GOVERNMENT OF INDIA MINISTRY OF RAILWAYS … · (Rail wheel) of the vehicle for locking the front axle while the vehicle is put on Road. 1.3.7 Rail wheel unit shall have positive

Page 1 of 34 Effective from -10.2012 TI/SPC/OHE/ERRV/0120 (10/12) Rev.’0’

DRAFT

(For official use only)

GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

SPECIFICATION FOR EMERGENCY ROAD CUM RAIL

VEHICLE (ERRV) FOR MAINTENENCE OF 25 KV

OVER HEAD EQUIPMENTS SPECIFICATION No. TI/SPC/OHE/ERRV/0120

October, 2012

Issued by:

Traction Installation Directorate

Research Designs & Standards Organisation

Manak Nagar, Lucknow- 226 011


SPECIFICATION FOR EMERGENCY ROAD CUM RAIL VEHICLE (ERRV) FOR MAINTENENCE OF 25 KV

OVER HEAD EQUIPMENTS

SPECIFICATION No. TI/SPC/OHE/ERRV/0120(10/12) Rev.’0’

Amendment Date of Total pages Amendment/

Number Amendment including Revision annexure.

0 NA First issue.

PREPARED BY CHECKED BY APPROVED BY

SIGNATURE

DATE

DESIGNATION SSE (TI) DD (TI) ED (TI)

COPY NUMBER

ISSUED BY ……………. SIGNATURE DATE……………

ISSUED TO ………………………………………………………………

NOTE : This specification is property of RDSO. No reproduction shall be done without

permission from DG (TI), RDSO. This specification is not for general use.


SPECIFICATION No. TI/SPC/OHE/ERRV/0120

CONTENTS

Sl No. Description Page No. 1.0 Description 4

2.0 Scope 4

3.0 Basic requirements 4 - 4

4.0 Climatic conditions 5

5.0 Service and spare part catalogue & Service engineering 4

6.0 Guarantee & Basic data 4-5

7.0 Mechanical Design 7

8.0 Dimension & Operating Requirement 9

9.0 Configuration 16

10.0 Electrical System 16 11.0 Inspection 17 12.0 Acceptance test 17

13.0 List of equipment 19


SPECIFICATION FOR EMERGENCY ROAD-CUM-RAIL VEHICLE

(ERRV) FOR MAINTENENCE OF 25 KV OVER HEAD EQUIPMENTS

CHAPTER -1

1.0 GENERAL CONDITIONS

1.1 DESCRIPTION The Emergency Road-cum-Rail Vehicle (herein after termed as ERRV) shall

be a self-propelled, workman and material transport vehicle capable of running on broad gauge (1676 mm normal) as well as on Road having a

diesel engine of adequate capacity as power source of standard truck

manufactured with power equipment and control with chassis shall be utilised.

1.2 SCOPE This specification covers performance and other requirements of Rail-

Cum-Road Vehicle of 8 tonnes (minimum) payload capacity, in

completely assembled and furnished condition for operation on Broad

Gauge track in Indian Railways as well as on roads including unpaved

ones.

1.3 BASIC REQUIREMENTS

1.3.1 While working on the Rails, Tractive Effort shall be provided through Rail wheels only. Rail wheels shall be hydraulically operated for ON/OFF Rail operation. Alternatively, the Road wheels may be lifted off and the complete vehicle supported on flanged Rail wheels having sufficient diameter for negotiating the curve. Suitable power transmission system shall be provided to work on Rail as well as on Road. The Road wheels and steering shall be positively locked in safe position when working on Rails.

1.3.2 The speed potential of the vehicle shall be at least 40 kmph on Rails

and 70 kmph on Road. The vehicle shall be capable of traversing

rough terrain having 1 in 20 grade on Road and 1 in 33 on Rail. The

manufacturer shall furnish detailed calculation sheet of engine power,


Tractive Effort and speed potential in support to prove this

negotiability.

1.3.3 The speed potential of the vehicle in reverse/rear direction on Rail shall

have same speed.

1.3.4 The payload capacity of vehicle shall be 8 tonne. The vehicle shall

be suitably designed to be capable of taking 30% overload over and

above the payload capacity. A truck of suitable capacity shall be

selected for conversion into ERRV.

1.3.5 The height of the loading platform shall be as low as possible in the range of 1300mm to 1500mm.

1.3.6 Steering of the vehicle shall have the provision for locking it mechanically while running on Rail. The provision of self (automatic)

locking of steering shall also be provided. A suitably designed

mechanical locking arrangement shall be provided at the front axle (Rail wheel) of the vehicle for locking the front axle while the vehicle

is put on Road.

1.3.7 Rail wheel unit shall have positive mechanical lock with safety pins to retain Rail wheel unit in position, while running on Road as well as on Rail.

1.3.8 The vehicle should be capable of high degree of maneuverability. It

shall be possible to transfer the vehicle from road to rail and vice-

versa at a level crossing or from specified location of station yard area to siding line/loop line/main line and vice versa within a short

time and limited space. The details of limited space and adjacent lines

constraints are detailed in clause 2.5.2 of this specification.

1.3.9 On tracking and off tracking of the ERRV shall be ensured within five minutes each.

1.3.10 The actual time of on / off tracking at level crossing and in the yard area shall be separately indicated by the tenderer in the offer. 1.3.11 Necessary adjustment/arrangement shall be provided on the vehicle to

avoid the infringement either to the gateposts of level crossing or adjacent line(s) during on-tracking/off-tracking operations.


