technical specification of mobile flash butt welding machine
Contents
1. NIN 1 p NIW SOE i ee eee LL SSS eae L annyoozor at py x W Sete 13 31 O 98 2801 7 XVW GEZE XVW OSZE ES92 H ozs SNOISNSAWIG UNIAUWN WAWIXVW 9 9 JONVO ON 3 2020 170037 ma 0 06 Annexure Page 21 43 Te ea E ers pre i I TN NR ye SS ce 213289 PRUSEDURE_OF DRAWING 1 DRAW A VERTICAL LINE X Y 2 DRAYV SEMI CIRCLE OF 14 58 TANGENTIAI TO INE X Y 3 DRAW LINE 1 2 5 TANGENTIALLY TO SEM CIRCLE 4 DRAY A HORIZONTAL LINE AT 0 FROM THE TOP OF THE FLANGE AND LOCATE Pt A AT 63 5mm FROM THE LINE X Y 5 FROM Pt A LOCATE CENTRE B OF ARC OF 350R ON A VERTICAL UNE AT Sf FROH X Y DRAV ARC OF 3308 FROM CENTRE B LOCATE CENTRE C ON VERTICAL LINE AT HORIZONTAL DISTANCE OF 65 5mm FRON THE LINE X Y SUCH THAT BC 33 100 ie 230mm 0 ARC OF 100R WIH CENTRE AS Cc DRAY ARC OF RADIUS 14mm TANGENTIA LLY TO 100R ARC AND LINE 7 2 5 10 DRAW LINE 1 20 TANGENTIALLY TO 330R ARC 11 DRAY A VERTICAL LINE AT A DISTANCE QF 30mm FROM THE FLANGE END 1 IN 20 a 2 28 SUPERSEDED BY ee 9 04 Fs p PROFILE nie ee 0 998 1 i 3 92 at EC pod s SKETCH 911462. 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 Total unsprung mass name per axle 2 3 A 5 in tonnes Machine Full weight of vehicle Front bogie Rear bogie 02 front bogie rear bogie vehicle car body or otal weight o full assembly full assembly aieri components in ull structure super structure tonnes Page 36 of 43 Primary suspension element stiffness Secondary suspension element stiffness per axle box between bogie and axle box per side between bogie and machine frame Suspension stiffness details in Kg mm Vertical stiti Lateral stir COmgituainal Vertical stiff Lateral stiff Longitudinal stiff Damping force details If hydraulic damper used give there rating force per meter second 4 Rotation Clearance a mm or Vertical directii Lateral Longitudinal Rotation about donee ee Rotation about radian provided for direction direction vertical axis longitudinal axis motion between axis 10 bogie frame and machine frame for relative motion motion stopper Page 37 of 43 Detail of location of suspension springs and dampers and shock absorbers with support drawing Dimension of location suspension elements Detail of location of suspension springs and dampers and shock absorbers with
3. 12 4 12 5 12 6 13 0 14 0 RCRV MFBW Machine as whole shall be supplied in duplicate along with the delivery of each ROCRV MFBW Machine OPERATORS The number of operators and allied staff for working of the RCRV MFBW Machine under normal condition shall be indicated specifying their duties and minimum qualifications INSPECTION OF THE MACHINE While inspecting the machine before dispatch from the supplier s premises the inspecting officer shall verify the conformity of the machine with respect to individual specification as above The conformity non conformity with respect to each item shall be jointly recorded before issue of the Inspection certificate and approval for dispatch of the machine as per Annexure VIII enclosed Following arrangements shall be made by the supplier Manufacturer at the inspection premises for carrying out inspection of the machine by inspecting officials e Machine to be stabled on straight amp level BG track The length of the track should be at least 10 m more than buffer to buffer length of machine e In order to check Maximum Moving dimensions in cross section a Sturdy frame of IR Max Moving Dimensions shall be provided by the manufacturer and passed over the machine holding it perpendicular to track centre aligned with track centre Adequate arrangements shall be made to the satisfaction of inspecting official The following documents shall be provided to the Inspecting Officer a
4. 18 3 18 4 19 0 19 1 a 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 X A X B amp XI can also be asked for issue of provisional speed certificate for the machine New suppliers whose models are new The technical details shall be supplied as detailed in para b above ACCEPTANCE TEST Apart from verification of the various items of specification covered above the following tests shall be carried out by the supplier in India in the presence of purchaser s representative at the time of commissioning of the RCRV MFBW Machine 1 Dimensional check of RCRV MFBW Machine loading gauge i e maximum moving dimensions clearances length of machine bogie distance etc in Road as well as Rail moving mode ii Testing for negotiability on 1 in 8 1 2 turnouts ii Testing of out stretch and rotation of the manipulator as per requirement in the Para 4 3 iv Running test of RCRV MFBW Machine in Rail moving mode for satisfaction to provisions of clause 3 10 Test to be conducted as per the provisions contained in Annexure Xll v Running test of RCRV MFBW Machine in Road moving mode for minimum 40 kmph self propelled speed vi Testing of Flash Butt Welding Unit 25 test welds each in 60 Kg 90 UTS and 52 Kg 90 UTS rail sections will be made both in cess and in
5. DATE CO ORDINATES OF ARCS SHOWN NOTE ARE BASED ON NOMINAL DIMENSION OF 28 5mm SCALE ia DESCRIPTION ee ESEN Annexure Il ANNEXURE Ill FINISHING TOLERANCES FOR WELDS Part A Welds with new rails i Vertical misalignment 0 3mm lat the centre of a 1m 0 0 mm straight edge ii Lateral misalignment 0 3mm at the centre of a 1 m straight edge lil 1 finishing in width Side of rail head should be finished to 0 25 mm on gauge side at the centre of 10 cm Straight edge iv Finishing of top table surface 0 2mm at the centre of 10cm 0 0mm straight edge v Web zone under side of head 3 0 mm o0f the parent contour web top of base both fillet 0 0 mm each side vi Upper sides under surfaces and edges of rail foot shall be ground smooth The edges of foot should be rounded and bottom of rail foot ground smooth without any minus tolerances to ensure proper seating on sleepers unhindered movement of welded panels on end unloading rakes avoid damage to elastic rail pads and eliminate stress riser Part B Welds with old rails 1 Vertical misalignment 0 5mm at the centre of a 1m straight edge ii Lateral misalignment 0 5 mm at the centre of a 1m straight edge iii Head finishing on sides 0 3 mm on the gauge side at the centre of a 10 cm straight edge iv Head finishing on top 0 2 mm on the gauge side at the table s
6. Page 15 of 43 maintenance and shall also provide assistance and logistics support concerning problem within and beyond the warranty period 18 2 The contractor shall provide at his own expense the services of competent engineers during the warranty period for warranty related issues and for future product support The service engineers shall be available for the commissioning of the RCRV MFBW Machine for regular service and for training of the operating repairing and maintenance staff of the machine RCRV MFBW Machine shall be inspected by OEM or his authorized representative at an interval of two years or execution of 20 000 joints whichever is earlier to conduct technical audit of its health The engineers shall also advise the railways on appropriate maintenance testing operating repair and staff training facilities that are necessary for the efficient performance of the RCRV MFBW Machine Trained Service Engineers should be available in India for ensuring quick repair in case of breakdown of the RCRV MFBW Machine During the warranty period of the machine the supplier must ensure trouble free availability of the machine in good working condition for at least 90 of the time and accordingly they must ensure availability of soares and services of competent service engineers and prompt disposal of complaint of user railways ISSUE OF PROVISIONAL SPEED CERTIFICATE Whenever a new rolling stock is introduced in Indian Railways a pro
7. 3 9 3 6 3 7 The rail wheel axle load shall be lesser than 20 32 tonne with minimum axle Spacing of 1 83 meter Load per meter shall not exceed 7 67 tonne Lower axle spacing may be permitted provided the load combinations do not cause excessive stresses in the tracks amp bridges of IR Stresses in the tracks amp bridges shall be calculated and submitted by the machine manufacturer based on design data for verification of IR RDSO It shall be capable of continuous operation during the varying atmospheric and climatic conditions prevailing throughout the year in India The range of climatic conditions is as follows a Ambient temperature 10 to 60 C b Altitude Sea level to 1800 m above mean sea level c Humidity 40 to 100 d Rail temperature 10 C to 75 C During transfer from one station to another self propelled travel mode on railway track it shall be capable of traveling on its own speed at preferably 50kmph but in no case less than 30 kmph in both directions During towing of the RCRV MFBW Machine by another locomotive or by attaching to another load neutral position of gears should be sufficient and speed should not be less than 20 Kmph No opening of cordon shaft etc should be required for safe movement It shall be capable of working and moving on Railway track without requiring power block in electrified sections On Indian Railways 25 KVA current is used for traction through an overhead
