FP te. 4 i 7 ee eee ee A ae Pe AER ee PA Ne PRO ANE oR Ref: QO-D-7.1-2 Ver. 7.0 | Page1of50 | Date of issue: 3) August 2018 | Specification No. | TM-215/May-2018 SPECIFICATION FOR 96 STONE RAIL GRINDING MACHINE (RGM) (Specification No. TM-215/May-2018) S. | Month & Year of | Revision/Amendment Reason for Amendment No. Approval a May-2018 Nil ae t Issue 2, August-2018 Ist Amendment Railway Board Letter No. 2018/Track-HII/13 dated | | 27.07.2018 Signature cs Vie. [wen f, Ad. | pesenge Frincekawmy Dikip kr|Musin Mad Om Prekath| $2. Sxivachave Name & Sst) Kev Ssehm | ARE be o™ IE Evi™ Designation _ | Prepared Bi Checked By Approved Bs Issued By Track Machine & Monitoring Directorate Research Designs and Standard Organization Manak Nagar, Lucknow-226011Ref: Q0-D-7.1-2 Ver.7.0 | Page 20f50 | Date of Issue: 31-August 2018 | Specification No. TM-215/May-2018 Specification of 96-Stones Rail Grinding Macl (Specification No. TM-215/May-2018) Pe 1 General > > 1.1, These specifications provide the technical requirements of Indian Railways to the manufacturers and supplier for supply, testing, commissioning, maintenance and operation of a self propelled rail-grinding machine of minimum 96 stones module (here after referred as machines) for use on the tracks of Indian Railways. Self-propelled is defined as “power transmission to the machine shall be from fully integrated power car of the machine”. The Rail Grinding Machine to be supplied is meant for grinding the rails in corrective mode and preventive mode, to improve the worn profile of rail head, rail wheel contact band, its location, to remove fatigued material having micro cracks and other surface defects on the rail head and remove corrugations. The Rail Grinding Machine shall be able to effectively grind rail in track on Indian Railways. The consist of RGM shall include two rest vans and ‘one water wagon. The supplier shall furnish all details and itemizes cast about delivery, warranty, operation and maintenances including supply of the 96 stone Rail-Grinding Machines as per these specifications and tender conditions yt a 2 ) 12. The Technical Specifications have been drafted to cover the performance and quality Tequirement of the equipment. Tenderers are requested to carefully study the specifications and assure that their equipment fully comply with these specifications. Thereafter, if a tenderer feels that his equipment can substantially meet the performance and quality Pe requirement of the specification in general but does not fully satisfy a particular specification, he should immediately seek clarification from the purchaser prior to 'e.> ry submission of bids as to whether such deviation is substantive or not. Whenever there are A any such deviation(s), tenderer should mention the same in the statement of deviation from ix the specification to be submitted along with bid and should clarify how his equipment will oe meet the functional requirement of such clause. A 1.3. The tenderer shall specify the model offered and furnish a detailed Technical Description of 7 the same, System/sub-systems of the working mechanisms of the Rail Grinding Machine as per para’3 of this specification & Annexure and all the items of the specifications in general shall be described in detail in the “Technical Description”, along with the sketches to show the manner in which the requirement of the specifications are accomplished by the machines ee (models) offered. ny 1.4. Photographs and video (in compact disc//Pen drive) of the type of machine offered in a working mode (showing the working of machine in real time under field conditions) be ts enclosed with the offer. This shall also show close-ups of various working assemblies/systems and the full machine, Tenderer shall also submit the names of countries & Railways where the offered machines are working and their working can be seen if felt a necessary by the purchaser. 2. Dimensional and Operating requirements: ~ 2.1. The diesel-powered engine for self-propelled Rail-Grinding Machine shall be robust, reliable and suitable for working on Indian Railways. The design and dimensions of the machine 2 : otFi eo 2 > Ref: QO-D-7.1-2 Ver. 7.0 | Page 3 of 50 l Date of Issue: August 2018 | Specification No. TM-215/May-2018 za 2.4, components shall be to SI (International) System of Units standards and also comply with provision of Indian Railways BG schedule of Dimensions-2004 incorporating all correction slips issued .Quality assurance during manufacturing of the machine shall be according to 1S0-9001.The welding standard followed for manufacturing of machine should be to 1S0:3834, EN:15085 or any other equivalent standard. The manufacturer should specify the standard followed and certify that it meets the welding standard mentioned above The Rail Grinding Machine shall be Diesel powered (preferably indigenous) self-propelled bogie type vehicle(s) with minimum 4 axles (2 bogies) for each vehicle. It should be reliable and suitable for working on Indian Railway’s straight, transitions and curved track up to 10° curves on broad gauge (1676 mm), Shared 2 axle bogies between two grinding cars and/or between two grinding buggies/carriages are not acceptable, The profile of the on-track machines longitudinally and in cross section during transfer as self-propelled vehicle or towed in train formation shall be within the Indian Railways standard metric BG schedule of Dimensions-2004 incorporating all correction slips up to date, The minimum and maximum moving dimensions are enclosed in Amnexure-IIL. The tenderer shall provide sketches of the machines in plan and cross-section and shall give calculations to show the extent of lateral shift at the ends, centre and any other relevant cross section and to prove that the machines do not cause infringement while moving on a 10° curve at any cross section. Where an infringement to Indian Railways Standard BG Schedule of Dimensions (metric)- 2004 incorporating all correction slips up to date 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 IR, the same shall be done with the prior approval of the Purchaser and decision of the Purchaser in permitting any such infringement shall be final and binding on the manufacturer. Tenderers may note that acceptance of any such deviation during consideration of preliminary design details in the offer is only in principle acceptance and the final decision will be taken by the Purchaser at the stage of consideration of machine design for issuing speed certificate. In the past, IR have condoned certain infringements to 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-a-vis safety and operational requirements of IR. 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 IR. Adequate clearance shall be allowed so that no component infringes the Minimum clearance of 102 mm from rail level while travelling, Wherever applicable, axle load shall be less than 20.32 T with minimum axle spacing of 1.83m. Load per meter shall not exceed 7.67 tones. Axle loads up to 22.82t and lower axle spacing may be permitted, provided the load combinations do not cause excessive stresses in the track and bridges of IR. A preliminary check in this regard will be conducted at the stage of technical acceptance of offers. Further at the stage of consideration on machine design for issuing speed certificate, stresses in the track and bridges shall be calculated by IR/RDSO based on design data submitted by the firm as per Annexure-VIII A.B&C and decision of IR/RDSO shall be final in this regards.- Ref: QO-D-7.1-2Ver.7.0 | Page4of50 | Date oflssue: 51-August 2018 | Specification No. nN TM-215/May-2018 2.7. The Machines shall have a desirable wheel diameter of 914mm or more (new wheel profile). r However, lesser diameter up to 760 mm for Rail Grinding machine can be permitted nq provided it meets the condition laid down in clause 2.5 at its condemnation limit as per 4 design and provided the rail wheel contact stresses for 72 UTS rails are within permissible oe limits. The.new wheel shall have a minimum wear margin of 50 mm before reaching condemnatida limit, Forged wheels to Indian Railways profile shall be provided on the A machine. The worm out wheel diameter (condemning wom out diameter) based on the A criteria of rail wheel contact stresses for various maximum axle loads are as under: - Maximum Minimum Axle load wheel ry (tone) diameter (mm) ry 22.82 908 a 22.00 878 za 21.50 860 21.00 841 ry 20.32 316 A ie 805 A 19.5 787 ie 19.0 768 18.5 SO e| o 18.0 eT3E n 175 713 a a 17.42 710 ms 17.0 700 = Permitted worn out wheel diameter should be specified by the manufacturer. The diameter of wheel for assessment of permitted axle load will be the wom out wheel diameter. The new fy wheel profile shall be as per Indian Railway standard wheel profile provided in Annexure-V. 2.8. Wheels shall be conforming to Indian Railway Standard R-19/93 or European Standard EN 13262 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 A machine. 2.9. The non-powered axles shall be conforming to Indian Railway Standard R-16/9S or A European Standard EN 13261(EAIN) or any other equivalent standard. The supplier shall me submit detailed design calculation along with material parameters at the time of supply of the machine, 5 2.10, The powered axles shall be conforming to Indian Railway Standard R-43/92 or European be 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 A machine. - 4 M4Ref: QO-D-7.1-2 Ver. 7.0 Page 5 of 50 Date of Issue: _31-August 2018 | Specification No. TM-215/May-2018 2.11. The machines shall be capable of negotiating curves up to 10° curvature (175 m radius), super elevation up to 185 mm and gradients up to 3% in travel mode. The supplier shall specify the minimum attainable speed under the above limiting conditions, which in any case shall not be less than 25 kmph. Water wagon and camping coaches shall be considered as part of consist/formation while travelling up to 3 % gradient. 2.12. The machines shall be capable of continuous operation during the varying atmospheric and climatic conditions occurring throughout the year in India. The range of climatic conditions is as follows Ambient temperature -5° to 55°C * Altitude Sea level 101800 m + Humidity upto 100% * Maximum rail temperature: 70°C All the system components on the machine shall be covered by roof or other suitable sturdy covering so that the system & components vulnerable to moisture ingress are not adversely affected during rains and the machine is able to work continuously even during rains. 2.13. The Rail Grinding Machine in consist/formation (in composition with all its integral part) shall be capable of travelling at a speed of 80 knvh in either direction when travelling on its ‘own power. In train formation, it should be capable of being hauled at a speed of 100 knwh. It shall be possible to haul the machines in both directions at the same speed. Since the machines are likely to cover long distances on their own power, the travel drive system should be robust to sustain these requirements during the life of the machine without much break down/failure. 2.14. The machines shall be capable of working without requiring power block in electrified sections. 25KV or 2x25 KVAC power supply is used for traction through an overhead wire at 5500mm above rail level. On bridges and tunnels, the height is restricted to 4800mm. The accuracy of measurement by measuring equipment/systems of the machine shall not be affected in any manner due to overhead electricity and also due to track circuit voltage (12 V & 1 AMP). 2.15. The machines and any of its parts shall not infringe the adjoining track as per ‘BG Schedule of dimensions of Indian Railways (metric)-2004 print with latest corrigendum and up to date correction slips issued while opening and closing of work. The machine shall be equipped with pneumatically operated brake blocks acting on all wheels. 2.16. In the work mode, no part of the machines should rise beyond 4265 mm. above rail level for safe working in the electrified sections. 2.17. While working on double line sections, the machines shall not infringe the adjoining track and it shall be possible to permit trains at full speed on that track. Minimum spacing of track is 4265mm. 3. WORKING MECHANISM OF RAIL GRINDING MACHINE 3 3.1. The working mechanism of the rail grinding machine shall be equipped with 3.1.1. Rail grinding mechanism of 96 stone modules 20> > Se 9: D> 7 35 3D, eS ed 577 > 553.9 3099) 2s oS OOS : > x Ref: QO-D-7.1-2 Ver. 7.0 | Page 6of50 | Date of lssue: a1-August 2018 | Specification No. TM-215/May-2018 3.1.2. Control system for rail grinding mechanism : 3.1.3. Optical rail profile measurement system and_ its transfer to onboard computer 3.2, 33 34. 