1.3.12 The gross weight of the vehicle shall be kept as low as possible to

enable it to traverse on all type of roads and ensure economical

payload to tare weight ratio. 1.3.13 At the design approval stage, manufacturer/supplier shall submit

necessary weight calculations sheet, indicating gross vehicle weight, chassis & cowl, weight of Rail wheels attachments etc. and weight with driving cab, and tare weight of ERRV after furnishing to enable verification of tare weight and payload capacity.

1.3.14 The tenderer shall furnish detailed working procedure and dimensional sketch showing suitable arrangement for transfer of

vehicle from Road to Rail and Rail to Road at a level crossing and in

station yard area to siding line or loop line or main line and viceversa,

alongwith tender papers. 1.3.15 The tare weight of ERRV shall be verified by weighing the vehicle on

a weigh bridge. During weighing, the vehicle shall be in fully furnished condition, loaded with a spare tyre, rim and maintenance tools/plants.

1.3.16 All hydraulic & other controls for above and other operations shall

be provided at the suitable locations so that a single operator as per

requirement can operate the system. Necessary controls for the

opening and closing of the hydraulic circuits shall be provided in the

driver cabin.

1.3.17 The vehicle shall be capable of working in hot, humid and dusty

atmospheric conditions as prevalent in India. The atmospheric

parameters are mentioned in Clause 1.4.


1.4 CLIMATIC CONDITIONS

The ERRV including the power equipment shall be in continuous operation under the following atmospheric and climatic conditions. The ERRV should be suitable to perform satisfactorily in J & K area also: -

i Atmospheric Metallic surface temperature under Sun: 75° C

temperature max. and in shade: 55 °C max.

Minimum temperature: (-) 10°C (Also snow fall in

certain areas during winter season).

ii Humidity 100% saturation during rainy season.

iii Reference i) Ambient Temp. : 50° C

site ii) Humidity : 100% conditions iii) Altitude : 1000 m above mean sea

level iv) Altitude : 2000 m in J&K area.

iv Rain fall Very heavy in certain areas.

v Atmosphere Extremely dusty and desert terrain in certain during hot areas. The dust concentration in air may reach a

weather high value of 1.6 mg/m³. In many iron ore and coalmine areas, the dust concentration is very

high affecting the filter and air ventilation system.

vi Coastal area RCRV and its equipment shall be designed to

work in coastal areas in humid and salt laden atmosphere with maximum pH value of 8.5, sulphate of 7 mg per litre, maximum

concentration of chlorine 6 mg per litre and

maximum conductivity of 130 micro Siemens/cm.

vii Vibration The equipment, sub-system and their mounting arrangement shall be designed to withstand

satisfactorily the vibration and shocks encountered in service as specified.

1.5 DOCUMENTS

1.5.1 Documents to be supplied by supplier / manufacturer at time of tendering: The tenderer while submitting his offer should present documents in the following order:


1.5.2 A brief description of the proposed vehicle, the way it will function and working procedure of transfer of Vehicle from Road to Rail & Rail to Road.

1.5.3 Paragraph-wise comments on the preceding paragraphs of this specification indicating compliance / conformity to the specification clauses. In case of any variation / difference from the specification clauses, the tenderer should give details of his proposals with adequate reason / justification to enable the Railways to appreciate and evaluate the proposed changes.

1.5.4 The tenderer should also supply all the details with proper calculation and supporting drawings as mentioned in proforma I, II, III & IV.

The tenderer should indicate details of technological collaboration

with any other firm and service net-work, if any, for spares and

maintenance for the model of Road vehicle proposed to be used by

him.

1.6 MATERIALS

1.6.1 Materials used in the construction of ERRV shall comply with the relevant IRS specification or Indian Standards Specification (ISS). Alternative materials can only be used with the prior approval of RDSO. Where IRS or ISS do exist for specialised components, the contractor shall submit his proposed material specification for approval of RDSO.

1.6.2 The major equipment used for manufacture of the ERRV including power, transmission and braking shall be indigenous origin, as far as possible. Wearing component shall be easily available.

1.7 DRAWINGS

1.7.1 The supplier/manufacturer shall submit detailed design drawings to

the purchaser or his authorised representative, the detailed design

drawings of the vehicle to be supplied within two months from the

date of issue of the purchase order. The design shall be examined by the purchaser or his authorised representative and modifications, if

any, shall be done by the supplier/manufacturer at his own cost.

1.8 SERVICE AND SPARE PARTS CATALOGUES


1.8.1 Detailed maintenance, service and troubleshooting manuals shall be

prepared for the equipment and copy of each manual shall be

supplied free of charge per set of equipment ordered. Detailed spare

parts catalogues shall be supplied in sufficient number, free of charge.

1.9 SERVICE ENGINEERING

1.9.1 The supplier/manufacturer shall provide, at his own expense, the

service of competent engineer during the guarantee period. The

service engineer shall be available for testing/commissioning of the

Rail-cum Road Vehicle and for training of operating & maintenance

staff. The service engineer shall also advice the Railway on

maintenance, testing and operating facilities considered necessary for

efficient performance of the ERRV.

