MAHARASHTRA METRO RAIL CORPORATION LIMITED (MAHA … · 2018-03-07 · MAHA-METRO Contract No. P1/TR-02/2018 Part 2 Works Requirements - General Specification Feb 2018 Page 1 of 170

MAHARASHTRA METRO RAIL CORPORATION LIMITED (MAHA-METRO)

PUNE METRO RAIL PROJECT

BIDDING DOCUMENT

FOR

DESIGN, SUPPLY, INSTALLATION, TESTING & COMMISSIONING OF 25KV FLEXIBLE & RIGID OVERHEAD CATENARY SYSTEM (OCS / OHE) AND

SECTIONING POSTS FOR PUNE METRO RAIL PROJECT

PART 2

Feb 2018

Issued by:

Maharashtra Metro Rail Corporation Limited

101, The Orion,

Opposite Don Bosco Youth Centre,

Koregaon Park, Pune- 411001

Maharashtra, INDIA

MAHA-METRO Contract No. P1/TR-02/2018 Part 2: Works Requirements

Feb 2018

Summary of Bidding Documents

PART 1: Bidding Procedures

Section I. Instructions to Bidders (ITB)

Section II. Bid Data Sheet (BDS)

Section III. Evaluation and Qualification Criteria

Section IV. Bidding Forms

Section V. Eligibility Criteria and Social and Environmental Responsibility

Section VI. Agency Policy – Corrupt and Fraudulent Practices

Annexure II-A: Toolkit for using e-tender portal

Annexure IV-A: Pricing Document

PART 2: Works Requirements

Section VII-A. Works Requirement - General Specifications

Section VII-B. Works Requirement - Particular Specifications

Section VII-C: Tender Drawings

Section VII-D: Reference Documents / Drawings (SOD, GADs etc.)

PART 3: Conditions of Contract and Contract Forms

Section VIII. General Conditions (GC)

Section IX. Particular Conditions (PC)

Section X. Contract Forms

Section XI. SHE Manual (or Conditions of Contract on SHE requirements)

MAHA-METRO Contract No. P1/TR-02/2018 Part 2 Works Requirements - General Specification

Feb 2018 Page 1 of 170



BIDDING DOCUMENT

For

DESIGN, SUPPLY, INSTALLATION, TESTING & COMMISSIONING OF 25KV FLEXIBLE

& RIGID OVERHEAD CATENARY SYSTEM (OCS / OHE) AND SECTIONING POSTS FOR PUNE METRO RAIL PROJECT

MAHARASHTRA METRO RAIL CORPORATION LIMITED (MAHA-METRO) 101, The Orion, Opposite Don Bosco Youth Centre,

Koregaon Park, Pune 411001 Maharashtra INDIA

PART 2: WORKS REQUIREMENTS

SECTION VII-A: WORKS REQUIREMENT – GENERAL SPECIFICATION

CONTRACT NO. P1/TR-02/2018



Contents CHAPTER 1 ............................................................................................................................................ 9

1.0 GENERAL .................................................................................................................................. 9

1.1 Application of the General Specification (GS) ....................................................................... 9

1.2 Abbreviations ......................................................................................................................... 9

1.3 Definitions ............................................................................................................................ 11

1.4 Glossary of Terms ............................................................................................................... 12

1.5 Submission for Review ........................................................................................................ 12

1.6 Standards, Codes of Practice .............................................................................................. 13

1.7 Employer’s Drawings ........................................................................................................... 13

1.8 Specifications in Metric and Imperial Units .......................................................................... 13

1.9 System Safety ...................................................................................................................... 13

1.10 Availability (Reliability and Maintainability) ........................................................................ 14

1.11 Suitability for Purpose ........................................................................................................ 14

1.12 Climatic Condition / Operating Environment ...................................................................... 15

1.13 Survey and Site Investigations .......................................................................................... 17

CHAPTER 2 .......................................................................................................................................... 19

2.0 PLANNING, PROGRAMME AND PROGRESS MONITORING .............................................. 19

2.1 Planning ............................................................................................................................... 19

2.2 Programming General Requirements .................................................................................. 19

2.3 IT Requirement of Employer ................................................................................................ 19

2.4 Progress Monitoring ............................................................................................................. 23

2.5 Works Programme ............................................................................................................... 23

2.6 Submission Programme ...................................................................................................... 25

2.7 Design, Procurement and Manufacturing Programme ........................................................ 26

2.8 Installation Programme ........................................................................................................ 27

2.9 Testing and Commissioning Programme ............................................................................ 28

2.10 Training and Transfer of Technology Programme ............................................................. 28

2.11 Time Chainage Programme (T/C) ..................................................................................... 29

2.12 Track Related Installation Programme (TRIP) ................................................................... 29

2.13 Programme Submissions ................................................................................................... 29

2.14 Programme Review ........................................................................................................... 29

2.15 Works Programme Revisions ............................................................................................ 30

2.16 Monthly Progress Report ................................................................................................... 30

2.17 Programme Analysis Report .............................................................................................. 30

2.18 Key Date and Access Date Report .................................................................................... 31

2.19 Physical Progress (Earned Value) Report ......................................................................... 31



2.20 Progress Meetings ............................................................................................................. 32

2.21 Quarterly Review Meetings ................................................................................................ 32

CHAPTER 3 .......................................................................................................................................... 34

3.0 MANAGEMENT PLANS AND SUBMISSIONS ....................................................................... 34

3.1 General ................................................................................................................................ 34

3.2 General Organisation ........................................................................................................... 34

3.3 Project Management Plan ................................................................................................... 35

3.4 Systems Assurance Plans ................................................................................................... 38

3.5 Design, Procurement and Manufacturing Plan .................................................................... 40

3.6 Construction and Installation Management Plan ................................................................. 46

3.7 Completion Management Plan ............................................................................................ 49

CHAPTER 4 .......................................................................................................................................... 52

4.0 DOCUMENTS SUBMISSION AND REVIEW .......................................................................... 52

4.1 Documents, Submissions and Correspondence ................................................................. 52

4.2 Submissions to the Engineer ............................................................................................... 52

4.3 Records and Reports ........................................................................................................... 54

4.4 Records ................................................................................................................................ 56

CHAPTER 5 .......................................................................................................................................... 57

5.0 QUALITY MANAGEMENT ....................................................................................................... 57

5.1 Introduction .......................................................................................................................... 57

5.2 General Requirements ......................................................................................................... 57

5.3 Management Quality Plan ................................................................................................... 58

5.4 Design Quality Plan ............................................................................................................. 59

5.5 Manufacturing Quality Plan .................................................................................................. 59

5.6 Site Quality Plan .................................................................................................................. 59

5.7 Inspection and Test Plans, Records and Reports ............................................................... 60

5.8 Review, Verification & Audit ................................................................................................. 60

5.9 Quality Control Register ....................................................................................................... 61

5.10 Summaries of Inspection and/or Test ................................................................................ 61

5.11 Notification of Non-conformities ......................................................................................... 61

CHAPTER 6 .......................................................................................................................................... 63

6.0 SOFTWARE MANAGEMENT AND CONTROL ...................................................................... 63

6.1 Prescriptive Framework ....................................................................................................... 63

6.2 Software Framework ............................................................................................................ 63

6.3 Software Management Control ............................................................................................ 63

6.4 Status Reporting .................................................................................................................. 63

6.5 Auditing ................................................................................................................................ 63

6.6 Software Acceptance ........................................................................................................... 63



6.7 Re-Use of Existing Software ................................................................................................ 64

6.8 Application of “Commercial Off The Shelf” Software (COTS) ............................................. 64

6.9 Test Software ....................................................................................................................... 64

CHAPTER 7 .......................................................................................................................................... 65

7.0 MATERIALS AND EQUIPMENT ............................................................................................. 65

7.1 Materials and Equipment Provided by the Employer .......................................................... 65

7.2 Materials .............................................................................................................................. 65

7.3 Equipment ............................................................................................................................ 66

7.4 Electronic Control Racks & Cabinets ................................................................................... 67

CHAPTER 8 .......................................................................................................................................... 68

8.0 PACKAGING, STORAGE, SHIPPING AND DELIVERY ......................................................... 68

8.1 Storage ................................................................................................................................ 68

8.2 Crating ................................................................................................................................. 68

8.3 General Precautions ............................................................................................................ 69

8.4 Packaging Procedures ......................................................................................................... 69

8.5 Shipping ............................................................................................................................... 69

8.6 Delivery ................................................................................................................................ 70

CHAPTER 9 .......................................................................................................................................... 71

9.0 TESTING AND COMMISSIONING.......................................................................................... 71

9.1 General ................................................................................................................................ 71

9.2 Manufacturing Test Plan ...................................................................................................... 71

9.3 Commissioning Plan ............................................................................................................ 73

9.4 On-Site Testing and Commissioning Plan ........................................................................... 74

9.5 Activity of the Employer and the Engineer ........................................................................... 78

9.6 Records and Reports ........................................................................................................... 79

9.7 Test Equipment and Facilities .............................................................................................. 80

9.8 Witnessing by the Employer and the Engineer .................................................................... 81

9.9 Failures ................................................................................................................................ 81

9.10 Repeat Tests...................................................................................................................... 82

9.11 Fault Categories................................................................................................................. 82

9.12 Fault Log ............................................................................................................................ 82

9.13 Hardware Failure Reports .................................................................................................. 82

9.14 Software Failure Reports ................................................................................................... 83

CHAPTER 10 ........................................................................................................................................ 84

10.0 TRAINING AND TRANSFER OF TECHNOLOGY ................................................................ 84

10.1 Training Requirements ...................................................................................................... 84

10.2 Training Method ................................................................................................................. 85

10.3 Employer’s Instructor Training ........................................................................................... 85



10.4 Training Plant & Equipment ............................................................................................... 85

10.5 Testing and Assessment ................................................................................................... 86

10.6 Training Records ............................................................................................................... 86

10.7 Transfer of Technology ...................................................................................................... 86

CHAPTER 11 ........................................................................................................................................ 88

11.0 OPERATION AND MAINTENANCE DOCUMENTATION ..................................................... 88

11.1 General .............................................................................................................................. 88

11.2 Arrangement and Format of Manuals ................................................................................ 88

11.3 Drawings ............................................................................................................................ 89

11.4 Submissions ....................................................................................................................... 89

11.5 Operation and Maintenance Manuals ................................................................................ 90

CHAPTER 12 ........................................................................................................................................ 91

12.0 SUPERVISION AND PLANNING OF MAINTENANCE ......................................................... 91

12.1 Scope ................................................................................................................................. 91

12.2 Maintenance Planning & Management Staff ..................................................................... 91

12.3 Supervisory Staff ............................................................................................................... 92

CHAPTER 13 ........................................................................................................................................ 93

13.0 SUPPLY OF SPARE PARTS, SPECIAL TOOLS AND TEST EQUIPMENT ........................ 93

13.1 Details of supply................................................................................................................. 93

13.2 Manufacture and delivery of Spare Parts .......................................................................... 94

13.3 Contract Spares ................................................................................................................. 95

13.4 Commissioning Spares ...................................................................................................... 95

13.5 Defects Liability Spares ..................................................................................................... 95

13.6 Special Tools and Test Equipment .................................................................................... 96

13.7 Coding and Tagging of Spare Parts and Special Tools and Test Equipment ................... 96

CHAPTER 14 ........................................................................................................................................ 97

14.0 THE WORKS AND CARE OF THE WORKS ........................................................................ 97

14.1 Methods of Construction .................................................................................................... 97

14.2 Temporary Works .............................................................................................................. 97

14.3 Normal Working Hours ...................................................................................................... 97

14.4 Drawings and Schedules ................................................................................................... 97

14.5 Notification and Inspection of Works ................................................................................. 97

14.6 Construction Restraints ..................................................................................................... 97

14.7 Protection from Water ........................................................................................................ 98

14.8 Protection from Weather .................................................................................................... 98

14.9 Protection of Work ............................................................................................................. 98

CHAPTER 15 ........................................................................................................................................ 99

15.0 SITE ESTABLISHMENT AND ATTENDANCE ...................................................................... 99



15.1 Use of the Site ................................................................................................................... 99

15.2 Survey of the Site .............................................................................................................. 99

15.3 Fences and Signs on the Site ............................................................................................ 99

15.4 The Contractor’s Site Accommodation .............................................................................. 99

15.5 Site Utilities and Access .................................................................................................. 100

15.6 Site Facilities for the Engineer ......................................................................................... 100

15.7 Clearance of the Site ....................................................................................................... 101

15.8 Attendance ....................................................................................................................... 101

15.9 Contractor’s Equipment ................................................................................................... 103

15.10 Security .......................................................................................................................... 103

CHAPTER 16 ...................................................................................................................................... 104

16.0 LIAISON WITH OTHERS .................................................................................................... 104

16.1 Liaison with others ........................................................................................................... 104

16.2 Work by Other Contractors .............................................................................................. 104

16.3 Interface Management ..................................................................................................... 104

CHAPTER 17 ...................................................................................................................................... 106

17.0 THE SITE ............................................................................................................................. 106

17.1 Access to Site .................................................................................................................. 106

17.2 Site Restrictions ............................................................................................................... 106

17.3 Site Services .................................................................................................................... 107

17.4 Site Cleanliness ............................................................................................................... 108

17.5 Prevention of Mosquito Breeding..................................................................................... 108

17.6 Prevention of Dust ........................................................................................................... 109

17.7 Engineering Conditions for Temporary Land Allocation .................................................. 109

17.8 Attendance by Civil Works Project Contractor ................................................................. 109

17.9 Access to the Site by Other Contractors ......................................................................... 109

17.10 Transportation to Site .................................................................................................... 110

17.12 Defined Area Working and Works Train Operations ..................................................... 111

17.13 Work in Vicinity of Operating Tracks ............................................................................. 111

17.14 Rodent Control ............................................................................................................... 113

CHAPTER 18 ...................................................................................................................................... 114

18.0 HEALTH AND SAFETY ....................................................................................................... 114

18.1 Health and Safety Philosophy .......................................................................................... 114

18.2 Health and Safety Management ...................................................................................... 114

18.3 Legislation, Codes of Practice, Standards, etc. ............................................................... 115

18.4 Breach of Health and Safety Obligations ......................................................................... 115

18.5 Contractor’s Health and Safety Documentation .............................................................. 115

18.6 Contractor’s Safety Arrangements................................................................................... 118



18.7 Site Conditions ................................................................................................................. 122

CHAPTER 19 ...................................................................................................................................... 128

19.0 DAMAGE AND INTERFERENCE ....................................................................................... 128

19.1 Damage and Interference ................................................................................................ 128

19.2 Watercourses and Drainage Systems ............................................................................. 128

19.3 Utilities ............................................................................................................................. 130

19.4 Structures, Roads and Other Property ............................................................................ 131

19.5 Access ............................................................................................................................. 132

19.6 Trees and Other Similar Obstructions ............................................................................. 133

19.7 Noise Control on Works Site ............................................................................................ 133

19.8 Spoil Disposal .................................................................................................................. 133

CHAPTER 20 ...................................................................................................................................... 134

20.0 ENVIRONMENTAL PROTECTION REQUIREMENTS ....................................................... 134

20.1 General ............................................................................................................................ 134

20.2 Housekeeping .................................................................................................................. 135

20.3 Air Quality ........................................................................................................................ 136

20.4 Water Quality ................................................................................................................... 138

20.5 Noise ................................................................................................................................ 139

20.6 Waste ............................................................................................................................... 141

20.7 Prevention of Mosquito Breeding..................................................................................... 142

CHAPTER 21 ...................................................................................................................................... 143

21.0 PHOTOGRAPHS ................................................................................................................. 143

21.1 Photographs..................................................................................................................... 143

CHAPTER 22 ...................................................................................................................................... 144

22.0 TEMPORARY WATER AND ELECTRICITY SUPPLY ....................................................... 144

22.1 Water and Electricity Supply for the Contractor by the Project Civil Works Contractors . 144

22.2 Applicability ...................................................................................................................... 144

22.3 Work on Site .................................................................................................................... 144

22.4 Electrical General ............................................................................................................ 145

22.5 Mains Voltage .................................................................................................................. 145

22.6 Types of Distribution Supply ............................................................................................ 145

22.7 Protection of Circuits ........................................................................................................ 146

22.8 Earthing ............................................................................................................................ 146

22.9 Plugs, Socket Outlets and Couplers ................................................................................ 146

22.10 Cables ............................................................................................................................ 146

22.11 Lighting Installation ........................................................................................................ 147

22.12 Electrical Motors ............................................................................................................ 147

22.13 Inspection and Testing ................................................................................................... 147



22.14 Identification ................................................................................................................... 147

22.15 Maintenance .................................................................................................................. 148

22.16 Maintenance Record ...................................................................................................... 148

22.17 Metering ......................................................................................................................... 148

22.18 Inability to Supply ........................................................................................................... 148

CHAPTER 23 ...................................................................................................................................... 149

23.0 MOCK-UPS, PROTOTYPES AND SAMPLES .................................................................... 149

23.1 Requirements................................................................................................................... 149

23.2 Purpose ............................................................................................................................ 149

23.3 Review ............................................................................................................................. 149

Appendix 1 .......................................................................................................................................... 150

Appendix 2 .......................................................................................................................................... 153

Appendix 3 .......................................................................................................................................... 154

Appendix 4 .......................................................................................................................................... 155

Appendix 5 .......................................................................................................................................... 159

Appendix 6 .......................................................................................................................................... 167

Appendix 7 .......................................................................................................................................... 168

Appendix 8 .......................................................................................................................................... 169

Appendix 9 .......................................................................................................................................... 170



CHAPTER 1 1.0 GENERAL

1.1 Application of the General Specification (GS)

1.1.1 The provisions contained in the Particular Specification (PS) and the Employer’s Drawings

shall prevail over the provisions contained in this GS.