35, 3.6. 39. The machine should be capable of producing good longitudinal profile of the railhead continuously in one pass on plain track as well on curve track. The machine should be capable of grinding operations on plain track and curves, track in tunnels, track on bridges having guard rails without removing the guard rails, and track on platform lines. It should also be capable of grinding operations on track on level crossings having check rails and curves with check rails after removing check rails. Maximum grind speed should not be less than 22kmph on plain track. The machine shall also be capable of grinding only one of the rails, if required, of the track as in the case of curves ete. The machine shall be capable of grinding profile of UIC 60 Kg rail section, 52 Kg rail heads in 72/90/110 UTS strength and Head Hardened rails and able to upgrade for UIC 65Kg, and 67kg. rail sections inclusive of fish plated joint, insulated joints and welded joints in long welded rails and short welded rails laid on pre stressed concrete sleepers, steel sleepers, composite sleepers and wooden sleepers. It shall also function effectively on rails having surface defects such as wheel burns, shelling etc. The number of grinding stones and grinding units of the machine shall be such as to carry out controlled grinding of all rail corrugation defects and also defects of long wave length to produce a smoot) cross. sectional profile without creating any sharp edge between the rail table and gauge face The supplier shall ensure that the offered rail grinding machines shall be capable of modular up gradation at a later stage and shall have such computer hardware and software which shall facilitate easy up gradation The rail grinding mechanism should be electric driven, drawing power from an on-board diesel generating set. All the components of the rail grinding machine must be robust and capable of continuous operation upto 8 hrs in one spell under the field working conditions. They must be shielded against heavy heat accumulation in the work area and good collection system of metallic dust generated at the work site To achieve the target profile with smooth curvatures, with minimum points of singularities, the Rail grinding machine shall have a minimum of 96 grinding stones (48 per rail), which can be configured in various configurations to achieve different target profiles, 3.10.Each grinding module shall be controlled by a hydraulic/pneumatic cylinder for its up/down movement 3.1L.It is mandatory that hydraulic fluid used for grinding applications in the machine shall be fire resistant water glycol fluid for safe working and to prevent fire hazards due to the extreme environmental condition and heat accumulation near grinding area, ela5 Pe De ee ae 2 > Ref: Q0-D-7.1-2Ver.7.0 | Page 7 0f50 | Date oflssue: 31 -August 2018 | Specification No. TM-215/May-2018 3.12. The machine shall be equipped with an inbuilt mechanism to stop the grinding and lift the grinding stones/carriages when the operating speed falls below a certain minimum speed to avoid metallurgical damage due to heat accumulation. The minimum speed, at which the grinding shall stop automatically, shall be as per supplier's design but it shall be mentioned in the offer. 3.13.Each grinding module shall comprise of a ring shaped stone and a grinding motor with suitable positioning mechanism to control the stone position, to achieve the target profile by the various grinding module configurations. Firm shall submit their module arrangement; configuration should have a fully adjustable angle range of +70° toward gauge face side and -20° to field side of the rail, independently controlled from the operator station in the cab. Each grinding motor spindle angle shall be accurate within +0.25° (plus/minus one quarter of a degree) of the designed spindle axis positioning angle. Each module shall contain one or 2 max. grinding motors with, independent tilt cylinder for each module and must have the capability of being positioned by the control system independent of any other grinding module. In each module grind motors\tilt cylinder should be separated by certain angle so that heating or other impact does not take place on rail. The tilting cylinders should not be shared with adjacent modules and must be independent for cach module. 3.14,At the work location, the prevailing temperature may be higher than the specified maximum temperature of 55°C. The peak load on the grinding motors, under the most demanding conditions shall not be more than 80% of the continuous load rating of the motor, at the prevailing temperature conditions. The supplier shall furnish the peak load for the motors at various locations and the continuous load ratings of the motors under the operating conditions, as per the manufacturer’ catalogues, 3.15. The grinding motor power shall be as per the supplier's design to achieve the output parameters laid down below and may vary with the total number of grinding motors provided on the rail grinding machine (not less than 96). However, the total grinding power provided on the rail grinding machine (number of motors x continuous load rating of each motor) shall not be less than 2880 HP. 3.16.The machine shall be capable of removing, a minimum of 20 sq, mm material from each rail (40 sq. mm for both the rails) per pass, from the rail top of a 60 kg. UIC (90 UTS) rail section, with top surface work hardened to BHN 315 to 380, while operating at a speed of 18 kmph, While assessing the rail grinding machines performance, the test rail profile (after grinding) shall be close to the target profile and the metal removal shall be fairly uniform over the entire rail surface to be ground 3.17.The capacity of rail grinding machine regarding depth of grinding per pass, for 60 kg 90 UTS work hardened rail top while grinding uniformly over full width and gauge faces at various working speeds, shall not be less than as mentioned below 22 kmph 0.13 mm 18 kmph 020mm 3.18, While achieving the above progress rate, the overall combination of grinding stones pressure, RPM and travel speed should be such that no chattering or uneven removal of the - oteo ye hy oe ee ) St 38 Ji ) Ref: QO-D-7.1-2Ver. 7.0 |Page8of50 ] Date of issue: as -August 2018 | Specification No. TM-215/May-2018 material occurs at high speeds nor are there any metallurgical changes or bluing of the rail top at the minimum operating speed. 3.19. The machine must be capable of bi-directional grinding i.e same track without loss of metal removal capacity or produ simultaneously or either rail independently both the directions on the , while grinding both rails 3.20.To ensure Gauge Face correction without flattening the root curve, all of the grinding modules shall have the ability of attaining spindle axis orientation with respect to the rail axis, up to 70° on the gauge side and 20° on the field side. At all angles the grinding effort must potentially be 100%, 3.21. While the machine is operating at full grinding load at the maximum working speed, the minimum life of each stone shall not be less than 5 hrs grinding time 3.22. Each module shall be provided with a stone stop mechanism to prevent accidental contact between the rail and grinding motor shaft chuck when the stone has completely worn out, to prevent damage to rail or the shaft. 3.23.Machine driving controls must be at both extreme ends of the rail grinding machine, irrespective of driving direction. However grinding controls can be housed in one cabin. 3.24. The unit must be capable of travelling and grinding under the following track conditions: (Maximum grade 3% Gi) Maximum curve 10 : 3.25. The unit must be capable of grinding a variety of profiling and re-contouring patterns depending on varying rail wear conditions. Such pattern changes and adjustments should be made instantly from an on board central control panel, 3.26.The unit must have the following controls/display the following operating data at the operator's console: (@) © Starv/stop buttons for individual motor and master stop button (to stop all grinding motors), (b) Current meters for various grinding modules and motor grinding power control. (©) Grinding Module/Grinding carriage up/down control (4) Operating speed monitor and control. () Stone condition monitor. (© Deviations in motor spindle angles. (g) Any other data monitor/control required for proper operation and control of the working, depending on the supplier’s design. (h) Angle setting of different grinding module. oud.Refi QO-D-7.1-2Ver.7.0 | Page90f50 | Dateoflssue: 31-August 2018 | Specification No. TM-215/May-2018 3.26.8 3.266. 3.26.6. There shall be computer controlled monitoring of input and output of different electrical/electronic devices with the facility of display of putloutput so as to monitor the functioning of electrical/electronic devices. The gomputer controlled functions may be as per the supplier's design, but as a representative illustration, the following functions shall be computer controlled fa) ) () @) © @ Auto horsepower adjustment of grinding stones with change in pattern Carriage Raising and lowering Module raising and lowering Pattern data input from Rail Profile measurement units. Storage of Profiles, Grinding pattern selection and down loading to grinding controls ‘The computer controlled system shall have the facility of System diagnostics in operator’s cabin (at least in one cab) which should be able to do following: (@) () © Detection of short circuit, open circuit conditions and measurement of amperage in connection to control devices. Diagnostics modules shall be provided for trouble shooting of various eleetronic printed circuit boards used up to card/board level fault finding. Communication between various sub systems used in the system shall be provided as a diagnostics feature. The on board computer will monitor the main system of rail grinding machine and maintain a log of following items (@) ) (©) (d) (©) ® Grinding Motor performance (amps). Stone usage. Grinding Motor idle amp. Stone spark time. Motor life. Performance monitoring, Quantitative assessment of metal removal fom each km oftrack to achieve target profile. Percentage deviation of ground profile from target profile ee‘Specification No. Ref: QO-D-7.1-2 Ver. 7.0 Page 10 of 50 | Date of Issue: TM-215/May-2018 = Grinding speed and no of grinding passes. = Quantum of work done in pass km ~,, History of existing rail profile, target profile and grinding pattern followed for a given km of track 3.28. The rail grinding machine must be capable of automatic adjustment of grinding patterns from the operator’s cab. The supplier shall furnish details of all possible number and patterns subjected to minimum of 100 patterns, The on-board computer must be capable of storing all these grinding patterns and changing from any of these patterns to any other within the length of the grinding consist. 3.29.It shall also be possible to record the grinding length vis-d-vis time on a print out to obtain information on the rail grinding machine output. The system shall be able to produce performance parameters and progress of work such as grind length, speed of grinding, number of passes done, pattern used, pre/post Grind Quality Index (GQI) etc in a way that should facilitate its transfer to pen drive at the end of day’s work 3.30.The grinding method must ensure the complete re-profiling of the railhead by metal removal. 3.31.Alll the grinding stones shall be equipped with an automatic vertical control or locking device preserving the stone from dropping into pitch corrugation 3.32. All the grinding units shall be so designed that it can be lowered or raised from grind cabin. Lowering and rising of grinding units should be automatic, electronically operated, which can be applied either on one rail or on both rails simultaneously 3.33. The rail grinding machine shall be equipped with Rail Grinding templates for Board Gauge (1676 mm)with different profiles. Further the machine shall be equipped with special track location templates for different profiles as required. After study of efficacy of existing grinding program and existing rail and wheel profiles, the supplier shall design the target rail profiles and software required for it and supplies the templates for the same for different routes of IR. This rail grinding profile design study shall be done by the supplier and shall part of the contract and it shall be completed before commissioning of the machine. The supplier shall ascertain the agency for this study, if any external agency is used. Acceptance of the study on IR, BG track required approval of IR officials. 