1.9.2 SPARE PARTS

The supplier/manufacturer shall submit to the user Railway, a list of

spare parts and special tools, including the name and address of the

manufacturers as detailed in para No.1.9.6

1.9.3 LIST A : (Maintenance spares for 18 months initial requirement) The manufacturer/supplier shall be responsible for ensuring subsequent availability of the spare parts for the efficient working of the respective equipment. The manufacturer/supplier shall submit the list of

maintenance spares with their costs along with tender. The cost of spares shall not be taken in to account for tender evaluation purpose and the decision to buy these spares shall rest with the purchaser. These spares may be purchased by Railways after expiry of warranty period and as and

when required.

1.9.4 LIST B: (Maintenance Tools)

A set of maintenance tools shall be provided along with each vehicle by

the manufacturer free of cost. Details of set of tools required shall be

enclosed with the offer. The maintenance tools shall include tool kit,

hydraulic jack with rod, Central Motor Vehicle Rule etc.

1.9.5 Manufacturer/supplier shall supply one number Road tyred wheel as spare wheel along with vehicle free of cost. However, if the Diameter/Dimension of rear wheel and front road wheel tyres are


different, then supplier/manufacturer shall supply one rear and one front

wheel spare wheel along with the vehicle.

1.9.6 As far as possible, spares of indigenous origin shall be used for conversion of road vehicle into ERRV. The list of imported spares, used if any, shall be separately mentioned as per proforma given in below:

SN Description Part No/ Material Make Address, telephone

of spares Drawing specificat No. E-mail address

No. ion No. of manufacturer / authorised dealer of the spares

1.10 GUARANTEE: As per IRS conditions of contract.


CHAPTER -2 DIMENSIONAL AND OPERATING REQUIREMENTS

2.1 BASIC DATA

2.1.1 Track Gauge 1676 mm

2.1.2 Minimum Radius on curve 175 meters

2.1.3 Wheel base Road 5000 mm (Approximate)

Bogie 6000 mm (Approximate)

2.1.4 Axle Load (Maximum) 4.75 Tonnes (Per Stub Axle)

2.1.5 Rail Wheel New 725 mm Dimension Worn Out 705 mm

2.1.6 Tread and Flange Profile of Rail RDSO Sketch No. 91146 with latest

Wheel alteration

2.1.7 Wheel gauge dimension (back 1600 mm

to back of type flange)

2.1.8 Maximum Own Power 70 kmph on Road and 50 kmph on Operating Rail

Speed In Train Not applicable

Formation

2.1.9 Floor Height Tare Condition 1400 mm (Approximate)

Gross load 1220 mm (Approximate) Condition

2.1.10 Payload Capacity 3.5 tonnes (minimum)

2.1.11 Gross weight 23 to 25 tonnes (approximate)


2.1.12 seating capacity: The 11 nos. of Railway personnel shall be seated on the ERRV. In the cabin, seating arrangement for 07 persons including driver shall be provided. Additional seats fixed / folding type, wherever found suitable for better space utilisation, shall be provided on the loading platform for 4 workmen at the rear of

driver’s cabin.

2.1.13 Clearance of vehicle: Complete vehicle shall meet all the road norms

as set by RTO to operate the vehicle on Indian Roads.

2.1.14 Maximum moving dimensions shall conform to diagram 1D of Indian

Railway Schedule of Dimension (SOD) 1676 mm gauge (BG) revised 2004 (with latest amendments) with the pantograph and platform in

lock down condition. Infringements, if unavoidable and fully justified,

may be considered, if within the limits shown in SOD 1676 mm gauge (BG) revised 2004.

Adequate clearance shall be allowed so that no component of the

ERRV shall infringe a minimum of 102 mm above rail level with

wheels in fully worn conditions, full deflection of springs and effect of

dynamics.

2.2. FACILITIES ON THE ERRV

2.2.1 The ERRV shall be provided with a pantograph similar to AM-12

type with foot insulators and its complete actuating mechanism

Pantograph shall be graduated to enable manual measurement of

stagger on either side of track centre. The Pantograph pan shall be

solidly earthed by two distinct and separate earths. It shall be

provided with a proper arrangement to keep it locked down when not

in use. The Pantograph is not meant for energising OHE.

2.2.2 A lifting platform with hydraulically/ motor operated mechanised adjustment for height with under noted features shall be provided over the fixed platform. The platform shall be capable to bear a load of 2.0


tonnes (including weight of 6 persons). The platform shall conform to principle dimensions /requirement specified hereunder:

S.N. Parameters Dimensions

1. Length 3000 mm

2. Width 1450 mm

3. Platform upper surface level 6150 mm above Rail when elevated

4. Side shifting reach of platform 2300 mm

5. Full height of collapsible Railing above 800 mm

platform floor

6. Lifting Time 45 s

7. Rotation range of platform towards sides 90º

8. Time of rotation from 0º position to 90º 36 s

Note: (i) Control for lifting & lowering shall be provided on the platform.

The movement of platform shall be gradual and not sudden or too

fast. Sufficient working lights shall be provided on the platform.

Suitable safety measures including interlocks between various equipments, access doors and line equipment shall be provided to ensure safety of men working, stability of car while in

operation. The tenderers shall indicate the interlocking and safety aspects the tenderer proposes to incorporate. The entire ERRV including axles, super-structure along with equipment is to be effectively earthed as per standard practice for rolling stock.

The equipment fixed to the under frame shall be able to perform efficiently under cast iron dust from brake blocks.

2.2.3 Inter-communication equipment hands free operated by battery may be provided for communication between driver and staff working on platform.