1.1.2 The provisions contained in the GS shall prevail over the provisions contained in International Standards, European Standards, British Standards, Indian Standards, British Standard Codes of Practice or any other equivalent standards and similar standard documents stated in the Contract.

1.1.3 This GS shall be read in conjunction with the other documents constituting the Contract.

1.2 Abbreviations

1.2.1 Common abbreviations used in the GS and in the PS shall have the following meanings:

ACB : Air Circuit Breaker

BCC : Backup Control Centre

BOQ : Bill of Quantities

BS : British Standard

CADD : Computer Aided Design and Drafting

CAR : Corrective Action Request

CNP : Construction Noise Permits

COTS : Commercial Off the Shelf

CPM : Critical Path Method

CV : Curriculum Vitae

DLP : Defects Liability Period

E&M : Electrical & Mechanical

EMC : Electromagnetic Compatibility

EMIP : Environmental Mitigation Implementation Plan

EMP : Environmental Management Plan

EMSD : Electrical and Mechanical Services Department

EMU : Electric Multiple Unit

EN : Euro-Norm (European Standards)

EPD : Environmental Protection Department

ETI : Employer's Training Instructors

FAI : First Article Inspection

FAT : Factory Acceptance Test(s)

FMEACA :Failure Mode Effect and Criticality Analysis


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GCC : General Conditions of Contract

GIF Graphic Information Format

GS : General Specification (this document)

HV : High Voltage

IEC : International Electro-technical Commission

IEE :The Institution of Electrical Engineers

IP : Ingress Protection

IS : Indian Standards

ISO : International Standards Organisation

ITB : Instructions To Bidders

ITU : International Telecommunication Union

LV : Low Voltage

MCB : Miniature Circuit Breaker

MMI : Man-Machine Interface

MTR : Mass Transit Railway

NSR : Noise Sensitive Receivers

OCC : Operations Control Centre

OSR : Operational Safety Report

OSR(S) : Operational Safety Report (Software)

P3 : Primavera Project Planner

PLC : Programmable Logic Controller

PPE : Personal Protective Equipment

PS : Particular Specification

PVC : Polyvinyl Chloride

QA : Quality Assurance

RAMS : Reliability, Availability, Maintainability and Safety

RTU : Remote Terminal Unit

SAR : Special Administrative Region

SAT : Systems Acceptance Test(s)

SCC : Special Conditions of Contract

SIL : Safety Integrity Level

SQAP

: Software Quality Assurance Plan

SRR : Submission Review Request

SWA : Steel Wire Armoured


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1.2.2 Further abbreviations may be defined within the body of the GS or PS where there is only

local applicability. Where such abbreviations exist the Contractor shall exercise great care that the abbreviation is not used out of context when communicating with the Employer, the Engineer or any Third Party.

1.2.3 Abbreviations of units of measurement used in the GS shall have the meanings as defined

under the SI system of units.

1.3 Definitions

Words and phrases defined in the GCC or SCC shall retain the same meaning within the GS and PS unless specifically redefined within this GS or under the provisions of Clause 1.1.1 for the purpose of a particular clause or group of clauses. (1) “Access Dates” are dates that are to be achieved by other than the Contractor and

which are considered to be essential to the successful completion of the Contract as per the original planned schedule. A list of the activities completion of which are considered to give rise to an Access Date are included in the PS.

(2) “Commissioning” means the process of setting to work the complete transportation

system through a series of integrated tests that demonstrate the installation and performance in accordance with the specified criteria.

(3) “Day” means calendar day unless expressly stated otherwise (4) “Defined Area” means an area within which works trains will be operated and the

Employer’s defined area working safety rules will apply. (5) “Factory Acceptance Tests” means the tests to be performed at the Contractor’s

factories prior to delivery to the Site to verify compliance with the Specification and quality standards

(6) “Installation Tests” means the tests to be performed to verify the conformity of

completion of an installation / assembly to the design documents previously reviewed without objection by the Engineer prior to the start of Commissioning. Installation Tests do not form part of the Tests on Completion to be performed by the Contractor in order to achieve Employer’s Taking Over of the Works or any Section however they must be successfully completed before the Tests on Completion can commence.

(7) “Key Dates” are dates which are to be achieved by the Contractor and which are

considered to be essential to the successful completion of the project to the original planned schedule. A list of the activities, completion of which gives rise to a Key Date, is included in the PS.

(8) “Partial Acceptance Tests” means the functional tests to be performed on

components and parts of systems to meet the specified criteria. Partial Acceptance Tests form part of the Tests on Completion to be performed under the Contract in order to achieve Employer’s Taking Over of the Works or any Section.

(9) “Service Trial” means the phase after completion of the System Acceptance Tests in

which the training and operating procedures are validated through the running of the trains to the published timetable. Service Trial form part of the Tests on Completion to be performed under the Contract in order to achieve Employer’s Taking Over of the Works or any Section.

T/C : Time Chainage

TRIP : Track Related Installation Programme


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(10) “Quality Control Point” means a point in time when a notice or other document is to be submitted to the Engineer in accordance with the Contract before the Contractor can commence, proceed with or terminate an activity.

(11) “Quality Hold Point” means a point in time when a notice of no objection by the

Engineer is required. (12) “‘S’ curve” means the graphical relationship between the planned (and actual where

appropriate) quantity of completed work (or resources) and time. The curve produced is to be illustrated on an accumulative basis where the slope of the line indicates the rate of undertaking the work or rate of expenditure of the resources.

(13) “Specification (the)” means the aggregate sum of the documents and any

amendments thereto, issued to the Tenderers by the Employer as part of the tender process before the final date for submission of the Tenders. This shall include, but not be limited to, design criteria, Employer’s Requirements, Employer’s Tender Drawings, preliminary operating plan and clarification on Tender Documents issued in accordance with the ITB but shall not include the ITB itself nor minutes of any meetings.

(14) “Specification (this)” means the particular document within which the reference is

made. (15) “System Acceptance Tests” means those tests that demonstrate the performance of

the installation/equipment to the specified requirements as detailed in the PS. SATs form part of the Tests on Completion to be performed under the Contract in order to achieve Employer’s Taking Over of the Works or any Section.

(16) “Integrated Testing and Commissioning” means those tests that demonstrate the

integration of the complete transport system meeting the requirements of the Specification in an operating environment. Integrated Testing and Commissioning form part of the Tests on Completion to be performed by the Contractor in order to achieve Employer’s Taking Over of the Works or any Section.

(17) “Validation” means the process of confirmation by examination and provision of

objective evidence that the application produced achieves the particular requirements as specified.

(18) “Verification” means the process of confirmation by examination and provision of

objective evidence that the specified requirements have been incorporated within the design.

1.4 Glossary of Terms

1.4.1 Words and expressions to which meanings are assigned in any paragraph of the GS shall

have the same meanings in other paragraphs of the GS except when the context otherwise requires.

1.4.2 Utilities are electricity, lighting, traffic control, telephone and other communication cables,

gas, water, sewage and drainage pipes and ducts, including all associated protection, supports, ancillary structures, fittings and equipment.

1.5 Submission for Review

1.5.1 Reference in the GS and PS to any submission made by the Contractor to the Engineer

having been reviewed without objection by the Engineer shall mean the issue of a notice of no objection by the Engineer issued in response to a submission made by the Contractor. Documents, drawings, specifications, calculations, technical papers, material samples, methods of construction and any other matters which have been reviewed


Feb 2018 Page 13 of 170

without objection by the Engineer shall not be changed without further submission for review to the Engineer of the proposed changes.

1.5.2 Clause 4.2 below prescribes the process to be adopted for submissions of documents,

material samples and any other items to the Engineer. Schedules of items that are to be submitted to the Engineer for review are contained within this GS and/or the PS.

1.5.3 Submissions for review shall be made in accordance with the dates (relative to the Works

Programme) stated in the GS and/or the PS, or in accordance with Appendix 4 of this Specification. For items not specifically given a submission date in the Specification, submissions shall be strictly in accordance with the agreed Submissions Programme or as directed by the Engineer.

1.6 Standards, Codes of Practice

1.6.1 Unless otherwise stated in the Contract, reference in the GS to International Standards,

European Standards, British Standards, British Standard Codes of Practice and similar standards shall be to that edition of the document stated in the PS, including all latest amendments issued by the relevant authority. In the event that no specific edition reference is given, the current edition as at the date of opening of tender shall apply.

1.6.2 Later editions of International Standards, European Standards, other national or

international Standards or Codes of Practice and other similar standards, or standards which are considered to be equivalent, shall not apply unless reviewed without objection by the Engineer. The Engineer shall give or withhold his notice of no objection after the Contractor has provided him with a copy of the relevant standard for information. If a notice of no objection is given, the Contractor shall provide two copies of the document for use by the Engineer.

1.6.3 Permanent Works, Temporary Works, Contractor’s Equipment, hardware, firmware, software, apparatus of all kinds, and, where appropriate, materials and workmanship shall be in accordance with the Standards quoted in the Specification and the requirements identified in the PS or, where no Standard is identified, the Contractor shall make a proposal which shall be subject to review by the Engineer.

1.7 Employer’s Drawings

1.7.1 The Employer’s Drawings assist in general describing the scope of the Works and

clarifying constraints, interface arrangements and defining the nature of the finished structures/system outline.

1.7.2 The Contractor shall carefully check all Employer’s Drawings and advise the Engineer of

discrepancies, omissions, errors or ambiguities should any be found.

1.7.3 The Contractor shall note that any drawings included but marked “For information only” do not form part of the Contract.

1.7.4 Dimensions shall not be obtained by scaling from the Employer’s Drawings. Dimensions that are not shown or are not calculable from dimensions shown on Employer’s Drawings shall be obtained from the Engineer.

1.8 Specifications in Metric and Imperial Units

1.8.1 Specifications in imperial units shall not be substituted for specifications in metric units

stated in the Contract without the prior consent of the Engineer.

1.8.2 Conversion of metric units to imperial units and of imperial units to metric units shall be in accordance with the standard international practice.

1.9 System Safety


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1.9.1 Safety philosophy

1.9.1.1 Safety of passengers, staff and the general public is paramount for railway operation.

Prime consideration shall be given to all issues that can have an effect on safety.

1.9.1.2 During the construction phase the safety of all staff involved in the Works and any members of the general public affected by the Works shall be the prime feature of all working methods, including storage and transport to Site as well as all Temporary Works not incorporated into the final construction.

1.9.2 Safety Management

The Contractor shall implement the Contract Systems Safety Management Requirements, as referenced in the Project SHE Manual and elsewhere in the tender document, in consultation with the Engineer.

1.9.3 Prescriptive Safety Criteria

1.9.3.1 The Contractor shall identify and list all applicable statutory and regulatory requirements

and codes of practice relevant to the installation of the works undertaken and work within the constraints and limitations imposed by the requirements and codes.

1.9.3.2 The safety of the Contractor’s supplied systems and equipment shall be developed by the Contractor in accordance with the requirements contained in Clause 3.4.6 below and the PS.

1.10 Availability (Reliability and Maintainability)

1.10.1.1 The reliability and maintainability of the Permanent Works shall be developed by the

Contractor in accordance with the requirements contained in Clause 3.4 below and the PS.

1.10.1.2 The Contractor shall prepare Availability and Maintainability plans as detailed in European

standard EN 50126. The first draft of these plans shall be submitted to the Engineer for review within 6 months of the Commencement Date of the Works.

1.11 Suitability for Purpose

MAHA-METRO shall be operating high-density passenger trains with high volume of traffic in the proposed corridors commensurate with the stage opening of the Sections. The works covered in the scope of this tender shall be capable of delivering required performance satisfactorily in such an environment.

1.11.1 Interference and Compatibility

The Contractor shall ensure that all Works and Contractor’s Equipment operate in a satisfactory manner without causing interference to other equipment and services including parties external to the Employer. The Contractor shall also ensure that the Permanent Works are physically and technically compatible with associated plant and in particular with that of other contractors.

1.11.2 Design for introduction to service

The Permanent Works shall l be designed in such a manner that they can be installed, tested and commissioned without adversely affecting the operation or safety of the Project. The Permanent Works shall be designed so that, where appropriate, considering the operating procedures adopted by the Employer, they can be brought into operational use during non-traffic hours and if necessary during a single night following maintenance, repair or overhaul during the life of the Permanent Works, equipment and systems.


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1.12 Climatic Condition / Operating Environment

1.12.1 General

The following information on climatic conditions in Pune shall be taken into account by the Contractor when constructing any part of the Permanent Works. The Contractor shall ensure that due allowance is made for more severe local conditions when Permanent Works are required to operate, for example, with restricted ventilation that may lead to higher local ambient temperatures, and any other factors that may affect the operating environment in any way.

(1) Unless specific figures are provided elsewhere, the Permanent Works will generally be required to function at its rated value with the values of ambient temperature and relative humidity appropriate to the location of it.

(2) The equipment within the classifications is shown in Table 1 below. Certain parts of

the Permanent Works may need to be rated for more onerous conditions as required by the PS.

(3) Clause 1.11.2 below gives the different classifications of environment to be

encountered. For any type of item, which is installed in more than one environmental class, the type shall be suitable for installation in the most severe environmental class conditions encountered by the type.

(4) The Contractor’s attention is drawn to the more severe environmental conditions that

may exist during the construction period and shall take adequate measures to protect the Permanent Works against any deleterious effects of such conditions during the time between installation and final completion of the Project.

(5) Air throughout the Project will contain considerable moisture content and the

atmosphere will be corrosive. The Permanent Works shall be tropicalised and made vermin proof.

(6) The information on climatic conditions in Pune is indicative and the Contractor should

familiarise himself with all aspects of meteorological condition. (7) As per IS: 1893-1970, Pune falls under Zone-III seismically.

1.12.2 Classification of Equipment Environment

The locations at which equipment may be installed have been divided into four environmental classes as shown in Table 1. The classes of environment are considered to become more extreme from A to D. Table 1: Classes of Environment

Class Location of Equipment

A Air Conditioned Offices, Computer and Equipment Rooms

B Ventilated Equipment Rooms in buildings at the surface or at the underground station or structures.

C Train Tunnels

D Out doors

The following are the minimum requirements for equipment to be installed in each class of environment. Where any class does not have a value for a parameter the most extreme value quoted for the lesser class environments should be used.

1.12.3 Requirements for Class A


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Minimum Temperature 5ºC

Ambient Temperature 24±2°C

Maximum Temperature 35ºC

Relative Humidity Minimum 0%, Nominal 65%, Maximum 95% (Non Condensing)

Electrical Noise High Frequency to 1MHz, 1kV damped to 50% after 6 cycles. Radio Frequency field strength 10 V/m, UHF & VHF bands

1.12.4 Requirements for Class B

Minimum Temperature 4.5ºC

Ambient Temperature 30°C

Maximum Temperature 42.5ºC

Relative Humidity Nominal 70%, Maximum 100% (Non condensing)

Air Quality Polluted and dusty

SO2 80-120mg/m3

Suspended Particulate Matter 360-540mg/ m3

Electrical Noise Impulse 1kV, 1.2/50 µsec rise/decay, 500Ω source impedance, 0.5 J source energy High Frequency to 1MHz, 1kV damped to 50% after 6 cycles. Radio Frequency field strength 10 V/m, UHF & VHF bands

1.12.5 Requirements for Class C

Minimum Temperature 4.5ºC

Ambient Temperature 46°C

Maximum Temperature 60ºC

Relative Humidity Nominal 70%, Maximum 100% (Non condensing)

Electrical Noise Impulse 5kV Others as in Class B

1.12.6 Requirements for Class D

The extreme climatic and environmental conditions observed in Pune during the past 15 years are given in Table 2 below: Table 2

Description Values

Maximum ambient temperature 42.5ºC

Minimum ambient temperature 2.5ºC

Solar radiation 5.44 kWH/m2

Relative humidity 82% saturation during rainy season

Rainfall Rain generally occurs from June to October. Average annual rainfall is approximately 722mm.

Atmosphere Dusty during hot season Hot & humid

Wind speed 39 m/sec

SO2 level in atmosphere 6.39 µg/m3

NOx level in atmosphere 7.8 µg/m3

Respiratory Suspended Particles Matter in atmosphere ((RSSPM)

𝑃𝑀2.5

Total Suspended Particles Matter in atmosphere (TSPM)

𝑃𝑀10

Altitude 560m above mean sea level

Conditions in stations

All underground stations will be fully air-conditioned Above ground stations shall have air-conditioning in certain designated rooms.


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1.12.7 Electromagnetic Compatibility (EMC)

Electronic equipment in a railway environment shall be immunised against the usual electromagnetic influences to be expected from the rail operations. For this, the following EMC classification in accordance to IEC 801 or similar, for the equipment rooms shall be achieved: (a) Electrostatic discharge

The electronic equipment rooms shall be designed in accordance to class 2 of IEC 801-2 or similar.

(b) Electromagnetic fields


(c) Fast transient interference (Burst)


(d) High energy transient interference


(e) Switching processes in high-voltage installations

The location of computer systems in the neighbourhood < 1m of high –voltage installations, such as medium voltage or transformer stations as well as direct parallel exposure of power and data cables should be avoided.

(f) Magnetic fields

The following magnetic field strengths at the place of installation of cathode ray tube (CRT) based visual display units (VDU) should not be exceeded: DC fields: 10 A/m or 12 µT AC fields: 1 A/m or 1.2 µT If the image quality is impaired by values exceeding the above the Contractor shall provide any necessary shielding or alternative corrective measures to restore the picture quality. Note flat screen VDU using LED technology or similar may be acceptable if a sufficiently high resolution and image size can be obtained.