3.34.To ensure minimum vibration of the rotating grinding stones, a self-centering system for holding the stones shall be provided. 3.35. The grinding trolley shall be designed for raising and lowering operation fom grinding control cabin. 3.36. The grinding power output per grinding stone shall be minimum25 Horse Power. 3.37. The rail grinding machine must be equipped with an obstacle sensing/detection system with manual lifting of the grinding carriages through controls from operators’ cabin before approaching the obstacle and restarting of the grinding process after the clearance of the eo> Rh ke REI tA ke ok Oe Sd 3 On en ek ok Be ee a SE ee 7 Ref: QO-D-7.1-2 Ver. 7.0 | Page 110f 50 | Date oflssue: 31-August 2018 | Specification No. ‘TM-215/May-2018 obstacles. The supplier shall specify the distance left ungrounded after the clearance of the obstacles at various operating speeds. This distance shall not be more than 12 m for an operating speed of 22kmph after obstacle clearance and restarting command 3.38. The rail grinding machine must be capable of setting down or picking up grinding stones in curves also 3.39, Grinding carriages should be capable of being raised and lowered and locked into position on curved track up to 10 degrees, 3.40. The grinding stone must be centered over the grinding spot at all intended grinding angles. To ensure proper positioning and angle of the grinding stone, the support structure must be equipped with pivot to permit the angular adjustment of the motor/stone in relation to the rail for centering of the stone over the area with adequate force to produce desired grinding power. 3.41.The grinding motors shall be controlled through suitable starter control for starting/stopping of motor. 3.42, Grinding patterns must be balanced and not change with curve super elevation of the track on which the rail grinding machine is operating except for changes will made from system The rail grinding machine must be equipped with a system to maintain a positive pressure and constant reference to the gauge face of the rail 3.43.The rail grinding machine must be equipped with a vertical rate of correction feature,to restrict the grinding in corrugation valleys, while smoothening the crests. For maximum grinding effort on rail running surface variations, the unit must be equipped with selective vertical stability control. The tenderer shall furnish the details of the mechanism to achieve this. 3.44. The unit must be capable of grinding any worn rail profile to shapes within plus or minus 0.30 mm of the selected target profile. 3.45. Metal removal rates must not vary more than 25% between grinding of rail with hardness ranging from 280-380 BHN, 3.46.The surface finishes after the grinding shall be that corresponding to RMS value of 12 microns roughness or less. 3.47. The rail grinding machine must be supplied with adequate lighting to perform grinding at night safely and efficiently 3.48. The rail grinding machine shall be equipped with suitable spark arresters to prevent sparks from flying around and be a potential fire hazard, The spark arresters shall be suitably designed to withstand the heat generated at the work spot and the flying metal sparks. 3.49. The rail grinding machine should have adequate water capacity to prevent and fight fires, and to carry on grinding irrespective of terrain or dry weather conditions. A minimum 20000 liters water storage capacity should be available on the rail grinding machine. There shall be separate arrangement of 55000 liters storage of water container in the rail grinding, CaeRef: QO-D-7.1-2Ver. 7.0 | Page 12 0f 50 | Date of issue: 31-August 2018 | TM-215/May-2018 S| machine consist by way of a separate wagon for use during prevention of fire. It should be possible to connect the water storage on the attached wagon with the rail grinding machine storage and use it for arresting fire as and when required. The visibility requirement of the rail grinding machine as specified in clause 13.1 shall not be obstructed on this account 3.50. The rail grinding machine shall be equipped with two water cannons (one in front and another in rear) of capacity up to 600 liters each per minute throughout with a reach of 40 meters. The rail grinding machine shall also be equipped with separately controlled sleeper and ditch spray, for front and rear. 3.51. There should be an installed, integrated backup of the following critical sub-systems to ensure maximum availability and minimal chances of disruption of rail grinding machine operations: a, Water system/pumps b, Hydraulic pumps/motors c. Air compressors A suitable by-pass mechanism should be installed and integrated to main system to operate the rail grinding machine with backup assembly. 3.52. The rail grinding machine shall be provided with a set of optical rail profile measuring system integrated with the onboard computer both in front of the rail grinding mechanjsm as well as rear of the rail grinding mechanism, a, The profile measurement system should be able to capture rail profile both ahead of and behind the grinding machine and should have capacity to store data of rail profile at Jeast 200 km of track length for real time comparison of rail profile before grinding and afier grinding. Optical rail profile measurement system should have facility to transfer data to onboard computer without human interface. b. The on board profile measurement system, in a real time basis, should show the actual rail profile ahead of work and after the work and difference between the measured profile and selected target profile, The system should save the captured rail profile data along with input location data such as milepost, curve-data, grinding, speed patterns used ete. ¢. Electronic/computerized rail profile data processing system and software plug-ins to grind the existing rail profile to a selected target rail profile shall be provided on board to Rail Grinding Machine. Rail Grinding Machine should be equipped with required following hardware and software- i. To capture, store and process rail profile data from other measuring devices of rail profile, ii, Optional merit given to supplier having quantitative assessment of metal removal per meter of rail to achieve target rail profile, iii, Recommended grinding pattern to achieve a target rail profile iv. Comparative picture of target profile and profile achieved after grinding on real time basis, s OtRef: QO-D-7.1-2 Ver. 7.0 | Page 13 of 50 | Date of Issue: _ 3)-August 2018 | Specification No. TM-215/May-2018__} 41. 42. 43 44 v. Quantitative assessment of deviation of ground profile fom target profile, d. The rail grinding machine should be provided with the necessary software and hardware system to store a library of desired railhead profiles (templates) and to calculate on real time basis the amount of rail grinding to be done. The supplier shall be responsible to provide technical support and services for software maintenance and up gradation during warranty and subsequent working life of the rail grinding machine (minimum 15 years) e. It should give: (@)__Best/optimum pattern to use for grinding, (ii) Number of grinding passes needed in order to achieve a predefined acceptance envelope Gili) Grinding speed for suggested pattern and profile £ To develop library of target profiles for various rail sections on different route, supplier of rail grinding machine will design the target rail profiles for all the locations where it will be deployed to work. The system should be equipped to store data of rail profile before grinding, its target profile and rail profile after grinding in an integrated way so that it could be retrieved for any given location of track. 3.53.The machine should be equipped with GPS, GSM/GPRS based remote monitoring capabilities for various track parameters and vital parameters of track machine, It should also have facility to interface with Human Machine Interface (HMI) / Display and various other sensors. The data transfer unit should be compatible with the Track Management System (TMS) of IR. DIESEL ENGINE/ELECTRIC GENERATOR: The machines 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. The manufacturer of the ‘engine shall have acquired quality assurance certification of ISO 9001, Adequate allowance shall be made to provide adequate reserve power to take care of the working of machines under most adverse climatic conditions, heavy grinding requirements on steep gradients, and to provide backup power in case of failure of one of the engines, The supplier shall furnish the details of diesel engine and its controls to assess its conformity with the engines already operating on track machines on Indian Railways. The engine should be of such design /brand which are being manufactured indigenously and/or such designs having after sale service facilities available in India. The supplier should furnish the information regarding agency which will provide after sales service support and availability of spares in India, Diesel tank fuel capacity of the rail grinding machine should not be less than 24000Its. or 40 hrs of working. Tenderer should mention the fuel storage capacity and average fuel consumption of machines. The engine shall be mounted on suitable Anti-Vibration Mountings. “tale| Ref Q0-D-7.1-2 Ver. 7.0 | Page 14 0f 50 Date of Issue: 31-August 2018 | Specification No. | TM-215/May-2018 45. 46. 47. 43. 49. 4.10. 4.11 4.12. 4.13 4.14, 415 High speed diesel oil to Indian Standard Specification shall-be normally used Sight glass type fuel measuring gauge preferably of full height shall be provided on the fuel tank or any electronic safe device built in to show the actual fuel quantity available in machine. For starting the engines, storage batteries of well-known make shall be provided. The engine Shall be push button start type or key type. Since the engines are to work outdoor under extreme dusty condition, the air intake system shall be designed suitably so as not to allow dust through air intake system There is likelihood of dust deposition over the engine body and surrounding area over the lubricants spill-over. These should be easy to access 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 The engine parameter monitoring system like temperature, rpm, lube oil pressure shall be in 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 should shut down automatically Suitable and rugged mechanism should be provided to start the prime mover at minimum / no load and gradual loading after the start of the prime move The diesel engines of Rail Grinding Machine shall be coupled to the electric generator(s) of a continuous rating to suit machine-operating requirements, Suitable cooling arrangement for the generator shall be provided. The electric generation parameter monitoring gauges shall be provided like wattmeter, voltmeter, ammeter, frequency meter etc. Generator shall have over voltage protection The grinding power distribution shall be either on a common bus or any other such suitable system so as to ensure grinding with all grinding modules may continue in case of failure of one of the engines / generators. The supplier shall furnish the details of power requirement for working under normal conditions as specified in clause 3.15 and total power provided on the machine. In order to adhere to pollution control norms, all the diesel engines provided on RGM consist shall be electronically controlled emmissionized engine with minimum compliance to tier 2 stage The engine should have Electronic Control Module (ECM) or similar arrangement for taking out operating parameters on real time basis such as RPM, load, temperature, pressure and diagnostic data as well as trip and historical data, These data should be displayed and stored on a centralized computer and monitoring system, It should also be possible to transfer these data on USB device through the centralised computer based control,Ref: QO-D-7.1-2 Ver. 7.0 | Page 15 0f 50 | Date of issue: 31-August 2018 | Specification No. TM-215/May-2018 416 gil 5.2, 53, 55 56. 