8. and shot blasting or grinding to bright metal and brand mark removed by grinding to give consistent and good electrical contact at interface The rails shall not be damaged by cleaning operation or through poor electrical contact The rails shall be positioned in the welding machine such that the welding interface is central to the contact electrodes as assessed by visual or mechanical means Ten weld samples two welds for each parameter shall be prepared in presence of RDSO representative 4 Approval Tests A Visual Inspection All welds and rails shall be inspected visually for welding trimming clamping or profile finish imperfections such as tears cavities cracks damage and thermal damage in particular in the electrical contact areas 4 2 Weld trimming and upset examination There shall be no sign of tearing chisel mark or cavity in weld metal due to trimming and upset shall not be raised more than 3mm and there shall be no depression in accordance with item v of part A amp B of Annexure Ill as applicable 4 3 Step across the weld All the welds shall be measured in as welded condition to determine step across the weld No step shall be permitted except as provided in 1 3 3 and 1 3 4 of Annexure IV 4 4 Dimensional check Finished weld samples shall be checked for weld geometry and shall conform to tolerance laid down in Annexure Ill Page 27 of 43 Ultrasonic test All welds shall be sub
9. as per the provisions of Manual of Instructions on Long Welded Rails 1996 for Indian Railways with up to date Addendum and Corrigendum Slips The welding process must be capable of welding new released but serviceable rails of various sections and metallurgies given in Specification of Rails Suitability of Rails for flash butt welding is enclosed herewith as Annexure IV Total rail usage per weld should be within 50 mm Visible heat affected zone shall be of a nominally symmetrical shape about weld line and fall within the width of 40mm maximum and 20mm minimum The permissible deviation between the maximum and minimum dimension of visible affected zone on any weld shall not exceed 5 mm This requirement shall apply equally to vertical axis cut through full rail depth and those taken from each rail foot Page 6 of 43 4 10 4 11 4 12 4 13 4 14 4 15 Quality of weld produced by the RCRV MFBW Machine should meet the various test standards and geometrical tolerances specified in Flash Butt Welding Manual Geometrical tolerances are attached as Annexure Ill and test requirements are attached as Annexure V 4 16 4 17 Welding parameters will depend on section and metallurgy of rail to be welded These are normally specified by the manufacturer of welding plants which shall be got approved from RDSO before adoption for production of regular welds Common welding parameters are as below a Welding current primary amps
10. b Primary voltage volts c Clamping pressure Kg cm d Butting pressure Kg cm e No of pre heats f Pre heating time On Off g Burn off time sec h Flashing time sec Upset length i e rail usage per weld mm The machine should have the arrangement for displaying all the welding parameters including alignment preferably These parameters should be automatically stored in the system in reproducible electronic and hard forms in a manner such that each welded joint has a unique identity As welding of higher UTS and higher section rails on low butting load plants by increasing the number of pre heats causes very pronounced heat affected zone and is detrimental to the service life of the joint RCRV MFBW Machine should have adequate butting load capacity to avoid the same The recommended butting pressure for different types of rails being used in Indian Railways is as under 72 UTS rails 5 Kg mm on cross sectional area of rail 90 UTS amp Head Hardened rails 6 Kg mm on cross sectional area of rail 110 UTS rails 7 Kg mm on cross sectional area of rail The Flash Butt Welding Unit should be of reputed make with proven credential 72 UTS and 90 UTS rails do not require any special post weld heat treatment However alloy steel rails of 110 UTS and head hardened rails need post weld heat treatment to ensure variation in hardness within acceptable limits in heat affected zone Therefor
11. panels aligning on operator side as well as non operator side may be resorted to Resulting step on non gauge face side after welding shall be ground out to slope not steeper than 1 500 In case of in situ welding and in case where it is possible to exactly determine gauge face when laid in track the rail ends shall be perfectly aligned to gauge face Any step as a result of unequal head width due to rolling tolerances shall be ground out to slope not steeper than 1 500 RAIL END GEOMETRY Rail ends to be welded shall meet following geometrical standards End bends in the vertical plane not greater than 0 7mm ona 1 5metre straight edge Sagging ends not permitted End bends in the horizontal plane not greater than 0 7mm on a 1 5 metre straight edge Deviation of the end from the square not greater than 0 6mm A thorough inspection shall be carried out at the plants with a view to avoid welding of rails with visible surface defects such as rolling guide marks wheel burns etc Rail should also be inspected to ensure that there is no chisel mark or dent of any type on bottom flange of the rail as this constitutes the tension zone The rails rejected due to non compliance of the requirements of paras 1 1 to 1 5 shall not be welded Such rails shall be marked and stacked separately for other uses In order to minimize the difference in head width of rail ends to be welded actual head width of rails shall be checked using template sh
12. vil 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 16 4 List of documents to be annexed in the draft Inspection Report should include i Maker s Test Certificate li Manufacturer s Internal Quality Inspection Report lil Quality Certificates of Bought out assemblies sub assemblies iv Cross section of the machine super imposed on the IR MMD v Vogels diagram vi List of spare parts to be dispatched along with the machine vii List of tools to be dispatched along with the machine vill List of Manuals Drawings Spare Parts Catalogues etc to be dispatched along with the machine duly indicating the number of sets of each The above documents shall form part of final inspection report 17 0 OPTIONAL EQUIPMENTS The tenderer is expected to quote for optional equipment or features separately for each item giving the advantages and functions of such optional equipment The tenderer shall also indicate whether such equipment is already in use on machines elsewhere indicating the user railway system 18 0 SERVICE ENGINEERS AND OPERATIONAL BASE IN INDIA 18 1 The supplier after supply of machine shall establish a permanent operational base in India for providing necessary technical support in terms of the
13. wire at 5 5 m above rail level On bridges and tunnels the height is restricted to 4 8 m While working and moving on multiple Railway line sections it shall not infringe the adjoining track and it shall be possible to permit trains at full speed on that track During on tracking off tracking there should be no infringement with the adjacent railway tracks at level crossing Minimum spacing of track is 4 265 m The RCRV MFBW Machine or its any part shall not infringe adjoining track as per Schedule of Dimensions of Indian Railways during traveling or its welding operation including opening and closing of the work The tenderer shall submit the details of the off tracking and on tracking arrangement of the machine at level crossing duly showing the methodology of prevention of infringement to adjacent track WORKING MECHANISM amp FUNCTIONAL REQUIREMENTS RCRV MFBW MACHINE AS A WHOLE The machine shall consist of a Flash Butt Welding unit mounted and fixed on Rail Cum Road Vehicle capable of moving on road as well as on rail and performing Flash Butt Welding of rail joints both on track and on cess In addition to the Pneumatic tyres of Road vehicle the Rail wheels for movement on Railway track will be provided separately Page 4 of 43 3 8 3 9 3 10 3 11 3 12 4 0 4 1 The RCRV MFBW Machine shall be self propelled and capable of moving in both directions The welding unit of RCRV MFBW Machine shall be fixed on a manipul
