Hkkjr ljdkj jsy ea=ky; - rdso.indianrailways.gov.in Railcar KLK... · Maximum Moving Dimension SK.DP -3347 ... Shimla section of Northern Railway of Indian ... Contractor shall prepare

RDSO (MP) Specification no. MP - 0.08.00.24 Rev.-07 Dec - 2015

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GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

TECHNICAL SPECIFICATION FOR

NARROW GAUGE DIESEL RAILCAR WITH TWIN POWER-PACK

(for 762 mm Gauge Kalka - Shimla Section over Northern Railway)

Specification No. MP - 0.08.00.24 Rev.-07 Dec - 2015

Issued by

vuqla/kku vfHkdYi ,oa ekud laxBu]

Ekkud uxj] y[kuÅ & 226 011 RESEARCH DESIGNS AND STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW – 226011


CONTENTS

Chapter Description

Page no.

I GENERAL 1-9

(General, Basic data, SOD, Kalka-Shimla section details, Design

development & approval of drawings, Quality assurance plan,

Inspection, Prototype acceptance test, Spare parts, Service engineering,

Training, Warranty etc.)

II ENGINE, TRANSMISSION, CONTROL AND AUXILIARY

EQUIPMENT

10-15

(Configuration, Diesel engine, Transmission system, Cooling

equipment, electrical system, Control system, Speed indicator cum

recorder etc.)

III VEHICLE DESIGN 16-23

(Body, Bogie, Axle gear drive arrangement, Underframe, Suspension,

Wheel, Axle & Axle boxes, External fittings, Interior Design, Driver’s

cab, Tool box, Seats, Small kitchen/Pantry, Toilet, Painting etc.))

IV BRAKE SYSTEM 24

ANNEXURES

Sl. No. Description Annex. No.

1. Fire retardancy norms of the major furnishing items Annexure-A

2. GA Layout of NG Railcar Annexure-I

3. Maximum Moving Dimension SK.DP-3347 Annexure-II

4. Tractive effort vs. Speed curve Annexure-III

5. Engine & Transmission equipment particulars Annexure-IV

6. Design data, calculation & drawing particulars Annexure-V


Specification for Narrow Gauge Diesel Railcar with twin power-pack (for 762mm Gauge Kalka –Shimla

Section over Northern Railway)

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SPECIFICATION FOR

NG DIESEL RAILCAR WITH TWIN POWER-PACK (For 762 mm Gauge Kalka - Shimla Section over NR)

Specification no. MP - 0.08.00.24 (Rev 0.07) March - 2014

CHAPTER- I

1. GENERAL

1.1 Scope

1.1.1 This specification covers the design, manufacture and supply of two- axle bogie type Railcar in completely assembled and furnished condition for operation on 762 mm Gauge in Kalka - Shimla section of Northern Railway of Indian Railways.

1.1.2 The Railcar is a self propelled, light weight, low cost rail passenger vehicle. The Railcar shall be bi-directional unit with driving cabs at both ends for better visibility and ease of operation. It shall be aesthetically and ergonomically designed with aerodynamic end profile. The design shall generally conform to the layout indicated in Annexure - I. However, details furnished therein are only indicative for the guidance of supplier except those covered under Basic Data in Clause 2.

1.1.3 The supplier shall propose & submit General Arrangement layout (G.A. Layout) indicating technical details of individual equipments as per details given in this specification. G.A. layout shall indicate the side view of railcar within MMD.

1.1.4 Any better G.A. Layout other than Annexure - I, shall also be proposed & submitted by the supplier for consideration of RDSO.

2. DETAILED OPERATING REQUIREMENTS AND OVERALL DIMENSIONS

2.1 Basic Data:

.1 Gauge : 762 mm

.2 Service : Passenger

.3 Unit length (over body) (mm) : 10200

.4 Bogie Centres (mm) : 5280

.5 (a) Body width over sidewall (mm) : 2220 (b) Body width over water wriggle (mm) : 2270 .6 Bogie wheel base (mm) : 1590 .7 Tare weight (estimated) : 17 t (max.) .8 Gross weight (estimated) : 20 t (max.) .9 Axle load (estimated) : 5 t (max.) .10 Seating capacity : 18 .11 Wheel diameter over tread - New

- Fully worn : 700 mm : 640 mm

.12 Height over roof above rail level (mm) : 2970

.13 Floor height (under Tare) (mm) : 950

.14 Maximum height above rail level for towing hook for unloaded vehicle (mm)

: 535

.15 Min. height above rail level for towing hook for fully loaded vehicle (mm)

: 480

.16 Installed engine power (Continuous rating) under site condition

: 300 hp (Min.) as per details given in Chapter-II

.17 Maximum Operating speed (km/h) : 35

Maximum Test speed (km/h) : 40




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2.2 Track data: The Railcar shall conform to the requirement of the N.G. Schedule of

dimensions 1962 for Kalka - Shimla Section as applicable for bogie vehicle and for the condition specified herein: -

.1 Sharpest curve : 48° .2 Standard crossing : Max. angle 1 in 4.88

: Min. angle 1 in 8.5 .3 Length of tongue rail : Max. 3658 mm

: Min. 2286 mm .4 Ruling gradient : 1 in 33 .5 Maximum Super-elevation (mm) : 64 .6 Max. Cant deficiency (mm) : 40 .7 Maximum wind pressure : 200 kg/m2 .8 Clearance above rail level : 76 mm - Under fully loaded condition and

with fully worn wheels. .9 Maximum moving dimensions : Shall conform to RDSO Drg. No. SK DP –

3347 (Annexure – II). .10 Dynamic augment : 30% max.*

Lateral flange force per axle : 3.3 t max.* Un-sprung weight per bogie : 2.3 t max.* (* These should be as low as possible)

2.3 Climatic conditions:

.1 Atmospheric Temperature : -100 C to 550 C Max.

.2 Altitude : 0 - 2100 m above mean sea level.

.3 Humidity : 100% saturation during rainy season.

.4 Rain fall : Very heavy in certain areas. The Railcar shall be designed to permit its running at 10 km/h with water level of 200 mm above rail level.

2.4 Schedule of Dimensions (SOD) 2.4.1 Copies of N.G. Schedule of dimensions 1962 for Kalka - Shimla Section may be

obtained on payment from the Controller of Publications, Government of India, Civil Lines, Delhi – 110054, India.

2.4.2 Copies of IS Specifications are available from the Bureau of Indian Standards, 9,

Bahadur Shah Zafar Marg, New Delhi – 110002.

2.4.3 The equipment layout and overall dimensions of Railcar shall be within the maximum,

minimum and recommended dimensions specified N.G. Schedule of dimensions 1962 for Kalka - Shimla Section. On straight tangent track, the Railcar shall be within the profile as shown in Annexure-II. The proposed layout of Railcar with equipment should be submitted along with the offer. The lateral dimension and shape of the Railcar shall be such that while negotiating the sharpest specified curve, the profile is within the extra clearance permitted in the section. Vogel‟s diagram indicating the throw-over at the end and in the middle of Railcar shall be submitted with the offer.

2.5 Curve, Grade, Tunnels and Bridges 2.5.1 The section has continuous grade and curves. It rises 1420 m from Kalka (at 656 m

above M.S.L.) to Shimla (at 2076 m above M.S.L.) with an average gradient of 1 in 67. Kalka to Kumar Hatti (38 km) has rising grade followed by falling grade between Kumar Hatti and Kandaghat (20 km). Then from Kandaghat to Shimla there is rising grade over remaining 38 km. The maximum gradient in the section is 1 in 33.




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2.5.2 The section has 918 transition curves. Almost 70% of the entire track is curved. The curves in the section are not compensated. The maximum curvature in the section is 48° i.e.36.38 m.

2.5.3 There are 102 tunnels aggregating nearly 8 km with longest tunnel being Barog tunnel

of length 1143.61 m. 2.5.4 Section has 869 bridges covering about 3% of route length. 2.6 Performance capability 2.6.1 The performance of the Railcar shall generally conform to the Tractive Effort Vs Speed

curve No. G/DP – 1071 (Annexure III) under the climatic conditions mentioned in Clause 2.3.

2.7 Vibration 2.7.1 The equipment, sub-system & their mounting arrangement shall be designed to

withstand satisfactorily the vibration and shocks encountered in service.

2.8 Noise Level 2.8.1 The noise level in the driver's cab and passenger compartment shall be kept as low as

possible by limiting the noise through appropriate measures (acoustic insulation, sound absorption). With all the doors and window closed, the noise level in the car interior (under tare condition) shall be less than 70 dB (A) when the Rail car is running at a speed of 35 km/h and all vehicle system operating simultaneously at normal condition. Exterior noise level of railcar shall be less than 80 dB (A).

3. DESIGN DEVELOPMENT & APPROVAL OF DRAWINGS

3.1 The contractor shall develop the design based on the details given in this specification and sound engineering practices. The entire design data shall be submitted in metric units with calculations to RDSO. The firm shall submit the drawings for approval to RDSO.

The detailed calculations shall cover:-

- Hauling capacity calculation.

- Braking effort and EBD calculation on plane section with maximum load/without load.

- Calculation of centre of gravity of Railcar from rail level, details of weight transfer calculation, tractive effort versus speed curve.

- Railcar balancing calculations in longitudinal and lateral modes.