1.13 Survey and Site Investigations

1.13.1 For reference to surveys external to the Contract, the Contractor shall refer all Levels to

Mean Sea Level (MSL) Datum, which is that generally used throughout Pune.

1.13.2 The datum used for the Contract shall be Mean Sea Level Datum.

1.13.3 The Contractor shall carry out all further site investigations necessary for the Permanent Works and to enable the determination of the methods of construction and the nature, extent and design of Temporary Works.

1.13.4 The Contractor shall investigate environmental factors also to determine suitable methods

of manufacture and installation, both for Temporary and Permanent Works. In particular


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the Contractor shall ensure that the dusty environment of Pune has no detrimental effect to the functionality, reliability or long term maintainability of the Permanent Works.


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CHAPTER 2 2.0 PLANNING, PROGRAMME AND PROGRESS MONITORING 2.1 Planning

2.1.1 The Contractor shall develop in detail, a logical method of executing the Works taking into

account their complex nature and different phases and shall provide programmes which reflect the detailed planning undertaken.

2.1.2 The programmes shall start with the Commencement Date of the Works as day one. The

programme are to be realistic, achievable as per Key Date given in PS and shall be accompanied by the detailed supporting plans referred to in Chapter 3.0 below.

2.2 Programming General Requirements

2.2.1 Programme activities shall be discrete items of work, which when combined, produce

definable elements, components, Stages and Sections of the Works and clearly identify the completion obligations of the Contractor

2.2.2 Key Dates shall be an integral part of all programmes and all activities, and sequencing

and interrelationships required to achieve each completion obligation shall be shown.

2.2.3 The critical path shall be clearly identified in the programme and fully described in the accompanying programme narrative.

2.2.4 Activity descriptions shall clearly convey the nature and scope of the Works. Programmes

shall take into account the activities of precursor, concurrent, adjacent and follow on Project contractors as well as utility service diversions, new utilities and connections and any other activity that may affect the progress of the Works.

2.2.5 The Contractor shall also incorporate the Engineer’s requirements for additional activities,

to further explain or subdivide complex or long duration tasks, without affecting completion dates.

2.3 IT Requirement of Employer

2.3.1 Employer is in the process of implementing an Enterprise wide cloud based IT system

project titled “Integrated Project Management Platform”. The objective of the IT project is to develop a working environment that enables higher efficiency and effectiveness, not only in internal functions, but also across the entire ecosystem of the Employer including Contractors. The IT project envisaged following application stack:

(a) Collaborative document control and management services (using Bentley

ProjectWise and AssetWise solution) (b) Scheduling services (using Oracle Primavera P6 Enterprise Project Portfolio

Management (EPPM)) (c) Project Management with progress and performance reporting (using Primavera

P6 & Unifier solution) (d) Progress and performance reporting with visualization (using RIB iTWO ) (e) Enterprise wide ERP SAP implementation

2.3.2 The proposed IT system has been conceptualized for facilitating preservation of important

artifacts (plans, drawings, notes, documents, reports etc.) in a secure and manageable environment in digitized format. Appropriate triggers shall generate dashboards and management reports every time an event causes a substantial shift in the project risk or a deviation in processes is developed. The envisaged system would expedite decision-making, ensure better planning and coordination between different functions, better data management, effective reporting, knowledge management etc. Program management shall provide senior management with critical information related to various contracts,


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activities and funds in the form of management dashboards with inbuilt triggers to ensure timely decision-making.

2.3.3 The effective use of such IT platform requires availability of system at all requisite

locations i.e. with Employers’ various offices, Engineer’s offices, Contractors’ end, major sub-contractors’ end, design consultant ends etc. with certain definite users’ rights. Data uploading by various authorized and trained users is key to effective implementation of the IT system. It is expected that Contractor would have previously worked on the similar packages also it is understood that such envisaged IT platform is already a part of detailed scope of work of successful bidder. However, MAHA-METRO has conceptualized the creation of a 5D BIM platform which would be the single collaborative environment among all stakeholders including contractors, General consultants, detailed design consultants etc. for efficient & seamless flow of information.

2.3.4 In view of the above, the Contractor shall be required to:

(a) Follow and comply the system guidelines to be issued by Employer (b) Comply all the software system competency (c) Upload / definition of Project Plans as per the template and using software defined by

the Employer; (d) Maintenance and updating of uploaded Project Plans in software used by the

Employer; (e) Upload of drawings / designs created by the Contractor as per the classification and

on the software platform defined by the Employer; (f) Key contract related communication and progress related data as per processes

defined on the software platform deployed by the Employer (g) Asset details need to be updated in the system in the format prescribed by the

Employer;

2.3.5 Employer and its IT Implementation Agency shall render necessary assistance for the training of the Contractor staff.

2.3.6 Contractor will need to be accessing MAHA-METRO’s digital platform for at least the

mentioned functions as applicable as per Contractor’s respective scope of work. However the function list is indicative and precise activities from bidder on MAHA-METRO’s digital platform will be updated and communicated to Contractor on time to time basis.

2.3.7 Following are the deliverables in form of collaboration with 5D BIM by Contractor:

2.3.7.1 Creation of 3D engineered intelligent Models using discipline specific modelling /

engineering applications.

2.3.7.2 Creating 2D drawings in CAD – plan, section, elevation and other relevant details (based on specific engineering disciplines) to be accessed by the contractors for construction.

2.3.7.3 Contractor will need to comply with the following requirements in regards to the production

of all the CAD (3D/2D) data files and building information modeling (BIM) work.

2.3.7.3.1 Model file production principles (a) Contractor need to follow British Standard BS 1192:2007+A2:2016 for Collaborative

production of architectural, engineering and construction information - Code of practice as a guide for drawing practice, convention, CAD data structure and translation.

(b) Contractor need to model all design and construction information as an individual discipline model and then collaborate it in single master 3D composite model, using object based software, allowing for 2D models to be extracted as required.

(c) Contractor need to create and share details of individual components of 3D models


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for each discipline involved.

(d) Contractor need to share all individual discipline models as well the collaborated single master model through the Engineering Information Collaboration System for review by GC/MAHA-METRO. Clash detection and resolution process will run in this composite area. All 3D model data together with all 2D drawing extractions needs to be spatially coordinated with the Geospatial System. UTM/WGS84 coordinate system needs to be followed for proper geo-referencing of all the engineered 3D models that will be created.

2.3.7.3.2 Model file composition

(a) Contractor need to generate model files using seed files/template (2D and 3D). Seed

files/template will standardize all the new drawings that one creates. It will standardize the same global origin, color table, cell library attachments, working units, views etc.

(b) Model files needs to contain one model view and one sheet view

(c) All graphical elements need to be placed in the model view

(d) Model files need to have a title box placed in the sheet view

(e) All model files need to be created at 1:1 scale

2.3.7.3.3 Model Outputs

Within the engineering collaboration system the central premise is that only approved data is shared. Each discipline WIP area can only reference data from the shared area i.e. approved data. When this data comes together in the composite model it can be fully coordinated and composite renditions can be produced in 3D.

2.3.7.3.4 Model Reviews

(a) Contractor needs to ensure that the level of complexity and granularity for each

discipline CAD model is appropriate for the stage of Works.

(b) Contractor needs to ensure that all disciplines integrate and coordinate their outputs in terms of both spatial and functional provision. This shall be demonstrated through the extensive use of coordinated design review sessions which shall include for the coming together of all relevant discipline models into a common master model (model composite) where engineering assurance and coordination checks shall take place.

2.3.7.3.5 Existing Infrastructure data sets

(a) Contractor need to model existing infrastructure and systems in sufficient detail as to

provide integration with the works under contract

(b) Contractor need to clearly highlight the unresolved areas of non-coordination in structure / services/finishes/clashes on the drawings and the model at all times in case of existing infrastructure data sets

(c) Contractor need to report back to the owner any discrepancy with the existing data for their action

2.3.7.3.6 Coordination and integration – Drawing Packages

(a) Within the BIM environment each of the disciplines need to reference other models in

a timely manner for coordination purposes. The head of each discipline group shall decide the extent and nature of supporting discipline data that shall be displayed in


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each of their own discipline drawing submissions. Clash detection software routines needs to be run on the multi-discipline model and on combined master models and any clashes resolved. The reports of which will be submitted on request of the Engineer

(b) Specific drawing packages are required from each discipline. The drawings need to comprise of 2D extractions of the 3D models from the engineering collaboration system.

(c) All CAD drawings need to be comprised of 2D models extracted from the 3D master model. Any subsequent design scheme changes that are required to be fully coordinated shall be modeled in 3D and the drawing extraction re-run to produce revised plots.

(d) All plot composition files need to be checked as prescribed by the workflow setup in the engineering collaboration system before submission to the Engineer.

2.3.7.4 The Contractor shall take full advantage of the 3D object attributes available in the BIM

environment to prove cost, constructional logic, fabrication, and program as required by the MAHA-METRO/GC. Engagement modality expected for Project Management works including 4D & 5D BIM requirements: (a) Contractor shall allocate a Project Coordinator who would be a single-point contact for

MAHA-METRO for monitoring day-to-day progress on the Project.

(b) Contractor will access the web-based Project Monitoring application (Primavera) of MAHA-METRO

(c) Contractor will have to create Work Breakdown Structure (WBS) for its scope of work in the master project prepared and released by MAHA-METRO on Primavera.

(d) Contractor will have to create all the relationships between various activities to generate a Critical Path Network on Primavera.

(e) The project plan will be detailed to reflect the planned construction progress as per the 3D BIM model. This is must, as Primavera plan will get linked to 3D BIM collaborated intelligent model to reflect and review time based planned progress of project on a BIM model. Contractor’s project plan on MAHA-METRO Primavera platform will be required at this level.

(f) Once the network has been scheduled and baseline by MAHA-METRO/GC, the Project Coordinator will have to provide periodical updates for various activities.

(g) Contractor will also be required to furnish key cost / budget details along with resources on MAHA-METRO’s Primavera platform. Level of details for time plan, cost, and resources from bidder will be communicated to bidder at appropriate stage.

(h) During the execution stage bidder will be required to operate on MAHA-METRO’s Primavera platform to reflect minimum details towards work performed, progress achieved, resources consumed, forecast dates, forecast resources, remaining work along with any other key details as Required by MAHA-METRO / GC. MAHA-METRO will be communicating on level of details as well frequency of such interactions at appropriate stage.

(i) Contractor shall update and revise their work program on the integrated master schedule of the project subject to directions & approval from MAHA-METRO.

(j) Contractor will be required to periodically capture actual progress visualization of respective package work using suitable technology which can be updated in 5D BIM platform.


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2.3.7.5 In order to adopt 5D BIM platform Contractor need to follow Employer’s Information

Requirement (EIR) Document which will be prepared by Owners Support Office (OSO) in consultation with General Consultant (GC) and handed over to the Contractor. The EIR will enlist the standards, methods and procedures that one has to follow in order to be BIM Compliant. EIR will have details such as CAD standards, BIM standards, Asset Dictionary, Asset Classes, file naming convention, layer naming convention, Attribute Standards, etc.

2.3.7.6 SAP ERP (Component of Digital Project Platform):

In order to adopt SAP ERP platform Contractor will be required to follow Employer’s Information Requirement (EIR) Document which will be prepared by OSO in consultation with General Consultant (GC) and handed over to the Contractor. The EIR will enlist the standards, methods, procedures and data related to defined functionality coverage in SAP ERP.

2.3.7.7 Minimum login credentials (as decided by MAHA-METRO) per Contractor will be provided

by MAHA-METRO to the Contractor to access MAHA-METRO digital platform. In case, Contractor envisages more user licenses for their internal data preparation through their internal user (like detailed drawing or project plan preparation by multiple users) which is required for finalizing data to be entered in MAHA-METRO’s digital platform, then it will be Contractor’s responsibility to ensure own licenses. However the access to MAHA-METRO’s digital platform will be through provided user credential only.

2.3.7.8 The engineering collaboration platform will be provided by MAHA-METRO and is

mandated for the structure and the controlled sharing of the information created during the process.

2.4 Progress Monitoring

The Contractor shall monitor its and its subcontractors’ performance against programmes to ensure its compliance with its obligations under the Contract. Monitoring of the Works shall include direct, daily monitoring of the progress of the Works and the preparation of written and computerised reports to be submitted to the Engineer. The reports shall include all necessary supporting data to apprise the Engineer of the status of the completion of the Works as described in Clause 2.16 below.

2.5 Works Programme

The Works Programme to be submitted under the Contract shall be developed from the Outline Works Programme submitted and developed during the Tender period. Similarly the Design Submission Programme shall be developed from the Outline Design Submission Programme submitted and developed during the Tender period.

2.5.1 Submission Dates

2.5.1.1 Within 7 days of the Commencement Date of the Works, the Contractor shall submit for

review by the Engineer, his proposed initial version of the Works Programme which shall provide full programme details for the complete Contract Period of the Contract.

2.5.1.2 Within 60 days of the Commencement Date of the Works, the Contractor shall submit for review by the Engineer the proposed full version of the Works Programme.

2.5.1.3 Should the Contractor fail to submit the initial and full versions of the Works Programme within the time scales nominated above, the Employer may nominate the Outline Works Programme as the first issue of the Works Programme required under the Contract.

2.5.1.4 In the event that the Employer does nominate the Outline Works Programme as the first issue of the Works Programme under the Contract, the Engineer may include any amendments that he sees fit to change external constraining dates, duration of activities


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by parties other than the Contractor and subdivide the Contractor’s own activities to provide additional detail and links to other activities but without altering the duration or sequencing of the activities shown in the Outline Works Programme.

2.5.1.5 Any either initial or final Works Programme resulting from a nomination by the Employer of the Outline Works Programme as amended shall be taken by the Contractor as his own Work Programme and any responsibility for further maintenance of the Works Programme as nominated shall remain the Contractor’s.

2.5.2 Content

2.5.2.1 The Works Programme shall demonstrate by reference to its Sub-Programmes,

Supplementary Programmes and associated Management Plans, the sequence and duration of activities and any restraints thereto, that the Contractor shall adopt to achieve Key Dates and to fulfil all Contractual obligations. The Works Programme shall become the Engineer’s basis of administration of the time-related aspects of the Contract.

2.5.2.2 The Contractor shall provide the Engineer with substantiation for each constraint whether

target start, target finish or mandatory constraint entered by the Contractor into the Works Programme. The number of constraints shall be kept to an absolute minimum in order that the CPM networks developed can be freely analysed.

2.5.2.3 The Works Programme shall include activities for all the phases and stages of the Works,

clearly showing all logical interdependencies and stages in the development of the Contractor’s procurement, installation, commissioning and setting to work. As a minimum, it shall include: (1) all work comprising the Permanent Works; (2) preparation, submission and review of Design Documents showing all items

where review by the Engineer is required; (3) procurement of all major materials and items of Contractor’s Equipment for the

Works, including the dates by which orders are to be placed, manufacture period and the expected delivery date to the Site for each item;

(4) any software development requirements and validation time frames; (5) all manufacture or prefabrication of materials or components; (6) all installation of major Temporary Works; (7) all activities associated with the securing of necessary permits and other statutory

approvals for the Works; (8) access and availability dates for all Project contractors; (9) all interfaces related to the Project that may affect the progress of the Works; (10) testing and commissioning activities which demonstrate an understanding of the

interfaces and requirements of Chapter 9 below; and (11) Training and Transfer of Technology

2.5.2.4 The Works Programme shall be divided into Sub-Programmes of manageable sizes

addressing in more specific detail, the content of the Management Plans as stated in Chapter 3 below. The Sub-Programmes shall be as follows:

(1) Design, Procurement and Manufacturing programme; (2) Installation Programme;


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(3) Testing and Commissioning Programme; and (4) Training and Transfer of Technology Programme

2.5.2.5 The submission of the full version of the Works Programme shall include the Procurement

and Manufacturing Programme and a preliminary version of the Installation Programme and the Testing and Commissioning Programme identifying all major installation, testing activities and associated interfaces.

2.5.2.6 In addition, the contractor shall submit any other programmes as required by the Engineer

from time to time.

2.5.2.7 The Contractor’s Works Programme shall comply with the following:

(1) all programmes, except the Time Chainage Programme, shall be computerised Critical Path Method (CPM) networks developed using the Precedence Diagramming Method (PDM), and submitted in both hard copy and electronic data format;

(2) all programmes, except the Time Chainage Programme, shall be prepared using the

latest version of CPM scheduling software Primavera Project Planner; (3) unless consent is otherwise obtained from the Engineer, all programmes shall be

accompanied by a Programme Analysis Report as described in Clause 2.17 below; (4) a standard Gregorian calendar shall be used for planning and execution of the Works.

All programme submissions shall include details of the Contractor’s allowance for Public Holidays and non-work periods. If a Key Date or Milestone falls on a Public Holiday or non-work day, it shall be effective the next working day;

(5) the planning unit for the duration of all programme activities shall be the day. Any

activity having a duration of more than thirty (30) days shall be divided into sub-activities that shall not exceed (30) days;

(6) CPM programmes shall reflect status using remaining duration and percent complete; (7) all programmes shall be fully resource loaded as appropriate or required by the

Engineer covering all stages and aspects of the Contract and shall include, but not be limited to:

(a) major manpower for both design and installation ; (b) number of items of Contractor’ s Equipment ; (c) number of drawings and other design deliverables ; (d) principle quantities of components or parts ; (e) principle quantities of bulk materials inclusive of cabling, pipe, ductwork and

equipment items, etc.