14. 4 7 1 The test joint shall be supported on cylindrical or semi cylindrical supports having a diameter of 30 to 50mm and distance of one metre between them In case of 60kg 110 UTS head hardened rail joints the test span shall be 1 25 metre The mandrel diameter shall be between 30 to 50mm The mandrel axis should be perpendicular to the horizontal axis of the rail section and it should be positioned at the centre of the weld The weld shall be in the centre of the span and loaded in such a manner that the foot of the rail is in tension The load shall be uniformly and gradually increased The rate of application of the load should not exceed 2 5 tons sec The test joints shall withstand the minimum load and shall show minimum deflection as given in Table below without showing any signs of cracking or failure 4 7 2 The test weld shall withstand minimum transverse breaking load as indicated in column 4 at table given below The deflection at center at the actual transverse breaking load shall not be less than that specified in column 5 of the table VALUES OF MINIMUM BREAKING LOAD AND DEFLECTION IN TRANSVERSE LOAD TEST Rail Section Min Minimum Frequency of breakin deflection testing g load in mm at the center Stationary Mobile at the FBW Plant actual transverse breaking load 1 60 kg UIC 1 in 500 Grade 1080HH 60 kg UIC Grade 1080Cr tonnes 60 kg UIC 1 in 1000 90 UTS Page 29 of 43 Wi kg 90
15. 52 kg MM 72 UTS Sample joints for first 1 000 joints welded by mobile flash butt welding plant will be tested at frequency of 1 in 100 joints and subsequently at a frequency of 1 in 500 joints 4 7 3 Each transverse test shall be continued until fracture occurs or be terminated when force limit of the press is reached provided that the bend test values have reached the values given in above mentioned table For the later case the weld shall be notched to ensure that fracture occurs in welding zone and the test weld shall be fractured If the fracture occurs about the weld line the fracture surfaces shall be inspected The details of any weld imperfection shall be recorded Lack of bond shall not be permitted Flat spots shall not be considered to be lack of bond lf fracture occurs remote from weld the fracture surfaces shall be checked for the presence of die burn which if detected shall cause the process to fail approval lf fracture occurs within rail for reasons other than die burn then another test weld specimen shall be substituted for testing Five tested welds shall meet the requirement of given rail profile and grade specified in table given above 4 8 Macro examination Five 1 weld from each parameter welds in finished condition shall be sectioned for macro examination For macro examination a longitudinal vertical section shall be taken centrally down the vertical axis of full rail and extend 50mm each side o
16. MFBW Machine offered and furnish a detailed Technical Description of the same System sub systems and working mechanisms of the machine as per Para 3 and 4 in particular and all the items of the specifications in general shall be described in the Technical Description in detail along with the sketches to show the manner in which the requirements of the specifications are accomplished by the offered model of RCRV MFBW machine The tenderer shall furnish video compact disc showing the working of RCRV MFBW Machine in real time under field conditions Photographs of the RCRV MFBW machine offered and technical literature shall also be enclosed with the offer The photographs shall also show close ups of various working assemblies systems and the full RCRV MFBW Machine DESCRIPTION RCRV MFBW Machine shall be self contained and self propelled vehicle consisting of following components i Flash Butt Welding Unit ii Carrier Vehicle Rail cum Road Page 1 of 43 1 0 1 1 2 0 2 1 Carrier vehicle shall be made by converting Standard Road Vehicle of adequate capacity into Rail Cum Road Vehicle However Rail vehicle duly converted into Rail Cum Road Vehicle will also be accepted subject to clearance of such vehicle from road authority of India for plying on Indian roads up to Major District Road MDR standard Clearance certificate in this regard shall be submitted with the tender document Flash Butt Welding Unit mount
17. Rails manufactured by steel Authority of India Limited India with dispensations having letter D in the rolling mark may have a maximum difference in height of 1 5mm The difference in height shall be transposed to the foot of the rail 1 3 DIFERENCE IN WIDTH OF RAIL HEADS TO BE WELDED 1 3 1 The difference in the width of rail heads of two rails to be welded Shall not exceed 1 0mm for new and 2 0mm for old rails New rails manufactured by Steel Authority of India Limited India with dispensations having letter D in the rolling mark may have a maximum difference of 1 5mm in the width of rail heads For new rails it is preferable to restrict the difference in width of rail heads to 0 5mm by adopting procedure laid down in para 1 7 below Page 23 of 43 Any difference in the widths of rail heads at the welded ends in case of both new and old rails as a result of rolling tolerances in case of new rail and wear in case of old rails the rail ends shall be aligned in accordance with 1 3 3 and 1 3 4 below In case of welding in depot where it is not possible to determine the gauge face side exactly when laid in track during setting up of rails any difference in the width of rail heads at welded ends shall be transposed to one side of the head keeping the other side perfectly aligned The aligned side of such welded panels shall be distinctly marked with green paint on the web at both ends of the panel To facilitate pairing of
18. TECHNICAL SPECIFICATION OF MOBILE FLASH BUTT WELDING MACHINE GENERAL Current system of repair to weld failure or rail fracture in service track is done by Alumino Thermic AT welding process Performance of these AT weld joints is not found to be very satisfactory The latest technology of welding of rails is by Flash Butt Welding process It is therefore desirable to repair such weld failure on Indian Railway track also by using Flash Butt welding process so as to avoid repeated problem A fully self contain Flash Butt Welding Unit mounted on Rail cum Road Vehicle hereinafter called Rail Cum Road Vehicle mounted Mobile Flash Butt Welding Machine RCRV MFBW Machine is required to carry out this job The technical specification has been drafted to reflect the performance and quality requirements of the RCRV MFBW Machine in a neutral manner without bias to any specific manufacturer Bidders are requested to carefully study the specification and ensure that their equipment fully complies with these specifications Thereafter if a bidder feels that his equipment can substantially meet the performance and quality requirements laid down herein but does not fully satisfy a particular item of this specification he shall mention the deviations if any in the statement of deviation from the specifications giving the details how the functional requirements of this specification are going to be met with The bidder shall specify the model of RCRV
19. ace corner as reference line except as provided in 1 3 2 1 3 3 and 1 3 4 of Annexure IV 2 For the reason of asymmetry rails should preferably be welded with brand marks on same side Page 32 of 43 Annexure VIl BRAKE DESIGN DETAILS OF THE MACHINE FOR CALCULATION OF EMERGENCY BRAKING DISTANCE Tare amp gross weight of the machine in Kilograms Brake power in Kilograms Type of Brake blocks Brake block area in Square Centimetres Brake Rigging Diagram Type of Brake system Page 33 of 43 ANNEXURE VIII INSPECTION CERTIFECATE CERTIFECATE OF INSPECTION 0 Model INO aori JBY INSPECTING OFFICIAL AND APPROVAL FORDESPATCH OF MACHINE Strike out whichever not applicable This is to certify that have inspected the ss sess bearing Dl NO E from dalte at eles ee ee for its conformity non conformity with respect to the laid down Technical Specification on contract Agreement NO at ateeaeeer aces enenceacestoa dated 4 between the president of India through and M s Name of Contractor s ES The detailed inspection note regarding its conformity non conformity to the laid down specification is enclosed along with Annexure A It is observed that Strike out whichever is not applicable TNC n c