- Life rating calculation of axle box bearings.

- Stress analysis of all major stress parts of the Railcar like body shell, bogie frame, suspension springs, axle, brake rigging including hand brake etc. FEM of body shell and bogie frame shall also be supplied.

- Calculation for safety against derailment. Calculation for stability of the Railcar against wind force shall be supplied.

3.2 The equipment layout & general arrangement of Railcar shall generally be Annexure-I. Contractor shall prepare a full set of working drawings in standard sizes complete in all respects. The drawings shall include general arrangement of Railcar, equipment layout




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and power pack arrangement & mounting details, diagram showing maximum and minimum moving dimensions, under frame assembly (section and details), Bogie arrangement (section and details), Wheel axle and axle boxes, Suspension arrangement (primary & secondary), brake schematic & rigging arrangement including hand brake and its details, Sanding gear arrangement with details, cab superstructure & control panel layout details, fuel tank arrangement with details, pivot lubricating arrangement, engine & transmission cooling arrangement with radiator mounting details, exhauster & compressor drive arrangement, axle drive gear box, control system & cubicles etc. Apart from it, submission of any additional drawings shall be indicated by RDSO to the contractor during design approval stage and contractor has to comply it. All drawings shall include description of equipment, weight, quantity per Railcar, material specification, welding symbol, tolerances etc.

3.3 Materials used for manufacture of the Railcar shall comply with the relevant IRS or BIS specifications. Alternate materials can be used only with the prior approval of RDSO. Where IRS or BIS specifications do not exist, the contractor shall submit proposed material specification for approval of RDSO.

3.4 "Approval” to the drawings denotes general “acceptability” of the design features. Notwithstanding such an approval, the contractor will be wholly and completely responsible for the adequacy of the design of the Railcar offered. The contractor when submitting proposals on designs for approval of the RDSO shall draw specific attention to any deviation or departure from the specification involved in his proposals or drawings.

3.5 To facilitate filing of drawings in RDSO, it is essential that each drawing prepared for the manufacture/operation/maintenance shall be marked so that it can be identified. The contractor shall, therefore, ensure that all prints submitted are marked legibly at the right hand bottom corner. The following information is required in respect of each drawing submitted:

.1 Contractor's drawing Number

.2 Contractor's name and date of submission

.3 Contract Number

.4 Nomenclature of the Railcar

.5 Descriptions 4. QUALITY ASSURANCE PLAN 4.1 The contractor shall formulate Quality Assurance Plan (QAP) detailing the methodology

proposed to be followed to ensure quality product. QAP shall cover quality assurance procedures to be followed during all stages of design, planning, procurement, manufacture, testing, commissioning and servicing. The contractor shall define the role of each functional group in the organisation for achieving the required quality of the products and submit a comprehensive document of QAP.

4.2 The supplier whose bid is accepted shall be required to submit a detailed “Quality Assurance Plan" which shall supplement the “Quality Assurance Manual” by giving details of how the quality of specific product is proposed to be assured. Manufacture of Railcar shall commence only after "Quality Assurance Plan" is approved by the purchaser.

4.3 The above shall apply to contractor as well as sub- contractors.

5. STAGE INSPECTION

5.1 All the materials, components, fittings, sub-assemblies etc., covered by this




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specification shall be subjected to inspection by the Inspecting Officer and shall be to his entire satisfaction.

5.2 The Inspecting officer shall have powers to:

- Adopt any means as deemed fit to satisfy himself that the materials used are strictly to the specifications.

- Take samples for such tests, as he may consider necessary, by an approved metallurgist selected by him, whose report shall be final and binding on the contractor.

- Visit at any reasonable time and without previous notice, the contractor's and sub-contractor's works to inspect the progress and quality of the work. The contractor and sub-contractor(s) shall provide free of charge all facilities viz. equipment, labour, gauges etc. required for this purpose.

- Reject materials or fittings not conforming to the relevant specification. Such rejected parts shall be replaced by the contractor without extra charge.

5.3 Tests of materials and fittings shall, as far as possible, be carried out at the respective manufacturer's works. All tests shall be at the cost of the contractor.

6. INSPECTION AND ACCEPTANCE TESTS OF PROTOTYPE RAILCAR 6.1 The contractor shall manufacture prototype Railcar for inspection and acceptance of

RDSO‟s representative before commencement of series production.

7. PERFORMANCE TEST

7.1 The supplier shall submit the test schedule during design approval stage and these will be mutually agreed between RDSO and contractor.

7.2 The prototype Railcar shall be subjected to tests pertaining to car body, tests pertaining to brake system, stall test, checking of various safety interlocks, mechanical tests (torque test of various power pack assemblies), dimensional, functional / operational tests etc. at manufacturer‟s works as per the mutually agreed test scheme between RDSO & the contractor.

7.3 A test scheme shall be finalized based upon the inspection of prototype for the remaining Railcars.

8. Weighment

8.1 On completion of the prototype, the weights upon each wheel in full working order shall be ascertained by fully calibrated measuring equipment. The Railcar shall be weighed 4 times successively, to get the arithmetic mean.

Check shall be made to ensure the following: i. Total weight is within ± 2% of nominal weight. ii. Axle load is within ± 2% of nominal axle load. iii. The difference between the loads on two wheels of same axle shall not be more

than 4% of the axle load.

The weighment will be done on the prototype only.

8.2 Oscillation Trial

The prototype Railcar shall be cleared for oscillation trial only after it has successfully cleared the tests under Clause 8.1 & 8.2. The trial will be conducted on track stretches in run down condition up to a speed 10% higher than the operating speed. The trial scheme for oscillation trial, braking and haulage capacity shall be finalized by RDSO.

8.3 Track standard

8.3.1 The following shall be the track standards of the test sections.




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i) Track structure : 60 lbs rails with wooden or metal sleepers to N+3 density on consolidated and stable formation.

ii) Permitted irregularities : Gauge : -3 mm to + 6 mm Unevenness on 3.6 m base : upto 10 mm Twist on 3.6 m base : upto 15 mm at the rate of 3mm/m Alignment on 7.2 m base : upto 5 mm

8.3.2 Riding quality

The riding quality tests shall be conducted upto maximum test speed of 40 km/h or upto a test speed permissible speed in section.

8.3.3 Acceptance criteria

The following shall be the acceptance criteria:-

i) The dynamic augment at maximum test speed shall preferably be within 30% at Rail level.

ii) The lateral forces* at maximum speed shall be within the following:-

Unladen : 1.7 t/axle

Fully laden : 1.9 t/axle

iii) The acceleration shall not exceed 0.3 g both in vertical and lateral modes in tare and loaded conditions however; a peak value up to 0.35g may be permitted, if the records do not indicate a resonant tendency in the regions of peak value.

iv) The sperling ride Index shall not exceed 3.5, both in vertical and lateral mode in tare and loaded condition.

v) The derailment co-efficient shall not exceed one.

vi) Ride Index shall be measured as per ORE C-116 Report 8 or RDSO method i.e. sperling Ride Indexed calculated in time domain.

*The equipment/Adaptor for measurement of lateral forces shall be supplied by manufacturer/supplier for the trial.

8.3.4 Braking trials:

Braking trials for both stationary and running shall be conducted as per requirement of Chapter III.

8.3.5 Haulage Capacity:

Trial runs shall be conducted over the sections specified by the purchaser with maximum load as specified to ascertain the hauling capacity of the Railcar.

8.3.6 Performance capability

The Railcar shall be subjected to suitable test to establish its performance based on data supplied by the supplier against Clause 2.5 of Chapter - I of this specification.

9. SERIES MANUFACTURING OF THE RAILCAR

9.1 The contractor at his cost will carry out the modification, If any, is required on any assembly/sub-assembly/equipment after the above tests on the prototype. Series manufacture shall not commence until and unless the purchaser or his authorized representative has approved the prototype.

9.2 Inspection and Acceptance tests of balance Railcars.

The inspection of the balance Railcars will be carried out as per Clause 8.

10. COMMISSIONING OF THE RAILCAR 10.1 The Railcar shall not be dispatched or packed until it has been passed by the

Inspecting Officer. Such passing shall in no way exonerate the contractor from




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obligation in respect of quality and performance of the equipment. In the event of dispute between the Inspecting Officer and the Contractor, the decision of the Purchaser shall be final and binding.

10.2 The consignee railways shall inform the contractor after the Railcar has reached at site. The Railcar shall be commissioned by the contractor after intimated by the consignee. The consignee railways will issue a commissioning certificate after it has been successfully commissioned.

11. MAKER'S CERTIFICATE

11.1 Copies of Maker‟s certificate guaranteeing the each Railcar performance of the Railcar shall be submitted in duplicate along with the delivery of.

11.2 Test certificates of major vendor items shall also be supplied along with each Railcar.

12. DESCRIPTIVE INSTRUCTIONS PAMPHLETS

12.1 The contractor shall supply to RDSO and the User Railway, adequate number of descriptive instruction OEM pamphlets/manual/brochure pertaining to items like Diesel Engine, Hydraulic transmission, Axle drive, Cardan shaft and brake equipments etc. The pamphlet shall include Dis-assembly and assembly procedure with suitable illustration and diagram/drawing with exploded view along with general arrangement, brake arrangement & schematic, electrical wiring diagram and lubrication diagrams/charts.