2.5.3 All programmes constituting the Works Programme shall be organised in a logical work breakdown structure including work stages or phases. Each activity shall be coded to indicate, as a minimum, the work group or entity responsible for the activity, the area, facility or location in which the activity is included, from information provided in the BOQ Document. Key Dates shall be coded so as to be separately identifiable. The Contractor may be required to assign additional activity codes as required by the Engineer.

2.6 Submission Programme 2.6.1 The Contractor shall, within 30 days of the Commencement Date of the Works, submit a

Design Submission Programme covering all proposed submissions to the Engineer. The Design Submission Programme shall be broken down into a submission programme for each of the Management Plans defined in clause 3.1.2 below each of which shall define the dates for individual submissions and these shall conform to the baseline dates shown in the Works Programme.


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2.6.2 The Submissions Programme shall include the requirements of the Design Submissions

as described in clause 3.5.1 below, including the procurement activities of all sub-contractors and suppliers.

2.6.3 The Submissions Programme shall include each submission for every item listed in the

Specification as being required to be submitted. 2.6.4 The Submissions Programme shall ensure that all submissions are properly coordinated

With the Contractor’ s overall Works Programme, particularly in respect of the following:

(i) progress of design, manufacture, installation and testing work; (ii) co-ordination with other Contractors; and (iii) including due allowance for the Engineer’ s review process to be undertaken,

including the time needed for any re-submissions. 2.6.5 The Design Submission Programme shall specifically include a milestone for the

submission by the Contractor of the Final Design on completion of the Preliminary Design stage referred to in clause 3.5.1.1 below. The Final Design shall include at least but not limited to; details showing all of the proposed equipment, interconnections, physical layout, installation locations and interfaces to other suppliers.

2.7 Design, Procurement and Manufacturing Programme

2.7.1 Within 60 days of the Commencement Date of the Works, the Contractor shall submit for

review by the Engineer a Design, Procurement and Manufacturing Programme that shall be an integrated part of the overall Works Programme.

2.7.2 The Design, Procurement and Manufacturing Programme shall show the

interdependencies between engineering disciplines as well as between the Contractor and its sub-contractors and suppliers. This programme shall demonstrate compliance with the requirements of the Submissions Programme in Clause 2.6 above.

The procurement and Manufacturing Programme shall include the proposals for vendor approval. The Contractor is required to submit proposals for vendor approvals for all equipment, assemblies, sub-assemblies, spare parts, M&P and any other item required for the project. Inter alia the details should include design, manufacturing and testing facilities available with the vendor. Quality Assurance Plans adopted by the vendor and his sub-vendors shall also be submitted for Employer’s review. The Contractor is also, required to submit the details of turnover of the vendor for last 5 years and turnover in respect of the equipment proposed to be supplied by the vendor. In case of off shore vendors, the Contractor is required to submit details regarding facilities available in India and duration for which they have been present in India, and their proposal as to how spares & after sales support will be made available for equipment used in the project, during the service life. The proposal should also include training and other technical support to be provided by the vendor. In case of off shore vendors, the proposed scope for technology transfer shall also be included. The proposed system should have been in use for at least 5 years on any metro system.

2.7.3 The Contractor shall submit a weighted bar chart of the Contractor’s design, procurement

and manufacturing activities. Each activity weight shall normally not be more than 5% of the total man-hour content or value of the respective work.

2.7.4 The Procurement and Manufacturing Programme shall include a separate breakdown, supported by the ‘Material Control Schedule’, which shall be a complete amplification of the Contractor’s programme and equipment list, including those items which are subject to long lead time or component parts which are manufactured from countries outside the country of assembly and testing.


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2.7.5 The Material Control Schedule shall be automated and shall detail the following information for each permanent major and minor material and significant component. The format of such a schedule shall include:

(1) name, description, supplier/sub-supplier details; (2) drawing information (where appropriate), title, drawing status, submission dates, shop

drawings/ fabrication drawing preparation, etc.; (3) the manufacturing process, manufacturing of test pieces, trial production, Engineer’s

inspection, monthly production of components and monthly supply of components; (4) the assembly process, erection and assembly sequences (particularly for the first

pieces) prior to shipment, test assemblies, monthly assembly requirement, Engineer’ s inspection, testing of assemblies; and

(5) transportation process, quality release from factory, factory storage, transport to dock, shipment.

2.7.6 The Contractor shall continuously maintain this schedule and report upon the status of

each item as part of the Contractor’s regular progress reporting.

2.7.7 From this base data, the Contractor shall prepare an exception report detailing all components that are in delay. This report shall be annotated with the reason for the delay and indicate what action the Contractor is taking to recover the lost time.

2.7.8 The Contractor shall submit, as part of the Procurement and Manufacturing Programme, a

Factory Testing Programme that shall support all aspects of the Factory Testing Plan. This Programme shall clearly demonstrate the logic and include the topics listed in Clause 3.5.3 below.

2.7.9 The Factory Testing Programme shall be fully detailed, with activities individually

identifying all tests for which a certificate will be issued, and shall include activities for preparation, submittal and review of the test procedures.

2.7.10 The Factory Testing Programme shall demonstrate the logical dependencies between the individual tests of the Works, and shall also show the interfaces and dependencies with the Contractor’s delivery programme.

2.7.11 The Factory Testing Programme shall include details of inspection, testing and witnessing

of the Contractor’s and subcontractor’s procurement and manufacturing activities. As a minimum, it shall include:

(1) First Article Inspection; (2) Quality Hold Points; (3) Quality Control Points; (4) Type Tests; and (5) Routine tests.

2.8 Installation Programme

2.8.1 The Installation Programme shall be submitted within 60 days of the Commencement Date

of Works in initial version. The final version of installation, programme shall be submitted as stated in PS or as directed by Engineer.

2.8.2 The Installation Programme shall include detailed activities describing all aspects of the

installation of the Works. It shall be clearly linked to the Procurement and Manufacturing Programme and Testing and Commissioning Programme to form an integrated part of the Works Programme.

2.8.3 The Installation Programme shall be fully supported by the Construction and Installation Management Plan as specified in Clause 3.6 below.


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2.8.4 The Installation Programme shall indicate the physical areas to which the Contractor requires access, access date, duration required and the required degree of completion for civil or architectural finishes prior to the access date.

2.8.5 The Installation Programme shall take into account the requirements for arrival at port, delivery, storage, preservation and positioning of large items of Contractor’s Equipment and Permanent Works and shall set out the Contractor’s proposed delivery route for such items to the Site.

2.8.6 Installation Tests shall be clearly shown in the Installation Programme and shall include those interface tests required to be carried out by others to establish a timetable for these tests.

2.8.7 Activities that may be expedited by the use of overtime, additional shifts or by any other means shall be identified and explained.

2.8.8 In preparing the Installation Programme, the Contractor should note that the following conditions shall apply:

(1) the Contractor shall not have exclusive access to any part of the Site except by the

specific consent of the Engineer;

(2) the Contractor shall take note that concurrent time allocations for certain areas may be given to more than one contractor. The Contractor shall co-ordinate the Contractor’s work in such areas with that of Project Designated Contractors through the Engineer;

(3) the absence of a programme date or installation period for the Contractor in a specific area shall not prejudice the right of the Engineer to establish a reasonable programme date or installation period for that area;

(4) the Contractor shall comply with the identified Key Dates. The Contractor shall also comply with the Access dates identified ;

(5) the Contractor shall deliver all Contractor’s Equipment and Permanent Works for stations by road and via temporary access openings unless otherwise reviewed by the Engineer.

2.9 Testing and Commissioning Programme

2.9.1 The Testing and Commissioning Programme shall be submitted as stated in the PS or as

directed by the Engineer and shall comply with the requirements of Clause 2.5.2.7 above.

2.9.2 The Contractor shall submit the Testing and Commissioning Programme that shall fulfil all the on-Site testing and commissioning requirements of Clause 9.3.2.2 below. The Testing and Commissioning Programme shall clearly demonstrate the logic and highlight the topics listed in the On-Site Testing and Commissioning Plan in Clause 9.3.2.2 below.

2.9.3 The Testing and Commissioning Programme shall be fully detailed, with activities

individually identifying all tests for which a certificate will be issued, and shall include activities for preparation, submittal and review of the test procedures.

2.9.4 The Testing and Commissioning Programme shall demonstrate the logical dependencies between the individual tests of the Works, and shall also show the interfaces and dependencies with all of the Project Contractors’ tests required to commission the Works and support the Commissioning Plan.

2.10 Training and Transfer of Technology Programme


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2.10.1 The Contractor shall, within 180 days of the Commencement Date of the Works, submit for review by the Engineer, a Training and Transfer of Technology Programme covering all proposed formal training courses, delivery of training equipment and accesses by the Employer’s personnel for informal ‘ hands on’ technology transfer. The Training and Transfer of Technology Programme shall also detail specific Transfer of Technology features as required by the Specification and proposed by the Contractor.

2.10.2 The Training and Transfer of Technology Programme shall be developed to the Training

Plan as required under Clause 3.7.4 below.

2.10.3 The Training and Transfer of Technology Programme shall be sufficiently detailed that the Employer can ensure the availability of staff for all the courses required under Clause 10.1.6.

2.10.4 The Training and Transfer of Technology Programme shall include the requirements of Chapter 10 below, including the Training and Transfer of Technology activities of all sub-contractors and suppliers.

2.11 Time Chainage Programme (T/C)

2.11.1 For installation to be carried out in sections of the railway (whether in guideway, in car

depot or in RSS/TSS areas), the Contractor shall submit a T/C Programme 60 days before the start of Site works. The format and content of the T/C Programme shall be submitted for review by the Engineer prior to submission of the substantive T/C programme itself.

2.11.2 The T/C Programme shall be compatible in all respects with the Works Programme and

shall include, but not be limited to, details of the planning of the Works in a linear time/location manner. The T/C Programme shall demonstrate how linear tasks interrelate with time, access points, access/handover dates, planned production outputs, construction material call-off rates, etc.

2.11.3 The T/C Programme shall be updated and submitted to the Engineer on a minimum three

(3) month basis or when installation methods, production rates or interfaces deviate from that shown in the Works Programme.

2.12 Track Related Installation Programme (TRIP)

2.12.1 The Employer and the Engineer shall, upon taking over the Permanent Works for works

train running, maintain a co-ordination between the various contractors wishing to work in the train tunnels.

2.12.2 The Contractor and each other contractor will submit his requirements in a form similar to

that required in the T/C in Clause 2.11 above. The Site Co-ordination Team referred to in Clause 9.5 below will maintain the TRIP and resolve conflicts between contractors by discussion at the weekly Works Train meeting to which the Contractor may send a representative.

2.12.3 The TRIP and associated safe working documentation issued by the Site Co-ordination

Team shall be accepted by all contractors as limiting their areas of working. Any work carried out in contradiction to that allowed by the TRIP will be considered to be a breach of the site safety arrangements.

2.13 Programme Submissions

The Contractor shall submit all programmes described in this Chapter in conjunction with the Management Plans described in Chapter 3 below to the Engineer for review.

2.14 Programme Review


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2.14.1 The Engineer shall, within 28 days of receipt of the initial submission of any programme for review, either give a notice of no objection or provide specific details as to why a notice of no objection is not given. If the Contractor is advised that the programme is not given a notice of no objection, the Contractor shall amend the programme taking into account the Engineer’s comments and/or requirements and resubmit the programme within 14 days.

2.14.2 In the case of further re-submittals, the resubmission time shall also be 14 days.

2.15 Works Programme Revisions

2.15.1 The Contractor shall immediately notify the Engineer in writing of the need for any change

in the Works Programme, whether due to a change of circumstances or for any other reason. Where such a proposed change affects the timely completion of the Works or any Section or Stage; the Contractor shall within 14 days of the date of notifying the Engineer submit for the Engineer’s review his proposed revised Works Programme and accompanying Programme Analysis Report. The proposed revised Works Programme shall show the sequence of operations of any and all work related to the change and the impact of changed work or changed conditions on the Works and Project Contractors and their works.

2.15.2 If at any time the Engineer considers the actual or anticipated progress of the work reflects

a significant deviation from the Works Programme, he may request the Contractor to submit a proposed revised Works Programme. Upon receipt of such a request, the Contractor shall submit within 14 days a revised Works Programme, together with an accompanying programme analysis report and narrative statement that shall demonstrate the means by which the Contractor intends to eliminate the deviation.

2.16 Monthly Progress Report

2.16.1 The Contractor shall prepare Monthly Progress Reports covering all aspects of the

execution of the Works. Such Monthly Progress Reports shall be in writing and shall be delivered to the Engineer by the 5th day of the month following the month to which the Monthly Progress Report relates. The Monthly Progress Report shall take account of work performed up to and including the last day of the month to which the Monthly Progress Report relates.

2.16.2 The Monthly Progress Report shall include an executive summary and contain clear and

concise statements in respect of every significant aspect of the Works including, without limitation, the requirements specified in Appendix 1 of this Specification.

2.16.3 The Monthly Progress Report shall contain evidence that documents and supports the progress of the Works, as stated in the Interim Payment Certificates, to the satisfaction of the Engineer.

2.16.4 The reports, documents and data provided shall be an accurate representation of the current status of the Works and of the work to be accomplished and shall provide the Engineer with a sound basis for identifying problems and deviations from planned work and for making decisions.

2.17 Programme Analysis Report

2.17.1 The Contractor shall submit a Programme Analysis Report that shall, in narrative format,

describe the basis and assumptions used to develop all programme submissions. The Programme Analysis Report shall be prepared in a format having been reviewed without objection by the Engineer and contain as a minimum the following:

(i) cycle times and work sequences; (ii) the deployment of Contractor’s Equipment and labour; (iii) the production rates used in determining duration; (iv) the shifts assumed in determining duration;


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(v) the breakdown of labour requirements by trades; (vi) the schedules of quantities used in developing the programme, to the extent that

such information is not provided elsewhere; (vii) interfaces with the Engineer and Project Contractors and other constraints; and (viii) any assumptions used in the programme.

2.17.2 The Programme Analysis Report shall be in sufficient detail to enable the duration, leads

and lags in the logic diagram to be reconciled and substantiated, and to enable the projected levels of labour (by trade) and staff and flows of goods, materials and equipment to be substantiated.

2.18 Key Date and Access Date Report

2.18.1 The Key Date and Access Date Report shall be prepared in a format reviewed by the

Engineer and identify and state the status of:

(1) all Key Dates and Access Date that were planned to be achieved in the reporting period or earlier but have not been achieved;

(2) all Key Dates and Access Date that have been achieved in the reporting period;

(3) all Key Dates and Access Date that are planned to be achieved in the next reporting period; and

(4) any future Key Dates and Access Date that appear unlikely to be achieved on time.

2.18.2 The Key Date and Access Date Report shall identify, for all relevant Key Dates and Milestones, the planned dates, the actual dates achieved, and where the original planned dates are forecast to be unachieved, the revised dates identified in the Contract, as the same may be revised from time to time in accordance with the Contract.

2.18.3 The Key Date and Access Date Report shall also provide an explanation for any deviation

from the planned dates. Measures taken or required to recover programme delays shall also be identified.

2.19 Physical Progress (Earned Value) Report

2.19.1 General

The Contractor shall prepare and submit monthly, a Physical Progress Report based on earned value techniques in accordance with the procedure described below. The proposal for the Physical Progress Report and basis for measuring progress shall be prepared in accordance with the requirements listed below and shall be submitted within 30 days of the Commencement Date of the Works.

2.19.2 Selection of work activities

(a) Earned value progress reporting requires that the Contractor’s work activities be

broken down into discrete measurable units that are time phased (0% to 100% complete) in accordance with the Contractor’s programme and maximum limit. These discrete measurable units shall be based on the physical deliverables and are weighted by the value of the items in INR in order to summarise the activities into a planned percent complete curve. The format for presenting the earned value progress measurement information in a Physical Progress Report is to be reviewed by the Engineer.

(b) Key work activities for reporting progress shall be determined by the Engineer in

consultation with the Contractor.


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(c) To the maximum extent possible, activities shall be chosen which can be measured quantitatively rather than subjectively as the work progresses. In the event it is necessary to use activities that can only be measured subjectively, intermediate activities or milestones shall be identified on the programme which will establish a predetermined intermediate percent complete for the activity at attainment of each intermediate milestone. Such milestones shall be no more than one month apart.

2.19.3 Activity weighting

In order to summarise the key individual activities into an overall planned or actual percent complete, activities must be weighted. Various methods for determining the appropriate weighting can be used. The Contractor may propose an existing methodology comparable to the intent of the earned value concept. The Engineer will assess and, if appropriate, review the method proposed by the Contractor. The sum of the weighting for all activities shall equal one hundred percent (100%).

2.19.4 Revisions to Physical Progress Report

Once the weightings have been established they shall not be changed unless there is a variation that significantly impacts on the programme and the weightings. If, after review, i t is decided by the Engineer to incorporate a major variation, the weightings shall be adjusted for the impact of the variation and both the plan and actual curves revised. The curves shall be recalculated by inserting the variation activity percent complete plan (0 to 100%) in the time frame it will occur and applying the revised weightings. This recalculation shall be submitted to the Engineer for consideration and review prior to its use in the Monthly Progress Reports. The other time-phased planned activities shall remain unchanged during this process in order to maintain the integrity of the baseline plan.

2.19.5 Measurement of activity progress

The actual percentage of the Works completed shall be calculated on a monthly basis as required to support the preparation of the Physical Progress Report and the Project status reviews. The Contractor shall ensure that sufficient reliable quantitative backup documentation exists to support these calculations for each activity within the Physical Progress Report. Periodic detailed reviews may be made by the Engineer to assess the Contractor’s calculations.