20. achine failing which the offered machine under consideration shall be rejected MARKING amp COLOUR OF MACHINE The machine body shall be painted in golden yellow colour Colour code to be ISC 356 conforming to RDSO specification No M amp C PCN 109 88 with latest amendment to minimum DFT of 80 mm Following should be written on the machine at appropriate location i Indian Railways logo of height between 300 mm to 600 mm as suitable on all four faces of the machine Page 18 of 43 21 0 22 0 22 1 22 2 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 i iii Below the text INDIAN RAILWAYS mentioned above Machine model and manufacturing year should be written in black colour and in letter of size less than the size in which Indian Railways is written but not less than 200 mm in any case lf the Manufacturers desire to write their name on the exterior of the machine the same may be written in size not more than 150 mm and should not be at more than four locations The Manufacturers Logo may be provided at not more than four Locations on the exterior of the machine and should be of size not more than 200mm KKKKKKKK Page 19 of 43 iv Page 20 43 7 0 3 UN Ni 39087 SNOISNSWIC 11 310O NIW 01
21. ance of axle box horn wheel flange rail and other locations f or the negotiability of the vehicle on curve and turn out enclose Vogels Diagram for negotiability on maximum degree of 8 9 Mia curve and turn out permitted on Indian Railways of new and worn out wheel Wheel and axle assembly drawings results designed Page 42 of 43 ACCEPTANCE CRITERIA DURING OSCILLATION TRIALS The speed potential of the machine offered by the firm should be established based upon oscillation trials conducted in India The tests will be conducted at a speed usually10 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 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 to assess the performance of the MFBW in oscillation trials will be as applicable in Indian Railways at the time of actual oscillation trials However the criteria applicable at present are given below 1 A lateral fo
22. at any cross section Where an infringement to Indian Railways Standard BG schedule of Dimensions metric 2004 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 vis safety and operation requirements of IR However condonation of an infringement in another Page 2 of 43 2 2 2 3 3 0 3 1 3 2 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 part infringes the minimum vertical clearance of 102 mm from rail level
23. ator which should be mounted on the rear end of the machine and should be secured to the vehicle frame It should have sufficient out stretch for welding of rails on track and also it should be capable of rotating sufficiently in both directions so as to also weld the rails placed in cess at minimum 3 m away from centre of track If required support from hydraulically operated out riggers fixed on the machine may be provided for stability of the machine during welding on cess These out riggers should be operatable from the main control panel as well as from a remote portable control panel wherever provided The RCRV MFBW Machine should be so designed that the welding head along with its rail clamping device rail pulling device rail aligning device rail lifting device weld trimming device and their manipulator with necessary control panels and other arrangements should be out stretchable from the container for welding work and can be retreated back into the container after completion of welding The complete operation of out stretching retreating and rotation of units should be hydraulically controlled The welding operation should be such that there is no infringement to over head electric equipment during welding head maneuvering extension shortening and there is no infringement to the Indian Railways Schedule of Dimensions 1676mm gauge BG Revised 2004 with up to date Addendum and Corrigendum slips lt should be possible to start
24. back gears The Carrier Vehicle in Rail movement mode should be compatible with IR track circuiting amp signaling installations Carrier Vehicle should have stabilizing arrangement to ensure higher stability while welding on track During welding the rail being welded should be released of the vehicle load Adequate capacity hydraulic jack out riggers should be provided separately for both left hand and right hand rail for this purpose These jacks out riggers should be fixed on the body frame of the vehicle and should be operatable from suitable location without any infringement to Schedule of Dimensions Page 9 of 43 4 2 4 28 4 29 4 30 4 31 4 32 4 33 4 34 4 35 4 36 4 37 4 38 Carrier Vehicle in Road movement mode should be provided with normal road braking system of the Road vehicle manufacturer The Carrier Vehicle of the RCRV MFBW Machine should have indigenous diesel engine prime mover with proven record of service in tropical countries Robust construction and low maintenance cost are of paramount importance There should be satisfactory service repair support facilities available throughout India Prime mover of adequate capacity should be ensured particularly if the same prime mover of Carrier Vehicle is being used for traction on rail and road The tenderer should submit the tractive effort verse speed characteristics and also give the tractive effort requirement calculations for various c
25. d brake blocks active on all rail wheels with an additional fail safe brake application arrangement In addition the RRCRV MFBW Machine shall be equipped with a mechanically pneumatically hydraulically operated parking brake system There should be provision of emergency brake application in the machine for working on Rail movement mode in addition to the normal braking system using the compressed air The firm should submit design calculation for the braking effort and EBD at the maximum design speed of the machine on level track and at falling gradient of 1 in 33 The brake design details are to be submitted as per Annexure VIl Emergency Braking Distance EBD on level track at maximum design speed shall not be more than 200 mirs On falling gradient of 1 in 33 it should not be more than 600 mtrs All braking systems shall be protected from ingress of water grease oil or other substances which may have an adverse effect on their performance All brake lining shall be suitable for high ambient temperature of 55 C The force required for operating the brake for rail wheel when moving on Rail movement mode shall not exceed 10 Kg at the handle while applying by hand and 15 Kgs on the pedal when applied by foot Air reservoir should be so designed as to meet the air reserve requirement for repeated braking under normal condition In Road movement mode the braking power should be adequate for the load of the vehicle and satisfy the provis
26. depot Total 4X25 100 In addition 10 test welds in 52 Kg 60 Kg 90 UTS rail section will be made in running track using pulling amp traction facility of the machine Welding parameters for acceptance test are to be decided by manufacturers Suppliers of the machine a Not more than one test weld of each type i e 60 Kg 90 UTS 52 Kg 90 UTS rail sections made in cess and in depot and 52 kg 60kg 90 UTS made in running track should fail in visual inspection weld trimming and upset examination step across the weld examination dimensional check and ultrasonic testing as per the provisions of Flash Butt Welding Manual Annexure V In case the failure is more than above specified limit one more set of equal no of similar type of test welds which have failed will be executed and tested for above mentioned parameters None of the test welds should fail in the re test conducted for above mentioned parameters or else the machine will be said to have failed to meet the specification and the machine will not be accepted Page 17 of 43 c 20 0 b If the test weld have passed the criteria mentioned in the Para a above 04 test welds of each type i e 60 Kg 90 UTS 52 Kg 90 UTS rail section made in cess and in depot and 02 test welds in 52 Kg 60 Kg 90 UTS made on running track shall be randomly selected for conducting hardness testing transverse load testing macro and micro examination as per the provisions of Flash Butt Welding Manual A