2.2.4 A small capacity water tank may be provided, if possible.

2.2.5 For illumination of roof for night inspection weather proof plug points shall be provided for connecting portable lights. These plug points shall be provided in suitable boxes with flushing covers, so that it


does not become obstruction when not in use. The storage space for

keeping tools and maintenance spares shall be provided in the vehicle

2.2.6 Two pneumatic points for connecting pneumatic operated/driven

tools and fasteners shall be provided.

2.2.7 Rear door shall be such that it is hinged at the bottom and shall

open upto horizontal position to become a loading platform. This

platform shall have vertical travel upto ground level to facilitate

loading. This platform shall be capable of lifting material upto one (1) tonne. The door should be watertight and open outside. The control for rear door should be provided on the backside of vehicle with proper interlocking arrangement.

2.2.8 The shelves / pigeonhole can be made taking support of cabin wall or fixed side wall. Supporting sheet shall be adequately designed to bear the load without any deformation. Sizes of various stacking- shelves shall be as per the size of Railway items to be stacked there without obstructing rear vision of the driver. Lists of Railway items, which are required to be stacked, are given in Annexure-I. The tenderer shall offer the best possible loading area utilisation ensuring space for stacking tools and plants, manpower, fittings etc. in one or two tier arrangement. However, taking out or putting in materials, should not be obstructed. Heavier items should be stacked on first-tier/floor of loading area.

2.2.9 The loading area shall be covered, except for the loading platform alongwith detachable frame, shelves, seating arrangement and maintenance tools will be part of tare weight of the ERRV.

2.2.10 The tenderer shall submit complete drawing- plan, elevation & cross-sections of loading platform showing various arrangements of stacking of Railway material and seating arrangement, alongwith the offer.

2.2.11 The successful tenderer shall be required to submit detailed design drawings and calculation of vehicle to purchaser or his authorised representative for approval before manufacture is started. Since the arrangement of various Railway items, seating, etc. can be critical from operational point of view, it is expected that


manufacturer/supplier will keep the purchaser or his authorised representative informed of his plans / designs of loading platform / compartment of ERRV at preliminary design stage itself.

2.2.12 A crane with cradle of 8 tonne meter capacity with vertical reach of 10-11 m, Horizontal Reach of 6 meter and cradle capacity shall have adequate capacity to carry two persons with tools weighing 350 kg

2.3. ON ROAD

2.3.1 The provisions of the Motor Vehicles Act-1988 shall be complied with.

2.3.2 It shall be the responsibility of the manufacturer to obtain the

technical certification of roadworthiness of the vehicle from the

authorised agencies in India such as the Automobile Research

Institute of India, Pune prior to the registration of the vehicle. For

plying the vehicles on roads of different classification, it may require

special permission from the Ministry of Surface Transport,

Government of India.

2.4 Infringement to Level Crossing Gatepost and Double/ Multiple Lines

2.4.1 At following locations, ERRV shall be allowed to do Off-Tracking/

On- Tracking:

i) Level Crossing- (a) Level Crossing manned having telephone.

Level Crossing manned without telephone. Level Crossing unmanned.

ii) Station yard Siding line / Loop line / Main line.

2.4.2 The minimum distance centre to centre of tracks on Indian Railway is

4265 mm. The minimum horizontal distance from centre of track to any structure except a platform from 305 mm above rail level to 4420

mm above rail level is 2135 mm. The minimum width of gates at right

angles to the centreline of the road will be 5000 mm for class III road. And in case of class II road, the minimum width of gates at right

angles to the centreline of the road will be 7500 mm. The minimum

distance of gateposts from centreline of track will be 3000 mm. It should be possible to off-track and on-track the ERRV on such gate

without disturbing any fixed structure of the level crossing or infringing

adjacent line(s).


2.4.3 In all of the above situations, infringement to adjacent line(s) shall be avoided during the off tracking / on tracking of ERRV, in order to ensure safety of traffic on adjacent line(s).

2.4.4 The level crossing or the specified place of station yard area from where ERRV shall be allowed to off-track & on-track shall be firm and levelled. This will be done strictly under traffic block of respective line(s).

2.4.5 Entry of ERRV shall be mostly through level crossing gate to minimise track possession time and ensure effective utilisation of the same.

2.4.6 Necessary clause(s) to this effect shall be incorporated in the working

instruction of the ERRV to be issued by the Railways.

2.4.7 To assess flexibility / manoeuvrability, the tenderer shall submit

whether on-tracking / off-tracking from road to rail or vice-versa can be done at places other than level crossing gate and station yard area.

2.4.8 Tenderer shall submit a dimensioned sketch indicating the minimum space and time requirement for on / off tracking from rail to road and vice-versa alongwith the offer. Any infringement to the above mentioned drawing during the process of on / off tracking shall be indicated by the tenderer alongwith the offer.

2.4.9 The details of infringements, if any, to adjacent line(s) during on tracking and off tracking, shall be specifically mentioned by the tenderer in the offer.

2.4.10 Necessary clause (s) for safety of working personal in the vicinity of

25 kV ac Traction shall be incorporated in the working instruction of

the ERRV to be issued by the Railways.


CHAPTER -3

MECHANICAL DESIGN

3.1 DESIGN STANDARDS

3.1.1 The design of different components as well as overall design of Emergency Road-cum-Rail- vehicle shall conform to IRS/IS Standards except otherwise stated in these specifications.

3.2 GENERAL CONSTRUCTION

3.2.1 The vehicle shall be robust, sturdy, compact in design and capable of working in conditions mentioned in clause 1.4. It shall have simple operation and easy maintenance during service.