13. SERVICE AND SPARE PARTS CATALOGUES

13.1 The tenderer shall submit three copies of operating, maintenance & service manual and complete spare parts catalogue along with the details of various sub-systems with illustrations and block diagrams at the address: Director General (MP), RDSO (Ministry of Railways), Manak Nagar, Lucknow – 226 011 And one set of Operation & Maintenance manual and spare parts catalogue shall also be supplied free of charge to the purchaser for use on the Railway.

13.2 Detailed operating manual, maintenance and service manual and driver hand book shall be specifically prepared for the Railcar and at least 3 copies each of the same shall be supplied free of charge per Railcar to the consignee and three copies to RDSO. The draft contents of the manuals shall be submitted for approval to RDSO. These documents shall also be supplied on compact disc (CD) compatible to MS-Office software.

The manual shall include chapters on : - General characteristics - Railcar design and its details including under frame design - Power equipment & details with mounting - Fuel, oil and cooling water circuit. - Grease, oil chart with specification and quantity - Bogie design & suspension details - Wheel, Axle & axle set assembly with axle box bearing details - Brake rigging arrangement with schematic diagram of pneumatic circuit - Wiring diagram with complete illustration of components - Controls and safety features & their test procedure, - Special tools etc.

13.3 The manual shall include Dis-assembly and assembly procedure with specific mention




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of any special tools required for carrying out the above work.

13.4 Manual shall include a separate chapter indicating the service and condemning/wear limits & tolerances for various assembly/sub-assembly, wherever applicable.

13.5 The manual shall contain a separate chapter pertaining to standard schedule of examination covering all equipments i.e. engine, transmission, axle drive, cardan shaft, controls, brake rigging, suspension etc for trouble free day to day maintenance of Railcar as per Railway maintenance norms.

13.6 A separate booklet containing Driver‟s operating instruction accompanied by suitable illustration and diagram and lubrication chart shall be prepared.

14. SUPPLY OF DRAWINGS

14.1 The contractor, after inspection and approval of the prototype shall correct, wherever necessary, the drawings and schedule of material conforming to the prototype unit. The contractor after incorporating all changes and modifications shall furnish three copies of final drawings along with schedule of material to RDSO. Two copies of drawings shall be supplied with Railcar to the consignee.

14.2 Two complete set of hard copies of drawings shall be supplied and soft copy in Auto

Cad Release 2010 on CD to RDSO after the final approval of Prototype unit. Also, scanned soft copy of all the approved drawing shall be submitted to RDSO for reference and record. The drawings shall include general arrangement of Railcar, equipment lay out and power pack arrangement, diagram showing maximum and minimum moving dimensions, under frame assembly (section and details), Bogie arrangement (section and details), Wheel, axle and axle boxes, Suspension arrangement (primary & secondary), brake rigging arrangement including hand brake and its details, Sanding gear arrangement & details, cab & superstructure with details, fuel tank arrangement & details, pivot lubricating arrangement, engine, transmission & radiator mounting details, engine cooling arrangement, compressor drive arrangement, axle drive gear box with torque arm assembly, control system & cubicles.

15. SPARE PARTS

15.1 The supplier shall submit a list of spare parts and special tools, both indigenous and imported, indicating the name and address of the manufacturers as detailed below:

List – A: Catalogue of unit spares, indigenous and imported, of the principal assemblies of the Railcar such as the diesel engine, transmission, cardan shaft, axle drive, compressor, exhauster, brake equipment etc. with price.

List – B : Recommended maintenance spares for two years initial requirements. The supplier shall submit the list of such spare parts giving their detail description, source of supply, part number of the supplier and price of each part.

15.2 The supplier shall be responsible for ensuring subsequent availability of spare parts for efficient working of the respective equipments.

15.3 The supplier shall also submit time bound plan/proposal for indigenous availability of imported components.

15.4 A spare part catalogue listing all components manufactured or purchased by the supplier shall be prepared and the draft of the same shall be submitted to RDSO for approval after clearance of the prototype. The contractor shall furnish three copies of spare parts catalogue to RDSO and two copies with Railcar to the consignee free of cost.

All manuals shall be dispatched to the address of the Director General (MP), Research Design and Standards Organisation, Ministry of Railways, Manak Nagar, Lucknow – 226 011.




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16. PHOTOGRAPHS

16.1 During manufacture colour photographs shall be taken of various assemblies/sub-assemblies especially of the bogie, under frame, power pack and body in various stages of production and of parts, which cannot be conveniently photographed after assembly. After completion, photographs of side and end views of Railcar as also of the interior layout will be taken.

16.2 The photographs shall not be less than 380 mm x 255 mm for the side view of the

completed Railcar, or less than 255 mm x 200 mm for other views and shall be taken on non-curl film. The negative and three prints of each photograph shall be furnished to RDSO, the prints being mounted on sheet to form complete sets.

17. TRAINING

17.1 The contractor shall provide training at the manufacturer‟s place for at least six working days for adequate number of Indian Railway personnel so that they acquire full knowledge of major assembly/sub-assembly used in Railcar. The training should help IR in trouble-shooting, maintenance and operation of the Railcar.

17.2 Besides the above, adequate number of maintenance and operating staff shall also be trained in the homing shed during the commissioning of the Railcar.

18. SERVICE ENGINEERING

18.1 The contractor shall provide, at his own expense, the services of competent engineers during the guarantee period and also during the first major overhaul of such nos. of Railcars as may be agreed upon. The service engineers shall be available for testing/commissioning of the Railcar, training of operating and maintenance staff. The service engineers shall also advise the Railways on maintenance, testing and operating facilities considered necessary for efficient performance of the Railcars.

18.2 The contractor shall submit a proposal for AMC with separate quotation for major equipments for trouble free maintenance of Railcar. The Railways will have right to accept or reject the offer for Annual Maintenance contract partly or completely.

19. TESTING KIT

19.1 The supplier shall indicate testing equipment required for ensuring optimum performance and trouble free service of Railcar as well as their major assemblies and sub- assemblies. The supplier with complete quotations shall submit details of testing equipments.

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CHAPTER- II

ENGINE, TRANSMISSION, CONTROLS AND

AUXILIARY EQUIPMENTS

1. CONFIGURATION

1.1 The Railcar shall be powered by twin power pack and each powerpack shall be powered by new generation diesel engine capable of producing 150hp (min.) continuous. The gross power of railcar shall be 300hp (minimum) continuous.

1.2 Both Diesel Engines shall preferably be centrally mounted with the railcar as shown in Annexure - I. Automatic transmission similar to modern hydrodynamic transmission shall preferably be directly mounted on the engines. The radiator / radiators shall be mounted in front of the engines or on roof depending on the availability of space.

1.3 The powerpack equipments shall be so mounted on the underframe that the whole assembly occupies as little over-floor space as possible. Supplier shall be responsible for integration of both power packs working as a single unit as per requirement of this specification.

1.4 Railcar shall be capable of running bidirectional with the same designed speed though single power pack / double power packs depending upon the requirements.

1.5 Both the driver‟s cab shall have all the controls & gauges alongwith safety devices for operating the railcar with single power pack / double power packs depending upon the requirements.

1.6 Hotel load required for passenger amenities

1.6.1 Power required for hotel loads, controls, lights alongwith auxiliaries shall be taken from both engines provided for traction. Traction of railcar shall not be affected by hotel load in any case during actual operation.

1.6.2 The details of additional passenger amenities are as follow.

i. Air condition in railcar ii. Fans iii. Lights iv. 17” LED/LCD/TV with DVD player- 2 nos. v. Laptop charging-2 nos. vi. Mobile charging- 2 nos. vii. Roof mounted CCTV Camera-2 nos. viii. Music system / FM ix. Water boiler (to be provided with mini-kitchen/small pantry) x. Soup warmer (to be provided with mini-kitchen/small pantry) xi. Bottle cooler (to be provided with mini-kitchen/small pantry) xii. Deep-freezer section (to be provided with mini-kitchen/small pantry) xiii. Refrigerator section (to be provided with mini-kitchen/small pantry) xiv. Hot case vegetarian food (to be provided with mini-kitchen/small pantry) xv. Hot case non vegetarian food (to be provided with mini-kitchen/small pantry) xvi. Microwave oven (to be provided with mini-kitchen/small pantry)

1.7 The supplier shall propose & submit power pack layout indicating technical details such as make, model, max. rating, envelope size, weight etc. of individual equipments as per details given in Annexure - IV of this specification.

1.8 Any better alternative proposal of power equipment layout shall also be proposed & submitted by the supplier for consideration of RDSO.




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1.9 The noise level due to operation of offered powerpack shall be within the limit as per clause 2.10 of UIC 651 OR.

2. DIESEL ENGINE

2.1 The new generation diesel engine shall be of reputed make indigenously available and of proven performance in traction / automotive application. The continuous rating of each engine under site condition shall not be less than 150hp.

2.2 The Diesel Engine shall work satisfactorily with fuel oil to Indian Standard Specification No. 1460 (2005).

2.3 The offered diesel engine shall meet the emission standard of Euro-III or equivalent standard. However, the supplier shall clearly spell out the emission standards of the engine being offered. Engine shall be fitted with the system for after- treatment of exhaust gases known as Selective Catalytic Reduction (SCR).