27. e machine should have a computer controlled temperature controlled cooling process based upon measurement of actual temperature with post weld heat treatment arrangements like quenching etc for welding of 1080 HH and 1080 Cr alloy rails Page 7 of 43 4 18 4 19 The welding head should be adequately designed so that it does not get heated up during continuous welding of minimum 50 joints A proper system should be provided for cooling of welding head Engine of adequate capacity for meeting the Flash Butt Welding requirement should be separately provided for welding operation High speed diesel oil conforming to Indian Standard Specification shall be normally used Unit should be equipped with quick change electrode inserts for various rail sections mentioned in Specification of Rails Unit should also be equipped with compressed air pistol to ensure that electrical contacts i e copper melloroy electrodes in the welding machine are free from loose oxides and other foreign matters so that no arcing takes place at the contact points on the rail The welding system should have self diagnostic software to allow easy maintenance and repair Unit should be able to meet with the welding requirements under the atmospheric and climatic conditions mentioned in 3 9 above 4 20 4 21 4 22 4 23 4 24 The machine should have the provision that parameter once fixed in machine by Railway Authorized person cannot be modified by the opera
28. ed on such carrier vehicle shall be with all necessary requisites attachments manipulator etc for carrying out all operations related to welding of rail joints as per Indian Railway s Manual for Flash Butt Welding of Rails Revised January 2012 with up to date Addendum and Corrigendum slips hereinafter called Flash Butt Welding Manual DIMENSIONAL AND OPERATING REQUIREMENTS The self driven diesel powered RCRV MFBW Machine shall be heavy duty robust reliable and suitable for working and travelling on the Indian Railways Broad Gauge Track 1676 mm gauge Quality assurance during manufacturing of the RCRV MFBW Machine shall be according to ISO 9001 The RCRV MFBW Machine shall be suitable for working on straight transition and curved track up to 10 on Indian Railways The profile of the RCRV MFBW Machine longitudinally and in cross section during transfer as self propelled vehicle on Railway track shall be within the Indian Railways Schedule of Dimensions 1676mm gauge BG Revised 2004 with latest corrigendum and up to date correction slips The maximum moving dimensions are shown in Annexure I The tenderer shall provide sketches of the RCRV MFBW Machine both in plan and elevation and shall give calculations for moving dimensions on 10 curve to show the extent of lateral shift at the ends centre and any other relevant cross section to prove that the RCRV MFBW Machine does not cause any infringement while moving on a 10 curve
29. f fusion line Similar section shall be taken from both sides of the foot 10mm in board of the foot tip The sections shall be polished to a Suitable finish using a minimum 220 grit paper One full depth rail sample and associated rail foot samples from each of the two welds shall be etched to show the weld boundary lines The etching agent shall be 5 10 Nitric Acid Etching at room temperature Page 30 of 43 shall be done for sufficient time 20 minutes maximum in order to show boundary lines clearly when examined These welds shall conform to following requirements a The visible heat affected zone shall be of a nominally symmetrical shape about weld line and fall within the width of 40mm maximum and 20mm minimum The permissible deviation between the maximum and minimum dimension of visible affected zone on any weld shall not exceed 5 mm This requirement shall apply equally to vertical axis cut through full rail depth and those taken from each rail foot b There shall be no evidence of lack of bond inclusion cracks or shrinkage Imperfections that cannot be positively identified by macro examination shall be inspected by micro examination c Incase that flat spots are found they shall be checked by micro examination at 100 X magnification If any cracks are found the process is rejected 4 9 Confirmatory Tests The joints showing minimum uniform amp parallel Heat Affected Zone with 5mm difference between widest and narro
30. heel dimension 3 Maximum design speed i Road vehicle converted to Carrier vehicle li RCRV MFBW Machine on Road 4 Weight i Weight of Road vehicle being converted to carrier vehicle li Weight of Flash butt welding Unit iii Weight of RCRV MFBW Machine 5 Technical detail of Road Vehicle being converted to Carrier Vehicle including engine capacity turning radius etc Page 41 of 43 Annexure XI Following information for Rail Moving mode as detailed below is also required along with the information required as per Annexure V A for processing the case for issue of provisional speed certificate for new vehicle Item b Gross Braking Ratio 3 Brake rigging arrangement drawing and calculation of braking force Maximum Braking Effort at start and at the speed of operation a at transfer drive at start at maximum speed Characteristics of springs used in suspension indicating free height working height dynamic range stiffness and locations etc 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 ili Rolling Wave length of free axle and bogie 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 clear
31. hicle where being converted to Rail Cum Road Vehicle carrier vehicle should be suitable to run on Indian Railways Network Carrier vehicle should be capable of moving on Road and Railway track when it will be said to be moving in Road Moving Mode and Rail Moving Mode respectively The Carrier vehicle for movement in Rail moving mode should have single axle in front for guiding and a bogie with two powered axle in rear for driving The wheels should be solid with or without rim and no spokes perforations are permissible For changing carrier vehicle from Road movement mode to Rail movement mode or vice versa hydraulic system should be provided for lowering and lifting of the front and rear Rail wheels and transferring vehicular load on these wheels When in Rail movement mode the complete load should be on Rail wheels and Road vehicle with welding units and other accessories along with its pneumatic tyres should be completely lifted above track Suspension lock should be provided for the suspended original Road Vehicle for securing the Road vehicle along with its unit In Road movement mode the rail wheel should be lifted and should have minimum clearance permitted as per Road Vehicle Act to avoid any infringement Rail Traction wheels of the Carrier Vehicle should be provided with hydrostatic drive The Carrier Vehicle in Rail movement mode if provided with mechanical drive should have minimum three speed front gears and three speed
32. ic and pneumatic circuit diagrams troubleshooting charts component drawings description and other relevant technical details as reference documents for the inspecting officer The firm shall provide detail technical drawings and specifications of wheels and axles used in a machine The above details shall be provided in four sets One additional set of all the manuals and diagrams drawings should also be sent each to the Track and TMM Directorate of RDSO Lucknow Track Machine Directorate of Railway Board and Director IRICEN Pune along with supply of first machine of similar group In case there is any subsequent amendment in any document based on field performance the amendment amended documents should also be sent to above mentioned authorities SPARE PARTS The tenderer should quote apart from main equipment separately for the mandatory spare as well as the recommended spares for two years of operation along with description part no quantity cost whether imported or indigenous The expected life of component shall be advised along with condemning limits The suppliers shall be responsible for the subsequent availability of spare parts to ensure trouble free service for the entire life of the machine as a whole 15 years MAKER S TEST CERTIFICATE Copies of the Makers certificate of different units guaranteeing its performance and the maker s certificate guaranteeing the performance of the Page 13 of 43 12 2 12 3