2.20 Progress Meetings

2.20.1 The Employer will chair progress meetings every month with the Contractor. These

meetings will be held at dates and times to be advised by the Engineer. Progress meetings shall not be later than 10 days after the issue of the Contractor’s Monthly Progress Report.

2.20.2 The Engineer may convene at his discretion, at any time upon reasonable notice to the

Contractor, any meeting in addition to the progress meetings, either on or off the Site, to discuss and address any aspect of the Works or the Contract. The Contractor shall attend any such meetings convened by the Engineer.

2.20.3 All meetings shall be convened in Pune unless directed otherwise by the Engineer. Meetings shall be attended by senior personnel from the Contractor who shall arrive properly briefed for all aspects of the meeting and shall be empowered to make executive decisions in respect of the execution of the Works.

2.21 Quarterly Review Meetings


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2.21.1 The Engineer may convene Quarterly Review Meetings in Pune at approximately three monthly intervals. The Engineer will notify the Contractor the date of such Quarterly Review Meetings not less than 28 days before they are to be held.

2.21.2 Quarterly Review Meetings shall be held over a period of up to 3 days in order to review

the overall progress of the Works in the context of the Project as a whole and to address and resolve any issues relevant to the execution and progress of the Works. Such Quarterly Review Meetings will be chaired by the senior officer of the Employer or his delegate. The Contractor shall have in attendance one senior representative of Director level from each of the companies comprising the Contractor (together with the Managing Director of the company acting as leader or sponsor of the Contractor if it is a joint venture, consortium or partnership whenever necessary and required by the Engineer).

2.21.3 The Contractor shall submit names of the persons whom the Contractor proposes to

attend each Quarterly Review Meeting to the Engineer for review not less than 7 days prior to each Quarterly Review Meeting.


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CHAPTER 3

3.0 MANAGEMENT PLANS AND SUBMISSIONS

3.1 General

3.1.1 In order to organise the various submissions required by the Engineer, and to ensure the Contractor’s understanding and compliance with the requirements of the Contract, a series of Management Plans shall be developed. These Management Plans will serve to structure the submittals in a manner that the Contractor can develop and prepare the submittals and the Engineer can review and comment on a prescribed programme.

3.1.2 The Management Plans shall be configured as a family of “stand-alone” plans and

associated documents each covering one of the subjects listed below.

The plans and documents shall be co-ordinated with each other and shall collectively define, describe and encompass the Contractor’s proposed methods, procedures, processes, organisation, sequencing of activities, etc. and shall show how these combine together to assure that the Works truly meet the requirements of the Specification in respect of the subjects listed. Unless otherwise stated in the PS, all plans and documents shall be submitted in preliminary form within 60 days of the Commencement Date of the Works followed by detailed plans within 60 days of the preliminary submission. Further submissions shall be made: (1) when required in accordance with the Works Programme;

(2) whenever the development of the Contractor’ s designs or planning allows the plan to

be developed further;

(3) in response to comments made by the Engineer in accordance with Clause 4.3.6 below;

(4) whenever any change occurs that invalidates the information contained in the previously submitted and reviewed document, within 14 days of the occurrence of such change; and

(5) when requested by the Engineer from time to time.

3.2 General Organisation

3.2.1 The Plans listed below shall be developed and submitted by the Contractor for the Engineer's review: - Project Management Plan

o Contractor’s Project Plan o Interface Management Plan

- Systems Assurance Plans o Quality Plans o Safety Plans o Electromagnetic Compatibility Management Plan o Software Quality Assurance Plan

- Procurement, Manufacturing and Delivery Plan o Design Verification and Validation Plan o Factory Testing Plan o Procurement, Manufacturing and Delivery Plan

- Construction and Installation Management Plan o Construction and Installation Plan o Health and Safety Documentation


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o Environmental Qualities Management Plan o Traffic Management Submissions (if required)

- Completion Management Plan o Commissioning Plan o Operation and Maintenance Manuals Plan o Training and Transfer of Technology Plan o Spares Management Plan o Spares Management Plan o

3.2.1.1 The Contractor shall submit for review by the Engineer a Spares Management Plan to furnish a priced, manufacturer-recommended list of spare parts necessary to support continuous operation of all such equipment for a minimum period of 24 months after the commencement of Revenue Operations, in accordance with Chapter 13 below.

3.2.1.2 The Contractor shall submit the Spares Management Plan by the date stated in the PS, or,

if none is given, not less than six (6) months prior to the issue of the Taking Over Certificate for the Works.

o Defects Liability Management Plan

3.3 Project Management Plan

The overall management of the Works shall be the Contractor’s responsibility. The organisation of the resources for the procurement, manufacture, delivery, installation, testing and commissioning, and setting to work is to be developed into a Project Management Plan. Each section of this plan shall fully describe the Contractor’s understanding of the Works and management skills and structure required to achieve the same.

3.3.1 Contractor’s Project Plan

3.3.1.1 The Contractor’s Project Plan shall provide a clear overview of the Contractor’s

organisation, management systems and methods to be used for the complete execution of the Works.

3.3.1.2 The Contractor’s Project Plan shall include a summary description of each and every

stage of implementation of the Works, clearly showing the principal organisational interfaces both within the Contractor’s own organisation (including sub-contractors of every tier) and with other contractors and relevant authorities, defining how each of these interfaces is to be managed and controlled. An organisation chart shall be produced to illustrate the subdivision of the work into elements for effective technical and managerial control, the reporting structure and the interface relationship among all parties involved. Names, addresses, telephone and fax numbers of all principal contacts shall be listed.

3.3.1.3 The Contractor’s Project Plan shall contain structured organisation charts showing the hierarchical relationship of the Contractor’s organisation (including sub-contractors of every tier). The organisation charts shall be produced as a “family” such that the basic chart shows the overall organisation structure supported by subsidiary charts detailing the internal structure of the various departments or sections of the overall organisation.

3.3.1.4 The Contractor’s Project Plan shall include full details of the qualifications, experience, authority and responsibility of the personnel assigned to all key positions of the Contractor’s organisation (including sub-contractors of every tier). As a minimum, this shall include all levels down to senior managers and shall include the personnel responsible for each individual department and functional group. A clear reference shall be given as to the location of staff (e.g. Site resident or factory based, etc.). Names, addresses, telephone and fax numbers of all principal contacts shall be listed.


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3.3.1.5 The Contractor’s Project Plan shall define the Contractor's management structure for the execution of the Works and for the control of the quality of the Works and shall, without limitation, identify and set out: (1) The procure for audit

(2) the procedures for the control of receipt and issue of all Works related

correspondence so as to ensure traceability;

(3) the procedures for filing system to be implemented to maintain the Contractor’ s records during the course of the work. The filing systems used by the Contractor and sub-contractors of any tier shall be compatible as far as is necessary;

(4) the procedures for the identification, production, verification, internal approval, review (when required) by the Engineer, distribution, implementation and recording of changes to all drawings, reports and specifications;

(5) the procedures for the evaluation, selection, engagement and monitoring of sub-contractors / suppliers together with the means of application of quality assurance to their work including audit and acceptance;

(6) the procedure for the regular review and revision of each type of quality plan and its supplemental individual specific quality plans to ensure their continuing suitability and effectiveness, in addition to the method to be used for revision and issue of revised documentation;

(7) the procedures for the control, calibration and maintenance of inspection, testing and measuring equipment;

(8) the procedures for the selection, indexing, disposition and maintenance of project records for storage in the archives. A list of items to be archived including their periods of retention shall be submitted for review by the Engineer;

(9) the procedures for identifying training needs and for the provision of training of all

personnel performing activities affecting quality; and (10) the procedures for the control of non-conformity.

3.3.1.6 Particulars of Contractor’s Representative

(1) The Contractor shall give and provide all necessary supervision during the execution

of the Works as long as the Engineer considers necessary for the proper fulfilment of the Contractor’s obligations under the Contract.

(2) The Contractor shall ensure that he is at all times represented on the Site by a competent and authorised English/Hindi speaking Contractor’s Representative who shall be deemed to have been approved without objection by the Engineer provided such Contractor’s Representative is not expressly objected to by the Engineer in writing within 14 days from the service of a notice upon the Engineer by the Contractor of the appointment of such Contractor’s Representative. Such Contractor’s Representative shall be constantly on the Site and shall give his full time to the superintendence of the Works.

(3) The Engineer shall have the authority to withdraw his notice of no objection to the Contractor’s Representative at any time. If such notice of no objection is withdrawn the Contractor shall remove the Contractor’s Representative from the Site forthwith and shall not thereafter employ him again on the Site in any capacity and shall forthwith replace him by another competent English/Hindi speaking Contractor’s Representative reviewed without objection by the Engineer.


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(4) Such authorised Contractor’s Representative shall receive on behalf of the Contractor directions and instructions from the Engineer.

(5) The following particulars of the proposed Contractor’s Representative shall be submitted to the Engineer for review:

a. name; b. copy of Identity Card; c. details of qualifications, including copies of certificates; and d. details of previous experience.

(6) The particulars of the Contractor’s Representative shall be submitted 30 days before

the agreed scheduled start of that part of the Works. Except in the case of a replacement of Contractor’s Representative (as provided for in Clause 3.3.1.6 (3), in which case the said particulars shall be submitted forthwith.

(7) The Contractor’s Representative shall possess relevant academic or professional qualification and have at least 10 years experience in relevant engineering works. The Engineer reserves the right to call upon the Contractor to prove such qualifications / experience to the satisfaction of the Engineer.

(8) The minimum qualification of the Contractor’s Representative shall be as approved by the Engineer based on the nature / importance of the work and experience of the person.

3.3.2 Interface Management Plan

3.3.2.1 The Contractor shall interface and liaise with other contractors in accordance with the

requirements of Clause 16.3 below.

3.3.2.2 Within 60 days of notification from the Engineer of the identity of each other contractor, the Contractor shall develop and submit to the Engineer an Interface Management Plan that is mutually acceptable to both the Contractor and the other contractors. The Interface Management Plan shall:

(1) identify the sub-systems as well as the civil works and facilities with interfacing

requirements;

(2) define the authority and responsibility of the Contractor’s and other contractors’ (and any relevant sub-contractors’) staff involved in interface management and development;

(3) identify the information to be exchanged, together with the management and technical skills required for the associated development work, at each phase of the Contractor’s and other contractors’ (and any relevant sub-contractors’) project life-cycles;

(4) include considerations of the Interface Hazard Analysis;

(5) specify the configuration and version control procedures in accordance with the Contractor’s and other contractors’ (and any relevant sub-contractors’) quality management system; and

(6) address supply, installation, testing and commissioning programme of the contracts to meet the key dates of each contract, and highlight any programme risks requiring management attention.

3.3.2.3 Once the Interface Management Plan has been reviewed without objection by the Engineer, the Contractor shall execute the Works in accordance with the Interface


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Management Plan. The Contractor shall advise the Engineer immediately of any difficulty in developing a mutually acceptable Interface Management Plan.

3.3.2.4 Within 90 days of notification from the Engineer of the identity of each other contractor, the

Contractor shall develop and submit to the Engineer for review a Detailed Interface Document for each other contractor that is mutually acceptable to both contractors. The Detailed Interface Document shall address in detail how the dates identified in the Interface Management Plan shall be achieved and shall identify the data required by the interfacing other contractors to meet the requirements of the PS.

3.3.2.5 The Detailed Interface Document shall specify the proposed method and schedule for verifying the interface integrity, the individual equipment / system performance and the combined system performance. The Detailed Interface Document shall include a programme of tests to demonstrate the performance and integrity of the integrated systems. The Interface Specification appended to the PS shall form the basis of the Detailed Interface Document, but does not relieve the Contractor’s obligation to identify any new interface to meet the Contract requirements. Any revision to the Detailed Interface Document shall be mutually acceptable by contractors and submitted to the Engineer for review.

3.4 Systems Assurance Plans

3.4.1 The Systems Assurance Plans shall be submitted for review to the Engineer in preliminary

and final forms.

3.4.2 The various plans shall be co-ordinated with each other and shall collectively define, describe and encompass the Contractor’s proposed methods, procedures, processes, organisation, sequencing of activities, etc. and shall show how these combine together to assure that the Works truly meet the requirements of the Specification in respect of the subjects listed.

3.4.3 Configuration management of all hardware and software shall be in accordance with ISO

10007.

3.4.4 Quality Plans

The Contractor shall submit for review by the Engineer quality plans in accordance with the requirements of Clause 5.2 below.

3.4.5 Safety Plans

3.4.5.1 Site Safety Plan

The Contractor shall prepare a Site Safety Plan incorporating the requirements of the SHE Manual and designed specifically for the various sites (including storage and overseas sites) on which work under the Contract is to be carried out. The Site Safety Plan shall form a part of the Health and Safety Documentation referred to in Chapter 18 below.

3.4.5.2 RAMS Plan

3.4.5.2.1 The Contractor shall implement a formal Reliability Plan and a formal Maintainability Plan

in accordance with the PS and EN 50126 (Railway applications - The specification and demonstration of dependability, reliability, availability, maintainability and safety (RAMS)).

3.4.5.2.2 The Contractor’s Reliability Plan and Maintainability Plan shall include Failure Modes,

Effects and Criticality Analysis and the production of a Reliability Critical Items List.


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(a) The Contractor shall submit for review by Engineer safety plan, as per this specification.

(b) The Contractor shall submit for review by the Engineer the Contractor’s Reliability

Plan and Maintainability Plan in accordance with the requirements of Clause 1.10 above.

3.4.6 Electromagnetic Compatibility Management Plan

3.4.6.1 The Contractor shall prepare and submit for review by the Engineer an EMC Management

Plan which shall, based upon a top-down approach, define the EMC philosophy, activities, means of control for the design processes and EMC submissions to be supplied to demonstrate compliance with the PS and GS.

3.4.6.2 The EMC Management Plan shall identify a comprehensive list of specifications,

standards, method statements and procedures to be submitted to the Engineer for review. The EMC Management Plan shall also include a programme that shall identify the dates for EMC submissions.

3.4.6.3 The EMC Management Plan shall include an initial list of design documentation, test

specifications and test reports with a single paragraph description of each document to indicate compliance with the Specification.

3.4.6.4 The EMC Management Plan shall include a definition and description of the process and methods used for Verification and Validation that the Works will achieve the required EMC parameters in all respects.

3.4.6.5 The Contractor shall co-ordinate the levels of interference emissions and susceptibility of

all equipment which are to be designed, manufactured, supplied and installed by the Contractor and its sub-contractors and suppliers. The Contractor shall designate a person as point of contact to deal with EMC matters. Details of the nominated person and any subsequent change of the nominated person shall be subject to review by the Engineer.

3.4.6.6 The Contractor shall liase and co-ordinate with all Other Contractors in the exchange of

EMC data and related equipment performance characteristics and advise the Engineer when any such information is requested from any Other Contractor. A copy of all EMC related information exchange shall be sent to the Engineer for review.

3.4.6.7 The Contractor shall comply with the following EMC requirements:

(a) The Contractor shall ensure that all electrical and electronic apparatus is designed

and constructed to operate without degradation of quality, performance or loss of function in the electromagnetic environment of the Project.

(b) The Contractor shall meet the requirements of the BS ENV50121 series of standards

(Railway applications – Electromagnetic compatibility), 1996 edition, the UK’s Electromagnetic Compatibility Regulation, the IEC 61000: Electromagnetic Compatibility or equivalent and other standards mentioned in the PS to be reviewed by the Engineer. EMC considerations shall be incorporated in the Contractor’s procedures for product safety and design Verification.

(c) Detailed requirements in respect of electromagnetic compatibility characteristics are

contained in the PS. (d) The design shall ensure that any electromagnetic interference emissions introduced

into the environment do not exceed those detailed in the PS and GS. The Contractor shall ensure that the specified electromagnetic compatibility (EMC) requirements are adequate. Any shortcomings shall be made known to the Engineer immediately and recommendations for corrective action formulated.


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(e) In respect of the design documentation, the Contractor shall demonstrate by theoretical analysis that the design of the electrical and electronic systems is fully compliant with the EMC requirements identified. The Contractor shall state clearly in the documentation all the assumptions made and parameters used in the analysis.

(f) The Contractor shall detail the methodology, verify and validate any simulation models

used in support of the analysis. The Contractor shall prepare and submit to the Engineer for review reports of the Verification and Validation of the models.

(g) In the circuit analysis, calculations shall be made for all component tolerance effects

due to manufacture, environment, ageing, and all possible component Failure Modes. If any component can exist in a Dormant Failure Mode, the analysis must assume that the component has failed. The Contractor shall identify all component Failure Modes considered and produce evidence to the Engineer for review.

(h) The Contractor shall identify all components to be tested, specify the interval between

routine tests, define the test procedure and provide Verification levels and pass marks, which must be achieved. The Contractor shall carry out proof testing of circuit components.

(i) The Contractor shall supply documentation showing how system safety and reliability

is ensured. It shall include Fai lure Modes, system failures, the effect of human intervention and how equipment thresholds have been set in order to keep them above worst case interference levels, and how equipment tolerances and other characteristics in the Specification have been allowed for in designing the system.

(j) The Engineer may conduct an independent EMC audit for both the system and its

component parts and shall therefore require access to all the relevant design and production information. The Contractor shall supply sufficient documentation and analysis in a form reviewed by the Engineer.

(k) EMC type testing shall be carried out on all equipment identified in the design stage

which requires attention regarding EMC. (l) The Engineer may request at his discretion, attendance at the manufacturing factory

prior to delivery to assist in providing confidence that the EMC requirements will be met. However, this will not give design acceptance that can only be given after successful completion of the System Acceptance Tests.

