technical specification of muck disposal unit - rdso
Contents
1. iv If the Manufacturers desire to write their name on the exterior of the machine the same may be written in size not more than 150 mm and 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 19 0 ACCEPTANCE TEST Page 12 of 24 20 0 21 0 22 0 In addition to verification of the various items of specifications covered earlier the following tests should be carried out in the purchaser s premises by the purchaser s nominee at the time of commissioning of the machine Dimensional check of loading gauge i e maximum moving dimensions buffer heights bogie distance length of machine and clearances at curves etc Engineering and construction of the machine Testing for negotiability of 10 curve and 1 in 8 1 2 turnouts for the first machine Running speed test on the Indian Railwa per Annexure ll on the first machine The capacity of muck disposal uni comply with minimum requireme above on the first machine The conveying output of pletely unloading a fully loaded unit to comp i nts mentioned in main line will carried out as imensional measurements to ed in para 3 8 described e and winding up time of the machine shall be e total time taken by the two operations of setting up y modification be found necessary as a result of the test these should be carried out by the s2. RDSO as well as the Inspecting offi he first machine OPERATORS The number of operators llied staff for wor f machine under normal condition should be minimum qualifica SPARE PARTS advised along with their oe supplied with necessary 2d or indigenous The manufacturers e subsequent availability of spare parts to vice for the life of the machines 15 years bected to quote for optional equipment if any separately S giving the advantages functions of such optional equipment Tenderer shall also indicate whether such equipment is already in use on machine elsewhere indicating the user railway system 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 machine s conformity non conformity issue in respect to each item shall Page 9 of 24 14 2 14 3 vi vii be jointly recorded before issue of the inspection certificate and approval for dispatch of the machine as per Annexure Ill 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 In order to check Maximu
3. Page 16 of 24 Annexure IVA Particulars Required in Respect of the Rolling Stock Under Consideration A diagram showing elevation salient dimensions Wheel spacing Wheel diameter bogie centres and axle load i Over all length of the vehicle ii Length over head stock iii 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 Centres Wheel dimension i New ii Worn out i Tread and flange profile of the indicating clearly Railway standard Expected lateral force in tonnes per axle 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 Page 17 of 24 Maximum tractive effort at start and at the speed of operation i at working drive at start at operation speed ii at transfer drive at start at maximum speed Maximum braking force coming on to the rails per wheel a at working axle b at transfer axle Drawing indicating suspension ar of bogie and axle Height of centre of gravity from rail le Height of floor from rail le Type of coupler provided Ind Page 18 of 24 Annexure IVB Following information as detailed below is also required along with the information required as per Annexure A for processing the case for issue of provision
4. as near as pto 0 6 g may be permitted if the records ant tendency in the region of peak value shicles where measurement of forces is not aluation shall be in terms of ride index based on the asured as detailed in Para 2 iv above which shall not 5 but a limit of 4 25 is preferred ation of stable running characteristics of the vehicle as evidenced by the movements of the bogie in straight and curved track and lateral force and derailment coefficient of accelerations as the case may be Page 15 of 24 ANNEXURE Ill INSPECTION CERTIFICATE CERTIFICATE OF INSPECTION OF TRACK MACHINE BY INSPECTING OFFICIAL AND APPROVAL FOR DESPATCH OF MACHINES STRIKE OUT WHICHEVER NOT APPLICABLE This is to certify that have inspected the machine type bearing SI No from date to at Place for its conformity non conformity with respect to the laid down Technical Specifications in contract Agreement No dated between President dia through Director Track Machines and M s Name of Supplier The detailed Inspection Note regardin laid specifications is enclosed along with a out whichever is not applicable ity non conformity to the is observed that strike e The Machine conforms to all the laid SI No e The above deviations are m the equipment in substantial we The following T and P ma SIGNATURE AND DATE INSPECTING OFFICIAL NAME AND DESIGNATION For M s for and on Behalf of President of India