2.4 Air intake arrangement for engine shall be mounted above the floor level and air shall be taken from either side of railcar. In any case, the temperature & humidity inside the railcar shall not be affected by air intake system and vice-versa.

2.5 Two stage paper element centrifuge type air filter of adequate capacity with restriction indicator shall be provided.

2.6 Exhaust silencer and exhaust pipe work shall be flexibly mounted. Exhaust discharge shall be on to the track. Exhaust pipe & silencer shall be provided insulating laggings.

2.7 The supplier shall furnish the technical details of the engine as per Annexure - IV.

2.8 A fuel tank of not less than 320 litres capacity or capacity of 8 hours of running of engine on full load, whichever is more shall be provided. The tank shall be provided with the fuel level gauge. The level indicator plate shall be graduated to indicate the quantity of fuel oil in the tank.

2.9 Provision of pre-heating device: Provision shall be made for necessary pre-heating arrangement to start diesel engine under cold climatic condition as per clause 2.3.1 of Chapter-I.

2.10 The supplier shall furnish a copy of 100-hours Type Testing report of the engine as per UIC-623-OR by a Statutory Body in support of their claim regarding performance, reliability & specific fuel consumption. In case, the offered engine is being used first time in Indian Railways, the 100-hours type testing shall have to be carried out in accordance with UIC 623-2-OR in the presence of RDSO's authorized representative and the scheme for type testing shall be finalised by RDSO & supplier jointly.

2.11 For all the remaining engines, other than the first engine offered for 100-hours type testing, the Routine test report shall be required to be submitted alongwith respective engines at the time of supply to RDSO for approval.

2.12 The supplier shall inform about any modification carried out in the diesel engine & accessories at any stage.

3. TRANSMISSION SYSTEM (AUTOMATIC)

3.1 Suitable transmission system similar to modern hydrodynamic transmission having the following features shall be proposed by OEM for approval by RDSO.

3.2 The transmission system with high efficiency shall be automatic for smooth acceleration & deceleration and shall be suitable for bi-directional operation and preferably directly mounted on to the engine. The reversing arrangement & retarder shall be integrated with the transmission. This shall be indigenously available, of reputed design, make and proven performance in automotive / rail application.




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3.3 The power shift system, if provided, shall be automatic.

3.4 The system shall provide smooth shifting at full power while changing direction of travel.

3.5 The Tractive effort Vs speed characteristic of the Railcar shall not be inferior to the curve shown in Annexure - III.

3.6 The contractor shall be responsible for carrying out detailed torsional vibration analysis of complete dynamic system to ensure their proper matching.

3.7 The supplier shall furnish the complete technical specification/details of the elements of transmission system, describing their working principles etc. as per Annexure - IV.

3.8 In case of breakdown of railcar in mid section, arrangement for safe towing of railcar to the homing shed, without damaging the powerpack, shall be provided with the transmission and shall be integrated. The instructions for safe towing shall be provided by OEM.

3.9 Special care shall be taken to ensure reliable and efficient performance of the transmission without failure during operation. The system shall not call for any special care on the part of the driver to protect the transmission from damage under any circumstances.

3.10 The supplier shall furnish a copy of Type Test report of the transmission by a Statutory Body in support of their claim regarding performance, reliability and efficiency. In case the transmission offered is not Type tested earlier, the testing shall be carried out in the presence of RDSO's authorized representative.

3.11 The supplier shall inform about any modification carried out in the transmission system & accessories at any stage.

4. COOLING EQUIPMENT

4.1 The cooling system shall consist of engine mounted cooling fan driven directly from the auxiliary end of the engine. If required, cooling system shall be mounted over the roof.

4.2 Composite type of radiator for cooling the water, lubricating oil shall be preferred. In case hydrodynamic transmission is used, separate radiator for transmission oil 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. The maximum water temperature shall not normally exceed 850C. The system shall be adequately pressurised and vented to avoid all possibilities of cavitation.

4.3 The calculation in support of above, mainly consisting of the following shall be submitted: -

Cooling requirement for all sources of heat (with break up).

Heat dissipation characteristic of the radiator and its resistance characteristics.

Radiator fan characteristics showing the air-cooling Vs total (heat) head at different speeds.

Cooling system-matching calculations.

Schematic cooling circuit diagrams showing water, oil and air flow through each equipment.

4.4 The cooling system shall be designed to perform efficiently for temperature range from –10 °C to 55 °C.

4.5 Suitable insulation arrangement shall be made to minimise heat transfer from power pack to passenger compartment.

4.6 The design of radiator cooling system shall be such that it must efficiently work in both direction of travel of NG railcar at the design operating speed.

4.7 The supplier shall inform about any modification carried out in the cooling system &




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accessories at any stage.

5. ELECTRICAL SYSTEM 5.1 Alternator (24V DC supply): Engine mounted auxiliary alternator with rectifier

equipment of adequate capacity for the speed range between idle and maximum of engine speed shall be provided to supply 24V DC. This auxiliary alternator shall cater to:-

.1 Fog light

.2 Two headlights

.3 Four tail lights

.4 Adequate lighting arrangement inside the Railcar including the driver's cabin i.e. entrance stairs, gangway, luggage compartment, passenger compartment shall be illuminated. LED type Ceiling lights, reading lights surface mounted/flat- flash mounted with precision reflector. Provision of reading lamps for passengers.

.5 Electrically operated heavy-duty windscreen wipers at the driving end.

.6 Engine starter motor.

.7 PA system and piped music system

5.2 Suitable arrangement to cater hotel load as mentioned in para 1.6.2 of chapter-I shall be proposed by the tenderer.

5.3 Battery: Low maintenance (LM) Lead acid storage batteries to IS: 7624 of 24 V, of adequate capacity with a fuse protection and of reputed make shall be provided in the Railcar. The battery shall cater to the following loads:

.1 Six cranking of engine at 10 seconds interval.

.2 All auxiliary generator load of the locomotive for two hours in case of auxiliary generator failure.

5.4 The cable layout shall be so done that number of junction boxes; cubicles etc. are minimum and shall be suitably located to facilitate easy maintenance. The cables used for control and power should be as per specification no. EDPS-179 and EDPS-304.

5.5 Two plug points, one on either side of underframe shall be provided for use of portable electric lamp.

5.6 The battery shall be in pull out container accessible from outside. Terminals for charging the batteries from external charging equipment shall also be provided. The location of the batteries shall be such that there is no danger of their getting damaged due to tools and equipment inadvertently falling on them. If the cells are packed in two rows in the battery box separated by a hylam sheet

6. CONTROL

6.1 Adequate control equipment including gauges, instruments, and safety devices shall be provided on a central control stand for safe and satisfactory operation of the Railcar. The equipment shall be so arranged on the control desk that it will be within the easy reach of the driver. The layout of the instrument panel shall be ergonomic. Interlocking

6.2 The Railcar shall generally work as a single unit. The control system shall have the provision to operate the railcar in towing mode.

6.3 Interlock shall be provided such that the railcar can be operated from one cab only at a time.

7. GAUGES, INSTRUMENTS AND SAFETY DEVICES:

The following gauges, instruments and safety devices shall be provided for safe and satisfactory operation of the Railcar:




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A. Diesel Engine

.1 Engine starting switch/push button.

.2 Engine stop switch/push button

.3 Engine emergency stop switch/push button

.4 Engine throttle controller

.5 Lube oil pressure gauge

.6 Lube oil temperature gauge

.7 Battery charge/discharge Ammeter

.8 Engine hour meter and engine speed indicator

.9 Cooling water temperature gauge

.10 Cooling water level indicator

.11 Booster Air Pressure gauge

.12 Glow type Fuel level indicator

All gauges shall be of proven and reliable design with self-illuminating dials. Graduations of the gauges shall be in metric units. The instrument panel shall be arranged in the form of a desk and suitably located on the control panel to ensure better crew efficiency and faster response. B. Transmission Essential gauges for transmission shall be proposed by OEM for approval by RDSO.

C. Other gauges

The Railcar shall be provided with the following gauges pertaining to brake system. All the gauges should be LED type self-illuminated.

.1 Main reservoir (MR) pressure gauge : 4 inches

.2 Brake cylinder pressure gauge : 4 inches (Duplex type indicating brake Cylinder pressure of both the bogies )

.3 Brake pipe gauge : 4 inches .4 Parking brake gauge : 4 inches

D. Safety Devices

.1 Water temperature high : Engine to idle

.2 Low lube oil pressure : Engine to shut down

.3 Engine speed high : Engine to shut down

.4 Radiator water level low : Engine to shut down

.5 Emergency engine stop : Fuel supply to engine cut off

.6 Emergency brake application : Engine to idle

.7 Provision of VCD and : Application of penalty brakes, Over speed trip device Transmission to neutral and

Engine coming to idle

E. Audio-visual Signals / Reference Panel Lights

.1 Lube oil temperature high

.2 Water temperature high

.3 Low water level

.4 Low lube oil pressure

.5 Engine over speed

.6 Engine shut down by safety relay

.7 Engine starting

.8 Battery discharging

8. CONTROL SYSTEMS




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8.1 The supplier shall submit the pneumatic and electric control diagram for all systems of the Railcar for approval of RDSO.