57. 58, 59. The engine should be enclosed in a weather protective, sound and dust resistant enclosure to minimise 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. DRIVE MECHANISM. The machine should be provided with an efficient traction drive system for traction during the operation, The machine’s driving system shall be through electric / hydro dynamically / hydrostatic capable of achieving full speeds in travel mode in both the directions, The system should 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, in working mode, shall be adequately designed to handle the acceleration and braking forces Suitable differential systems may be provided between coupled wheels on the same bogie Suitable throttling arrangement may be provided to equalize the tractive effort amongst different bogies. The supplier shall provide the necessary technical details including circuit diagrams and detailed technical specifications of all electrical/electronic parts to confirm the above requirements Adequate gauges to monitor driving and working performance of machine should be provided in working and driving cabins near operator's seat. Solenoid valves shall be provided near linkage assembly, for indication, flow control and carrying out necessary adjustment in the field, To the extent possible hydraulic and pneumatic component/assembly should 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, The pneumatic circuit should be provided with air dryer for the smooth working of pneumatic components. The machine shall be equipped with adequate safety circuit such that if any unit/part which may endanger the safety is unlocked and the air pressure in brake circuit is less than 5 bars, the machine shall not move during run drive. The indication of locking and unlocking of all units should be displayed in the cabin Onboard system for online filtration and monitoring the quality of water glycol base hydraulic oil in hydraulic circuit should be provided. The gauge should clearly indicate if the hydraulic fluid is contaminated beyond the permissible limits and requires immediate replacement. oeRef: QO-D-7.1-2 Ver. 7.0 | Page 16 of 50 | Date of Issue: 3rAugust 2018 | Specification No. TM.215/May-2018 61 6.2, 1. 71 Te ia TA, 15. 8. 81 COOLING SYSTEM: x The cooling system shall be efficient and designed for a maximum ambient temperature of 55°C. Supplier must note that the machine shall be working under extreme dusty conditions and the cooling mechanism should be maintainable under these conditions. Adequate heat transfer arrangement shall be designed and provided so that the system oil temperature does not go beyond specified range. REST VANS: One No’s crew rest van having total resting capacity of about 12 to 15 persons will be integral part of the Rail Grinding Machine and shall be supplied with the same and for second rest van with driving control as a last vehicle of the RGM Typical layouts of coaches, with/without operational controls are given at Annexure I & II of the Technical Specification. These layouts are for guidance of tenderer in respect of the facilities required and general arrangement thereof Tenderer can propose modifications in layout as a part of technical proposal while providing the required facilities as per typical layout, Overall dimensions of the rest van will be within (+/-) 10% of the typical layout subjected to conformity to the Indian Railways standard metric BG schedule of Dimensions-2004 incorporating all correction slips up to date. The modifications proposed by tenderer will be discussed with tenderer during technical evaluation and necessary modifications required by IR will be incorporated by the tenderer as per mutual consent, If any further modifications are required by the successful contractor at the stage of detailed design, the same will be subjects to approval of RDSO. Rest vans should be air conditioned and fully furnished for comfortable stay of operation & maintenance crew and IR personnel. Minimum amenities to be provided in rest vans, its color scheme and other details shall be as per IRTMM-2017. A Washing machine, Microwave oven and communication gadgets are also to be provided BRAKES: Machine shall be equipped with compressed air brake system applying brakes equally on all wheels and provision shall be made to connect air brake system of the machine to that of camping coach/wagons when the machine is hauling it. Fail safe braking mechanism system shall be provided so that in case of any failure of brake circuit, will result in automatic application of brake. The pneumatic parking brake should also be spring loaded so that in case of drop in pneumatic pressure below certain value the brake will be automatically be applied. The brakes shall be protected from ingress of water, grease, oil or other substances, which may have an adverse effect on them. The brake 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. In addition, mechanical brakes shall also be provided for parkingRef: QO-D-7.1-2 Ver. 7.0 | Page 17 of 50 | Date of issue: 31 -August 2018 | Specification No. TM-215/May-2018 8.2. 83. 84. 85. 86, 91 9.2. 93. The rail grinding machine shall have provision for suitable air brake system in the driving cabins to brake the entire consist including camping coach/crew rest van and water wagon attached as a part of its consist/formation. Fail safe braking mechanism system shall be provided so that in case of any failure of brake circuit will result in automatic application of brake. The pneumatic parking brake should also be spring loaded so that in case of drop in pneumatic pressure below certain value the brake will be automatically be applied The machines shall be equipped with suitable air brake valves so that while working in train formation, machines can be braked by the traction vehicle There should be provision of emergency brake application in the machine either travelling alone or coupled with the coach/wagons, in addition to the normal braking system of the machine, using the compressed air. The emergency braking distance (EBD) of the machine on the Indian Railway Track, at the maximum design speed on level track shall not be more than 600 m. Design calculations for the braking effort and EBD at the maximum design speed of the machine on level track & at falling grade of 1 in 33 should be provided by the supplier, Provision of “Manual operated hand brake” system shall be provided. 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 to alert the operator of machine following this machine when the machines are working in groups. HORN, HOOTER ANDSAFETY MECHANISM: The Machines shall be provided with dual tone (low tone & high tone) electric horns! at suitable locations facing outwards at each end of the machine for use during travellingto warn the workmen of any impending danger Controls/switches 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 meter from horn (source of sound). The higher tone horn shall have fundamental frequency of 370 +15 hertz. These electric horns shall be operated by means of push buttons provided in the cabs. ‘The Machines shall have arrangement for flasher lights at both ends. Pheumatically/electrically operated hooters capable of producing intensity of sound between 105-110 dB at a distance of S meter (when measured in still air in a closed room) and variation in intensity of sound shall not be more than S 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 hooter shall be provided outside on 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 operatable from remote point at a distance of at least 300 m from the hooter.Ref: Q0-D-7.1-2 Ver.7.0 | Page 18.0f50 | Date of Issue: 3 August 2018 | Specification No. TM-215/May-2018 94, 95, 96. 97. 98. 9.9. 9.10. 10. . Safety equipments like jacks, pullers, tinfor and other such equipments specific to the machines for restoring failed units of the machines during working, shall be provided on the machines, The tenderer should submit the list of safety equipment to be provided Adequate numbers of safety stop/ switches should be provided all around so that in case of any danger fo worker as well as hitting of any obstructions by working unit like signalling cable, joggle fish plate etc. during work, so that the operator can be warned or the machine can be stopped immediately. 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 Machines shall be provided with emergency backup system to wind up the machines in the event of failure of prime mover or power transmission system of the machine. The emergency backup system should able to be operated manually and may also use a manual hydraulic power pack in addition to the emergency generator / battery based electric hydraulic system. ‘The grinding carriages of rail grinding machine should have non-flammable shields and guards so as to avoid damage due to sparks, grinding dust and flying debris. The rail grinding machine shall have a UV and Temperature based fire detection system that will alert the operator also there shall be an arrangement that the fire extinguisher is activated. If electronic control of engine detected malfunction, the engine automatically shuts down There shall be arrangement on rail grinding machine to prevent dust from the grinding process from escaping into the air. A suitable and efficient “dust collection system” shall be provided on the machine HOOKS AND BUFFERS: The machines shall be fitted with transition CBC couplingas per RDSO specification no 56-BD-07 with latest revision along with side buffers to RDSO drawing no. RDSO/SK- 98145, with latest alterationon both the ends for coupling it with other vehicles for running it in train formationand for attachment with the coach, locomotives and wagon. HEAD LIGHT, FLASHER LIGHT AND OTHER LIGHTING ARRANGEMENTS: The electrical equipment to be provided on machines shall conform to relevant standard specifications and shall be suitable for Indian climatic conditions. The machine shall be equipped with Twin beam headlight assembly conforming to RDSO’s specification no. ELRS/SPEC/PR/0024 Rev-1, Sept 2004 with latest amendments 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 cach 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 pressurize floodlights shall also be provided to illuminate the working area sufficiently bright for efficient working during night.In addition minimum eight power point locations shall be provided on outside frame of the machine two in front, two in rear and two on both sides for providing lighting oyRef: Q0-D-7.1-2Ver.7.0 | Page 19 0f50 | Date of Issue: _ar-August 2018 | Specification No. TM-215/May-2018 ils 152, 13.3, 13.4. 13.7. 138. arrangements during night working, The umber colour LED based flasher lights producing not less than 500 lux at | meter and $5 lux at 3 meter in line measurement in axial direction from flasher light shall be provided at both ends on the machine to give indication for the train arriving on the other line CHASSIS AND UNDERFRAME: The chassis of machines shall be fabricated from standard welded steel section 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 and shall be designed to withstand a maximum static squeeze test load of 102t at buffers i.e, 51t at each buffing point without any permanent distortion. The under frame shall be sufficiently robust for safe travel of the machine in train formation. CABINS: The machines shall be equipped with fully enclosed air conditioned and pressurized cabins with safety glass window at both the ends. The noise level in the cabins should be less than 70 dB for operator’s comfort. It shall be possible to have a clear view of the track ahead while driving the machine in both the directions from the cabins at either end. The cabin layout shall be such that, before leaving the machine, the operating staff has full view on both the sides, to avoid any danger to them from trains on the adjacent tracks, ‘The gauges, instruments and controls panel shall be suitably located in the operator’s cab so that they can be observed without undue fatigue to the operator. ‘The operator's cabin shall be ergonomically designed to have easy access to all controls, Screen wipers preferably operated by compressed air or electricity shall be provided on the windscreens Suitable number of fire extinguisher shall be provided in all the vehicles. The chemicals used for extinguishing fire by such fire extinguishers shall not chemically react with electronic equipments/components, PCBs, cables etc The machines shall be provided with well-defined space for keeping the tools and spares required for at least one week of operation and onsite repair of the machine to attend the breakdowns and other working requirements Large window shall be provided in both cabs of the rail grinding machine at low level to ensure good visibility for the operator controlling working and driving of machines to observe the track features and to operate the controls based on the features/obstructions being approathed and cleared Facility of driving the machine for travelling purpose shall be from both the cabins. All travelling and grinding control shall be housed in the air- conditioned cabins Inter-communication system wired/wireless shall be provided inter-connecting all the cabins and coaches and outside of machine should be so oriented that the operator, seating on the seat of either cabins/working cabin, can distinctly hear the conversation and communicate with other staff. ed.Ref: QO-D-7.1-2 Ver. 7.0 | Page 200f50 | Date of Issue: _31-August 2018 | Specification No. TM-215/May-2018 | 13.9. 