33. ions in motor vehicle act HORN AND SAFETY SWITCHES The RCRV MFBW Machine shall be provided with electric horns hooters facing outwards at each end of the RCRV MFBW Machine at suitable locations to warn the workmen of any impending danger at the work spot or from oncoming train These electric horns hooters shall be operatable from the cabin and the back end of the machine HOOKS AND BUFFERS The RCRV MFBW Machine shall be fitted with suitable arrangement like hooks etc on both ends A suitable transition coupler sufficiently strong and of design compatible to attach existing couplings in locos rolling stock of IR to the arrangement in RCRV MFBW Machine be provided for towing of the RCRV MFBW Machine Page 11 of 43 7 0 7 1 72 7 3 7 4 7 9 7 6 8 0 9 0 ELECTRIC EQUIPMENT AND LIGHTING The electrical fittings instruments including head lights to be provided on the Carrier Road Vehicle shall conform to relevant Motor Vehicle Rules For Rail movement mode additional twin beam headlight assembly to be provided conforming to RDSO Specification No ELRS SPEC PR 0024 Revision 1 Sept 2004 with the 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 each end with two front and rear parking lights which can be switched to red or white according to the direction of the travel Powerful swiveling floodlights shall also be provided to illumina
34. jected to ultrasonic testing for detecting presence of internal defects in the weld This test can be done by installing an on line USFD equipment or as an interim measure manually with portable USFD machine Entire cross section of the rail i e head web and foot shall be tested by trained personnel as per the procedure laid down for Ultrasonic testing of Flash butt welds in Manual for Ultrasonic testing of rails amp welds and its correction slips issued by RDSO Lucknow to detect internal flaws Welds having defects shall be rejected Defective joint shall be distinctly marked and panels with defective joints shall be separately stacked The defective joint shall be cut and removed before the panel is dispatched from the Flash Butt Welding Plant Another panel of matching length should be welded and the short panels minimum 3 rail lengths dispatched in pairs Hardness Testing Brinnel hardness test shall be conducted on the test weld samples before conducting transverse load test The hardness value in HAZ shall not vary from the hardness of the parent rail by more than 20 HB The location of hardness test shall be as under Fusion Line Location of Hardness test shown as small circles Page 28 of 43 4 5 4 6 4 7 Transverse Testing Five welds 1 weld from each parameter in as welded condition having met the requirement of 4 1 to 4 6 shall be subjected to transverse test in accordance with procedure given below
35. le At maximum design speed Method of operation Whether single only or coupling together is possible If coupling is possible the number which can be coupled and what is trailing load Maximum tractive effort at start and at the speed of operation i at transfer drive at start ii at maximum speed Maximum braking force coming on to the rails per wheel a at transfer axle Drawing indicating suspension arrangement details of bogie and axle Height of centre of gravity from rail level Height of floor from rail level Type of coupler provided Indian Railways Standard Coupling or different should be clarified Any infringement to the moving dimensions as given in Annexure l Page 40 of 43 10 11 12 13 14 15 Annexure X B Particulars Required in Respect of the RCRV MFBW Machine Under Consideration in Road Movement Mode 1 Sketch showing plan elevation of Road vehicle being converted to Carrier vehicle l Overall length of the Road vehicle li Wheel base li Overall height iv Overall width v Clearance over plain Road vi Wheel spacing 2 A sketch showing plan elevation of RCRV MFBW machine After road vehicle is converted to RCRV MFBW machine with salient dimensions i Overall length of the carrier vehicle li Wheel base li Overall height iv Overall width v Clearance over plain Road vi Wheel spacing vil Axle load on each axle 2 Road W
36. nnexure V None of these test welds should fail in the above tests In case of any failure another set of four similar type of test welds which have failed shall be randomly selected from the above prepared welds and the test shall be repeated None of the welds should fail in the re test so conducted In case of any failure the machine will be said to have failed to meet the specification and the machine will not be accepted c At the time of preparing the test welds 10 welds made in cess and 04 welds made on running track will be considered for measuring the output of the offered machine Average time required in complete welding operation from start to finish including trimming for one rail joint prepared in all respect excluding post weld heat treatment wherever required and rail track related preparatory works should not be more than 5 minutes d At the time of preparation of test welds on running track the traction and pulling capacity of the machine shall be verified and should meet the provision of Para 4 12 of this specification The machine shall be commissioned after pre commissioning test within 90 days of its arrival at the final consignee end should any modification be found necessary as a result of the tests these shall be carried out once by the supplier at his own expense after which the modified machine shall again be subjected to relevant tests mentioned in this specification for confirmation and acceptance of the m
37. of tools to be provided shall also include all tools necessary for maintenance and repair of the entire RORV MFBW Machine including specialized equipment All special tools shall be listed and catalogued illustrating the method of application Page 12 of 43 10 0 11 0 11 5 12 0 12 1 Detailed operating maintenance service and major assembly component overhauling manuals shall be specifically prepared in English language and four copies of these shall be supplied with each machine As a part of service manual the manufacturer shall also supply circuit diagram of electrical hydraulic pneumatic and electronic circuits used on the machine Troubleshooting diagram table shall also be supplied In additions the manufacturer shall provide dimension drawings with material description of items like rubber seals washers springs bushes metallic pins etc Performance specification working parameters and standard part numbers with supplier name of items like hydraulic pumps motors and such other bought out components assemblies shall be furnished by the tenderer This Shall be in English language and four copies of these shall be supplied with each RCRV MFBW Machine While offering the RCRV MFBW Machine for first inspection the supplier shall submit one copy of complete technical literature in English language including operation service and field maintenance manuals instructions Spare catalogue and complete electric electrical hydraul
38. onfiguration to assess the prime mover adequacy High speed diesel oil conforming to Indian Standard Specification shall be used A minimum fuel tank capacity sufficient for continuous operation for 8 hrs and minimum 100 joints will be desirable GUARANTEE CLAUSE In addition to the special conditions of contract dealing with warranty the following will apply should any design modification be made in any part of the equipment offered the period of 24 months would commence from the date of the modified part is commissioned in service for the purpose of that part and those parts which may get damaged due to defects in the new replaced part the cost of such modification should be borne by the supplier COOLING SYSTEM The cooling system shall be efficient and designed for maximum ambient temperature of 60 C Supplier may note that the RCRV MFBW Machine shall be working under extreme dusty conditions and the cooling mechanism should be maintainable under these conditions for all prime movers Adequate heat transfer arrangement for the hydraulic system shall be designed and provided so that under extreme heat conditions as mentioned in 3 9 above the temperature of system oil does not go beyond limit recommended by Oil Company Page 10 of 43 4 39 4 40 4 41 4 42 4 43 5 0 6 0 6 1 6 2 BRAKES The RCRV MFBW Machine for working on Rail movement mode shall be equipped with pneumatically hydraulically operate