9. SPEED INDICATOR CUM RECORDER 9.1 Speed indicating and recording equipment of 0 – 75 km/h range, shall consist of an

axle box mounted opto-electronic speed sensor, one speed indicator, one recorder cum indicator unit with micro controller containing FLASH EEPROM internal memory for calculating and recording the journey data a portable FLASH memory card for external memory. The equipment shall conform to RDSO specification No. MP-0.3700-07 (Rev.05) of August‟ 2008 or latest.

10. FLASHER LIGHT

10.1 The Railcar shall be provided with Flasher light using high intensity LEDs conforming

to specification No. ELRS/Spec/FlasherLight/0017 (Rev-1) of Sept‟2004 or latest.

11. HEAD LIGHT 11.1 Two twin beam Head light, one at each end, shall be 100 W/90 W, 24 V, sealed beam

type as per RDSO specification No. ELRS/SPEC/TR/0024 (Rev-1) of Sept‟2004 or latest.

12. MARKER LIGHT 12.1 The Railcar shall be provided with Marker light to RDSO specification for LED Marker

light for electric loco/diesel electric loco No. ELRS/SPEC/ PR/0022 (Rev-1) of Oct‟2004 or latest.

.

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CHAPTER-III

VEHICLE DESIGN

1. BODY

The body shall be fabricated with stainless steel (306) due to better strength & corrosion resistant. The body shall be of all welded construction consisting of the underframe, body sides and roof carlines. Steel roof shall be provided as shown in Annexure - I. The weight shall be kept as low as possible consistent with adequate strength.

1.10 The supplier shall propose drawing of complete body shell structure indicating technical details of individual parts.

1.11 Any better alternative proposal of body shell structure shall also be proposed by the supplier for consideration of RDSO.

1.12 While designing of railcar static & dynamic balancing shall be taken care of by supplier.

1.13 Railcar, in any case, shall not infringe to MMD.

2. BODY SHELL

a. The body shell shall be of stainless steel (306). The body structure shall be fabricated by using pressed stainless steel members welded together. The exterior of the body sides and end panels shall be without bulges or depressions.

b. Suitable pillars shall be provided in railcar, if necessary to support the roof of railcar.

c. The Railcar body shall be protected from corrosion.

d. The body shell shall be provided with suitable insulation to minimise transfer of heat to Railcar.

e. The driving ends of Railcar may be designed with aerodynamic profile as shown in Annexure-I or better.

3. UNDERFRAME

3.1 The underframe shall be designed for 100% overloading and shall be capable of withstanding the maximum static and dynamic stresses under the loaded conditions.

3.2 Design shall incorporate lifting pockets and jacking pads at suitable locations.

3.3 The Railcar shall be longitudinally and laterally balanced such that difference in wheel loads does not exceed 5% of the nominal value.

3.4 Provision shall be made in the end structure of the under frame for the fitment of draw and buffing gear as used in existing NG locomotives in service in Kalka-Shimla section.

3.5 The underframe shall be provided with two pivot pins at suitable locations. The design of the pivot pin shall be such that it shall be capable of withstanding the traction and braking force.

4. BOGIE

4.1 The Railcar shall have two axle bogies of radiographic quality weldment and of appropriate design suitable for taking the brake gear, suspension, drive gear boxes etc. The bogie shall consist of two longitudinal members connected by a cross member at a suitable location and shall preferably be of a box section fabricated from steel plates to IS: 2062, Grade WC, welded together. The bogie shall be capable of withstanding the maximum static and dynamic stresses under 100% overloading condition with 30% dynamic augmentation and meet the performance requirements as specified in




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Clause 2.4 of Chapter-I. The weight of the bogies shall be as low as possible consistent with strength and robustness. The design shall provide suitable suspension. The design shall particularly ensure that the Sperling Ride Index value does not exceed 3.5 at a maximum test speed of 40 Km/h. The bogie shall be capable of negotiating curves of 36.38 m radius and turnouts of 1 in 4.88.

4.2 Effective measures shall be adopted to minimize the weight transfer while starting, stopping and during runs. The supplier shall furnish detailed calculations for weight transfer and adhesion efficiency of Railcar.

4.3 The general design of the bogie shall permit easy access to running gear, brake gear and axle drive gears, when in position under the body and shall permit easy replacement of brake block without the need of special pit on the track.

4.4 The safety straps of adequate size shall be provided to ensure support in event of failure of brake hangers, link or other components.

4.5 Centre pivot arrangement

4.5.1 The centre pivot arrangement shall be suitably located in the cross-member of the bogie to accommodate pivot pin. The design of centre pivot shall be such that the bogie rotation is guided at this point which also transmits the braking and traction force between the bogie and underframe but does not share any vertical load. This arrangement shall be arranged in an oil bath. The bellow type seal shall be provided for the oil bath between the bogie and underframe to prevent ingress of dirt/ foreign particles.

4.6 Suspension and axle box guidance

4.6.1 The design of suspension system shall be such as to provide safe running of Railcar at the maximum design speed with adequate comfort to passengers.

4.6.2 The suspension and axle box guidance system shall be suitable for providing adequate riding comfort, ability to negotiate sharp curvature and safety against derailment with highest possible safety margin.

4.6.3 The springs shall be designed for 100% overloading and 30% dynamic augmentation. Only helical springs shall be used and these shall be as per RDSO's specification No.WD-01-HLS-94 (Latest revision with all amendments) and shall be procured from RDSO's approved sources.

4.6.4 The supplier shall furnish detailed design drawings of suspension and axle box guidance system with supporting calculations. Procedure for towing hook height adjustment shall be indicated by the supplier.

5. WHEELS, AXLES AND AXLE BOXES

5.1 The wheels shall be of solid rolled type. The wheel shall be to IRS DRG. No. D/WL - 4970 (700 dia.).

5.2 The powered axles shall be to IRS: R-43/92. The non-powered axles shall be to IRS: R-16. The axles shall be designed to take up roller bearings of approved design.

5.3 The design of powered axles shall be suitable for fitment of axle drive gear box and torque reaction arm brackets. Design calculation for the powered axles shall be submitted for approval of RDSO.

5.4 Roller bearings shall have minimum life rating of 650000 kms when computed as per methodology given in ISO 281/1.

5.5 Lubrication of the roller bearings shall be in accordance with the recommendations of the manufacturers.

6. DRAW & BUFFING GEAR

6.1 Draw and buffing gear shall be specified by the Northern Railway and shall be as being




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used on the rolling stock in service in Kalka – Shimla section.

7. SANDING GEAR

7.1 Pneumatic sanding shall be provided on the wheels of the Railcar and shall be effective in either direction of travel. The sand boxes shall be preferably bogie mounted.

7.2 The sanding gear shall be capable of functioning properly in humid climatic conditions where sand does not remain dry and also absorbs moisture from the compressed air.

8. WHEEL SLIP PROTECTION

8.1 Wheel slip protection to protect the wheel from damage associated with sliding when braking or spinning in traction shall be provided with railcar.

9. WIND SCREEN WIPERS

9.1 Heavy duty wind screen wipers to RDSO specification of wiper arm and blade assembly No. C-K306 or latest shall be provided to protect against weather conditions like snowfall, heavy rain etc.

10. CATTLE GUARD

10.1 Cattle guard of suitable design shall be fitted at driving end of the Railcar. Suitable rail guards shall also be provided.

10.2 The provision for cattle guard/rail guard height adjustment shall be made.

11. EXTERNAL FITTINGS

11.1 Door openings

11.1.1 Two doors, one on either side of the Railcar for passenger entry and exit shall be provided. There shall be separate door for driver‟s cabin.

11.1.2 All door openings shall be perfectly square so that doors open and close freely and when closed shall be reasonably weather proof and dust proof. The door shall be single leaf inward opening hinged type with locking arrangement.

11.1.3 Door foot steps The door footsteps shall be provided and shall also have chequered stainless steel plates”

11.1.4 Door hand holds Door hand-holds of stainless steel tubes with stainless steel brackets shall be provided on either side of the doors. The door hand holds shall not project beyond the width of Railcar body.

11.1.5 Door locks All body side doors shall be fitted with guards lock to be operated from outside.

11.1.6 Water wriggles Continuous water wriggles extending over the entire length of the Railcar shall be provided on either side.

11.1.7 Rain water gutters Rain water gutters of suitable design over the doorways shall be provided.

11.1.8 Destination board The destination boards shall be programmable electronic type displaying in alfa numeric system. The supplier shall quote separately for it.

11.1.9 Electronic section board for Kalka-Shimla section shall be provided which would




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indicate the name of the station, the distance between two stations and height above mean sea level. The display shall be at suitable location in the compartment. The controls shall be with the driver. The supplier shall quote separately for it.

12. INTERIOR DESIGN

12.1 Finishing

Interior design of railcar shall minimize the risk of injuries to passengers. Interior finish and furnishing shall combine a good and clean appearance with durability and serviceability. All surfaces liable to frequent handling shall be finished with materials suitable for periodical washing or cleaning and shall be of a colour which will not show up stains.

12.1.1 The materials used for finishing and furnishing shall be suitable for use under the conditions specified in clause 2.3 of Chapter I and shall be fire retardant non-hygroscopic and vermin and rot proof. All materials used for interiors shall conform to the fire retardant properties as mentioned in Annexure - A.