5. machine Page 4 of 24 3 6 It should be possible to unload discharge the material on either side of the track beyond cess at a distance of not less than 5 meter from the centre of the track into a Railway wagon or a lorry Truck by the side of Railway Line 3 7 While working in series it should be possible to unload all units simultaneously or to unload all units only through the leading units by transferring the material from one unit to the other 3 8 The capacity of muck disposal unit should not be less than 65 m The pay load it can carry should not be less than 95 tonne A fully filled unit should be capable of fully self unloadi 10 to 15 minutes time Tenderer should furnish details of di ns along with calculation to show the carrying capacity of the m volume of 50 cum Officials to load ight of material 3 9 Marking on inside face of th 55 cum 60 cum and 65 cu material upto different volume for ensuring total pay lo whether the vehicle ed to its full pay load capacity echanism on the machine so that Cleaning Machine Shoulder Ballast 3 12 It should have independent power source i e Diesel engine for working its own system except for haulage The diesel engine should be installed in a covered area to protect it from bad weather dust and rain 3 13 The tenderer may be required to show the working of his machine under field conditions The names of countries where such demonstrations will be feasible shall b
6. rigging 2 3 Rear Bogie frame including brake rigging Page 20 of 24 Transmission system device hydraulic Mechanical or electrical traction motors Wheel axle set including axle boxes which constitute the unsprung mass Mass of ltems included in unsprung mass partially or fully along with their name per Total unsprung mass tonnes in Page 21 of 24 axle Total weight of components in Front assembly bogie full Rear bogie full assembly Full weight of vehicle front bogie rear bogie vehicle car body or super structure 7 tonnes Primary y suspension element stiffness per Suspension stiffness details e between bogie and machine frame in Kg mm 8 a Vertical stiff Lateral stiff UL stiff Damping force details 9 If hydraulic damper used give there rating force per meter second 10 Clearance in mm or radian Longitudi Rotation Rotation Rotation about l Vertical Lateral ae provided for motion between nal about vertical about lateral longitudinal Page 22 of 24 bogie frame and machine frame for relative motion motion stopper direction direction direction axis axis axis 11 Dimension of location of suspension elements n of suspen
7. shall be coupled to the main gearbox through a flexible coupling The engine shall be mounted on suitable Anti Vibration Mountings HORN AND CONTROL PANEL The machine should be provided with electric pneumatic horn at suitable location to warn the workmen of any impending danger at the work spot distinctly audible from a distance of at least 400 meters from the machine The horn should be operated by means of push button provided on the Page 6 of 24 body of the machines at suitable locations and also from all portable control panel connected by flexible cable to the machine The portable control panel should also have control switches for the operation of bottom and swiveling conveyors 52 Machine shall be provided with emergency backup system to retract the disposal conveyor to its normal position in the event of failure of prime mover or power transmission system of the machine 6 0 LIGHTING The machine should be equipped with swiveling lights at both the ends for movement and for lighting the wor area working unit during night working Also it should have nt and rear parking lights which can be switched to red or whi ording to the direction of the travel at each end 7 0 BRAKES brakes system be protected echanical brakes shall also as well as for parking The chassis shall be of standard welded steel sections and of steel sheets so as to permit transportation of the machine in train formation without endange
8. 1 0 1 1 2 0 TECHNICAL SPECIFICATION OF MUCK DISPOSAL UNIT 1676MM GAUGE Specification No TM HM MDU Spc 01 GENERAL After mechanized screening of ballast on Indian Railways the muck spoil is usually thrown on the slope of the formation through the waste conveyors of ballast cleaning machines BCM or SBCM However the muck has to be necessarily collected in a muck disposal unit connected to the BCM SBCM when screening ballast on multiple line sections or in cutting or in areas where space by the side of the track is limited It is also essential for such muck disposal unit t le to self unload itself into similar units coupled in series to continuous working of the BCM SBCM It should be possibl the muck into a wagon either on the adjacent track or r in a lorry by the side of the track or on the slope o This technical specification h he performance and quality requirements of suc in after called machine reflect the performance and tral manner without bias to eels that his machine can ce and quality requirements of the fy a particular system specification e statement of deviation from the ow the functional requirement are going model offered and furnish a detailed technical machine System sub systems of the working machine shall be as per para 3 0 in particular and all sketches to show the manner in which the requirements of the specifications are accomplished by the machine model offered T