(m) The Engineer may request that tests be carried out to simulate the Failure Mode of

any critical hardware / software component that is considered to have a significantly detrimental effect.

(n) The Contractor shall implement corrective actions to rectify any EMC problems

identified during design, on-Site testing and when the whole system is in operational service.

(o) The Contractor must be fully aware of the EMC requirements and any modifications to

systems and equipment carried out by the Contractor during the Defects Liability Period shall not cause the immunity or emission levels of the installed system and equipment to exceed such values. Detailed EMC documentation on all modifications carried out shall be submitted to the Engineer for review. Modification work shall not commence until the respective submission has been reviewed without objection by the Engineer.

3.4.7 Software Quality Assurance Plan

Where software is a design deliverable, the Contractor shall submit a Software Quality Assurance Plan in accordance with the requirements of Clause 6.1 below. The Software


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Quality Assurance Plan shall address all elements of the design and development of software required as part of the Works.

3.5 Design, Procurement and Manufacturing Plan

The Procurement and Manufacturing Plan shall be configured as a family of “stand-alone” plans and associated documents each covering one of the subjects listed below. The plans shall be co-ordinated with each other and shall collectively define, describe and encompass the Contractor’s proposed methods, procedures, processes, organisation, sequencing of activities, etc. and shall show how these combine together to assure that the Works fully meet the requirements of the Specification in respect of the subjects listed.

3.5.1 Design Plan

3.5.1.1 Design shall be undertaken to ensure a smooth flow of information for review by the

Employer’s Engineer. Submissions shall be strictly in accordance with the Design Submissions Programme prepared in accordance with Clause 2.6 above.

3.5.1.2 The Contractor shall perform his designs for the Works and prepare a design plan for his design work in accordance with the following design stages. The Contractor shall submit to the Employer’s Engineer for his review, relevant design information as identified under each stage: (1) Conceptual Design Stage

Design of the overall system and elaborating on the proposed system configuration with emphasis on how the interface requirements are to be achieved. (a) The Contractor shall prepare and submit to the Employer’s Engineer for his

review a System Requirement Specification (SRS) which includes, as a minimum, operational, functional, performance and design requirements of the proposed system.

(b) The System Requirement Specification, serving as a means of system requirement management and the Contractor’s top level design document, shall state all the requirements completely and unambiguously and how each requirement can be verified and validated.

(c) The System Requirement Specification shall include a compliance matrix that includes cross-references to the requirements stated in the PS, the System Requirement Specification and the Design Verification Table (DVT).

(d) The conceptual design stage, as a minimum, shall identify the function of each system, sub-system, equipment or other element within the overall SRS and specify the relationships and interfaces between each element of the system, including the systems of the interfacing elements of other Contractors.

(2) Design Review

(a) A series of Baseline Design Reviews shall be arranged prior to the conclusion of the Conceptual Design Stage. Within 30 days after completion of each critical design submission during preliminary design, the Contractor shall arrange a Design Baseline Review meeting to baseline the design for the next stage of activity.

(b) Upon completion of the Conceptual Design Stage the Contractor shall submit for review by the Employer’s Engineer a homogenous Preliminary System Design.

(3) Preliminary Design Stage

The preliminary design stage shall address each element of the SRS as developed in the Preliminary Design. Equipment and interconnection specifications, with supporting calculation, shall be developed at this stage. Manufacturing of production units will


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only be allowed to commence after receiving a notice of no objection for the relevant design elements. (a) Preliminary electrical and control schematics shall be developed to illustrate how

the various operational and functional requirements can be achieved. Software design and development shall also be carried out during this stage.

(b) The submission shall clarify and confirm as necessary all technical aspects of all interfaces with other elements of the Contractor's overall design and of any interfaces with works being supplied by other Contractors.

(c) Ergonomic design, followed by the production of mock-ups and prototypes shall be developed as part of the preliminary design.

(d) If at any time in the development of the preliminary design, the Contractor wishes to modify the conceptual design by dividing any system or subsystem into a number of smaller systems or by reconfiguring the interfaces or for any other reason, the Contractor shall resubmit the SRS and/or the Preliminary Design for the Employer’s Engineer’s review.

(e) A detailed submission list for the preliminary design shall be submitted to the Employer’s Engineer for review 30 days prior to the start of the preliminary design. The submission shall be in sufficient detail to evaluate the progress and technical adequacy of the selected design approach.

(f) Upon completion of the Preliminary Design Stage the Contractor shall submit for review by the Employer’s Engineer a homogenous Final Design.

(4) Site Design Stage

Installation detail and method statements for various areas and sections shall be released progressively during this stage. Installation works on Site will only be allowed to commence following the Employer’s Engineer’s review of the relevant design information with no objection raised.

3.5.1.3 Separate parts of the design plan shall be prepared for Contractor and subcontractor

design activities. The design plans shall define the Contractor's policy for the design of the Works and shall, without limitation, define: (1) the organisation of the Contractor's design staff with particular reference to the design

interfaces;

(2) the specific allocations of responsibility and authority given to identified design staff with particular reference to the review and Verification of design specification, drawings and calculations by the Contractor;

(3) the specific methods of design necessary to identify any relevant method statements and develop those method statements to a sufficient degree of detail reviewed by the Employer’s Engineer; and

(4) the list of procedures and work instructions to be applied to manage and control the quality of the design work, including without limitation:

(a) the design and performance requirements which shall be defined in terms of

basic data and design assumptions made; relevant codes, standards and regulatory requirements; safety, reliability, security and environmental requirements; and commissioning requirements;

(b) the design methods. Software applications to be used in the design, both proprietary and public domain, including any requirements for physical and mathematical model testing;

(c) the preparation, checking, issue, distribution, indexing and filing of reports, calculations, drawings and specifications together with the means for their revisions;

(d) the formal design review, authorisation and approval of design documentation; and


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(e) the independent design Verification and Validation.

3.5.2 Design Verification and Validation Plan

3.5.2.1 The Design Verification and Validation Plan, supplementary to the Design Plan, shall be prepared by the Contractor in order that design Verification and Validation activities are properly directed. The plan shall address, but not be limited to, the following:

(1) the objectives of each Verification phase and each Validation phase; (2) defined input and output criteria for each development phase; (3) identification of types and detailed methods of test, Verification and Validation

activities to be carried out; (4) detailed planning of Verification and Validation activities to be carried out,

including schedules, resources and approval authorities; (5) selection and utilisation of the test equipment, and their test environmental

conditions; and (6) criteria on which the Verification or Validation is judged to be acceptable. These

criteria shall be traceable to the design and performance requirements as referred to in Clause 3.5.1.3.(4) (a) above.

3.5.2.2 The Contractor shall, by means of a design Verification and Validation process,

demonstrate that all requirements within the Specification have been met. The Contractor shall prepare a Design Verification Table (DVT) that identifies the Contractor's proposed methodology for demonstrating compliance.

3.5.2.3 The DVT shall be supplied to the Employer’s Engineer for his review and shall be monitored throughout the design and construction of the Works. Any changes to the DVT must be submitted to the Employer’s Engineer for review before implementation.

3.5.2.4 The DVT shall identify the proposed Verification and Validation process(es) for each specification requirement and the acceptance criteria for achieving the requirement. The DVT does not relieve the Contractor of any other requirements of the Specification in relation to design review, Verification, Validation, conformance or planning.

3.5.2.5 For each item in the DVT, the Verification and Validation methods to be used shall be listed by the Contractor. The methods used shall be reviewed by the Employer’s Engineer. At least one stage of Verification and Validation shall be performed prior to production of an item.

3.5.2.6 Subject to review without objection by the Employer’s Engineer for each application, the Verification and Validation methods listed below are acceptable if implemented (whether singly or in combination): (1) Similarity - equipment and requirement are identical to those successfully applied on

other projects. (2) Historical - requirement has been met by numerous previous design. (3) Calculations and Drawings - for review. (4) Design Review - either scheduled or specifically targeted. (5) Mock-Up - actual size representation of design. (6) Development Test - performance testing on equipment or material under

development. (7) Type Test - performance testing of the as-built component, assembly or system. (8) Routine Test - test every component, assembly or system. (9) First Article Inspection (FAI) - acceptances of the exact look and fit of equipment. (10) Inspection - formal inspection of the finished item. (11) In Service - for service demonstration requirements only.

3.5.2.7 After each Verification or Validation activity, a Verification Report shall be produced including, as a minimum, the following:


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(1) the Verification or Validation results stating whether the objectives and criteria of the Design Verification and Validation Plan have been met; and

(2) the reasons for failure if there is a failure, and proposal for remedial actions.

3.5.3 Factory Testing Plan

3.5.3.1 The Contractor shall prepare and submit for review by the Engineer the Contractor’s Factory Testing Plan detailing and explaining how the Contractor will plan, perform, and document all inspections and tests that will be conducted to verify and validate the Works prior to delivery to the Site. The plan shall consist of a narrative description supported by graphics, diagrams and tabulations as required.

The plan shall contain but not be limited to the following topics: (1) the Contractor’ s strategy for inspection and Factory Acceptance Tests of all

constituent parts of the Works and how this relates to the sequence of delivery;

(2) the sequencing and interrelationships of the inspections and tests including:

(a) all Quality Hold Points; and (b) all Quality Control Points;

(3) the type and extent of inspection and Factory Acceptance Tests to be undertaken and

the parts of the Works to be proven by that testing; (4) the objective of each inspection or test, what particular design and operating criteria

the test or inspection will prove and how the success of the test or inspection will be demonstrated or measured;

(5) organisation chart and CV of key personnel in inspection and test team; (6) the plan for the production and submission of the inspection and test procedures to

the Engineer for review including the submission of the inspection and test reports and records; and

(7) Type Tests, Routine Tests, First Article Inspections and any other tests constituting

the Factory Acceptance Tests.

3.5.3.2 The Contractor shall arrange for all equipment and systems manufactured for incorporation into the Permanent Works to undergo a Factory Acceptance Test (FAT) before shipment from the place of manufacture. Any particular requirements for inspection and testing at the place of manufacture are prescribed in the PS.

3.5.3.3 The Contractor shall be responsible for re-inspecting and re-testing any failed inspection

and Factory Acceptance Test including regression testing on previously passed items.

3.5.3.4 Inspections and tests that are to be witnessed by the Employer or the Engineer shall be sensibly grouped and scheduled so that as many inspections and tests as possible may be witnessed during a single visit.

3.5.3.5 Type Tests as detailed in Clause 9.2.6 below shall be performed on all items of equipment

to be installed as part of the Permanent Works under the Contract. The Type testing shall be based on the environmental class of the sites into which the equipment will be installed. Refer to Clause 1.12.2 above for the different environmental classifications or otherwise as required in the PS.

3.5.3.6 For all production items a First Article Inspection shall be undertaken as detailed in Clause

9.2.7 below. Routine production testing methods shall be detailed for review by the Engineer. Routine testing shall ensure that all samples of a production item are within the tolerances required for complete interchangeability.


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3.5.3.7 The Contractor shall prepare two copies of an inspection or test report immediately after

the completion of each inspection or test whether or not witnessed by the Employer or the Engineer. If the Employer or the Engineer has witnessed the inspection or test, he will countersign the inspection or test report to indicate his review of the information and conclusions (i.e. whether or not the equipment being inspected or tested has passed satisfactorily) contained therein. If the Employer or the Engineer has not witnessed the inspection or test (i.e. if a waiver has been granted, or the Employer or the Engineer has not witnessed the inspection or test for some other reason in accordance with the Contract), the Contractor shall forward two copies of the inspection or test report without delay to the Engineer. The Engineer will countersign the report to indicate his review of the information and conclusions (i.e. whether or not the equipment being inspected or tested has passed satisfactorily) and return one copy to the Contractor. Where the results of the inspect ion or test do not meet the requirements of the Specification, the Employer or the Engineer may call for a re-inspection or re-test.

3.5.3.8 For standard equipment which is serial or bulk manufactured, manufacturer’s type test

certificates (or equivalent) may, subject to review by the Engineer, be accepted. It is to be ensured that type test should not be more than 5 years old.

3.5.3.9 Test equipment and instrumentation shall be subject to approved calibration tests within a

properly controlled calibration scheme, and signed calibration certificates shall be supplied to the Engineer in duplicate. Such calibration checks shall be undertaken prior to testing and, if required by the Engineer, shall be repeated afterwards.

3.5.3.10 Materials and equipment shall not be released for shipment until all applicable inspect ions

and tests including Factory Acceptance Tests have been satisfactorily completed.

3.5.4 Procurement, Manufacturing and Delivery Plan

3.5.4.1 The Contractor shall prepare procurement, manufacturing and delivery plans in respect of all items and goods. Separate parts of the plan shall be prepared for Contractor or sub-contractor off-Site activities. Each plan shall identify the scope of work to be applied. In relation to such scope of work, it shall, without limitation, define: (1) the organisation of the Contractor's staff directly responsible for the day-to-day

management of the manufacturing activity on or off the Site;

(2) the specific allocations of responsibility and authority given to identified personnel for the day-to-day management of the work with particular reference to the supervision, inspection and testing of the work;

(3) the interfacing or co-ordination required with the Contractor's other related plans;

(4) the specific methods of manufacture to identify any relevant method statements and develop those method statements to a degree of sufficient detail reviewed by the Engineer; and

(5) the list of procedures and work instructions to manage and control the quality of work during purchasing, manufacturing and delivery, including without limitation:

a. the purchasing of items and goods and ensuring they comply with the requirements of the Specification, including (without limit) purchasing documentation and specific verification arrangements for Contractor / Engineer’s inspection of material or manufactured product prior to release for use;

b. the manufacturing process so as to ensure compliance with the design;


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c. the manufacturing process so as to ensure clear identification and traceability of material and manufactured parts;

d. the inspection and testing of incoming materials, in process and final product so as to ensure specified requirements for the material and/or manufactured product are met;

e. the identification of the inspection and test status of all material and manufactured products during all stages of the manufacturing process to ensure that only products that have passed the required inspections and tests are dispatched for use and/or installation;

f. review and disposal of non-conforming material or product so as to avoid unintended use;

g. the assessment and disposal of non-conforming material and manufactured product and approval for reworking or rejection as scrap;

h. the identification of preventive action so as to prevent recurrence of similar non-conformance; and

i. the handling, storage, packaging, preservation and delivery of manufactured product.

3.5.4.2 Deleted

3.5.4.3 The Contractor shall propose a structured set of inspection hold points. The hold points shall be structured such that a formal hold point is allowed for each significant element of the manufacturing process. At each hold point, the Engineer shall hold a formal inspection or advise that the inspection has been waived.

3.5.4.4 Once the inspection and any required remedial actions are completed to the satisfaction of the Engineer, the Engineer shall give a notice of no objection for unit shipment. The Engineer will not withhold his notice of no objection for shipping unreasonably, provided all pre-delivery assembly and testing has been successfully completed.

3.5.4.5 Any unit delivered without the Engineer’s notice of no objection shall be rejected at the Site and all expenses thereby incurred shall be borne by the Contractor.

3.6 Construction and Installation Management Plan

The Construction and Installation Management Plan shall be configured as a family of “stand-alone” plans and associated documents each covering one of the subjects listed below. The plans shall be co-ordinated with each other and shall collectively define, describe and encompass the Contractor’s proposed methods, procedures, processes, organisation, sequencing of activities, etc. and shall show how these combine together to assure that the Works truly meet the requirements of the Specification in respect of the subjects listed.

3.6.1 Construction and Installation Plan

3.6.1.1 The Contractor shall prepare plans for the construction and installation activities on and off

the site, as referenced in Clause 14.1.1 below, and shall ensure that these are properly related to the subsequent testing and commissioning activity.

3.6.1.2 Separate parts of the plan shall be prepared for other contractor(s) or sub-contractor(s)

off-site activities.


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3.6.1.3 Each construction plan shall identify the scope of activity to be controlled. In relation to such scope of activity, it shall, without limitation, define:

(1) the organisation of the Contractor's staff directly responsible for the day-to-day management of the activity on or off the Site;

(2) the specific allocations of responsibility and authority given to identified personnel for the day-to-day management of the Works with particular reference to the supervision, inspection and testing of the Works;

(3) the interfacing or co-ordination required with the Contractor's other related plans;

(4) the specific methods of construction and installation to identify any relevant method statements and develop those method statements to a sufficient degree of detail reviewed by the Engineer;

(5) a detailed method statement which shall include but not be limited to:

a. description of main operations and sub-operations; b. sequence of sub-operations; c. quantities of the work and production rates to be achieved; d. resources to be employed; and e. quality checks to be carried out, supervision being exercised and safety

precautions to be employed;

(6) the list of procedures and work instructions to manage and control the quality of construction and installation works, including without limitation:

a. the inspection and testing activities of incoming materials, in process and final product so as to ensure specified requirements for the material and/or product are met;

b. the purchasing of materials and ensuring they comply with the requirements of the Specification, including purchasing documentation and specific verification arrangements for Contractor / Engineer’s inspection of material or manufactured product prior to release for use / installation;

c. the construction processes including Temporary Works so as to ensure compliance with drawings and Specification. In addition, any software to be used in the construction, installation and commissioning process shall be identified and details of the Verification and Validation processes for the software application shall be given;

d. the construction and installation process so as to ensure clear identification and traceability of material and manufactured product;

e. the identification of the inspection and test status of all material and manufactured products during all stages of the construction and installation process to ensure that only products that have passed the required inspections and tests are despatched for use and/or installation;

f. review and disposition of non-conforming material or product so as to avoid unintended use/installation;

g. the assessment and disposition of non-conforming material and product and approval for reworking or rejection as scrap;

h. the identification of preventive action so as to prevent recurrence of similar non-conformance; and

i. the handling, storage, packaging, preservation and delivery of product; and

(7) the security control of the Site and the works area for Contractor’s accommodation, storage, car park and other works facilities, etc. in accordance with Clause 15.10 below.