14, 141 144. 14.5, 14.6. 147, The machine shall be equipped with speed indicator and recording equipment of range between 0 - 120km/h for recording the speed of the machine in real time basis, The recorded data should be retrievable on computer through memory card/pen drive. It should be provided in the driving cabin at suitable place and recording system should have sufficient memory to keep the speed record of minimum 15 days which should always be stored for retfieving as per requirement TOOLS AND INSTRUCTION MANUALS: Each machine shall be supplied with a complete kit of tools required by the operator in emergency and for normal working of the machines. The list of tools to be provided shall also include all tools necessary for maintenance and repair of the entire machine including specialized equipment, like hydraulic jacks, welding equipment, wheel truing shoes, refractometer, power tools, air hoses/wands, etc. all special tools shall be listed and catalogued illustrating the method of application.The list can be modified to suit the purchaser's requirement, while examining the offer. The supplier shall include all items, tools and accessories required for proper operation, servicing, maintenance, assembly overhauling, periodical overhauling of the machine along with the offer and not mentioned in these specifications and supply the same along with the machine. Detailed operating manual, maintenance and service manual shall be specifically prepared in English Language and four copies of these shall be supplied with each machine. The manufacturer shall also supply circuit diagrams of electrical hydraulic, pneumatic and electronic circuits used on the machine. Trouble shooting diagram/tablé shall also be sup} In addition, the supplier shall provide dimension drawings with material description of items like rubber seals, washers, springs, bushes, metallic pins etc., main features such as type, RPM & discharge etc. of items like hydraulic pump-motors, and the tenderer shall furnish the details of such other bought out components/assemblies. These shall be specially prepared in English language and four copies of these shall be supplied with each machine. ‘Complete technical literature in English to be supplied with the machines should be sent 3 ‘months in advance of inspection of the first machine to RDSO for their review regarding adequacy and manner of detailing. Necessary modifications and further detailing as per RDSO’s comments should be carried out and compliance should be reported to RDSO as well as the Inspecting officer of the first machine ‘The firm shall provide detailed technical drawings and specifications of wheels and axles used on the machines. The above details shall be provided in four sets with each machine. One set each of all the manuals and diagrams should be sent to the PrincipalARTMTC/ Allahabad, — ED/TM/RDSO/Lucknow, DTK — (MC)/Railway Board and Director/IRICEN/Pune along with supply of first machine. In case there is any subsequent amendment in above documents based on field performance, the amendment/amended documents should also be sent to above mentioned authorities. Each machine should be supplied with following Equipments- a, Two contact based rail profile measuring equipment shall be supplied by ‘manufacturer along with machine as per RDSO Specification no. TM/SM =323 20Ref: QO-D-7.1-2 Ver. 7.0 | Page 21 0f 50 | Date of issue: stAugust 2018 | Specification No. TM-215/May-2018 15.3. 16, 16.1 17. 11 18, 18.1 19, 19.1 19.2, Bar gauge with appropriate templates : Digital inclinometer Rail Hardness measuring equipment Rail Roughness measuring equipment SPARE PARTS: ‘The expected life of the components shall be advised along with their condemning limits, ‘The manufacturer shall be responsible for the subsequent availability of spare parts and gtinding stones to ensure trouble free service for the life of the machine. (Minimum 15 years) For indigenous parts and bought 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. MAKER'S TEST CERTIFICATE: Copies of maker’s certificate guaranteeing the performance of the machine shall be supplied in duplicate along with the delivery of each machine. OPERATORS: The number of operators and allied staff for working of the machines under normal condition shall be indicated, specifying their duties and minimum qualifications, OPTIONAL EQUIPMENT: Tenderer is expected to quote for optional equipment separately for each item giving the advantages/functions of such optional equipment. Tenderer shall also indicate whether such equipment is already in use on machines elsewhere indicating the user Railway system. INSPECTION: While inspecting the machine before dispatch from the supplier’s premises, the inspecting officer to be nominated by the purchaser shall verify the conformity of the machine respect to individual clause of technical requirements laid down in this specification. The machine’s conformity/non-conformity with respect to each item shall be jointly recorded, before the issue of the “Inspection certificate and approval for dispatch of the machine” as per Annexure-VI enclosed Following arrangements shall be made by the supplier/Manufacturer at the inspection premises for carrying out inspection of the machine by inspecting officials: i. Machine to be stabled on straight & level BG track. The length of the track should be at least 10 m more than buffer to buffer length of machine. ii, 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 - betPage 22 0f50 | Date oflssue: 3'-August 2018 | Specification No. TM-215/May-2018 19.3, 19.4, machine holding it perpendicular to track, centre alignéd with track centre. Adequate arrangements shall be made to the satisfaction of inspecting official. The following documents shall be provided to the Inspecting Officer at least 30 days in advance of the date of inspection, i. One copy of complete technical literature mentioned in clause 14, in English language, including operation, service and field maintenance manuals/instructions and complete electrical, hydraulic and pneumatic circuit diagrams, troubleshooting 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 IR maximum moving dimensions envelope shall be provided to 10 in advance. iii, Clause by clause comments of the manufacturer to be sent to Inspecting Officer (IO) in advance for his review. Comments should state manufacturer's conformity of compliance of each of the requirement stated in each clause, elaborating where necessary the details/manner in which the requirement has been complied. The proforma of draft inspection report for the clause-wise comments is given below: Clause No. Clause | Comments of |Comments of — Inspecting Supplier/manufacturer | Officer (To be filled by inspecting officer) iv. Manufacturer's Internal Quality Inspection Report of the machine. v. Manufacturer's quality certificate and/or test reports for bought out assemblies/ sub- assemblies to be provided to IO, containing serial number wherever applicable. vi, Draft: Inspection Report to be prepared by the manufacturer, containing all annexure mentioned at para 19.4. 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 List of documents to be annexed in the draft Inspection Report should include i Maker’s Test Certificate. ii, Manufacturer’s Internal Quality Inspection Report Quality Certificates of Bought out assemblies! sub-assemblies Cross section of the machine super imposed on the IR MMD 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 pRef: QO-D-7.1-2Ver.7.0 | Page 23 of 50 | Date of Issue: 3!-August 2018 | Specification No. | TM-215/May-2018 20. 20.1 20.2. viii, List of Manuals, Drawings, Spare Parts Catalogues, etc. to be dispatched along with the machine, duly indicating the number of sets of each. Above documents shall be part of final inspection report SPEED CERTIFICATE: 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. 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 ete. 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 pattem of the vehicle etc. and the distribution of axle loads, lateral forces, unsprung mass and braking force coming on rail 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 not approved / or new: As soon as the supplier completes the design of the machine as per specifications, the technical details as per Annexure (VIIA, B & C) shall be supplied for processing of provisional speed certificate for the machine so that it can be permitted to move on track. On case-to-case basis, more technical details (other than mentioned in Annexure VIIA, B & C) can also be asked for issue of provisional speed certificate for the machine. C- New suppliers, whose models are new: The technical details shall be supplied as detailed in para (B) above. Final Speed certificate: Final speed clearance of the vehicle is given after conducting detailed oscillation trials of the vehicle.. For this purpose railway shall conduct running speed test on the Indian Railway main line track on one of the machine supplied to them preferably within warranty, in accordance with procedure outline in Annexure-VIIA with the machine running up to speed 10% higher than the maximum speed mentioned in clause 2.13 above. OLRef: QO-D-7.1-2Ver.7.0 | Page 24.0f50 | Date of sue: 31-August 2018 | Specification No. ] ‘TM-215/May-2018 a 2 2 1 3, 22 200, MARKING & COLOUR: . The machine body shall be painted in golden yellow colour, conforming to RDSO specification No M & C/PCN/109/88 (with latest amendment) to minimum DFT of 80 mm. Colour cade to be ISC: 356. Following should be written on the machine at appropriate location (as per Annexure IX) (i) Indian Railway’s 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” to 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, (iii) Below the text “INDIAN RAILWAYS” mentioned above, Machine model and manufacturing Year should be written in black color 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 desired by the Manufacturers, his Name may be written in size not more than 150 mm and should not be at more than four locations. Also the Manufacturers Logo may be provided at not more than two Locations and should be of size less than 200mm, Acceptance test-The acceptance test as below shall be carried out at the time of commissioning of machines in India at the consignee Railway. Rail Grinding Machine ; The acceptance test of Rail Grinding Machine shall consist oft Dimensional test of the loading gauge, maximum moving dimensions, buffer heights, clearances etc. Testing for negotiability of 10-degree curve and 1 in 8.5 turnouts. Train running speed tests (light running) on the Indian Railway main line track in accordance with the procedure outlined at Annexure —VITA Construction and engineering of the machine. Output performance quality tests with High carbon 90 UTS/110 UTS H.H. rails with 60-kg/52 kg UIC section Profile of the rail section shall not be deformed. For the purpose of metal removal capability of the machine (clause 3.17), 5 sites of minimum 500m cach shall be selected. At each site measurement of both left and right rail shall be taken i. At each site, the machine shall grind a length of at least 500 meters to ensure that the stones are not heated up ii, The profile of the rail shall be close to the desired profile. iii, ‘The rail hardness shall be measured and recorded. iv. A each site, on the test