3.2.2 All controls, hydraulic, electrical, electronic, mechanical, etc., shall be preferably located in the driver's cabin within easy accessibility of the driver.

3.2.3 The vehicle shall be designed and constructed in such a way so as to ensure easy access to different assemblies and sub-assemblies of the vehicle.

3.2.4 A suitable battery / manually operated emergency system, which can energise / activate hydraulic system in case of failure of engine, shall be provided to ensure winding up operations of various assemblies like rear door of loading plarform, turn table, Rail wheel unit etc. and off tracking of the ERRV.

3.3 VEHICLE DESIGN

3.3.1 BODY: The body frame shall be made from suitable structural steel

sections shall be used to build the body sides, roof and the under-

frame, to make it conforming to IS: 2062-1992. The sheet metals

conforming to IS: 2062-1992 platform durable corrugated MS sheet of

designed thickness shall be used.

3.3.2 The complete body and chassis shall be protected from corrosion with suitable anti-corrosive paint. The exterior of body sides shall be without bulges or depressions.

3.3.3 Exterior surface of the vehicle body shall be coated with an approved two pack epoxy paint system. A grey base coat and golden yellow colour will form the paint system.


Appropriate flooring shall be provided in the driver’s cab and in the loading compartment. The cabin and loading platform's width shall be preferably kept as the same.

3.4 UNDER FRAME

3.4.1 The under frame shall adequate strength and shall be suitable for conversion to ERRV and under frame shall be fitted with towing hook at both ends (front & rear) of the vehicle similar to towing hook provided in truck. The under frame shall be able to withstand an overload condition of 30% of pay load capacity.

3.5 SUSPENSION: Under fully loaded condition; the suspension system should not be over stressed and should provide safe running at maximum test speed.

3.5.1 The springs shall be designed to cater for actual service conditions

assuming 30% dynamic augmentation. Necessary suspension design

calculations shall be furnished by the manufacturer / supplier at the

design approval stage.

3.5.2 Anti-friction bearings of adequate life rating shall be used.

3.6 WHEELS, AXLES AND AXLE BOXES

3.6.1 The Rail wheel shall be of solid rolled/cast steel as per IRS-R-19. The wheel profile (thick flange) shall be as shown in RDSO drawing CSL 3040. The wheel arrangement and vehicle wheel base may be specified.

3.6.2 Difference in tread diameter of rail wheels on same axle shall not be more than 0.5 mm

3.6.3 Rail wheels shall be capable of being lifted and lowered hydraulically.

3.6.4 Rail wheels shall have positive mechanical lock with safety pins to retain them in position while running on road and on Rails.

3.6.5 Anti-friction bearings of adequate life rating shall be used.

3.6.6 A stopper / scrapper pad of suitable design shall be provided in the front Rail wheels to clear the Rail top from any obstruction like stone ballast, etc during movement on the track.


3.6.7 Necessary strength calculations of wheel & axle shall be furnished by

the manufacturer/ supplier.

3.6.8 Diameter of Rail wheels shall be as large as possible to attain speed,

stability and negotiation of points and crossings including diamond

crossings at suitable speed. However, diameter of solid Rail wheel, in

any case, shall not be less than 400 mm. 3.6.9 Electrical continuity between the rail wheels of the same axle and

between the two Rail wheel axles shall be maintained all the time to ensure proper response of the signaling system. Axle/wheel system shall be designed accordingly. Generally DC Track Circuit of specified length is provided.

3.6.10 The Rail wheel and axle assembly shall be such that hunting and

differential running are minimum.

3.6.11 The vehicle shall fulfil the requirements of acceptance criteria during oscillation trials mentioned in clause 6.6 of this specification.

3.7 DOOR:

3.6.1 Two doors, one on either side of the driver’s cabin shall be provided and other doors shall be approved by purchaser at drawing approval stage.

3.6.2 All door openings shall be such that doors can be opened and closed smoothly. When the doors are closed, the interior of the cabin shall be completely protected against rain and dust.

3.6.3 Necessary door locking arrangement shall be provided to secure the

doors on the run.

3.6.4 Door footsteps shall be provided for each door. The assembly shall be

of mild steel having chequered steel plates in tread portion.

3.7 INTERIOR DESIGN AND FURNISHING OF REAR SPACE

3.7.1 The complete rear space behind driver’s cab shall be covered as per

enclosed drawings and shall give good and clean appearance with

durability and serviceability. All surface liable to frequent handling

shall be finished with materials suitable for periodical washing or

cleaning and shall be of a colour which will be resistant to stains.

3.7.2 The material used for finishing and furnishing shall be suitable for use under Indian climatic conditions and shall be fire retardant, non- hygroscopic, vermin and rat proof.


3.8 WINDOWS

3.8.1 Side windows of suitable size with toughened glass shall be provided

in driving cab. 3.8.2 Driving cab of vehicle shall be provided with front windscreens covering the full width of the front of the cab. The windscreen shall be of toughened glass and impact laminated and shall also be provided with electrical wipers. 3.9 CABIN DESIGN & SEATING ARRANGEMENTS

3.9.1 Drivers cabin and seats shall be ergonomically designed and driver’s

cabin shall have provision for two berths.

3.9.2 All gauge, fuse board and switches for the lights shall be located in driver’s cabin.

3.10 STEERING SYSTEM

3.10.1 The vehicle shall have a properly designed steering system for quick and easy manoeuvrability of vehicle while running on Road.