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10. al speed certificate for new vehicle S no Item 1 a Brake System details b Gross Braking Ratio 2 Brake rigging arrangement drawing and calculation of braking force 3 Maximum Braking Effort at start and at t eed of operation a at working drive at start at operati b attransfer drive at start at 4 Characteristics of springs u i ting free height working height dynamic range stiff 5 Characteristics of the damper ping factors and locations of dampe Calculation of the fo J he vehicle to be attached i Bouncing ji iii Calculation of natural frequency 12 Calculation of spring characteristics and critical speed of the vehicle 13 Simulation result showing ride index lateral force and acceleration results 14 A certificate regarding the speed of the vehicle for which it has been designed Page 19 of 24 Machine details required for simulation of machine on NUCARS or simil Annexure IV C k vehicle simulation software Parameters required C G of component in x oment of inertias in Kg 2 a Component s Name i ension space about their NO 0 mm Referenced poi u axle X lyy Izz Super structure with vehicle 1 frame machine structure kept on secondary suspension of front and rear bogie Front Bogie frame inc brake
11. e indicated in the offer 4 0 DIESEL ENGINE Page 5 of 24 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 9 5 0 5 1 The machine should be powered by diesel engine with proven record of service in tropical countries and wide service network in India Adequate allowance should be made for de rating of the diesel under most adverse climatic conditions The engine should be able to unload the fully loaded muck disposal unit in ten to fifteen minutes at 70 rated capacity The supplier should furnish the information regarding make and model of the engine proposed to be used and details of agency which will provide after sales service support and availability of spares in India High speed diesel oil to Indian Standard Specification shall be normally used Sufficient fuel storage for continuous operation for minimum eight hours shall be provided Sight glass type fuel measuring gauge provided on the fuel tank conditions the dust through ges like temperature rom and lube J type mounted on the engine backed up Electronic gauges display system in the he absolute readings along with safe limits ere shall be audio visual warning safety mechanism ase of any of the parameters exceeding the safe limit n circuit in case of operator s failure to respond Suitable and rugged mechanism should be provided to start the prime mover at no load and gradual loading after the start of the prime mover The engine power take off
12. er keeping in view the Inspecting Officer s comments if any List of documents to be annexed in the draft Inspection Report should include i Makers Test Certificate ii Manufacturers Internal Quality Inspection Report iii Quality Certificates of Bought out assemblies sub assemblies iv Cross section of the machine super imposed on the IR MMD v Vogel s diagram vi List of spare parts to be dispatched along with the machine vii List of tools to be dispatched along wi vii List of Manuals Drawings Spa dispatched along with the machi sets of each These above documents shal i pection report rts Catalogues etc to be ly indicating the number of In addition to the special con following will apply The machine shall b months from the date of issioni proving test of equipment or in India which ever shall be ngine hours which the of muck spoil Should 2 the equipment offered the ce from the date of the modified part is pose of that part and those parts which ed by RDSO based on certain design parameters of d clearance of the vehicle is given after conducting Therefore issue 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 wh
13. he tenderer shall furnish a compact disc computer enabled or DVD or USB showing the working of machine under field conditions Also Photographs of the type of machine in working mode shall be enclosed with the offer The photographs shall also show close ups of various working assemblies systems and the full machine DIMENTIONAL AND OPERATING REQUIREMENT Page 1 of 24 2 1 2 2 2 3 2 4 25 The Machine should be robust and suitable for working on Indian Railway broad gauge track The design and dimensions of the machine components shall be to metric standards Quality assurance during manufacturing of the machine shall be according to ISO 9001 The machine shall be suitable for working on straight transition and curved track up to 10 on broad gauge 1676mm of Indian Railways The profile of the machine longitudinally and in cross section during movement duly towed in train formation shall be within the maximum moving dimensions shown in the Indian Railways Standard BG schedule of Dimensions metric 2004 print and is enclosed as Annexure l The tenderer shall provide sketches of the machine in plan and shall give calculations for moving dimension on 1 rve to show the extent of lateral shift at the ends centre and an r relevant cross section and to prove that the machine does not c ringement while moving on a 10 curve at any cross section Where an infringement to i rd BG schedule of Dimensions metr