rails, 5 X-sections shall be selected on both rails. These X- sections shall be atleast 2 meters eway from any weldfish plated joint and notin heavily corrugated rail. ¥. The X-sectional area shall be recorded, at each X-section, before the grinding, and after 1 grinding pass. The working speed, while grinding shall be maintained as specified. on ro op amRef: QO-D-7.1-2Ver. 7.0 | Page 250f50 | Date of issue: _3)-August 2018 | Specification No. TM-215/May-2018 vi. The average material removal per pass for the site shall be the average of material removal per pass at 5 X-sections. vii, The average material removal per pass at the specified speed at cach of the 5 sites both left and right rail separately shall be more than that specified in clause 3.16. H. For the purpose of depth of metal removal capability of the machine (clause 3.17), 5 sites “Of minimum 500m each shall be selected for carrying out tests at the speeds mentioned in clause 3.17. At each site, measurement of both left and right rail shall be taken: i, At each site, the machine shall grind a length of at least 500 meters to ensure that the stones are not heated up. ii, The profile of the rail shall be close to the desired profile. iii, The rail hardness shall be measured and recorded, iv. 5 points shall be chosen at 5 locations across the X-section, one towards gauge face side, three in the middle of rail top and one towards non-gauge face side such as to cover full width of rail head, at 5 X-sections on both rails at each of the 5 sites. v. The working speed, while grinding shall be maintained as specified. The depth of metal removed shall be measured by measuring the depth of cut before and after 1 grinding pass (as per para no. 21.1/G/v). Measurement to be done with Contact based Rail profile measurement Device with or better precision/accuracy vi. The average of the 25 observations at each site for each rail shall be worked out. The average depth of metal removal per pass for the site shall be the average depth of material removed for all 25 test points. vii, None of the average depth of metal removal per pass for a site, out of 5 selected sites for both rails should be less than as specified at clause 3.17 for the respective grinding speed. 1. Stoppages of work not attributable to machine shall be discounted J. The difference in the target profile and ground profile ie profile achieved after grinding, shall not more than + 1% in terms of cross sectional area of rail head. K, The machine will also be operated at suitable locations in wor continuous 5 hours to ensure the machine’s continuous working capabil of work and test the life of the grinding stones as specified at clause 3.21 22.2. Should any modifications be found necessary as a result of the tests, these shall be 23. 2a 23.2. carried out by the supplier at his own expense. TRAINING The supplier shall impart professional training to IR Personnel in various aspects of operation, maintenance and management of the machine, planning and designing rail grinding program, inspection, monitoring, quality control and review as per the brief scope defined in Annexure-IV. ‘The tenderer will submit detailed program covering scope and coverage in detail, place and manner in which the training will be imparted so that a satisfactory level of knowledge and skill is developed by IR Personnel for satisfactory implementation of grinding program E-Learning courses module should be arranged for imparting training to railway operators In addition, the service engineer shall provide hands on training to railway staff in calibration operation, repairing and maintenance of the machine in field to make them fully : OrtFi Re d Ref: QO-D-7.1-2 Ver. 7.0 Page 26 of 50 | Date oflssue: 3!-August 2018 | Specification No. 3 TM-215/May-2018 | conversant with the machine. 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 machines. 24. WARRANTEE AND POST WARRANTY OPERATION AND MAINTENANCE CONTRACT The machine shall be warranted for 24 months from date of commissioning at ultimate destination in India. Design modification made in any part of the machine offered, the warranty period of 24 months would commence from the date of modification and proving test of machine 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 should be borne by the supplier Other warrantee and post warranty clause wise term and conditions are attached as Annexure -X1. 0Ref: Q0-D-7.12 Ver. 7.0 | Page 270f50 | Date of Issue: _31-August 2018 | Specification No. TM-215/May-2018 TAD Pe aap es Be es Ps ee ade Dt ee ey Be ke DY De Be Ds) OR Ds Bel De he Do ao Annexure I rarew RE “ae we Te aS TET Tee F HN ' { Br I im f @ fl ae (Annexure I TM-215/May-2018 31-August 2018 | Specification No. % 6 RGI CAMP COACH -LAYOUT PLAN 3 me ee f jeepers 5 saaraneee i g = — | z 2 re : < 3 PROPOSED TYPICAL LAYOUT FORRGICAMP COACHES [auiw [omewa™ [aw maura a AT RAYANAPADU (A.P) & ALLAHABAD (U.P) [emoeneow _femvanine | netoummeraosemanene 5 ae a 3 8 2 CL CCCCECCL CX CCC SiC Ree CR Ot ee eee ee eeC Annexure II ‘TM-215/May-2018 ‘31-August 2018 | Specification No. Page 29 of 50. | Date of Issue: Ref: Q0-D-7.1-2 Ver. 7.0 DIAGRAM No. ID CE DO/T-2232) MAXIMUM MOVING DIMENSIONS a3 MAX 167$mm GAUGE 1170 MIN-= 4 RAIL far LEVEL | ig NOTE a4 ALL DIMENSIONS ARE IN MILLIMETRES Ni EXCEPT WHERE OTHERWISE SHOWN. Cr rit eo c c 2 Ca «oeRef: Q0-D-7.1-2Ver.7.0 | Page 30 0f50 | Date of issue: 3August 2018 | Specification No. TM-215/May-2018 me > Annexure- IV Sec ining to be impar by Manufacturer/Suy wv to IR Personnel < ‘The training program shall consist of the following modules- oO 1. For Serlior Engineering officers of IR- Four senior IR personnel shall be given training for a period of two weeks in ® manufacturing plant of manufacturer/supplier and/or affiliated institute/training centers and field operation where the machines are already in operation. Broad scope of this training shall be to provide quality training in the areas of management of grinding, machine familiarization, machine utilization, managerial aspects of operation and maintenance of the machine, grinding strategy, best practices for optimal performance, % reporting, quality control, producing quality rail profiles, progressive review of grinding 3 strategy program, important safety aspects, vendor support. 2. For Track Machine organization Personnel — This training will cover operation and maintenance of the machine. The broad scope of a this training will be as under: * Machine's general arrangement including air systems, mechanical systems, hydraulic He systems, electrical systems, rail measurement systems, controls ete os * Operation of the machine in working mode (grinding) and travel mode. * Maintenance and overhauling of rail grinding machine, a * Recording of rail profiles, use of Rail Inspection data and preparing the grinding " program. 5 * Trouble shooting skills. a + Responses of emergency situations ot ‘* Basics of producing quality rail profiles. o The training will be conducted as per following sub-modules- A 2.1, 12 IR, personnel shall be given training for a period of Three weeks at contractors A manufacturing premises about machine assembly line in different shops, operation, 5 repair and maintenance. Also they will be given on-site training in field operation Bw abroad where same type of machine is already in operation for the contract. ie 22, In India, training of 12 IR personnel per machine for four weeks will be given in o operation and maintenance of the machine, Out of four weeks, at least two weeks As training will be imparted at the site of commissioning of the machines and has to be 5 completed before commissioning of machines, The remaining period of training will be imparted in one or two modules spread over warranty period in the form of reffesher/updating training at the time of delivery of each machine, Details of the proposed program should be given in the offer. is 3. For P-Way Personnel — a This training will cover design, planning, quality control, monitoring and review of grinding program. The broad scope of this training will be as under: t fs eeSP SPREE ST SP SS as > 0) 723963 d Fe (eave! J Di es. F 2 oF RefiG0-0-7.4-2 Ver.7.0 | Page 31 of50 | Date of usue avAugust 2018 | Specification No. | ‘TM-215/May-2018 Bal 3.2, * Technical aspects of Rail Grinding and the benefits ~ «Rail grinding functions and best practices for optimal performance. * Basics of producing quality rail and wheel profiles. #, Rail and wheel interaction. ** Technical aspects of rail lubrication, and planning the lubrication strategies. © Understanding and development of rail grinding program based on RCF, surface defects and profile deterioration. * Monitoring of rail grinding result, its benefits and review of the grinding program. + Rail Grinding Implementation and quality control. © Track inspection and data collection for rail grinding, * Designing of optimal rail- wheel profiles Establishment of test sites and monitoring * Designing rail grinding strategies and program ‘The training will be conducted as per following sub-modules- 12 IR personnel shall be given three weeks training at manufacturer's premises and/or affiliated institute/training centre, this training shall include taking rail profile, wheel profile, work on simulation software for different contact location of rai-wheel interface, designing theory for developing required rail profiles, different pattem for achieving the required rail profile and calculate rail life and such other aspects in the contract. In India training for 12 IR personnel per machine for six weeks will be given at site of grinding / railway premises. This training includes taking rail profile pre-post grind and use of other handheld gadgets for inspection of grounded rail and contact bend before and after, how to maintain data base for grind quality, for establishing efficient Rail Grinding Management system on Indian Railways for each machine. This module of training may be staggered in suitable phases prior to supply of machines, post supply and mid warranty review/reiresher. Tenderers are required to submit detailed proposal of the training program along with their offer. The topics, detailed content of training, demonstrations, site visits and hhands-on experience should be elaborated in detail in the offer. The names of manufacturing premises, affiliated institute/training centre where abroad training is proposed to be conducted should be detailed in the training proposal in the offer. Further details of places where field visits, demonstrations, hands on experience etc are proposed to be conducted may be submitted within 90 days of signing the contract agreement. All the cost for arranging and facilitating the training are to be borne by the supplier. Tenderers are required to quote the prices for training as per tender conditions However training as per 2.2 and 3.2 will be at suppliers cost and nothing extra shall be paid for the same. The cost of boarding, lodging and air fare of IR personiiel shall be bome by the purchaser and should not be included in tenderer’s quote. get2, DRAW SEMIACIRCLE OF 14.5R TANGENTIAL TO INE 2. DRAV LINE 1:2.5 TANGENTALLY 10. 