3.10.2 The steering system shall remain in locked position while the vehicle

is running on rail. For this purpose, the manufacturer shall provide a

properly designed mechanical locking system.

3.11 BRAKE SYSTEM

3.11.1 Vehicle shall be provided with pneumatic standard service brake system to ensure that emergency braking distance for 60 km/h speeds under loaded condition is within 250 m on level section while running on Rail. A pneumatic brake pressure gauge shall be provided at the suitable location in the driver's cabin.

3.11.2 Vehicle shall be provided with parking brakes. The parking brake

power shall be adequate to hold totally immobile vehicle on 1 in 33

down gradient under fully loaded condition on rail and 1 in 20 down

gradient under fully loaded condition on road.


3.11.3 Vehicle shall be provided with suitable standard service brake of dual circuit full air S-CAM brake for stopping the vehicle on Road within the stopping distance as stipulated for heavy Road trucks.

3.11.4 Vehicle shall be provided with hand operated spring actuated parking brake acting on rear wheels. The parking brake power shall be adequate to hold totally immobile.

3.11.5 The Vehicle shall have engine exhaust brake air operated coupled with

service brake with electromagnetic air cylinder and electrical isolator

switch.

3.11.6 Rail wheels (both front & rear) shall also be provided with suitable pneumatic brakes.

3.11.7 The manufacturer / supplier shall submit the brake power and braking distance calculation sheet at the time of design approval stage. The maximum braking force at rail level may be furnished. The functioning of the brake system on rail/road shall also be explained.

3.12 LOAD DISTRIBUTION

3.12.1 While running on Rail, the weight distribution on Road and Rail wheels

shall be such that adequate adhesive tractive effort and requisite

guiding force is available on Rail wheels. While running on Road, full

load shall come on tyred wheels.

3.12.2 The load transfer to Rail wheels as well as tyred wheels shall be through properly designed suspension system.

3.12.3 Other Accessories: The Vehicle shall be fitted with top corner blinkers, first aid box and fire extinguishers.


CHAPTER -4

4.6.1 DIESEL ENGINE, TRANSMISSION AND CONTROL SYSTEM

4.1 CONFIGURATION

4.1.1 The ERRV shall be powered by a diesel engine centrally mounted at one end of the vehicle similar to a Road Truck. Suitable power transmission with flexible hydraulic coupling shall be directly mounted on the engine. The drive arrangement shall be through suitably designed torque converter and/or mechanical multi-speed gearbox.

4.6.1 DIESEL ENGINE

4.2.1 The diesel engine shall be of reputed make, indigenously available and

have proven performance in traction/automotive application. The

continuous rating of engine under extreme operating conditions shall

be adequate to meet the full load power requirements.

4.2.1 Exhaust, silencer and pipe work shall be flexibly connected. Exhaust discharge shall be along the track while vehicle is running on Rails, and shall meet the emissions standard regulations in vogue.

4.2.2 A fuel tank of adequate capacity shall be provided for a run of 250 km

on 1 in 200 up gradient with 30 % idling time.

4.2.3 The manufacturer shall furnish tank capacity and fuel consumption per kilometre in fully loaded condition.

4.2.4 Details of power calculation / design shall be submitted by the manufacturer / supplier at the design approval stage. Engine power should be properly designed to take care of full load and provide power to all secondary units.

4.3 TRANSMISSION SYSTEM

4.3.1 The transmission shall be directly mounted on the engine. This shall be indigenously available, of reputed design & make and proven performance in automotive/rail application.

4.3.2 The drive system shall consist of an intermediate gearbox (if required),

cardon shafts and an axle mounted drive gearbox.


4.3.3 All the elements of drive system shall be of robust design, reputed

make and proven performance in automotive/rail applications.

4.3.4 The transmission system shall not call for any special care on the part

of the driver to protect it from damage under any circumstances.

4.3.5 The tenderer shall furnish complete details of transmission. Drawing and specifications should be submitted, if any, modification / changes are contemplated. If the vehicle movement on rail is proposed through drive given to rail wheels, then complete details of such arrangement along with drawing may be submitted along with offer.

4.3.6 Tractive effort versus speed curve for the ERRV shall be submitted

along with calculation.

4.4 COOLING EQUIPMENT

4.4.1 The cooling system shall consist of engine mounted cooling fan driven

directly from the auxiliary end of the engine.

4.4.2 Suitable radiator for cooling the water shall be provided. The fan and the cooling arrangement shall be of adequate capacity to cope with the service demands under the most severe temperature conditions.

4.5 CONTROL 4.5.1 The vehicle shall have one driving position at one end only.

4.5.2 Adequate control equipments. Gauges (Engine oil pressure gauge, Air

pressure gauge, Water temperature gauge, Fuel gauge, etc),

instrument, safety devices shall be provided for safe and satisfactory

operation. The equipment shall be so arranged on the control desk

that they are within easy reach of the driver.

4.6 VIBRATION AND NOISE LEVEL

4.6.1 The vehicle, sub system and their mounting arrangement shall be designed to satisfactorily withstand the vibration and shocks encountered in service.

4.6.2 Noise level in driving cab shall be such that there is no discomfort to the driver and on- board staff


CHAPTER -5

5.0 ELECTRICAL SYSTEM

5.1 The ERRV shall have 12 V system and with an alternator of reputed make having output 35 Amperes (Minimum).

5.2 Battery of 12 V, 120 Ah capacity shall be provided with its charging

arrangement. 5.3 The ERRV shall be provided with 02 head lights, (one at front and one

at rear end), tail lights, adequate lighting arrangement inside the driver’s cab, staff cabin and storage space, loading platform electrically operated windscreen wipers, engine starter motor, as requirement of the Vehicle.