12.1.2 Material used for furnishing shall comply with following Norms for Fire Retardancy properties for other properties approval shall be taken by RDSO before fitment:-

12.2 Windows

12.2.1 Railcar shall be provided with large size of side windows & lookout glasses for all round vision as indicated in Annexure-I or better. Side windows of the passenger area shall be glazed with 5 mm toughened glass. The windows shall be suitably spaced. The win-dows may be tinted to minimize sun glare.

12.2.2 Both ends of the Railcar shall be provided with single piece stone resistant look out glass to RDSO Specification No. ELRS/SPEC/L.OGLASS/0016 (Rev.0) or latest. Laminated shade shall be provided.

12.2.3 All body side windows shall be provided with fire retardant curtain to RDSO STR No. C-9911 (Rev.3) or latest.

12.3 Emergency exit

12.3.1 Railcar shall be provided with standard design of exit window alongwith emergency hammers to be used in emergencies.

12.4 First aid-box

12.4.1 Railcar shall be provided with standard first aid box and shall be fitted at suitable location for easy access to the passengers.

12.5 Temperature cum altitude digital display

12.5.1 Railcar shall be provided with standard design of digital temperature cum altitude display and shall be fitted at easy access to the passengers.

12.6 Flooring

S.No.

Properties Test Method Accepted Value (To be amended as)

i. Resistance to Spread of Flame

UIC Code 564-2 Apendix 8

As per annexure-A.

ii. Deterioration of visibility Due to Smoke

UIC Code 564-2 Apendix 15

iii. Limiting Oxygen Index IS 13501

iv. Toxicity Index NCD 1409

v. Heat release rate EN 45545 part-2




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12.6.1 Option-1: Underframe top plate shall form the base for the flooring. Floor construction shall consist of 1.25 mm thick SS 301 to RDSO specification C-K201 corrugated trough floor laid over under frame cross members. 8mm compreg floorboards to RDSO specification C-9407 (Rev.3) or latest shall be provided over the trough. Design and spacing of under frame cross members should be adjusted to prevent sagging of compreg floorboards. The floor shall be covered with 2mm thick PVC sheets conforming to RDSO schedule of technical requirements RDSO/2006/CG-12 with amendment slip1or latest. Any joint on the PVC sheet shall be welded with heat by hot air gun. Anti corrosion and noise deadening measures shall be taken on the trough floor, under frame and body shell. To avoid any stagnation of water, adequate nos. of 19 mm diameter drain holes to be drilled at suitable locations in all valleys to trough floor.

12.6.2 The floor shall be blended at its junction with the interior body lining by a fillet corner moulding of light metal alloy material of corrosion resistance property and made impervious to seepage of water.

12.6.3 Good quality fire retardant carpet shall be laid over the PVC flooring. Same shall be approved by the purchaser.

12.6.4 Option-2: Fire retardant anti skid teak wooden paneling (Teak finish) on side walls, roof and floor shall be provided for better appearance / aesthetics.

12.7 Seats (Similar to Shatabdi Express)

12.7.1 The Railcar shall have passenger friendly seats with hand rests and double reclining back rest with locking arrangement in each position. The seat shall be similar to Shatabdi Express. Other option may be considered by Railway Board / Northern Railway. Such as the seats shall have PU foam cushion to RDSO/2007/CG-04 or latest and backrests and hand rests shall have PU foam cushion to RDSO/2007/CG-04 or latest, properly vented and upholstered with suitable fire retardant upholstery to RDSO schedule of technical requirements CK610. Seats shall be designed to combine comfort and pleasing appearance and shall permit easy cleaning, both of seat and backrest. Seats and backrests shall be non-inflammable. Suitable netting pockets shall be provided at the back of the each seat for keeping books & magazines etc. The seat shall be firmly fixed to the frame which shall be robust enough to stand overload and misuse, and shall provide easy access to the floor below the seat for cleaning. The seats shall be provided with movable footrest. While travelling passenger needs to be served breakfast / meals, hence a collapsible type serving tray with suitable design shall be provided. The tray shall be flushed with surface.

12.7.2 Luggage space / racks for passenger luggage shall be provided, as shown in Annexure - I.

12.8 Interior fittings

12.8.1 The charging points for Mobile phones & laptop shall be provided at suitable locations.

12.8.2 Adequate lighting arrangement inside the Railcar entrance stairs, gangway, passenger compartments, luggage compartment, both driver‟s cab, mini-kitchen and toilet alongwith reading lamps for passengers, shall be provided. All the lights shall be LED type Ceiling lights, reading lights surface mounted/flat- flash mounted with precision reflector.

12.8.3 Approved type of headphones with volume control and selector switch shall be provided for individual seats for stereo piped multi-channel (4 nos.) music system.

12.8.4 Provision shall be made for announcement by the driver through microphone along with two sets of speakers flush mounted in the Railcar.

12.9 Panelling

12.9.1 The interior panelling shall consist of 3mm thick resin bonded thermosetting laminated




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plastic sheets of approved shades. The laminated plastic sheets shall conform to RDSO schedule of Technical requirements No.C - K514 or latest. Alternatively, claddded aluminium panels shall be used for internal paneling which can also be easily fastened with sidewall using „Blind Rivets‟ for providing better interior finish. Steel paneling with suitable insulating packing shall be used for panelling of electrical cubicles.

12.9.2 Sidewall panelling shall be so constructed as to facilitate removal for attention to window sliders runners and repainting of interior steel surfaces of the body sheathing.

12.9.3 Sun roof ceiling: In the ceiling for each bay, suitable arrangements shall be made to cover and uncover the underneath of sun roof with movable roller blinds, easily by passengers. The material used for these covers shall be fire retardant, attractive and permit easy cleaning/washing.

13. DRIVER'S CABS

13.1 For bi-directional operation, there shall be a driving cab at both ends as indicated in Annexure – I.

13.2 The driving cab shall be fully equipped with necessary gauges and controls as per Clause 10 of Chapter - II.

13.3 Microphone for PA system and stereo deck of 500 Watt with facility to play 4 CD at a time with appropriate tone and volume control. PA / Music system shall be able to work from the power supply system provided in the Railcar.

13.4 Driver's cab and driver's seat should be ergonomically designed and should afford easy visibility and access to controls/gauges.

13.5 Suitable design of drop down sun visor shall be provided in both drivers‟ cab.

13.6 Half slider opening side window shall be fitted in the driver's cab.

13.7 A sliding door between the driver's cabin and passenger compartment with the provision of locking from inside shall be provided.

13.8 Distribution fuse board and switches for the lights of passenger area shall be located in driver's cabin.

13.9 Electric bell communication between the driver and passengers shall be provided, with switches at suitable locations in the compartment.

13.10 Layout of driver's control desk and other equipment in the driver's cabin shall be submitted for approval.

13.11 Railcar shall have single piece look out glass at both the ends.

13.12 Both driver‟s cab shall be air-conditioned alongwith provision of small fans. In each cab, provision for switch on / off / adjustment of the air condition, shall be provided.

14. Heating, Ventilation and Air conditioning system (HVAC)

14.1 To meet day to day varying climatic condition of Kalka-Shimla section, Railcar shall be equipped with two compact roof-mounted air-conditioning units which have a total cooling capacity of approximately 24 kW and a total heating capacity of 30 kW and which shall be controlled by a microprocessor. The fresh air comes in through the air inlet of the AC unit. The conditioned air is transported in heat insulated aluminum ducts mounted below the roof and distributed through the perforated ceiling into the passenger area. The return air flows back through openings above the doors to the AC unit. The entrance area, toilets and pantry are connected to the exhaust air system.

14.2 While mounting HVAC over roof, the system shall be flushed with the roof, so that it

shall not infringe with MMD while it in running.




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15. CCTV Camera 15.1 Railcar shall be fitted with CCTV camera with latest design in passenger area, at passenger doors and over roof at both ends so that driver can have a look. 16. LED / LCD TV 16.1 Portable 17” (2 nos.) LED/LCD TV alongwith DVD player shall be provided in

passenger area of railcar at suitable location. There shall be provision to connect CCTV camera to LCD/LED TV., CD changer,

17. Music system & speakers

17.1 Railcar shall be fitted with standard music system, FM radio & audio system with high

quality speakers and 8-channel coach amplifier-50W subwoofers and shall be fitted at suitable location in the railcar. There shall be provision to connect the speakers to LED/LCD TV.

18. Mini-Kitchen / Small Pantry:

18.1 Railcar shall be provided with a mini- kitchen/ Small Pantry alongwith sink, water tank (minimum 100 litres), serving platform for serving readymade tea/coffee/ breakfast/meals to the passengers. For this purpose the following facility shall be provided with the kitchen. i. Water boiler ii. Soup warmer iii. Bottle cooler iv. Deep-freezer section v. Refrigerator section vi. Hot case vegetarian food vii. Hot case non vegetarian food viii. Microwave oven Suitable arrangement for filling the water tank shall be provided. A suitable exhaust fan shall be provided in mini-kitchen.

19. Toilet: 19.1 A small toilet, with western seat alongwith wash basin & water tank with a capacity of

200 litres, shall be provided in Railcar. Provision for filling the water tank, similar to Narrow Gauge passenger coaches running in Kalka-Shimla section, shall be provided. A suitable exhaust fan shall be provided in toilet.