14. ic 2004 i i cessary by the ments of IR the same shall be rchaser and decision of the acceptance of any such gn details in the offer is al decision will be taken by the deration of machine design for issuing nave condoned certain infringements to deration of their design features vis a vis quirements of IR However condonation of an e shall be allowed so that no component infringes the minimum ve clearance of 102 mm from rail level while travelling Axle load of the machine shall be lesser than 20 32 T t with minimum axle spacing of 1 83 m Load per metre shall not exceed 7 67 t Axle loads upto 22 82 tonnes and 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 by IR RDSO based on design data submitted by the firm as per annexure IVA B amp C and decision of IR RDSO shall be final in this regard Normaly the stocks running on IR are two axled or three axle bogie stocks For new combinations of axles bogies the supplier shall submit Page 2 of 24 2 7 2 8 2 9 the necessary technical detail in order to evaluate the offerered design for its suitability with respect to stresses generated on Indian Railway track and Bridges If considered necessary by IR prior technical approval of RDSO may be required before issue of the purchase order finalization of the contract It shall have a mi
15. l be These shall be ur copies of these shall for operation servicing e shooting along with his offer The list can be aser s requirement while examining the offer 2 machine for first inspection the supplier shall submit one cor nplete technical literature in English language Including complete electiical hydraulic and pneumatic circuit diagrams trouble shooting charts component drawings description and other relevant technical details as a reference documents for the inspecting officer One set of all the manuals and diagrams should be sent to the Principal IRTMTC Allahabad one set to ED TM RDSO Lucknow one set to DTK MO Railway Board and one set to Director IRICEN Pune alongwith supply of first machine In case there is any subsequent amendment in above documents based on field performance the Page 8 of 24 11 0 13 0 14 0 14 1 amendment amended documents should also be sent to above mentioned authorities The firm shall provide detailed technical drawings and specifications of wheels and axles used on the machine The above details shall be provided in four sets with each machine A draft copy of all documents to be supplied with the machine 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 ance should be reported to
16. m 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 inspecti cial The following documents shall be pro 4 weeks in advance of the date of i Inspecting Officer at least One copy of complete technic ause 10 in English language including maintenance manuals instructions and comple i d pneumatic circuit diagrams troub ponent drawings description and other relevant te eference documents for the inspecting officer gt manufacturer to be sent to Inspecting review Comments should state ce of each of the requirement stated Comments of Comments of Supplier manufacturer Inspecting Officer Manufacturer s Internal Quality Inspection Report of the machine Manufacturers quality certificate and or test reports for bought out assemblies sub assemblies to be provided to IO containing serial number wherever applicable Draft Inspection Report to be prepared by the manufacturer containing all annexure mentioned at para 14 4 Details of arrangements made for checking Maximum Moving Dimensions for his approval Page 10 of 24 14 4 15 0 Warranty a Supplier will incorporate amendments further clarification in the above documents to the satisfaction of the Inspecting Offic
17. m rail temp 70 C 2 10 It shall be capable of working without requiring power block in electrified sections On Indian Railways 25 KV power is used for traction through an overhead wire at 5 5 m above rail level On bridges and tunnels the height is restricted to 4 8 m 2 11 The machine or its any part 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 uipped with pneumatically operated brake blocks acting on all whe shall be possible to haul the machine in both directions at the sa 2 12 In the work mode no part of t i rise beyond 4 265 m 2 13 While working on double line i i i ot infringe the adjoining tracks and i i i other tracks excep discharge muck on 4265mm eyor is in inclined position to spacing between tracks is 2 14 3 0 apable of discharging waste like muck into another such unit attached to it in front or 3 2 able of unloading the material at any suitable discharging 3 3 able to work on single and or double line track as well as between station platforms 3 4 The continuous and complete loading should be possible by a longitudinal bottom conveyor belt at the floor of the machine 3 5 It should be capable of unloading discharging complete material by an inclined swiveling conveyor belt located at the front end of the
