to 600 mm as suitable on all four

faces of the machine. (ii) On both side faces, below the Indian Railways logo, the text “ INDIAN RAILWAYS”

shall be written in bold and in black colour of size equal to or slightly smaller than the size of logo but of size not less than 250 mm.

MFBWP-2019 of 31

(iii) Below the text “INDIAN RAILWAYS” mentioned above, machine model and manufacturing year shall be written in black colour and in letter of size less than the size in which Indian Railways is written but not less than 200 mm in any case.

(iv) If the manufacturers desire to write their name on the exterior of the machine, the

same may be written in size not more than 150 mm and shall not be at more than four locations. The manufacturer’s logo may be provided at not more than four locations on the exterior of the machine and shall be of size not more than 200 mm.

***********

MFBWP-2019

2019

2019 of 31

Annexure-I

MFBWP-2019 of 31

Annexure II

MFBWP-2019 of 31

Annexure-III

BRAKE DESIGN DETAILS OF THE MACHINE FOR CALCULATION OF EMERGENCY

BRAKING DISTANCE

Tare & gross weight of the machine in Kilograms

Brake power in Kilograms

Type of Brake blocks

Brake block area in Square Centimetres

Brake Rigging Diagram

Type of Brake system

MFBWP-2019 of 31

Annexure –IV

INSPECTION CERTIFICATE

CERTIFICATE OF INSPECTION OF TRACK MACHINE (....... ................................................) BY INSPECTING OFFICIAL AND APPROVAL FOR DESPATCH OF MACHINES. (STRIKE OUT WHICHEVER NOT APPLICABLE)

This is to certify that I have inspected the machine (type)_______________________________bearing Sr. No._________________ from (date) ____________to _____________at (Place) ________________ for its conformity/non-conformity with respect to the laid down Technical Specifications in contract Agreement No.________________________________ dated_______________________ between President of India through Director Track (Machines) and M/s. (Name of Supplier) ___________________________ ___________________________________. The detailed Inspection Note regarding its conformity/non-conformity to the laid specifications is enclosed along with this certificate. It is observed that (strike out whichever is not applicable):-

• The Machine conforms to all the laid down specifications. • The machine conforms to all the laid down specifications except those at Sl.

No.________________________. • The above deviations are minor/major affecting/not affecting the performance of the

equipment in substantial way. The following T and P/manuals/drawings are to be supplied along with the machine:

1. __________________________ 2. __________________________ 3. __________________________

Based on the above, the Machine is certified/not certified to be conforming to the specifications.

The machine is approved/not approved for dispatch to _____________ ________________(Consignee) Indian Railways.

SIGNATURE AND DATE For M/s.__________________ INSPECTING OFFICIAL _________________________ (NAME AND DESIGNATION) for and on Behalf of President of India

Annexure –V

MFBWP-2019 of 31

Machine details required for simulation of machine on NUCARS or similar Track- vehicle simulation software

S.No.

Component’s Name

Parameters required

C.G. of component in x, y, z direction from rail level in mm (reference point 1st axle)

Mass in kg and mass moment of inertias in kg. m2 of component in three dimension space about their C.G.

X Y Z Mass Ixx Iyy Izz

1. Super structure with vehicle frame (Machine structure kept on secondary suspension of front and rear bogie)

2. Front Bogie frame including brake rigging

3. Rear Bogie frame including brake rigging

4. Transmission system device (hydraulic. Mechanical or electrical traction motors

5. Wheel axle set including axle boxes which constitute the unsprung mass

6. Mass of Items included in unsprung mass partially or fully along with their name per axle

1 2 3 4 5 6 Total unsprung mass in tonnes

7. Total weight of components in

Front bogie full

Satellite bogie full

Central bogie

Rear bogie

Machine frame full

Full weight of vehicle

MFBWP-2019 of 31

tonnes assembly assembly full assembly

full assembly

structure (All bogies + vehicle car body or hydraulic structure)

8. Suspension stiffness details in kg/mm

Primary suspension element stiffness per axle box between bogie and axle box

Secondary suspension element stiffness per side between bogie and machine frame

Vertical stiff Lateral stiff Longitudinal stiff Vertical stiff

Lateral stiff

Longitudinal stiff

9. Damping force details

(If hydraulic damper used give there rating force per meter/second)

10. Clearance in mm or radian provided for motion between bogie frame and machine frame for relative motion (motion stopper)

Vertical direction

Lateral direction

Longitudinal direction

Rotation about vertical axis

Rotation about Lateral axis

Rotation about Longitudinal axis

11. Detail of location of suspension elements

Detail of location of suspension springs and dampers and shock absorbers with support drawing

Detail of location of suspension springs and dampers and shock absorbers with support drawing

12. Details of centre pivot arrangement working and location

Provide detail arrangement drawing and description

13. Set of drawings and design description

Concerning with general arrangement of vehicle, bogie general arrangement, suspension arrangement details, suspension clearances drawing, detail written description of configuration and loading pattern accompanies design particular of vehicle bogie.

Annexure –VI/A

MFBWP-2019 of 31

Particulars Required in Respect of the Rolling Stoc k under Consideration

1. A diagram showing elevation salient dimensions

a) Wheel spacing, Wheel diameter, bogie centres, and axle load.