39. onforms to all the laid down Specifications e fhe ee conforms to all the laid down Specifications except those at SI NO s sss e The above deviations are minor major affecting not affecting the performance of the equipment machine vehicle in substantial way The following T amp P manuals drawings are to be supplied along with the machine 1 ee ee Based on the above the Z sss is certified not certified to be conforming to the specifications 85 6 OO eS is approved not approved for 015081650 to eee consignee Indian Railway For M s SIGNATURE AND DATE ee C INSPECTING OFFICIAL a fy NAME AND DESIGNAQTION for and on Behalf of President of India Page 34 of 43 Annexure IX Machine details required for simulation of machine on NUCARS or similar Track vehicle simulation software Parameters required C G of component in x y Z Mass in Kg and Mass moment of inertias in Kg 2 of Component s Name direction from rail level in mm Referenced point 1 axle omponent in three dimension space about their C G x F ew eer WN 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 Page 35 of 43 SL NO
40. own below The deviations shall be marked on the rail head so that rails with same or minimum relative deviations are selected for welding Page 24 of 43 1 3 2 1 3 3 1 3 4 1 5 1 1 6 1 7 60 Kg UIC TO BE STAMPED HERE 50 0 5 0 HEAD WIDTH CHECKING GAUGE FOR 60 Kg UIC RAILS DIMENSIONS SHOWN IN BRACKETS ARE FOR RAILS MANUFACTURED BY SAIL WITH DISPENSIONS ALL DIMENSIONS ARE IN MILLIMETRES Page 25 of 43 _ 52 TO BE STAMPED HERE 50 0 5 22 68 A 67 5 HEAD WIDTH CHECKING GAUGE FOR 52 Kg RAILS DIMENSIONS SHOWN IN BRACKETS ARE FOR RAILS MANUFACTURED BY SAIL WIT DISPENSATIONS ALL DIMENSIONS ARE IN MILLIMETRES Page 26 of 43 Annexure V Procedure for Standardization of Welding Parameters 1 Procedure approval shall be carried out by RDSO for each individual machine no type approval by testing weld samples produced in accordance with procedure enumerated below 2 Quality Assurance Programme QAP of each individual welding plant shall be submitted to RDSO through concerned Railway administration who shall scrutinize and approve by ensuring compliance of this manual 3 Sample Preparation The samples shall be prepared from rail pieces having ends conforming to tolerances mentioned in para 1 4 of Annexure IV Before welding end faces to be welded and electrode contact area shall be thoroughly cleaned of loose scale rust paint etc by brushing
41. rades 880 C Mn Cu Mo Ni Cr Cu Niobium Vanadium and 1080 HH Cr continuously to form LWR CWR in situ or on cess or long rail panels in depot The welding unit should have a trimming arrangement as an integral part of the unit so that it can trim the excess upset immediately after welding The weld should be in compression during trimming and removal of excess upset The trimmer should have the capability to trim excess hot upset metal all round the rail section in such a way that minimum grinding is required to achieve final finished profile at weld as prescribed in Flash Butt Welding Manual which is enclosed herewith as Annexure lIll The maximum thickness of trimmed surface shall be in accordance with provisions of item v of Part A amp B of Annexure lll lt should be dual purpose unit that can be locked to do normal welding and also should have the capability of getting auto extended amp using an integral rail pulling arrangement to do long closure welding up to minimum 200 mm of traction amp 150 Ton minimum traction force The Unit should be able to do on track welding to repair rail gap with without use of a rail pulling arrangement as per site requirement Rail pulling arrangement should be integral part of the welding unit and should not be provided separately Rail pulling arrangement should be capable of generating adequate pulling force for doing in situ welding in existing LWR CWR tracks at required temperature
42. rce lasting more than 2 metres should not exceed the Prud Home s limit of 0 85 1 P 3 tonnes where P is the axle load in tonnes 2 Isolated peak values exceeding the above limit are permissible provided the record shows stabilizing characteristics of the vehicle subsequent to the disturbances 0 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 of Hy Q shall not exceed 1 4 The values of acceleration recorded in the cab at location as near as possible to axle shall be limited to 0 55 g both in vertical and lateral directions The peak values up to 0 60 g may be permitted if the records do not indicate a resonant tendency in the region of peak value 5 In case of such vehicles where measurement of forces is not possible evaluation shall be in terms of ride index based on the accelerations measured as detailed in para 4 above which shall not be greater than 4 50 but a limit of 4 25 is preferred 6 A general indication of stable running characteristics of the whole vehicle as evidenced by the movements of the bogie in straight station yard and curved track and lateral force and derailment coefficient or accelerations as the case may be Page 43 of 43
43. support drawing Details of centre pivot arrangement working Provide detail arrangement drawing and description location Concerning with general arrangement of vehicle bogie general arrangement suspension arrangement details suspension clearances drawing detail written description of configuration and loading pattern accompanies design particular of vehicle bogie Set of drawings and design description Page 38 of 43 Annexure X A Particulars Required in Respect of the RCRV MFBW Machine Under Consideration in Rail Movement Mode A diagram showing elevation salient dimensions Wheel spacing Wheel diameter bogie centers and axle load i Over all length of the vehicle li Length overhead stock i Wheel base li Axle load max iii Bogie Centers Rail Wheel dimension 1 New ii Worn out 1 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 flange Whether the stock is designed to be used as a general purpose or ina closed circuit in specified sections under defined conditions Maximum design speed 1 Own Power ii In train formation clearly stating if it can move in train formation or not Unsprung weight per axle in tonnes I Driving axle ii Running axle Page 39 of 43 1 Expected lateral force on rails in tonnes per ax
44. t least 4 weeks in advance of the date of inspection i 006 copy of complete technical literature mentioned in clause 12 in English language including operation service and field maintenance manuals instructions and complete electrical hydraulic and pneumatic circuit diagrams trouble shooting charts component drawings description and other relevant technical details as a reference documents for the inspecting officer li Cross section of the machine super imposed on IR maximum moving dimensions envelope shall be provided to Inspecting Officer in advance iii Clause by clause comments of the manufacturer on this specification to be sent to Inspecting Officer IO in advance for his review Comments should state manufacturer s conformity compliance of each of the requirement stated in each clause elaborating wherever necessary the details manner in which the requirement has been complied The proforma for the clause wise comments is given below Page 14 of 43 15 0 16 0 16 1 16 2 16 3 Clause Clause Comments of Comments No Supplier manufacturer Inspecting Officer iv Manufacturer s Internal Quality Inspection Report of the machine v Manufacturers 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 16 4
45. te the working area sufficiently bright for efficient working on railway track during night The amber color flasher lights at both ends shall be provided in the RCRV MFBW Machine to give indication for the train arriving on other line when working on track about any impending danger CABIN All operations for travel shall be controlled from a spacious fully enclosed cabin with safety glass permitting unobstructed view and movement in both directions in Rail movement mode For additional visibility during movement in reverse direction CCTV or any other suitable and adequate arrangement may be provided The details of arrangement for visibility during reverse movement should be submitted with the offer In view of the high ambient temperature prevailing in India special attention should be paid to free circulation of air and ventilation in the drivers cabin Cabin fans of adequate capacity shall be provided in the cabins Seating arrangement for 4 persons in addition to the driver shall be provided in the cabin Fire extinguisher dry chemical type shall be provided in the cabins The Machine shall be provided with adequate space for keeping the tools equipments and spares required for on site repair of the machine and other working requirements TOOLS AND INSTRUCTIONS MANUALS Each RCRV MFBW Machine shall be supplied with a complete kit of tools required by the operator in emergency and for normal working of the machine The list