14.5R SEM~CIRCLE, 4. DRAV A HORIZONTAL. FROM THE TOP of LOOTE PLA AT 63: UNE X—Y, 5. FROM Pt. A LOCATE CENTRE ‘BOF af OF §30R ON A VERTICAL UNE AT FROM X-¥, DRAV ARC OF 330R FROM CENTRE ‘6B’ LociTE CENTRE | a eter e9) CEDURE OF DRAWING zg 5 1. DRAV A VERTICAL LINE ¥-Y. TM.215/May-2018 Annexure- V 3) -August 2018 | Specification No. zs 130 < et S 3OOR WiNH CENTRE AS 'C! DRAW ARC OF RADIUS 14mm TANGENT: 3 i 3 I | i | | Date of Issue: ‘ORAV UNE 1:20 TANGENTALLY TO 3308 ARC. DRAY A VERTICAL LINE AT A DISTANCE OF “30mm FROM THE FLANGE. END. NOTE: soe eee Se agers ara oc, eee — ‘ARE BASED ON NOMINAL DIMENSION OF asi. (© [74+ [onension 73.7 oeseren | 3/0 [ene [ee ean : ©O-ORDNAES OF ME SHON] 3/5 z mel Sire Page 32 of 50 olen TIAUTH. [DESCRIPTION pate] Ref: QO-D-7.1-2 Ver. 7.0 Race NCR ROR aC RC yc ec PCC RC ACS SC AC RC Cae ee AC Ae RAC Ce EC ac CC a aa A a ) 2g ae ae AF F327 DAS OSD 1 Beat ea oe ae a a ae Oe oe Ref: Q0-0-7.1-2 Ver. 7.0 | Page 330f50 | Date oflssue: 31-August 2018 | Specification No. | 1M-215/May-2018 Annexure-VI INSPECTION CERTIFICATE CERTIFICATE OF INSPECTION OF TRACK MACHINE( ) BY INSPECTING OFFICAL AND APPROVAL FOR DESPATCH OF MACHINES (STRIKE OUT WHICHEVER NOT APPLICABLE) This is to certify that I have inspected the machin (type) ~-from (date) — {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 an Annexure “A’. I is observed that (strike out whichever is not applicable):- The machine conforms to all laid down specifications. © The machine conforms to all the laid down specifications except those at SINo. ~ ‘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 Railway SIGNATURE AND DATE For Mis INSPECTION OFFICIAL (NAME AND DESIGNATION) For and on behalf of President of India okRef: Q0-D-7.1-2 Ver.7.0 | Page 34 of 50 | Date of Issue: _#"-August 2018 | Specification No. TM-215/May-2018 ii) iii) vi) > ANNEXURE-VIIA CCEPTANCE CRITERIA DURING OSCILLATION TRIALS The spted potential of the machine offered by the firm should 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 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. ‘The criteria applicable for establishing speed potential will be as follows: A lateral force lasting more than 2 meters should not exceed the Prud Homme"s Timit of 0.85 (1+P/3) where P is the axle load. Isolated peak values exceeding the above limit are permissible provided the record shows establishing characteristics of the vehicle subsequent to the disturbance. A derailment coefficient should be worked out in the form of ratio between the lateral force (Hy) and the wheel load (Q) continuously over a period of 1/20" second; the value Hy/Q shall not exceed 1 ‘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 0.55g both in vertical and lateral directions. The peak values upto 0.6 g may be permitted if the records do not indicate a resonant tendency in the region of peak value. 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 (iv) above which shall not be greater than 4.5 but a limit of 4.25 is preferred. ‘A general indication of stable running characteristics of the vehicle as evidenced by the movement of the bogie in straight and curved track and lateral force and derailment coefficient of accelerations as the case may be.yO ) Ref: Q0-0-7.1-2 Ver. 7.0 | Page 35 0f 50 | Dateofissue: 31-August 2018 | Specification No. TM-215/May-2018 Annexure-VIB 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 e UType_ of Brake systemRef Q0-D-7.1-2Ver.7.0 | Page 360F50 | Dateofissue: 31-August 2018 TM.215/May-2018 6 b) * Annexure: VIILA Particulars Required in Respect of the Rolling Stock Under Consideration A diagram showing elevation salient dimensions Wheel Spacing, Wheel diameter, bogie centers, and axle load. i) Overall length of the vehicle ii) Length over head stock iif) Length over buffers iv) Distance apart for Centre of buffers v) Max/Min. height of centers of buffers above rail level i) Wheel base ii) Axle load (max) iii) Bogie Centers Wheel dimension i) New ii) Wom out i) Tread and flange profile of the wheel indicating clearly whether it is Indian Railway standard profile or differs from standard flange profile. ii) Wheel gauge dimension — (back to back of tyre Mange). Whether the stock is designed to be used as a general purpose or in a closed circuit in specified sections under defined conditions, Maximum design speed i) Own Power ii) Intrain formation Unsprung weight per axle in tonnes i) Driving axle it) Running axle Expected lateral force in tonnes per axle at maximum design speed. Method of operation -Ref: Q0-D-7.1-2 Ver. 7.0 | Page 37 0f50 | Date of issue: 3!-August 2018 | Specification No. ‘TM-215/May-2018 10, ul 13. 4 15. Whether single only or coupling together is : possible. If coupling is possible, the number which can be coupled and what is trailing load. Maximum tractive effort at start and at the speed of operation - i) at working drive at start at operation speed ii) attransfer drive at start al maximum speed Maximum braking force coming on to the rails per wheel a) at working axle b) at transfer axle Drawing indicating suspension arrangement details of bogie and axle. Height of centre of gravity fom rail level Height of floor from rail level ‘Type of coupler provided -Indian Railways Standard Coupling Buffer Any infringement to the moving dimensions Sketch provided in the Indian Railways Standard Schedule of Dimensions ~ Chapter IV (A),5 OR Ae Pee Ref: Q0-D-7.1-2 Ver. 7.0 | Page 380f50 | Dateofissue: 30 -August2018 | Specification No. | TM-215/May-2018 Annexure: VIIIB Following information as detailed below is also required along with the information required as per Annexure °A’ for processing the case for issue of provisional speed certificaté for new vehicle. S.No ee Tem 1a) 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) attransferdrive at start at maximum speed 4. | Characteristies of springs used in suspension indicating free height, working height, dynamic range, stiffitess 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 / hom, wheel flange’rail and other locations for the negotiability of the vehicle on curve and tum out (enclose Vogels Diagram “for negotiability on maximum degree of curve and tum out permitted on Indian Railways) of new and won out wheel & | Wheel and axle assembly drawings 19. | Calculation for flange force 10. Technical specifications of Vehicle supplied. TI, | 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 désigned. QeRef: Q0-D-7.1-2 Ver. 7.0 | Page 39 of SO Date of issue: _31-August 2018 | Specification No. ] TM-215/May-2018 * Annexure VIHC Machine details required for simulation of machine on NUCARS or similar Track-vehicle simulation software SL. Component’s Name Parameters required “G. of component in x, /, Z direction from rail -vel in mm (Referenced joint 1" axle) Mass in Kg m2 of ‘Mass moment of inertias in Kg- component in three dimension space about their CG ass ix ivy a Super structure with vehicle frame (machine structure kept on secondary suspension of | front and rear bogie) Front Bogie frame including brake rigging Rear Bogie frame including brake rigging ‘Transmission system device (hydraulic ‘Mechanical or electrical traction motors) Wheel axle set including axle boxes which constitute the unsprung | mass Mass of Items included in unsprung mass, partially or fully along with their name per axle | Total unsprung mass in tonnes Total weight of Front bogie [Rear bogie lachine Full weight of vehicle oata = Ref.QO-D-7.1-2Ver.7.0 [Page 40050 | Dateofissue: 3tAugust 2018 | Specification No. cane TM-215/May-2018 ‘components intonnes [full assembly full assembly frame “(front bogie + rear bogie | vehicle car body or super pu structure) structure Lea 8. | Suspension stiffness Primary suspension element stiffhess Secondary suspension element details in Ke/mm tiffiness er axle box between bogie and axle ee side between bogie and machine te fertical stiff feral [Longitudi [Vertical [Lateral tiff al stiff bist if | | ea { 6. | Damping force details | (ifhydraulic damper used give there rating force per meter/second) | 10. | Clearance in mm or fertical direction Lateral [Longitudi cae Rotation [Rotation about radian provided for lirection yut bout longitudinal motion between bogie irection vertical — Jateral axis axis frame and machine frame} sis: for relative motion ES (motion stopper) | { | |I1. | Dimension of location of [Detail of location of suspension springs [Detail of location of suspension springs suspension elements and dampers and shock absorbers with and dampers and shock absorbers with support drawing support drawing fI2. | Details of centre pivot Provide detail arrangement drawing and description arrangement working and location 13. | Set of drawings and ‘oncerning with general arrangement of vehicle, bogie general arrangement, design description suspension arrangement details, suspension clearances drawing, detail written 9f vehicle bogie. lescription of configuration and loading pattern accompanies design particular asRef: Q0-D-7.1-2 Ver. 7.0 | Page 41 of 50 | Date of Issue: 2 -August 2018 | Specification No. TM-215/May-2018 Annexure-IX, 300 to 600 mm NDIAN RAILWAYS cee Series NO.--- -------. I 200 mm in black color Manufacturing Year ------- 2 | 200mm Manufacturers Name apis i 200 mm aRef: Q0-D-7.1-2 Ver. 7.0 | Page 42 0f50 | Date cf issue: 31 August 2018 Specification No. TM215/May-2018 List of Track features Km post, TP/OHE Mast, PL& Crossing In PL& Crossing out Level Crossing, Switch Expansion Joint, Fish plated joint Axle counter Bridge Q In, Bridge 0 Out Curve In, Curve Out, Tunnel [n, Tunnel Out, 10 spare keys as user options Platform () In Platform () Out. Annexure-X,PSSVITFDIFIAVITFISISOWIFVIGIOS IPSS SISGITFIIFGIDIAAPPIAIIAIWIG Ref GO-D-7.12 Ver. 7.0 | Page 43 0f50 | Date of issuer # August 2018 | Spedfication No | Tw.215/May-2018 Ll 12 13 L4 1s Annexure-XI OPERATION AND MAINTENANCE CONTRACT (DURING WARRANTY PERIOD) ‘The following clauses outline the key requirements of the O&M conditions for Indian Railways to be met by the supplier for a period of 24 months post commissioning: ‘The supplier or their designated Indian agent/Indian counterpart has to execute works of Operation & maintenance of 96 stones Rail Grinding Machine which will be deployed over many Zonal Railways as per the instructions of Consignee Zonal Railways office. During the execution of the contract fuel, oil, water and lubricants are to be provided by Zonal Railways free of cost to the supplier. ‘The operation & maintenance clause is included in the specification of the 96 stone Rail Grinding machine for fully utilizing its potential. The tenderer is responsible for ensuring the availability of machine for 08 hour every day for grinding operation (which might be increased upto 2 to 3 hours depending on traffic condition over IR during operation). During maintenance shift, the stipulated maintenance of RGM stipulated preventive checks and schedule maintenance of RGM machine including all assemblies (like engines, generators, electrical control system etc.) or sub- assemblies (various water & HSD oil pumps sensors etc) as specified by OEM/supplier updated time to time to ensure it’s upkeep shall be carried out. ‘The supplier or their designated Indian agent/Indian counterpart has to provide sufficient number of skilled/semi-skilled staff (Minimum 12 staff including 6 supervisors at a time) required for operation and maintenance of RGM. Grinding operator shall be certified by the OEM and with valid competency certificate in train operation issued by ZRTVIR and medically fit in A-I Category. In case initial/refresher course to be done for G & SR from ZRTW/IR during the currency of this contract, the same shall be got done for the operators by the contractor and it shall payable as applicable. Zonal Railways shall facilitate in expediting the process, All the operators shall have valid PME certificate issued by IR and all the cost for medical examination connected with PME, shall be payable by the contractor. One 4 wheeler vehicle in good condition with proper road permit and insurance(Safari/ Scorpio or similar) for transporting men and material required for day to day working will be provided by tenderer during O&M period for use by O & M crew and IR crew (on RGM) without any extra payment ‘The contractor must ensure the care /safety/health hazards of the labours engaged by him/her during the course of the execution of work. Necessary safety equipment /gadget shall be provided by the contractor for the staff engaged by the tenderer and also for 2-4 IR official nominated on this machine. No extra amount is payable toward this. Railway shall provide adequate and appropriate security at their disposal to protect and preserve the RGM Machine from anti-social elements especially in insurgency defined areas, where the machine maybe required to operate from time to time oH[ Ref:Q0-D-7.1-2 Ver. 7.0 | Page 44 of 50 | Date of issue: 31-August 2018 | Specification No. ‘TM-215/May-2018 7 18 19 1.10 12 The contractor's staff & labour’ shall not have any claims of appointment in Railways in future. Authorized Railway's representative having route learning of the particular section Where the RGM is working will be present for supervising the grinding work and to mofiitor the movement of the RGM from one section to another. RGM shall not be moved without authorized Railway's representative. The same would be provided free of charge All tools and plants, drawings, manuals which are supplied by the manufacturer to the Railways will be handed over to the contractor free of cost for use along with the machine. All these to be handed over back in good condition after expiry of the contract period to authorized Railways RGM shall be made available for grinding operation for minimum period of 22 days ina