19.2 Hot air hand drier & smoke sensor shall be provided with toilet.

20. Rear View Mirrors

20.1 Mekra type outer rear view mirrors at the driver‟s cab RHS and LHS shall be mounted

for loco pilot similar to mainline locos shall be provided on both ends of railcar as shown in Annexure - I. Mirrors shall be electrically adjustable.

21. Mobile and laptop charging facility 21.1 Railcar shall be provided with mobile and laptop charging facility mounted at suitable

location.




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22. TOOL BOX

22.1 A tool box with locking arrangements, for driver‟s essential equipments, shall be provided near one drivers cab suitably.

23. FINISH & APPEARANCE

23.1 The Railcar will primarily cater to tourist traffic. The interior of Railcar shall present elegant look with aesthetically arranged furnishing material and fittings. The joints between side wall panels, partition panel, sunroof sheets etc. shall be arranged in such a manner so that these joints are not visible. Mouldings wherever used, the same shall be designed and fitted so as to avoid use of screws, rivets etc. visible in the compartment. The exterior fittings shall be matched with the finish of the Railcar. The complete Railcar shall have a pleasing and attractive appearance. Supplier shall submit exterior and interior colour scheme of the Railcar and shall take approval of RDSO.

24. PAINTING

24.1 All parts made out of steel sheets of thickness 4 mm and below should be degreased, derusted and phosphate coated before they go to assembly. Immediately after phosphate coating, Epoxy Zinc phosphate primer to a dry film thickness of minimum 60 microns should be painted.

24.2 Painting of the railcar shall be done as per following specification(with latest revision)

i. Exterior painting - PU painting as per RDSO Spec PCN/100/2009 ii. Anti corrosion paint - As per RDSO Spec PCN/123/2006 iii. Interior painting - As per ICF/M/D/Spec 045 Rev.3 based upon IS:8622/2004. iv. Primer as per RDSO Spec PCN/123/2006 and Top coat is two component

epoxy high build paint as per MDTS 094. v. Aluminum paint - As per RDSO spec PCN/110/88 vi. Epoxy zinc phosphate primer - As per RDSO spec PCN/102 vii. Sound insulation paint - As per MDTS 076 Rev.2

24.3 All parts made out of stainless steel sheets/plates of thickness above 4 mm, rolled stainless steel sections, forgings, springs etc. should be grit blasted, cleaned and painted with primer to a dry film thickness of minimum 60 microns.

24.4 The Railcar shall be painted with modern painting system by using approved brands. The colour scheme shall be as agreed to between the purchaser and contractor. Surface preparation to Sa 2½ standard as per ISO-8501-1 shall be carried out prior to painting. Roof shall be painted with fire retardant Aluminum PU paint to RDSO Specification M&C/PCN/110/2006.

24.5 All the above paint items shall be applied by air / airless spray technique.

24.6 Brush application for these paint items is not recommended.

24.7 Aluminium parts, where used, shall be anodised.

25. LETTERING AND MARKING

25.1 This shall be done as agreed to between the supplier and purchaser.

26. FIRE FIGHTING EQUIPMENT

26.1 The fire fighting equipment of proven design with provision to operate manually shall be provided in the Railcar.

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CHAPTER - IV

BRAKE SYSTEM

1. The Railcar shall be fitted with a failsafe type compressed air brake system, which shall have graduated application and release.

2. The automatic brake valve shall be self-lapping type in 'application' as well as in 'release' position.

3. The Railcar shall be provided with emergency brake valve located suitably within approach of the driver from his seat in the cab which shall prevent the railcar from over speeding beyond a limit by cutting off the power and emergency application of brake. During emergency application, the engine shall come down to 'idle' position. The system shall be reliable and for this proper stand-by shall be provided.

4. Panel mounted air brake system of approved make conforming to spec no. MP-0.01.00.19 (Rev-01), Jun’2010 or latest shall be provided but multiple unit features need not be provided.

5. Stand alone VCD of approved make conforming to spec no. MP- 0.34.00.04 (Rev-04), December’ 2008 or latest shall be provided. The unit shall be suitable for power supply available in Railcar.

6. Air dryer of approved make conforming to spec no. MP-0.01.00.06 (Rev-03), March’2007 or latest shall be provided.

7. Railcar shall be provided with parking brakes capable of holding fully loaded Railcar on 1 in 33 down gradient under wet condition.

8. Stand-by brakes to operate in case of failure of any component in the main brake system shall be provided.

9. The brake rigging shall be as light and simple as possible.

10. It should be ensured that emergency braking distance from 35 km/h speed under gross weight condition of 20t is within 40m on level section and 45 m on 1 in 33 DN section.

11. The supplier shall submit details of the brake system covering brake schematic diagram indicating part No./drawing No. of each brake valve in the bill of materials, working principles, literature on brake equipments, calculation of brake power, emergency braking distance and compressor capacity proposed along with the offer and get the brake system approved from RDSO during design approval of the prototype.

12. Railcar shall be provided with both pneumatic and electric horns of approved design.

13. Automatic drain valve shall be provided in addition to manual drain cock in main reservoir.

14. COMPRESSOR

Diesel engine driven compressor of reputed make with FAD of 30 CFM or 849 LPM at rated engine speed and 13 CFM or 368 LPM at idle engine speed shall be provided. The compressor shall also be provided with suitable governor to cut-in and cut-out at 7 kg/cm2 and 8 kg/cm2 respectively and a safety valve set at 8.5 kg/cm2.

15. Suitable after cooler shall be provided. 16. Brake system shall be such that in dead condition Rail car can be hauled by another

air/ vacuum braked stock. 17. Provision of vacuum train pipe (VTP) to make continuity of VTP during haulage with

vacuum braked stock.




25

Annexure - A Fire retardancy norms of the major furnishing items are as under;

Sl. no.

Material Resistance to spread of flame

Deterioration of visibility due to smoke

Limiting oxygen Index

Toxicity Heat release rate

1. LP Sheets to RDSO Spec C-K514

Min. Class B

Class-A Min. 32 Less than 1 HL-2

2. Fire retardant curtain fabric to RDSO Spec C-9911

Class-A Class-A Min. 35 Less than 1 HL-3

3. Fire retardant upholstery to RDSO Spec C-9901

Class-A Class-A Min. 35 Less than 1 HL-3

4. UIC Vest. To RDSO Spec RDSO/2007/CG-05

Class-A Class-A Min. 35 Less than 1.3

HL-2

5. Densified Thermal bounded polyester block to RDSO Spec. C-K607 (Rev-1)

Class-B Class-A Min. 30 Less than 1 HL-3

6. PVC Flooring to RDSO Spec RDSO/2006/CG-12

Class A Min Class B Min. 35 Less than 1 HL-3

7. NFTC Roof ceiling to RDSO Spec C-K511

Class A Class A Min. 35 Less than 1 HL-2

8. * Compreg to RDSO Spec C-9407 (Rev.3)

Class A Class A Min. 35 Less than 1 HL-3

Class B Class A Min. 30 Less than 1 HL-3

9. Pre laminated shaded compreg to RDSO Spec C-K513

Class B

Class A Min. 30 Less than 1 HL-3

*At Sl. no. 8 upper row shows the property material thickness ≥10 mm and lower row shows the property of material thickness <10 mm.


ANNEXURE - III

Specification for Narrow Gauge Diesel Railcar with twin power-pack (for 762mm Gauge Kalka –Shimla Section over Northern Railway)

0

500

1000

1500

2000

2500

3000

3500

0 10 20 30 40

Tra

cti

ve

Eff

ort

(K

g)

Speed (Km/h)

TRACTIVE EFFORT Vs. SPEED CURVE (NG Railcar for KLK-SML 762mm Guage)


Specification for Narrow Gauge Diesel Railcar with twin power-pack (for 762mm gauge Kalka-

Shimla Section over Northern Railway) Page 1

Annexure - IV

TECHNICAL DETAILS OF POWER EQUIPMENTS TO BE SUPPLIED BY THE TENDERER: 1. The following particulars pertaining to diesel engine and auxiliary equipment shall be submitted by the tenderer :- 1.1 Diesel Engine I General Data .1 Exact description and model of the engine .2 Rated output of the engine under UIC and site condition .3 Rated engine speed .4 Number and arrangement of cylinders .5 Cylinder bore .6 Piston stroke .7 Compression ratio .8 Mean piston speed .9 BMEP at rated output .10 Normal no load idling speed .11 Peak firing pressure .12 Full test result and data pertaining to UIC or equivalent engine tests .13 Specific fuel consumption at various throttle position with tolerance band

under UIC and site conditions Indicate the lower calorific value of the fuel used in arriving at the specific fuel consumption figure.