18. nimum wheel diameter of 914 mm new wheel profile However lesser diameter upto 730 mm new wheel profile can also be considered provided it meets the condition laid down in Clause 2 3 at its condemnation limit and rail wheel contact stresses for 72 UTS rails are within permissible limits It is desirable that 50mm margin between new and permitted worn wheel diameter should be available but this should not be less than 20mm Forged wheels to n Railways profile shall be provided on the machine The worn eel diameter condemning worn out diameter based on the crit il wheel contact stresses for various maximum axle loads are as Maximum Axle load ton ut wheel diameter 22 82 22 00 el diameter should be specified by the diameter of wheel for assesment of permitted axle out wheel diameter The wheel profile shall be as per dard wheel profile provided in annexure V It shall be capable of continuous negotiating curves up to 10 curvature 176 m radius super elevation up to 185 mm and gradients up to 3 in travel mode It 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 0 55 C Altitude Sea level to 1800 m above mean sea level Page 3 of 24 Humidity 40 to 100 Maximu
19. ose 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 Page 11 of 24 arrangement loading pattern 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 IVA IVB amp IVC 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 IVA IVB amp IVC may also be required sue of provisional speed certificate for the machine c New suppliers whose models 17 0 MAKER S TEST CETIFE Copies of maker machine should b ied i along with the delivery of each 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
20. ring safety of the train The under frame shall be constructed with rolled steel section and or plates shall be designed to withstand a maximum static squeeze test load test 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 and not necessarily as the last vehicle 10 0 TOOLS AND INSTRUCTION MANUALS Page 7 of 24 10 6 Each machine should be supplied with a complete kit of tools required by the operator in emergency and for normal working of the machine The list of tool to be provided should also include all the tools necessary for the maintenance and repair of entire machine including specialized equipment All special tools should be listed and cataloged illustrating the method of application The list can be modified to suit the purchaser s requirement while examining the offer Detailed operating manual maintenance and service manual should be specifically prepared in English language and four copies of these should be supplied with each machine The supplier shall also supply ci s of electrical hydraulic pneumatic and electronic i the machine Trouble shooting diagram table sh ied ditions the supplier shall provide dimensional i i i cription of items like rubber seals washers ins etc Main features such a i ke hydraulic pumps motors and shall be furnished ier aforesaid details shal
21. sion springs and k absorbers with support Detail of location of su springs and dampers and absorbers with s Details of centre pivot 12 arrangement working and location 13 Set of drawings and description Page 23 of 24 An nexure V of a PROCEDURE OF DRAWING 1 DRM A VERTICAL LINE 2 DRAV SEMI CIRCLE OF 14 5R TANGENTIAL TO LINE X Y 3 DRAW LINE 1 2 5 TANGENTIALLY TO SEM CIRCLE 65 5 100 3 oa 4 DRAV A HORIZONTAL LINE AT 28 5mm FRO4 THE TOP OF THE FLANGE AND LOCATE Pt A AT 63 5mm LINE X Y 5 FRO Pt A LOCATE CENTRE B OF ARC ROM E 6 DRAV ARC OF 330R FROM CENTRE B 1N 20 7 LOCATE CENTRE C ON VERTICAL LINE AT HORIZONTAL DISTANCE OF 65 5mm FROM THE LINE X Y SUCH THAT BC 33C 100 ie 230mm ix A 5 8 DRAV ARC OF 100R WIH CENTRE AS C 9 DRAV ARC OF RADIUS 14mm TANGENTIA LLY TO 100R ARC AND LINE 1 2 5 NINE 10 DRAV LINE 1 20 TANGENTIALLY TO 330R ARC m 11 DRAW A VERTICAL LINE AT A DISTANCE y eT IDO cae OF 30mm FROM THE FLANGE END NOTE SUPERSEDED BY ne DEUS CO ORDINATES OF POINTS B amp C TBE ARE BASED ON NOMINAL DIMENSION OF 28 5mm DIMENSION 73 7 DELETED 9 04 REVISED amp REDRAWN X94 CO ORDINATES OF ARCS SHOWN 3 92 DESCRIPTION DATE Page 2
22. upplier at his own expenses Page 13 of 24 Annexure 1 RATRE SST vas eel rele ED let ax SASL IAN NI 38V SN ISNGWIG Ty xS NIW cot EE i 39nv99791 Ner AUS Sif NIN 0411 4 NIW SOE XVW SE E XVW S92 4 XV 082 EG9c SNUISN3WIG ONIAOW AMIKA EM UAE Ve ee le U Pose GT PE SN vee il a Page 14 of 24 ANNEXURE II 1 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 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 restrictio The vehicle will be tested generally for new and worn clearan nditions and where relevant for operation in the forward an d directions The vehicle selected for tests will be e condition for normal maintenance follows Homme s limit of 0 is the axle load ii Isolated peak valu i bove limit are permissible provided the record 1 load Q continuously over lue HY Q shall not exceed 1 ded in the cab at location
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