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3.6.1.4 The Contractor shall prepare and submit the inspection and test plans to manage and control any test and inspection activities in accordance with Clause 5.7.1 below.

3.6.1.5 Where all or part of the Works is within the MAHA-METRO protection zone, the Contractor

shall follow the guidelines issued by the Employer’s appropriate authority. The Contractor shall submit to the Engineer for review his construction method statement and detailed design of any Temporary Works proposed to be erected within this zone adjacent to MAHA-METRO properties.

3.6.1.6 The following particulars shall be submitted to the Engineer for review within 14 days of the Commencement Date of the Works:

(1) drawings showing the layout within the Site of the Engineer’s and Contractor’s

accommodation, Project signboards, access roads and major facilities required early

in the Contract;

(2) drawings showing the layout and the construction details of the Engineer’s

accommodation; and

(3) drawings showing the details to be included on Project signboards.

3.6.1.7 Drawings showing the location of stores, storage areas, work areas and other major

facilities shall be submitted to the Engineer for review as early as possible, but in any case not later than 28 days before construction of the facilities.

3.6.2 Health and Safety Documentation

3.6.2.1 The Contractor shall submit Health and Safety Documentation to fully comply with the

requirements of the Project conditions and proposed work activities in accordance with Chapter 18 below.

3.6.2.2 The Contractor shall submit to the Engineer the Health and Safety Documentation for

review within 30 days of the Commencement Date of the Works.

3.6.3 Environmental Qualities Management Plan

3.6.3.1 The Contractor shall submit an Environmental Plan based the Outline Environmental Plan submitted and adapted during the Tender period. The Environmental Plan shall comprise a set of Environmental Plans as detailed below:

- Environmental Management Plan; - Environmental Mitigation Implementation Schedule (if required); and - Traffic Management Submissions

3.6.3.2 Environmental Plans shall include the Contractor’s proposed means of complying with his obligations in regard to:

a. The Site Environment as found; and b. System Environment as described in the Specification

The Environmental Plan shall include as required detailed policies, procedures and applicable regulations.

3.6.3.3 Environmental Management Plan

(1) The Contractor shall submit for review by the Engineer, an Environmental

Management Plan (EMP) which will set out in detail the approach for dealing with each of the potential environmental impacts arising from the various different construction activities.


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(2) The EMP shall address all the potential impacts outlined in the Employer’s Final Assessment Report and shall follow the EMP Outline.

(3) The Contractor shall submit the final EMP, for review by the Engineer, 30 days prior to

the commencement of construction activities.

3.6.3.4 Environmental Mitigation Implementation Schedule

(1) The Contractor shall submit for review an Environmental Mitigation Implementation Schedule (EMIS) which is a plan for the provision of the mitigation measures identified in the EMP.

(2) The Contractor shall submit the EMIS, for review by the Engineer in conjunction with the EMP 30 days prior to the commencement of construction activities.

3.6.3.5 Traffic Management Submissions

Where the Contractor is required to become involved with traffic or footpath management activities, submissions shall be made by the Contractor for the Engineer's review 30 days before implementation proving all relevant details and implications.

3.7 Completion Management Plan

3.7.1 The Contractor shall organise the services required under the Contract to bring the Works

into service under one plan. This co-ordinated approach shall allow the Engineer the ability to review all aspects of the Works and services in an integrated manner.

The Completion Management Plan shall be configured as a family of “stand-alone” plans and associated documents each covering one of the subjects listed below. The plans shall be co-ordinated with each other and shall collectively define, describe and encompass the Contractor’s proposed methods, procedures, processes, organisation, sequencing of activities, etc. and shall show how these combine together to assure that the Works truly meet the requirements of the Specification in respect of the subjects listed. Unless otherwise stated, all plans and documents shall be submitted in preliminary form within 15 days of the Commencement Date of the Works followed by detailed plans within 15 days of submission. Further submissions shall be made: (1) when required in accordance with the Contractor’s Works Programme;

(2) whenever the development of the Contractor’s planning requires the plan to be

developed further;

(3) in response to comments made by the Engineer in accordance with Clause 4.3.6 below;

(4) whenever any change occurs that invalidates the information contained in the previously submitted and reviewed document, within 15 days of the occurrence of such change; and

(5) when requested by the Engineer from time to time.

3.7.2 Commissioning Plan

3.7.2.1 The Contractor shall ensure the timely preparation of the Commissioning Plan in a format and to a level of detail in accordance with Clause 9.3 below. The Contractor shall submit the first draft of the Commissioning Plan to the Engineer within 180 days of the Commencement Date of the Works.


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3.7.2.2 The Commissioning Plan shall consist of the following:

(1) Factory Testing Plan (see Clause 3.5.3 above) (2) On-Site Testing and Commissioning Plan

a. Installation Tests Schedule The Contractor shall submit to the Engineer a comprehensive schedule of Installation Tests as required by Clause 9.4.3 below and the PS and in accordance with the Installation Programme as stated in Clause 2.8 above. The schedule shall be submitted within the period of time laid down in the PS, or, if none is given, not later than two months in advance of the date for the commencement of the Installation Tests.

b. Partial Acceptance Tests Plan

The Contractor shall submit to the Engineer a comprehensive Partial Acceptance Tests Plan including al l requirements detailed in Clause 9.4.4 below and the PS. The plan shall be submitted within the period of time laid down in the PS, or, if none is given, not later than four months in advance of the date for the commencement of the Partial Acceptance Tests.

c. System Acceptance Tests Plan

The Contractor shall submit to the Engineer a comprehensive System Acceptance Test s Plan including all requirements detailed in Clause 9.4.5 below and the PS. The plan shall be submitted within the period of time laid down in the PS, or, if none is given, not later than four months in advance of the date for the commencement of the System Acceptance Tests.

d. Integration Testing & Commissioning Plan

The Contractor shall submit to the Engineer a comprehensive Integrated Testing & Commissioning Plan including all requirements detailed in Clause 9.4.6 below and the PS. The plan shall be submitted within the period of time laid down in the PS, or, if none is given, not later than three months in advance of the date for the commencement of the Integrated Testing & Commissioning.

3.7.3 Operation and Maintenance Manuals Plan

3.7.3.1 The Contractor shall develop an Operation and Maintenance Manuals Plan to suit staged

commissioning of the system and to ensure the timely preparation of the Contractor’ s Operation and Maintenance Manuals and the ‘ As-Built’ drawings in a format and to a level of detail reviewed without objection by the Engineer and in accordance with Chapter 11 below.

3.7.3.2 The Contractor shall submit the Operation and Maintenance Manuals Plan by the date

stated in the PS, or, if none is given, not later than nine (9) months prior to the issue of the Taking Over Certificate for

3.7.4 Training and Transfer of Technology Plan

3.7.4.1 The Contractor shall ensure the timely preparation of the Contractor’s Training and

Transfer of Technology Plan in a format and to a level of detail reviewed without objection by the Engineer and fulfilling the requirements of Clause 10.1 below.

3.7.4.2 The Contractor shall submit the Training and Transfer of Technology Plan by the date

stated in the PS, or, if none is given, not less than six (6) months prior to the issue of the


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Taking Over Certificate for the Works and also to suit the staged commissioning of the relevant systems.

3.7.5 Spares Management Plan 3.7.5.1 The Contractor shall submit for review by the Engineer a Spares Management Plan to

furnish a priced, manufacturer-recommended list of spare parts necessary to support continuous operation of all such equipment for a minimum period of 24 months after the commencement of Revenue Operations, in accordance with Chapter 13 below.

3.7.5.2 The Contractor shall submit the Spares Management Plan by the date stated in the PS, or,

if none is given, not less than six (6) months prior to the issue of the Taking Over Certificate for the Works.

3.7.6 Defects Liability Management Plan

The Contractor shall submit for review by the Engineer a Defects Liability Management Plan to repair, replace and perform any remedial item upon the Works identified by the Engineer during the Defects Liability Period (DLP). The first submission of this plan is required upon issuance of the Taking Over Certificate for the Works. The Contractor shall: (1) endeavour to complete all necessary work in a timely responsible manner;

(2) not proceed with any remedial work without the consent of the Engineer;

(3) submit a plan that details the methods and timing of any proposed work; and

(4) update the plan monthly, showing progress of the work and the time to completion.

3.7.7 Supervision of Maintenance Plan

The Contractor shall prepare outline plans for the management of the maintenance function in accordance with the requirements of Clause 12.2.1 below and submit them for review by the Engineer at least 3 months prior to the scheduled commencement of Service Trial.


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CHAPTER 4

4.0 DOCUMENTS SUBMISSION AND REVIEW

Note: Contractor shall refer to Para 2.3 of General Specifications regarding Employer’s IT Requirements. The requirements pursuant to this Appendix shall be effected through the ‘Integrated Project Management Platform’.

4.1 Documents, Submissions and Correspondence

Copies of correspondence relevant to the execution of the Works and not of a confidential nature received from or despatched to Government departments, utility undertakings and Project contractors employed by the Employer shall be submitted to the Engineer for information as soon as possible but in any case not later than 7 days after receipt.

4.2 Submissions to the Engineer

4.2.1 General requirements

4.2.1.1 All submissions shall be made to the Engineer in a format reviewed without objection by

the Engineer and in accordance with the requirements in:

(1) the Contract; (2) the Computer Aided Design & Drafting (CADD) Manual; and (3) the Document Submittal Instructions to Contractors

4.2.1.2 Paper and drawing sizes shall be “A” series sheets as specified in BS 3429.

4.2.1.3 The following software (versions quoted or higher) compatible for use with Intel-Windows

based computers shall be used, unless otherwise stated, for the various electronic submissions required:

Document Type Electronic Document Format

Text Documents MS Word latest version

Spread Sheets MS Excel latest version

Data Base Files MS Access latest version

Presentation Files MS Power Point latest version

Programmes Primavera for Windows P6 or later version

AutoCAD Graphics AutoCAD 2016 or later version

Photographic Adobe PhotoShop latest version

Desktop publishing Quark Xpress, Ver 3.32

CADD drawings Micro Station SE/95

Media for Electronic File Submission

One copy shall be submitted unless otherwise stated.

Internet File Formats/Standards

The following guidelines shall be followed when the Contractor uses the Internet browser as the communication media to share information with the Employer. All the data formats or standards must be supported by Microsoft Internet Explorer / Google chrome / Apple Safari running on Windows (latest version) / linux / Apple computers.


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The following lists the file types and the corresponding data formats to be used on Internet. The Contractor shall comply with them unless the Engineer has previously reviewed without objection the Contractors proposal to adopt an alternative:

File Type Data Format

Photo Image Joint Photographic Experts Group (JPEG)

Image other than Photo GIF or JPEG

Computer Aid Design files (CAD) Computer Graphics Metafile (CGM)

Project documents refer to the document type in Clause 4.2.1.3 above

Video Window video (.avi) or .mp4

Sound Wave file (.wav) or .mp3

The following states the standards to be used on Internet when connecting to database(s). The Contractor shall comply with them unless the Engineer has previously reviewed without objection the Contractors proposal to adopt an alternative:

Function to be Implemented Standard to be Complied With

Database connectivity Open Database Connectivity (ODBC)

Publishing hypertext language on the World Wide Web

Hypertext Mark-up Language (HTML)

4.2.1.4 The hard copy of all documents shall be the contractual copy.

4.2.1.5 If required, two copies of all internal and external orders placed by the Contractor for

equipment or materials required for the Works shall be forwarded to the Engineer at the time of issue. All orders shall state the Engineer’s requirements for inspection and testing, shall bear the Contract reference, Contractor’s name and address and shall indicate, where applicable, the sub-section of the Works for which the equipment or material is required.

4.2.1.6 Distribution of copies of the orders shall be in accordance with the Engineer’s instructions.

4.2.1.7 The Contractor shall have the obligation to upgrade, at his own cost, all the relevant software to the latest version upon instruction by the Engineer, after the new version of the relevant software has been launched for more than six months in Pune.

4.2.1.8 The Contractor shall submit a drawing register to the Engineer in electronic copy and hard copy with each submission of drawings and at an interval agreed by the Engineer. The drawing register shall be in a format submitted for review and agreed without objection by the Engineer and shall include each document reference number, version, date, title and data-file name.

4.2.1.9 Specific additional requirements in respect of the numbering scheme shall be as defined in the PS.

4.2.2 Content

4.2.2.1 Unless otherwise specified or permitted by the Engineer, each submission shall comprise:

(1) for drawings - one A1 master on vellum (signed by the Contractor), one A1 copy on

vellum, one paper A1 copy, six paper A3 copies and an electronic data copy of all drawings; and

(2) for documents - the unbound original, six bound copies and an electronic copy when

applicable.


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4.2.2.2 The A3 copies of drawings shall be produced as reduced versions of the A1 original.

4.3 Records and Reports

4.3.1 Reports and records that are to be submitted to the Engineer shall be in a format reviewed by the Engineer. Reports and records shall be signed by the Contractor’s agent or by a representative authorised by the Contractor.

4.3.2 Within 28 days of the Commencement Date of the Works, the Contractor shall submit a

Project document control procedure to the Engineer for review, which shall include but not be limited to the following:

(1) a document approval system which shall specify the level of authority for approval of all documents and material before submission to the Engineer;

(2) a system of issuing documents to ensure that pertinent documents are issued to all appropriate locations;

(3) a document change or re-issue system to ensure that only the latest revision of a document can be used; and

(4) a submission identification system which identifies each submission uniquely by the following:

a. contract number; b. discipline; c. submission number; and d. revision indicator

4.3.3 Project records will eventually be used by the Employer to manage, operate and maintain the Works after the completion of the Project under construction and for future reference.

4.3.4 The Contractor shall submit the documents as required by the Engineer as Project records

in full and on time. The Engineer shall determine the adequacy of the Project record.

4.3.5 Submission and review procedure

4.3.5.1 Except where specific procedures are given for certain items, all submissions shall be submitted and reviewed according to the procedure laid down in the following clauses.

4.3.5.2 Each submission shall be accompanied by a brief introduction to explain which sub-

system, part or Section of the Works to which the submission refers, listing the documents enclosed with the submission, and describing in outline how all relevant requirements of the Specification are achieved by the proposals.

4.3.5.3 For each stage of submittal, the Contractor shall prepare a Submission Review Request (SRR) carrying the date of submission, the submission reference number as defined in Clause 4.3.2 (4) above, the submission title, the stage of submission and the authorised signature of the Contractor’s responsible engineer in the format shown in Appendix 3 of this Specification, to confirm that, in the opinion of the Contractor, the submission:

(1) complies with all relevant requirements of the Specification;

(2) conforms to all interface requirements;

(3) contains, or is based on auditable and proven or verified calculations or design criteria;


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(4) has been properly reviewed by the Contractor, according to the Contractor’s QA system, to confirm its completeness, accuracy, adequacy and validity; and

(5) has taken account of all requirements for approval by statutory bodies or similar organisations, and that where required, such approvals have been granted.

4.3.5.4 The Engineer’s response to the submission will normally be made within 30 calendar days of receipt of the submission, provided that the submission is made no later than the date shown on the Submissions Programme described in Clause 2.6 above. The Engineer may extend the review period depending on the amount of documentation accompanying the submission.

4.3.5.5 Throughout the design period, the Contractor shall attend monthly design review meetings

with the Engineer. At these Engineer’s review meetings, the Contractor shall present information, drawings and other documents to the Engineer in respect of all submissions programmed to occur during the following five week period. The Contractor’s presentations shall be in sufficient depth to enable the Engineer to obtain a clear understanding of the Contractor’ s proposals and to discuss the methodology and process used in reaching the proposed design solutions. Unless directed otherwise by the Engineer, all meetings shall be convened in Pune.

4.3.5.6 The Contractor shall record all of the Engineer’s observations and any agreed actions

resulting from the Engineer’ s review meeting and shall address each of these fully before submission of the respective documents for formal review.

4.3.5.7 If, in the Engineer’s opinion, following receipt of a submission there is benefit to be gained

from a meeting with the Contractor to clarify or discuss any of the contents of the submission, he will notify the Contractor accordingly with not less than 5 days advance notice, and the Contractor shall attend at the time and place appointed by the Engineer.

4.3.6 Engineer’s Response

4.3.6.1 The Engineer will respond in one of the following three ways:

(1) “ Reviewed without Objection” (2) “Reviewed without Objection, Subject to” (3) “Rejected”

4.3.6.2 If the Engineer, having reviewed the submission, has not discovered any non-compliance

with the Contract, the SRR will be returned endorsed with the Engineer’s signature and the words “Reviewed without Objection”. Receipt of such notice of no objection does not in any way imply the Engineer’s approval of the submission, nor does it remove any responsibility from the Contractor for complying with the Contract. Issue of a “Notice of No Objection” entitles the Contractor to proceed to the next stage of the programme of work.

4.3.6.3 If the Engineer discovers minor non-compliance, discrepancies, omissions, etc. that, in his

opinion, are not of a fundamental nature, he may return the SRR endorsed with the Engineer’s signature and the words “Reviewed without Objection Subject to”, and including a list of the features that are required to be amended, included or improved to comply with the Contract. Issue of a “Notice of No Objection Subject to” entitles the Contractor to proceed to the next stage of the programme of work provided that all of the Engineer’s comments are taken into account fully and implemented exactly.