46. tor Welding parameters for different section amp metallurgy of rails used in Indian Railways shall be given by OEM Original Equipment Manufacturer with machine catalogue However before executing actual welding work welding parameters are to be fixed by RDSO as per provisions of Para 5 6 of Flash Butt Welding Manual attached herewith as Annexure V Once rails clamped and ready for welding the operator should have nothing to do after weld cycle starts except wait for the weld to complete and the software should facilitate auto incorporation of the date and timing of welding from computer memory and this data should be un editable The unit should be able to align the running surfaces of two rails at interface avoiding any step defect as per the provisions of Flash Butt Welding Manual attached as Annexure VI CARRIER VEHICLE RAIL CUM ROAD The Road Rail vehicle which is to be converted as carrier vehicle should be of robust design with capacity and chassis of sufficient length amp strength for carrying Flash Butt Unit The firm should submit the sketch and technical detail of this carrier vehicle The chassis should be strong enough to take reversal of stress likely to be generated when changing from rail vehicle mode to road vehicle mode and vice versa Page 8 of 43 4 25 4 26 The road vehicle where being converted into carrier vehicle should be of reputed make with proven credential and should be Euro III Compliant Rail Ve
47. urface centre of a 10cm straight edge v Web zone under side of 3 0 mm of parent head web top of base 0 0 mm contour and both fillets on each side vi Upper sides under surfaces and edges of rail foot shall be ground smooth The edges of foot should be rounded and bottom of rail foot ground smooth without any minus tolerances to ensure proper seating on sleepers unhindered movement of welded panels on end unloading rakes avoid damage to elastic rail pads and eliminate stress riser vil The above tolerances are finished tolerances of welds inclusive of tolerances of rail Page 22 of 43 ANNEXURE IV SUITABILITY OF RAILS FOR WELDING 1 1 OLD RAILS 1 1 1 Permissible vertical wear of rails to be welded The vertical wear in old rails to be welded shall be within the limits specified below Rail Section Standard height of Minimum height of the new rail worn rail 60kg 172 00 mm 164 mm 1 1 2 Permissible lateral wear of rails to be welded Old rails to be welded shall preferably show similar pattern of side wear and the minimum width of rail head shall be as specified below Rail Section Standard width of the Minimum width of the head of new rail head of old rail 60kg 72 00 mm 66 mm 1 1 3 Rails with cyclic wear shall not be welded 1 2 DIFFERENCE IN HEIGHT OF RAIL ENDS TO BE WELDED The individual rail ends for new rails may have a maximum difference in height of 1 2mm at the welded joints
48. visional speed certificate is issued by RDSO based on certain design parameters of the vehicle The firm shall submit design data as per Annexure IX 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 Current suppliers whose models are approved The supplier shall give details of the model year of introduction in Indian Railway details of speed certificate issued etc The supplier shall certify that no change has taken place in the model being offered with respect to design of under carriage i e Suspension system arrangement wheel amp axle assembly bogie braking arrangement loading pattern of the vehicle etc and the distribution of axle loads lateral forces un sprung mass and braking force coming on rails is the same If there is any change in above respect the action shall be taken as detailed in para b below Current suppliers whose models are new and not approved As soon as the supplier completes the design of the machine as per Specifications the technical details as per Annexure X A X B amp XI shall Page 16 of 43
49. welding by the RCRV MFBW Machine at site within five minutes of its arrival including fixing of out riggers etc wherever required The time required in complete welding operation from start to finish for one rail joint excluding the time taken for post weld heat treatment wherever required and all rail track related preparatory works should not be more than 5 minutes The system should be fitted with an emergency backup arrangement to windup the welding unit and retract the unit and its manipulators into the container in all respect for cancellation of traffic block in the shortest possible time say 10 minutes All hydraulic hoses should either be fire proof or contained in fire proof sleeves FLASH BUTT WELDING UNIT All components of Flash Butt Welding units should be housed in a self contained enclosure lined and insulated with fire retarding sound proof Page 5 of 43 4 2 4 3 4 4 4 5 4 6 4 4 8 4 9 material and automatic fire protection system in the engine compartment It should be suitable to be used for depot welding on track welding weld renewal replacing fractures cess welding and cess welding at construction sites The RCRV MFBW Machine should be designed to weld rails of various sections and metallurgies specified in Indian Railway s Standard Specification for Flat Bottom Rails IRS T 12 2009 with up to date Addendum and Corrigendum slips hereinafter called Specification of Rails viz 60 52Kg of g
50. west points along with satisfactory mechanical test results will be considered satisfactory By using welding parameters of above satisfactory joints again 6 joints shall be made Out of these 3 joints shall be subjected for Transverse Testing and remaining 3 joints for Macro Examination after having met the requirements of 4 1 to 4 6 All 6 joints shall pass the requirements 4 10 Micro examination Following completion of macro examination a micro examination shall be carried out of one of the three welds taken for macro examination having maximum HAZ during contirmatory joint making The micro sample 15mm high and 25mm wide it includes 2mm on one side of fusion line and 23 mm on other side of fusion line shall be drawn from the foot 3mm above rail foot bottom surface The microstructure shall be free from martensite and bainite and grain size shall not be coarser than ASTM 4 at 100X magnification 5 Approval of other rail profiles or grades 5 1 Following the initial approval with particular rail profile and grade other rail profiles and other rail grades as contained in IRS T 12 shall be undertaken for approval as and when required 5 2 Approval tests For approval of each rail profile and grade samples shall be tested in accordance with para 4 above Page 31 of 43 Annexure VI RAIL ALIGNMENT 1 The running surfaces of rails at interface shall be aligned carefully to avoid any step defect generally keeping gauge f
51. while traveling on track The axle load and other dimensional requirement of RORV MFBW Machine shall comply with Motor Vehicles Act 1988 and the Central Motor Vehicles Rule 1989 with latest amendments if any for plying on Indian roads The maximum safe axle weight as per the latest rule is reproduced below for guidance Tonnes Single axle single wheel fitted with 1 tyre 3 0 Single axle fitted with 2 tyres 1 Single axle fitted with 4 tyres Single axle fitted with 8 tyres The Road vehicle used should be Rigid vehicles The RCRV MFBW Machine when moving on track should be able to operate on the axle counters and track circuits used on Indian Railways system and the diameter of the rail wheels shall not be less than 730 mm The minimum worn out wheel diameter permitted is 710 mm The worn out wheel diameter based on the criteria of rail wneel contact stresses for various maximum axle loads on IR rolling stock are as under Maximum Axle load tonne Minimum worn out wheel diameter mm When travelling on track it shall be capable of negotiating curves up to 10 curvature 1 76 m radius super elevation up to 185 mm and gradients up to 3 The supplier shall specify the minimum attainable speed under the above limiting Conditions which in any case shall not be less than 20 kmph The Rail Wheel Profile shall be as per Indian Railways Standard Wheel Profile provided in Annexure ll Page 3 of 43 3 3 3 4
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