I. Overall length of the vehicle II. Length over head stock III. Length over buffers IV. Distance apart for center of buffers V. Max./Min. height of centers of buffers(above rail level) b) I. Wheel base II. Axle load (max) III. Bogie Centres

2. Wheel dimension

I. New II. Worn out

3. I. Tread and flange profile of the wheel indicating clearly whether it is Indian Railways standard profile or differs from standard flange profile.

II. Wheel gauge dimension (back to back of tyre flange). 4. Whether the stock is designed to be used as a general purpose or in a

closed circuit in specified sections under defined conditions. 5. Maximum design speed I. Own Power II. In train formation

6. Unsprung weight per axle in tonnes I. Driving axle II. Running axle

7. Expected lateral force in tonnes per axle At maximum design speed. 8. Increase in the impact load during motion(Dynamic Augment) 9. Method of operation - Whether single only or coupling together is possible. If coupling is

possible, the number which can be coupled and what is trailing load. 10. Maximum tractive effort at start and at the speed of operation - I. At working drive at start at operation speed II. At transfer drive at start at maximum speed

11. Maximum braking force coming on to the rails per wheel at working axle at transfer axle

MFBWP-2019 of 31

12. Drawing indicating suspension arrangement details of bogie and axle.

13. Height of centre of gravity from rail level.

14. Height of floor from rail level.

15. Type of coupler provided -Indian Railways Standard

I. Coupling

II. Buffer

16. Any infringement to the moving dimensions

(Sketch provided in the Indian Railways Standard Schedule of Dimensions – Chapter IV (A)).

MFBWP-2019 of 31

Annexure –VI/B

Following information for Rail Moving mode as detailed below is also required along with the information required as per Annexure ’VI/A’ for processing the case for issue of provisional speed certificate for new vehicle Name of the machine ________________ Model________________

Sr.No. Item 1. a) Brake System details b) Gross Braking Ratio 2. Brake rigging arrangement drawing and calculation of braking force 3. Maximum Braking Effort. at start and at the speed of operation -

a) At working drive at start : at operation speed :

b) At transfer drive at start :

at maximum speed : 4. Characteristics of springs used in suspension indicating free height, working height,

dynamic range, stiffness and locations etc. 5. Characteristics of the dampers if used, and over all damping factors and locations of

dampers. Calculation of the following frequency of the vehicle to be attached :- i) Bouncing ii) Pitching iii) Rolling Wave length of free axle and bogie

6. Write up and salient design calculation on suspension system, type of suspension- whether it is of coil suspension with or without dampers and laminated bearing springs and double link suspension.

7. What are lateral clearance of axle box/worn wheel flange/rail and other locations for the negotiability of the vehicle on curve and turn out (enclose Vogel’s diagram for negotiability on maximum degree of curve and turn out permitted on Indian Railways) of new and worn out wheel.

8. Wheel and axle assembly drawings. 9. Calculation for flange force. 10. Technical specifications of Vehicle supplied. 11. Calculation of natural frequency. 12. Calculation of spring characteristics and critical speed of the vehicle. 13. Simulation result showing ride index, lateral force and acceleration results. 14. A certificate regarding the speed of the vehicle for which it has been designed.

MFBWP-2019 of 31

Annexure-VII

ACCEPTANCE CRITERIA DURING OSCILLATION TRIALS 1. The speed potential of the machine offered by the firm shall be established

based upon oscillation trials conducted in India. The tests will be conducted at speed usually 10% higher than the maximum speed potential indicated by the firm for the machine under consideration and the following criteria satisfy for the same. For conducting the tests, a section of mainline track will be selected over which there is no temporary speed restrictions and which is considered by the Railway as being in a generally run down condition for mainline standards, but without speed restrictions. The vehicle will be tested generally for new and worn wheel clearance conditions and where relevant for operation in the forward and backward directions. The vehicle selected for tests will be one in average condition for normal maintenance.

2. The criteria applicable for establishing speed potential will be as follows:

a. A lateral force lasting over a length more than 2 metres shall not exceed the Prud-Homme’s limit of K(1 + P/3) tonnes. Where P is the axle load in tonnes, K=0.85 for wooden sleepers and K= 1 for concrete sleepers.

b. Isolated peak values exceeding the above limit are permissible provided the record shows establishing characteristics of the vehicle subsequent to the disturbances.

c. A derailment coefficient shall be worked out in the form of ratio between the lateral force (Hy) and the wheel load (Q) continuously over a period of 1/20th second, the value Hy/Q shall not exceed 1.

d. The values of acceleration recorded in the cab at location as near as possible to the bogie pivot (as near as possible to axle in case of four wheelers) shall be limited to 0.55 g both in vertical and lateral directions. The peak values up to 0.60 g may be permitted if the records do not indicate a resonant tendency in the region of peak value.

e. In the case of such vehicles where measurement of forces is not possible, the evaluation shall be in terms of ride index based on the accelerations measured as detailed in Para 2 (d) above which shall not be greater than 4.5 but a limit of 4.25 is preferred.

f. A general indication of stable running characteristics of the vehicle as evidenced by the movements of the bogie in straight and curved track and lateral force and derailment coefficient of accelerations as the case may be.

HYDRAULIC PULLER FOR BG (1676 mm) 1.0 GENERAL

Documents

Transcript of HYDRAULIC PULLER FOR BG (1676 mm) 1.0 GENERAL