month, keeping in mind typical international norms and 66days in consecutive 3 ‘months. The balance 24 days are meant for maintenance functions during which time all maintenance activities are to be completed by the tenderer. While the RGM is on transit from one station to another or waiting for loco for hauling, it will be considered as availability unless the RGM is under breakdown preceding to this. ‘The supplier will be responsible for ensuring the availability of machine for eight hours every day for at least 22 days a month, minimum 132 days to maximum]50 days in total six months spell and the availability certificate will be rendered (as per enclosed Annexure - A). During these 8 hours (which may be in two shifis with one break of maximum upto 2 to 3 hours) of daily availability of machine, the working hours (actual grinding) will in general for about 4 hours per day. The machine availability for penalties purposes will be worked out by taking average availability of machine after 6 months (132 days over 6 months) Availability of machine for work less than 132 days in half year on account of supplier during the warranty period will invite a penalty of Rs 30,000/- per day and the penalty certificate will be rendered (as per enclosed Annexure - B) When the RGM is on transit with its own power from one station to another, since there will be no routine maintenance, and RGM shall be made available for movement in two shifts of 10 hours each (2x10 hours) in 24 hours time frame till it reaches destination. The staff of operation and maintenance shall be so redistributed to perform transit work with sufficient staff. All the fixtures in Camping coach shall be maintained in good condition. Special cleaning of camping coach (once a month) to be carried out so as to maintain in excellent condition. All electrical, plumbing, furniture, electronics, computers/laptop, TV&DVD, Genset, Washing machine, freezer, geysers, microwave/oven, communication and all other fixtures available in camping coach to be maintained at all times in good feitle and at the end of the contract period. The fixtures would be handed over the Zonal Railways in good condition, as-received at the beginning of the contract.J ae ) FO ht Ref: Q0-D-7.1-2 Ver. 7.0 | Page 45 0f50 | Date of issue: 8 August 2018 | Specification No. TM215/May-2018 114 11s 1.16 LI8 119 1.20 1.21 1.22 Special cleaning of RGM to be carried out once a month (as far as possible) with detergents and other cleaning agents to remove all soot, dust and to keep the entire ‘machine in good appearance. RGM will be stabled at a place so that adequate water (to be provided by Zonal Railways) & non-OHE siding are available so as to ensure proper cleaning. Patch panting at rusted locations should be done after cleaning with matching colour. No amount is separately payable towards this, Complete and up to date records for daily, weekly and monthly maintenance will be maintained by the contractor and countersigned by IR officials, The daily/wweekly/monthly and all progress report in the special format shall be mailed to division/zone/RDSO/Rly board daily. The daily progress, grind history shall be mailed to the nominated IR official along with weekly and monthly progress reports in the existing format Contractor shall furnish adequate VHF sets for crew communication for safe operation of RGM. This should include at least 6 hand held devices. Spares for repair/maintenance and consumables would be supplied by Railways, Each party agrees to indemnify, defend. and hold harmless the other party from all liability, cost or expense (including any court costs) caused by the joint and/or concurring negligence of the parties, arising on account of injury to or death of any employee, agent or representative of the indemnifying party during the performance of the Services or who shall, if not performing Services, be present as a bystander or otherwise on the property of either party, provided always, however, that if the injury or death to an employee of an indemnifying party is caused solely by the negligence of the other party then this indemnity and hold harmless provision shall be null and void, and the party who solely caused the injury or death shall bear the cost or expense. Notwithstanding any provision herein to the contrary, Tenderer total cumulative liability for any or all claims arising out of this agreement shall not exceed the three month value of this contract. If there is deficiency of staff on RGM w.r.t, minimum stipulated staff in operation and maintenance (minimum staff. in © & M shift put together), penalty of Rs 3000.00 per head per shift or part thereof shall be imposed, For maintaining attendance of the staff for this purpose, the contractor has to provide one finger print attendance system in the camping coach & shall ensure it is working condition always. No extra payment shall be admissible on this account. ‘The maintenance role encompasses undertaking all schedule/periodic/ routine of RGM machine including all assemblies (like engines, generators, electrical control system etc.) or sub-assemblies (various water & HSD oil pumps, sensors etc) as specified by Supplier / OEM updated time to time, either by day or night. OEM recommended spares will be provided by Zonal Railway on the machine and the released spares/material shall be retumed to Zonal Railway on the machine. The transport of spares would be done by Zonal Railways. - ‘Scheduled Maintenance: Daily maintenance will be strictly followed after grinding operations. Other schedule maintenance (weekly, monthly, two monthly, quarterly, half yearly, yearly SL= Ref: QO-D-7.1-2 Ver. 7.0 | Page 46 of 50 Z| Date of issue: 3) -August 2018 | Specification No. | TM-215/May-2018 A and two yearly checks) are to be performed at appropriate time intervals in the balance time available afler offering the RGM for operational activities. ii, Routine maintenance of undercarriage systems shall be undertaken by the tenderer iii, Tenderer shall be responsible towards mounting and dismounting of unserviceable = ‘components/ parts / materials on the RGM. Zonal Railway shall be responsible for providing serviceable components! paris/materials on the RGM. iy. Wheel and Bogie tumings (if needed) will be coordinated and executed by Zonal A Railway and wheel turing charges of as applicable by wishop per wheel would be oe paid by the tenderer. ry 1.23 Maintenance of Records a i, Maintenance records during Schedule and breakdown maintenance shall be maintained in hard copy as well as soft copy as per format provided and updated .% time to time. 5 ii, ‘These records shall be provided to Zonal Railway crew on the machine in a timely a manner. iii, ‘Tenderer shall complete a standard daily report accurately depicting operational times, delays, and machine availability. Zonal Railway crew/ representative has to sign daily report based on satisfactory completion of daily operational services. The signed daily report shall be the basis for invoicing and shall constitute Zonal Railway's acceptance of day to day work apart from the completion of scheduled 5 maintenance in timely manner. So 1.24 Test Site Management: Ki (i As part of the O&M Services provided by the tenderer or their designated Indian = agent, 12 test sites would be actively managed by them. This would include atleast 4 mild curves, 4 sharp curves and 4 tangents. Breakup would be as follows: 0 = 2 mild curves at same location on UP Line and DOWN Line = 4 Total - 2sharp curves at same location on UP Line and DOWN Line = 4 Total ~ 2 tangents at same location on UP Line and DOWN Line = 4 Total 0 Final = 12 test sites and would be jointly selected by IR/Zonal Railways in tenderer. ‘These locations should be maintained as permanent test sites and should be re- marked periodically by proper paint by Zonal Railways, Format for Test site a location marking by paint has been shown as Annexure C. Gi)_As part of requirement of the Test site management, tenderer or their designated Indian agent shall note the following for each test site: is Pre Grinding MiniProf, surface photograph and dye penetrant test, within 10 days before grinding - Post Grinding MiniProf, surface photograph and dye penetrant test, within 10 days afier grinding aS ~ Maintaining proper record of the same. = Sharing run on run analysis for all 12 test site locations. - _ Review of grinding pattern changes needed, if any post analysis A ~ Review for further changes in profile and grinding cycle. < (iii) As part of this exercise, any existing templates would also be reviewed and A modified as needed. - Ore4) ma A REODT Iver. 7.0 | Page a7 of50 | Date ofiesue: s-August 2018 ] Specification No | TM-215/May-2018 1.25. During the currency of the O&M period, the supplier or its Indian agent may seek documents for importing spare parts/material/testers/manuals/equipment’s on required basis for Customs clearance. These will be provided by Consignee Zonal Railways in required format for speedy clearance on arrival at port 1.26 Spare Parts: Complete OEM spare parts list broken down to the last level for 96 stone Rail Grinding Machine classified into: i. Recommended ~ these are those parts covered under warranty period and will be either replaced/repaired. During repaired/replacement period, Recommended parts held on Railway Inventory can be fitted on the machine on returnable basis and is provided by IR only to ensure machine uptime. ii, Essential - resulting from fair, wear and tear and do not necessarily constitute a warranty claim, iii, Consumables — are those which will be as per actual consumption/supply during the 2 21 warranty period is to be provided. It may be noted that the Spare Paris List indicates for O&M Period must indicate the anticipated quantity of use. This would be used to establish a budget and the total budget per machine would remain fixed, while actual used quantities may vary based on usage. During the 24 month O&M period, in case spares beyond the budget need to be used, the additional spares would be supplied free of cost by the supplier. Cost of Spares needed for the 24 month O&M period would be considered as part of price calculation for the determination of successful bidder. 11 is important to note that spares not included in the list would be provided by the supplier free of charge during the O&M period. The supplier must ensure that spares, are properly budgeted keeping in mind the IR working and environmental conditions, Tenderer should insure availability of spares for machine stipulated service life of 15 years by providing. ware house or store in India for uninterrupted working of machine. Furthermore, spares per year per machine should generally not exceed 5% of machine price, POST-WARRANTY OPERATION & MAINTENANCE CONTRACT: The supplier shall quote for a two year extension of O&M services after the expiry of the warranty period. The additional extension for 2 years is on the sole discretion of Railway Board / Zonal Railways. All terms and condition for post warranty O&M of RGM shall be same as in case O&M of RGM tnder warranty, except clause for spare parts(1.18, 1.26) Spare Parts: Spares for repair/maintenance and consumables would be supplied by Railways. Rate contract for supply of spares is to be decided by respective Zonal Railways separately. ontRef: Q0-D-7.1-2Ver.7.0 | Page 48 of 50 | Date ofissue: 3) -August 2018 | Specification No. TM-215/May-2018 ANNEXURE A ~ QUARTERLY AVAILABILITY CERTIFICATE FORMAT “THE OPERATION AND MAINTENANCE OF RAIL GRIDING MACHINE HAS SATISFACTORILY PERFORMED FOR DAYS DURING THE SIX CONSECUTIVE MONTHS / 180 DAYS PERIOD FROM TO FOR WHICH PAYMENT INSTALMENT IS CLAIMED”, ‘The details of RAIL GRINDING MACHINE availability in SIX MONTHS are furnished below | Month MC MIC Non- Remark Period = | From To | Availability | Availability | Days Days Ist Quarter | | | | TI Quarter | Total days | Average no of days available/month = Days Dy CE/TM/Lines C/-CE/TM For kind information. C/- Supplier, ey.Ref: Q0-D-7.1-2Ver. 7.0 | Page 490f50 | Date of Issue: 3-August 2018 | Specification No. ‘TM-215/May-2018 ANNEXURE B : HALF YEARLY PENALTY DEDUCTION CERTIFICATE FORMAT “AMOUNT OF PENALTY DEDUCTION TO BE MADE AS PER CLAUSE NO 1.11 (Annexure XI) OF THE TECHNICAL SPECIFICATION TO RAILWAY BOARD CONTRACT AGREEMENT NO. Is Dy CE/TM/Lines C/- CETM For kind information. C/- Supplier, ot-2 Ver. 7.0 | Page 50 of SO Date of Issue: ‘Bi August 2018 Specification No. TM.215/May-2018 ANNEXURE C