.14 Fuel oil consumption at idle speeds (normal & low) .15. Lube oil consumption at rated output as percentage of fuel oil consumption .16 Derating calculation for site condition .17 Safety devices provided - Overspeed - Low lube oil - Overload - High cooling water temperature - High lube oil temperature - High exhaust temperature - High intake temperature - Any other .18 Number of engines of this type in traction service .19 Weight of engine excluding oil and water .20 Weight of water contained in the engine .21 Weight of oil contained in the engine .22 Weight of major equipment - Turbocharger - Charge Air cooler - Crank case bare - Piston and connecting rod - Cylinder liner - Cylinder head




.23 Temperature of exhaust gas at turbo inlet at rated output under UIC and site conditions .24 Method of starting giving details of equipment .25 Estimated period between top and major overhaul .26 Periodicity of overhauling the following critical items - Turbocharger - Piston and piston rings - Air and exhaust valve - Main bearings - Connecting rod bearings - Fuel injection pump - Fuel injectors .27 Special design features of engine high-lighting the measures which have

been taken to achieve : - - Lower specific fuel consumption - Lower lube oil consumption - Reduced thermal and mechanical loading of critical components - High reliability

- Maximum availability .28 General arrangement and dimensional details .29 Characteristic curves for torque, output and specific fuel consumption for

different setting of the fuel injection pump .30 Torque-speed curve which the manufacturer considers to be the maximum

torque that should be used for rail traction. .31 The curve of fuel consumption for no-load running commencing from the

minimum idling speed, expressed in kg/h

II Fuel injection system .1 Type of fuel injection system .2 Nozzle opening pressure III Turbocharger .1 Number of turbocharger used per engine .2 Make and model .3 Exhaust gas/mechanically driven .4 Air flow at rated output .5 Speed of turbocharger at rated output .6 Types of bearings .7 Details of lubrication .8 Whether pre and post lubrication provided IV Charge Air cooler .1 Type of cooler

.2 Details of mounting indicating whether cooler can be removed without removing turbocharger




V Exhaust System .1 Type of exhaust system .2 Method of cooling .3 Number of exhaust gas entry segments .4 Whether the exhaust manifold is shrouded/ insulated

VI Piston and rings .1 Material specification of piston & rings .2 Method of cooling .3 Shape of bowl in piston crown .4 Number and configuration of piston rings

VII Valves .1 Material specification of valve .2 Single/composite type .3 Whether valve rotators used .4 Recommended tappet clearance .7 Angle of valve and seat

VIII Cylinder Head .1 Material .2 Coolant flow distribution .3 Whether reclaimable by welding

IX Cylinder Block .1 Material .2 Whether cast or fabricated .3 Is the mounting rigid or on resilient pads .4 Experience regarding block distortion X Crankshaft .1 Material specification .2 Type of bearings calculate bearing loads .3 Particulars of vibration damper XI Cylinder Liner .1 Material .2 Dry or wet liners .3 Water sealing arrangement between liner and cylinder block XII Connecting Rod and Bearings .1 Material of connecting rod .2 Material composition of bearing shells XIII Governor .1 Make and type .2 Minimum idle speed, rated full load speed and droop characteristics .3 Torque available on the output shaft .4 control/ safety feature provided




XIV Cooling Water System .1 Detail of cooling circuit .2 Type of water pump and its characteristic viz. delivery vs. flow resistance .3 Is the cooling system pressurised ? If so, upto what pressure ? .4 Max. permitted cooling water temperature at inlet & outlet of circuit .5 Normal cooling water temperature at full load under UIC and site conditions .6 Radiator construction and dimensional details XV Lube Oil System .1 Details of circuit .2 Lube oil pressure at full & idle speed .3 Max. temperature at hottest point .4 lube oil pump characteristic and power absorption at various points .5 Details of all filters used in the lube oil circuit .6 Efficiency of filtration and periodicity of attention XVI Fuel system .1 Schematic fuel oil circuit .2 Details of fuel oil lift pump and its drive .3 Details of filters used in fuel oil circuit .4 Periodicity of attention XVII Intake air system .1 Details of engine intake air system .2 Type of primary and secondary stage filters and their efficiency .3 Pressure drop permitted at the operating point for new and dirty filters .4 Periodicity of attention 1.2 Air compressor .1 Make .2 Model .3 Maximum pressure .4 Capacity (at idle & full speed of engine) .5 Installation drawing showing overall dimensions. .6 Weight of the unit complete with accessories. .7 Cooling .8 Graph showing speed Vs. horse power & capacity at pressure of 6,7 & 8 kg/cm2. .9 Type of cofuguration, size and stroke of cylinders. .10 Type of valves .11 Type of lubrication .12 Details of drive arrangement .13 Maximum permissible temperature at Inlet & Exhaust valve.




1.3 Auxiliary Alternator .1 Make .2 Model .3 Continuous / short time rating with details of voltage and current regulation .4 Installation drawing showing overall dimensions. .5 Weight 1.4 Battery Box .1 Make .2 Models .3 Ampere-hour rating .4 Maximum size .5 Weight In case of Hydraulic transmission: 1.4 Hydraulic Transmission .1 Make .2 Type .3 Maximum input hp .4 Complete transmission characteristic curves including input power, output

power, input & output torque, transmission efficiency for 100%, 75%, 50% & 25% of full load, against output speed.

.5 Basic characteristic curve of torque converter/ hydraulic coupling .6 Normal & max. permissible oil temp. of torque converter .7 Weight of transmission dry & with full supply 1.5 Reversing Arrangement .1 Method of reversing with full details .2 Ratio - forward & reverse 1.6 Axle Drive Gear Box .1 Make & Type .2 Gear ratio .3 Installation and detail design drawings .4 Horse power rating & torque and speed characteristic 1.7 Cardan Shaft .1 Make & Type .2 Torque rating, life rating and permissible angularity .3 Minimum compressed length with permissible length compensation .4 Installation drawings -----x-----


Specification for Narrow Gauge Diesel Railcar with twin power-pack (for 762mm Guage Kalka-


Annexure-V

DESIGN DATA CALCULATION AND DRAWINGS TO BE SUBMITTED BY THE TENDERER WITH TECHNICAL OFFER: 1. General Design

1.1 Outline diagram of the coach being offered showing front and side elevations

alongwith M.M.D. of drawing number SK.DP-3347. This drawing should indicate principle dimensions and the front elevation in relation to Moving Dimension as specified. This drawing should also show the location of centre buffer couplers, auxiliary equipment, traction equipment and control equipment along with locating dimensions.

1.2 A transverse section of the Railcar 1.3 Railcar equipment layout diagram showing the location of centre of gravity of

each equipment and its locating dimensions in all three planes. 1.4 Maximum axle load under gross load condition. 2. Design Data 2.1 Design data should include the following particulars: 2.1.1 Car design: Design detail of shell structure including material used for

construction, strength calculation, centre of gravity, weight balancing under tare and loaded condition, tare weight and pay load, welding details, preventive measures for corrosion & noise etc.

2.1.2 Bogie design: Make and type of bogie, general arrangement of bogie

illustrating the system of suspension in detail and calculation for natural frequency and damping requirement in various modes of oscillation and critical speed, unsprung mass per bogie (in tonnes), bolster arrangement, axle float, dimensions and weight of bogie complete. details of shock absorber/damping arrangement in suspension and suspension calculations,. Wheelbase, distance between journal centres, Dia. of wheels when new and fully worn. Details of connection between body and bogie. Service experience etc.

2.1.3 Wheel, Axle, Axle box and Roller Bearings: Make and type , details of wheel,

axles, wheel profile, roller bearing and its lubrication. Dimensions, calculation of bearing life.

2.1.4 Brake system: Details of brake system and Parking Brake. Brake power of the

Rail car as percentage of tare weight. Thermal capacity of brake system. Details of pipe and pipefittings. Any other details.




2.1.5 Buffer and couplers: Details of Buffer and couplers and its capacity. Type of Draft gear along with its characteristics, calculations on the basis of which choice is based and its capacity.

3. Riding Behaviour: The predicted running behavior of the proposed Rail car in

reference to clause 2.4 of the specification. 4. Weights: Weights of the fully furnished Rail car alongwith details of break-up of

the following components (i) Bare shell (ii) Bogie (iii) Bogie bolster, bogie frame and other bogie components. (iv) Axles boxes. (v) Springs (vi) Wheel & Axle assembly (including Roller Bearings) (vii) Brake equipments (viii) Piping (ix) Buffer & couplers (x) Ceiling and Paneling Material. (xi) Furnishings. (xii) Electrical equipments (xiii) Control equipment (xiv) Air conditioning / Heating equipment.

5 Corrosion protection:

(i) Details of anti-corrosion treatment of steel members. (ii) Special features provided in design of coach and manufacturing process

for providing corrosion protection. (iii) Features of floor construction to prevent water seepage and corrosion. (iv) Details of paint system for exterior of coaches.

6 Details of insulation:

(i) From Heat. (ii) For Noise suppression.

7 Fatigue life assessment of body structure and body components. 8 Air conditioning and ventilation details. 9 Camber diagram 10 Height of C.G. of complete bogie from rail level 11 Basic performance specification for bogie, springs, shock absorbers,

rubber fittings.




12 Brake rigging details giving the brake power calculation including an

explanatory write-up. 13 Schematics diagrams of brake system. 14 Details of passenger alarm apparatus. 15 Layout of brake piping on coach. 16 Materials: List of materials used in the construction of structural, shells and

bogies, and their respective locations. Details of furnishings proposed to be provided on railcar. Details of floor arrangement.

17 Source of components: Names and addresses of manufacturers of

assemblies/components along with their technical catalogues and experience. (i) Wheels and axles. (II) Roller bearings.

(iii) Recommended lubricant for roller bearings. (iv) Brake system and equipments

(v) Air conditioning and ventilation equipments

Documents

Hkkjr ljdkj jsy ea=ky; - rdso.indianrailways.gov.in Railcar KLK... · Maximum Moving Dimension SK.DP -3347 ... Shimla section of Northern Railway of Indian ... Contractor shall prepare