5.4 The two headlights provided in both directions (rear and front) should

have provision to switch these lights ON only when the truck is

required to travel on Rails. 5.5 An additional air pressure horn of adequate capacity shall be provided.

There shall be a provision to utilise this horn only when the vehicle is

running on the track. 5.6 Electrical circuit diagram shall be submitted along with the each

vehicle supplied to Railways.

5.7 Complete wiring of the ERV shall be done as per IS Standards applicable for Automobile.

5.8 The Tenderer shall submit details of all above equipments and

accessories including wiring for approval of purchaser during design

approval stage.


CHAPTER -6 6.1 INSPECTION

6.1.1 All the materials, components, fittings, sub-assemblies covered by the specification shall be subjected to inspection by the inspecting officer, to be nominated by the purchaser and shall be to his entire satisfaction.

6.1.2 The equipment shall not be despatched or packed until; the inspecting

officer has passed it. Not withstanding such passing by the inspecting

officer, the ultimate responsibility in respect of quality and

performance of the equipment shall rest with the

supplier/manufacturer.

6.1.3 The supplier for journey to the final consignee shall register the vehicle, before dispatch by Road to the final consignee, temporarily. The vehicle, before commissioning by the final consignee shall be got

registered in the office of the local Road Transport Officer by the supplier, in the name of the final consignee. The registration certificate shall be handed over to the final consignee before the commissioning of the vehicle. Charges if any, for the registration,

shall be borne by the supplier/manufacturer.

6.2.2 Cost of all inspections and tests to be carried out at the works of the supplier or any test house shall be borne by the supplier/manufacturer. 6.2.3 In the event of dispute between the inspecting officer and the supplier / manufacturer, the decision of the purchaser shall be final and binding.

6.3 MAKER’S CERTIFICATE

6.3.1 Copies of maker’s test certificate guaranteeing the performance of

the vehicle shall be submitted in duplicate along with delivery of each

vehicle.

6.4 ACCEPTANCE TEST

6.4.1 PERFORMANCE CAPABILITY

The ERRV shall be subjected to suitable tests/trials to establish its performance.


6.4.2 RIDING QUALITY

The Riding Quality tests on Rails shall be conducted at a speed 10 %

higher than the maximum operating speed offered, on a track having the

following standards: 6.4.3 MINIMUM TRACK STRUCTURE

90 R Rails with M+4 sleeper density and 200 mm ballast cushion below sleepers, of which at least 75 mm clean and the rest in caked up condition.

6.5 SELECTION OF TEST TRACK

6.5.1 Oscillation trials shall be conducted over a section containing the

following:

A tangent (straight) track of about 1 km length. Efforts shall be made to

conduct trials over two such stretches.

A Station Yard having facing/trailing points, and

(iii) A curved track having about 2º curve of length about 700 - 800m.

6.5.2 The parameters of the selected track should not be worse than the

following:

Parameter Main Line C&M I Vol. I

Unevenness C B

Twist C or D C

Gauge C A or B

Alignment C C

6.6 ACCEPTANCE CRITERIA

It should be as per fourth report of standing criteria committee.

Comments of testing directorate may be taken.


PROFORMA - I

1. Diagrams showing general arrangement and elevation, plan, end view indicating the dimensions, wheel spacing, axle loads, etc.

2. Rail-wheel diameter in

i) new condition ii) maximum worn condition

3. Tread and flange profile of the rail wheel.

4. Maximum design speed that the designer expects the vehicle to

achieve, keeping in view the riding criteria specified.

i) On rail

ii) On road iii) In reverse direction on rail and road separately.

5. Unsprung weight per axle in tonnes.

6. a) Expected accelerations / derailment coefficient / ride indices / lateral force in tonnes per axle at maximum designed speed.

b) Expected critical speed.

7. Maximum tractive force at start and at speed of operation -

performance diagram required.

8. Maximum braking force coming on to the rails.

9. Type of suspension - description alongwith necessary diagram.

10. Height of centre of gravity from rail level in empty and loaded condition when it is moving on track.

11. If any infringement in the design over the Indian Railways standard schedule of dimensions -1939 (Edition 1973) in tare/maximum

loaded/worn condition of vehicle should be condoned from Railway Board.

Sketches to be attached indicating whether the vehicle in all the cases is

within maximum moving dimensions.


12. Proposed layout of the cab indicating the seating arrangement proposed. A preliminary sketch of the equipment compartment will be highly appreciated.

PROFORMA -II

1. What are the lateral / longitudinal clearances of axle boxes / horns if

any. 2. Lateral clearance of wheel flange / rail and other locations for

negotiability of the vehicle on curves and turnouts (enclose Vogel's diagram for negotiability on maximum degree of curve and turnout permitted on Indian Railways).

3. Enclose wheel axle assembly drawings. Suspension system drawings to be attached.

4. Characteristics of the springs used in suspension indicating free height, working height, dynamic range, stiffness, etc., characteristics of dampers used.

5. Calculation of the frequency of the vehicle in the following modes:

a) Bouncing

b) Pitching

c) Rolling

d) Damping factor in bouncing mode in tare and loaded condition.

6. Brake rigging arrangement drawings and calculation of braking force.

7. Enclose roller bearing drawing. Indicate minimum life rating.

8. The following may be furnished :

a. Total number of axles

b. No. of driving axles c. Axle load of each driving axle having rubber tyre wheels

d. Axle load of each axle having rail guide wheels


PROFORMA - III

Technical data to be furnished by tenderer regarding the Emergency Road- cum-Rail Vehicle selected and modifications proposed.

1. DIESEL ENGINE

1.1 Make

1.2 Type

1.3 Number of cylinders

1.4 Type of fuel injection

1.5 Horse power

1.6 RPM

1.7 Starting tractive effort

- Available

- In at 1 in 33 gradient

1.8 Type of cooling

1.9 Type of governor

1.10 Method of starting

1.11 Engine performance curve, including Specific Fuelling Consumption at

no load condition.

2.0 (a) MECHANICAL GEAR BOX 2.1 Type

2.2 Number of speeds in forward direction with gear ratios.

2.3 Number of speeds in backward direction with gear ratios.

(b) HYDRAULIC TRANSMISSION


All the relevant details like make, type, maximum input hp,

transmission characteristic curves, weight of transmission (empty and

with full supply) to be given.

3. AIR COMPRESSOR

3.1 Type

3.2 Make

3.3 Capacity

3.4 Number of air compressor provided

4. BRAKE SYSTEM

Type of brake system provided.

(a) To control the braking on road

(b) To control the braking on rail

Furnish details.

5. TRACK GUIDING WHEELS

5.1 Type

5.2 Material of construction

5.3 Type of bearings provided 5.4 Type of heat treatment

5.5 Other technical details.

6. ELECTRICAL SYSTEM

6.1 Battery:

(a) No. of cells.

(b) Voltage. (c) Type and make.

(d) Capacity (in Amp. Hr.) (e) Rating.


6.2 Battery charging arrangement - Technical details to be furnished.

7. MISCELLANEOUS TECHNICAL DATA

7.1 Guide wheel diameter

7.2 Maximum admissible tractive load

7.3 Capacity of air brake reservoir

8. RUBBER WHEELS: Give details

a) Type b) Size

c) Nos. d) Make

9. A technical pamphlet of the model of road vehicle proposed to be used.

10. The following information to be furnished:

- Overall length of the vehicle - Width of the vehicle

- Height of the vehicle and whether within maximum moving dimensions specified in BG Schedule of Dimensions 1973, inclusive of locked down height of platform and pantograph.

- Wheel base (minimum & maximum) -

Floor height


PROFORMA - IV

1. All the Relevant Dimensional Drawings Of Suspension System

2. Weight of vehicle body and wheel axle sets.

3. Mass moment of inertia of vehicle body and wheel axle sets in X, Y, Z

direction (i.e. roll, pitch, and yaw modes).

4. Centre of gravity of vehicle body and wheel axle sets.

5. Location of springs and damper in X, Y and Z direction.

6. Spring and damper characteristics.

7. Lateral and longitudinal clearance between wheel and axle assembly

and body. Details of stops provided, if any.

8. Flexible mode natural frequencies and damping ratios of vehicle body.

9. Selected wheel profile to be attached. 10. Wheel base.


Annexure -1

LIST OF EQUIPMENT FOR EMERGENCY ROAD-CUM-RAIL VEHICLE

SN Description of items to

be kept on ERV.

Length Width (m) (m)

Height Unit (m) Qty weight

(kg)

Total weight

(kg) 1 Walkie Talkie (5W)(04 sets 0.2 0.1 0.1 4 01 04

in a box) sets

2 Portable field telephone 0.15 0.15 0.15 1 04 04

3 Rail drilling machine 1.03 0.45 0.57 1 60 60

4 Safety equipment 1 2 2

consisting of set

4.1 Red banner flag 2 - -

4.2 Red hand signal lamp 0.30 0.25 0.25 1 - -

(in a box)

4.3 Green hand signal flag 1 - -

4.4 Detonator 10 - -

5 Gas cutting equipment with 1 5 5

accessories

6 First-Aid-Box 0.25 15 20 1

7 Tirfor 1.5 tonne 2 15 30

8 Tirfor 3 tonne 2 30 60

9 Tirfor 5 tonne 1

10 Pull-lift 3.2 tonne 2 25 50



13 Portable 1.5 kVA DG set 1 60 60

14 Come-along clamps for 4 1 4

catenary suitable for

19/2.108 mm conductor

15 Come-along clamps for 4 1 4

contact wire 107 mm2

16 Come-along clamps for 4 1 4 Aluminium spider conductor (20 mm2)

17 Rail Jumpers with clamps at 10 1 10

both ends

18 Earthing discharge rod 6 15 90 complete

19 Portable Electric Drill 21.0 1 200 200

mm, 1 phase, 230 V (for drilling rails for bonding)

20 Portable Fire extinguisher 1 10 10

(cap. 5 kg.) dry chemical

powder

21 Catenary 200 4 120 480


22 Contact wire 200 4 190 760

23 Jumpers 50 2 36 72

24 Droppers 10 2 4 8

25 Insulators 12 33 400

nos

26 Section insulator Assembly 50 50

(with insulator)

27 Tubes (Stay, bracket etc.) 6 5 24 120

28 Tools and light tackles 200 200

29 Small parts steel 300 300

30 Aluminium Extension ladder 11.2 m 1 30 30

with locking system

31 Inflatable Emergency light 02 1 02

Total weight 3012