4.3.6.4 If the Engineer issues a “Notice of No Objection Subject to”, the Contractor shall resubmit the affected parts of the submission, clearly demonstrating how the Engineer’s comments have been taken into account and resubmit amended or corrected material within 10 working days of issue of the Engineer’s comments, using the process described in Clause 4.3.5 above.


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4.3.6.5 If the Engineer discovers major non-compliance, discrepancies, omissions, etc. that, in his opinion, are of a fundamental nature, he may return the SRR endorsed with the Engineer’s signature and the word “Rejected”, and including a list of the features that are required to be amended, included or improved to comply with the Contract. Issue of a “Notice of Rejection” does not entitle the Contractor to proceed to the next stage of the programme of work until all of the Engineer’s comments are fully taken into account and a satisfactory re-submission has been made (i.e. one which results in a “Notice of No Objection” or “Notice of No Objection Subject to”).

4.3.6.6 If the Engineer issues a “Notice of Rejection”, the Contractor shall resubmit the complete submission, clearly demonstrating how the Engineer’s comments have been taken into account and resubmit amended or corrected material within 10 working days of issue of the Engineer’s comments, using the process described in Clause 4.3.5 above.

4.4 Records

4.4.1 The Contractor shall establish and maintain a place for the storage and archiving of all the

documents relating to the Works and not required to be submitted to the Engineer under Clause 4.1 above which shall be:

(1) the same place or office where the Contractor is performing the work and storing

documents reviewed by the Engineer, or;

(2) at the Site or elsewhere in Pune, a records office, which contains all other, documents that the Contractor is required to maintain in accordance with the Contract.

4.4.2 All documents shall be filed, indexed and suitably stored to permit easy identification and necessary audits.

4.4.3 The Contractor shall maintain in Pune his archive of all documents in connection with and

arising out of the Contract, until 28 days after the issue of the Final Certificate or until final settlement of all Disputes, whichever is later.


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CHAPTER 5

5.0 QUALITY MANAGEMENT

5.1 Introduction

5.1.1 The Contractor shall maintain and implement a Quality Management System that shall remain in effect during the execution of the Works. The Contractor’s Quality Management System shall be based on the International Standard ISO 9001:2008 “Model for quality assurance in design, development, production, installation and servicing.” The Contractor shall submit its Quality Management System documentation for the Engineer’s review as specified in this Chapter.

The Quality Management System documentation shall include, but shall not be limited to the following: (1) quality manual; (2) quality procedures and work instructions; (3) quality plans; and (4) inspection and test plans

5.1.2 The Contractor shall plan, perform and record all quality control activities to ensure that all

work is performed in accordance with the requirements of the Contract and is detailed in the quality plans which are required under this Chapter. Such activities shall include, without limitation, the inspections and/or tests expressly or implicitly required by the Contract.

5.1.3 Without prejudice to such requirements, the Engineer may from time to time instruct the

Contractor in relation to such further or other inspections and/or tests as are in his opinion appropriate.

5.1.4 Quality audits will be conducted by the Engineer to verify the Contractor’s implementation and compliance with the quality management system as specified herein.

5.2 General Requirements

5.2.1 All quality system documents and plans to be submitted shall embrace all activities of the

Contractor and sub-contractors of any tier, including its suppliers and any design consultants.

5.2.2 Quality Plans

The quality plans to be submitted by the Contractor shall comprise of: (1) a Management Quality Plan, for the control of all management related activities;

(2) a Design Quality Plan, for the control of all design related activities for the Works,

including Temporary Works; and

(3) Manufacturing Quality Plan and Site Quality Plan, for the control of activities within each category of work or discrete element of procurement, manufacturing, delivery, construction and installation of the Works, including Temporary Works.

5.2.3 Within 30 days of the Commencement Date of the Works, the Contractor shall submit for

review by the Engineer:

(1) a quality manual;

(2) the quality system procedures and any associated system instructions and/or forms which he proposes to use for the Works; and


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(3) the initial submission of quality plans shall be a development of that submitted at Tender stage and shall contain as a minimum, the Contractor’s proposed Management Quality Plan as detailed further in this Chapter.

5.2.4 The Contractor shall submit separate Manufacturing Quality Plan and Site Quality Plan covering all elements of the Works. These shall be in accordance with the specific requirements of this Chapter and shall be submitted to the Engineer for review 30 days prior to the commencement of the manufacturing and construction works covered by the quality plans. In addition, the Contractor shall prepare inspection and test plans for the management and control of the inspection and/or testing by the Contractor of the Works identified in each quality plan.

5.2.5 The Contractor shall promptly supply the Engineer with two (2) controlled copies of his

quality manual, quality plans, inspection and test plans and related procedures / instructions / forms upon such documents being reviewed without objection by the Engineer. The Contractor shall maintain such controlled documents throughout the Contract Period. For any amendment to quality system documentation, the Contractor shall as soon as reasonably practicable prepare and submit the proposed amendment for review by the Engineer. In addition, the Engineer may request further copies of the quality system documents and these documents shall reach the Engineer’s office within fourteen (14) days of notification.

5.2.6 The Contractor shall appoint (a) suitably qualified and experienced person(s) as Quality

Manager(s), who shall be directly responsible to senior management level and is able to discharge his duties without hindrance or constraint, and provide such other resources as may be required to ensure effective implementation of the Quality Management System and all quality plans. Details of the qualifications, experience, authority and responsibility of the proposed Quality Manager(s) shall be submitted for review by the Engineer within 30 days of the Commencement Date of the Works.

5.2.7 During the Contract period, upon receipt of a Corrective Action Request (CAR) or similar

document issued by the Engineer as a result of quality audits, the Contractor shall submit a proposed corrective and preventive action plan within 14 days to the Engineer for review.

5.3 Management Quality Plan

5.3.1 The Management Quality Plan shall define the Contractor's management structure for the

execution of the Works and for the control of the quality of the Works and shall submit this plan within 30 days of Commencement Date of the Works. The management quality plan shall without limitation, define:

(1) the appointment of a Quality Manager in accordance with Clause 5.2.6 above; (2) the organisation of the Contractor’s managerial staff with particular reference to any

joint venture partners and main sub-contractors. An organisation chart shall be produced to illustrate the sub-division of the Works into elements for effective technical and managerial control, the reporting structure and the interface relationship between all parties involved;

(3) the hierarchy of the overall quality management system documentation to be applied to the Works;

(4) the quality management system of the Contractor in monitoring and controlling sub-contractors and suppliers; and

(5) the list of quality system procedures and work instructions to be applied to manage the quality of the Works.


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5.4 Design Quality Plan

5.4.1 The Contractor shall prepare a Design Quality Plan for its design works. The Design Quality Plan shall define the Contractor’s policy for the design works and shall, without limitation, define: (1) the organisation of the Contractor’s design staff; (2) the specific allocations of responsibilities and authorities given to identified design

staff or sub-contractors for particular design work; (3) the hierarchy of quality management system documentation for managing and

controlling design works, including design works of subcontractors of any tier; and (4) the list of procedures and instructions to be applied to manage and control the quality

of the design works.

5.5 Manufacturing Quality Plan

5.5.1 The Contractor shall prepare a Manufacturing Quality Plan for his manufacturing works and submit this plan 60 days prior to the commencement of manufacturing works. The Manufacturing Quality Plan shall, without limitation, define: (1) the organisation of the Contractor’s staff directly responsible for the day-to-day

management of the manufacturing activities on or off the Site;

(2) the specific allocations of responsibilities and authorities given to identified personnel or sub-contractors for particular manufacturing work;

(3) the hierarchy of quality management system documentation for managing and controlling manufacturing works, including manufacturing works of sub-contractors of any tier; and

(4) the list of procedures and instructions to be applied to manage and control the manufacturing works, together with the procedures and instructions which have not been previously submitted for review.

5.5.2 The Contractor shall also prepare inspection and test plans to manage and control any test and inspection activities in accordance with the Clause 3.5.3 above.

5.6 Site Quality Plan

5.6.1 The Contractor shall prepare a Site Quality Plan for its construction and installation works.

The Site Quality Plan shall, without limitation, define: (1) the organisation of the Contractor’s staff directly responsible for the day-to-day

management of the construction and installation activities on or off the Site;

(2) the specific allocations of responsibilities and authorities given to identified personnel or sub-contractors for particular construction and installation work;

(3) the hierarchy of quality management system documentation for managing and controlling construction and installation works, including construction and installation works of sub-contractors of any tier; and

(4) the list of procedures and instructions to be applied to manage and control the construction and installation works together with the procedures and instructions that have not been previously submitted for review.

5.6.2 The Contractor shall also prepare inspection and test plans to manage and control any test and inspection activities in accordance with Clause 5.7.1 below.


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5.7 Inspection and Test Plans, Records and Reports

5.7.1 Inspection and test plans shall be produced for every activity requiring test and/or inspection. Each inspection and test plan shall identify the quality objectives and include, without limitation: (1) the personnel responsible for undertaking and certifying the inspection and/or test;

(2) the procedure or instructions for the inspection and/or test;

(3) the test method or a reference to the relevant standard of testing;

(4) the inspection and/or test required prior to commencement of an activity;

(5) the inspection and/or test during an activity and its frequency;

(6) the inspection and/or test required to complete an activity;

(7) all Quality Control Points, Quality Hold Points and any notices or other documents to be given to the Engineer in relation to Quality Control Points and Quality Hold Points;

(8) the compliance criteria;

(9) the method of analysis of test data;

(10) the procedure for correction or disposal of any work which fails the compliance criteria;

(11) examples of the documentation to be used for reporting the results of inspections, tests and analysis of test data;

(12) examples of the documentation to be used for recording the status of inspections and tests in accordance with Clause 5.9.1 below; and

(13) the procedure for the distribution, filing and storage of inspection reports, test reports and reports on analysis of test data.

5.7.2 Each report of the inspection and/or test shall be prepared in accordance with Clause 9.6.7 below.

5.7.3 The Contractor shall ensure that a signed copy of each report of inspection and test is filed

in his filing system within 3 (three) working days of the date of inspection and test.

5.7.4 In relation to all Quality Control Points and Quality Hold Points involving inspection and/or test by the Contractor, the Contractor shall give the Engineer notice of when the relevant work will be inspected and/or tested in accordance with Clause 9.8.1 below.

5.8 Review, Verification & Audit

5.8.1 The Contractor shall continuously monitor the performance of each quality plan related to

the execution of the Works and shall include in each Monthly Progress Report the status of all quality system documentation, an up-to-date audit schedule and status and an up-to-date non-conformity register providing the status of all non-conformities identified by the Engineer and the Contractor. The Contractor shall make an appraisal of such performance and identify in particular any non-conformity(ies) or other shortcomings in the quality management system, the actions being taken to dispose of these non-conformities, any necessary corrective action taken or proposed to be taken to prevent the re-occurrence of


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these non-conformities or shortcomings and, any other items as instructed by the Engineer.

5.8.2 The Contractor shall ensure that audits of all the activities in each quality plan are carried

out at quarterly intervals, or at such other intervals as the Engineer may require, to ensure the continuing suitability and effectiveness of the quality management system. Reports of each such audit shall be submitted promptly for review by the Engineer.

5.8.3 The Contractor shall ensure that the requirements for supervision and verification of work

by the Contractor and/or his sub-contractors of any tiers are identified in the quality plans and adequate resources and trained personnel are provided for these activities.

5.8.4 The Contractor shall submit for review by the Engineer details of the authority,

qualifications and experience of personnel assigned to design verification and to audit activities.

5.8.5 The Engineer may, by notice to the Contractor, require external audits of the Contractor's

quality management system to be carried out either by the Employer's staff or by his representative. In such case, the Contractor shall afford to such auditors all necessary facilities and access to the records to permit this function to be performed.

5.9 Quality Control Register

5.9.1 The Contractor shall provide and maintain at all stages of the Works a quality control register or registers to identify the status of inspections, sampling and testing of the work and all certificates. Such registers shall be updated by the Contractor to show all activities in previous months and shall reach the Engineer’s office before the 7th working day of each month. Each register shall: (1) list the certificates received for each batch of goods and materials incorporated in the

Works and compare this against the certification required by the Contract and the Contractor’s quality plans;

(2) list the inspection and testing activities undertaken by the Contractor on each element of the Works and compare these activities against the amount of inspection and testing required by the Contract and the Contractor’s quality plans;

(3) show the results of each report of inspection and/or test and any required analysis of these results and compare these results against the pass/fail criteria; and

(4) summarise any actions proposed by the Contractor to overcome any non-conformity identified in Clauses 5.9.1 (1), (2) & (3) above.

5.10 Summaries of Inspection and/or Test

The Contractor shall submit to the Engineer for his information summaries based on quality control register in accordance with the summaries of Inspection and/or Test described in Clause 9.6.11 below.

5.11 Notification of Non-conformities

5.11.1 If, prior to the issue of the Taking Over Certificate for the Works or the relevant Section,

the Contractor has used or proposes to use or repair any item of the Works which does not conform to the requirements of the Contract, he shall immediately submit to the Engineer such proposal, supplying full particulars of the non-conformity and, if appropriate, of the proposed means of repair which shall include any calculation analysis or other documentation to support the repair or acceptability of the non-conformity.

5.11.2 If the Engineer issues non-conformity reports or similar documents to notify the Contractor

of any item of the Works which he considers to constitute a non-conformity and which has


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not been reported in accordance with Clause 5.11.1 above, the Contractor shall promptly investigate the matter and, within 14 days of notification by the Engineer, submit to the Engineer for review the remedial measures to be taken and stating the reasons for such measures.


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CHAPTER 6

6.0 SOFTWARE MANAGEMENT AND CONTROL

6.1 Prescriptive Framework

All software to be developed or modified (re-engineered software) shall follow the normative requirements of EN50128 (Railway Applications: Software for Railway Control and Protection Systems). The Software shall be designed, developed and tested according to the Software Quality assurance Plan, Software Integrity Level (SIL) and the Software Lifecycle. The Contractor shall define within the Software Quality Assurance Plan what techniques and measures are to be applied for software development. In addition to the requirements of the Software Quality Assurance Plan, justification, which shall be reviewed without objection by the Engineer, shall be required in respect of any highly recommended EN50128 Annex A normative clauses which are not to be applied to software development and supply.

6.2 Software Framework

As defined in EN50128, all software produced or supplied for the project shall be subject to a defined quality framework. The Contractor shall use a Quality Assurance System which is compliant with CENELEC specifications, with EN29000 series and others and meet the requirements as stipulated in the PS. ISO 9000-3 is considered appropriate for Safety Integrity Level 0 or 1 software.

6.3 Software Management Control

The Contractor shall ensure that a full time Software Project Manager and Software Quality Manager are appointed for software development, if software development and/or modification are required under the Contract.

6.4 Status Reporting

The Contractor shall include in the Monthly Progress Report details of the status of the software development/modifications 1 upgrades.

6.5 Auditing

The Engineer shall audit the Contractor in line with Employer s procedures. Further external independent audits may also be arranged at the Engineer’s discretion.

6.6 Software Acceptance

6.6.1 Software acceptance shall be based upon the supply of software functioning in a manner

reviewed without objection by the Engineer supported by an Operational Safety Report (Software) reviewed without objection by the Engineer. The report shall be provided by the Contractor and submitted to the Engineer for review in the format described below. All the documents for the design, development, testing, verification and validation as defined in CENELEC standards including EN50128 shall be submitted. The Engineer’s review without objection shall be obtained prior to Employer’s Taking Over of the Works.

6.6.2 The Operational Safety Report (Software) (OSR(S)) shall include, as a minimum:

6.6.2.1 OSR(S) - Introduction

Shall describe the nature of the software sufficiently to ensure that the Engineer is given a comprehensive overview of primary characteristics such as structure, functions, criticality, volume and language.

6.6.2.2 OSR(S) - Evidence of Quality Management


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Shall provide evidence to demonstrate that the software development has been subject to acceptable quality assurance.

6.6.2.3 OSR(S) - Evidence of Safety Management

Shall provide evidence to demonstrate that the software development has been subject to acceptable safety management.

6.6.2.4 OSR(S) - Technical Report

Shall describe how software integrity has been achieved.

6.6.2.5 OSR(S) - Operation and Maintenance Report

Shall describe the software operation and maintenance characteristics.

6.6.2.6 OSR(S) - Restrictions for Use

Shall define what restrictions are applied to the use of the software.

6.7 Re-Use of Existing Software

6.7.1 Where existing software (defined to module level) is to be re-used without modification,

the Contractor shall provide evidence acceptable to the Engineer as to why that software is suitable for use in the proposed application. All software developed earlier and intended to be used for the Contract shall meet the requirements laid down in the PS.

6.7.2 The certified evidence of previous satisfactory use in a similar environment and application

and cross acceptance from another railway authority shall be submitted. The Engineer reserves the right to implement an assessment of the developed software by further validation or re-validation by an outside agency nominated by the Employer.

6.8 Application of “Commercial Off The Shelf” Software (COTS)

COTS shall not be applied to any operation software at level SIL2 and above. Where COTS is used, the Contractor shall define within the SQAP, to the review of the Engineer, the software support period following delivery. The software support activities shall include but not be limited to, supply of software and supporting documentation, training and maintenance contracts.

6.9 Test Software

All test software, with the exclusion of built-in test software, shall be produced in accordance with a quality system controlled under the requirements of ISO 9000-3. Test software shall be developed and documented using structured techniques and shall be designed to be maintainable throughout the term of the Contract. All test software shall be documented to be supportive of maintenance. Any test software that is to be delivered to the Employer (for long term testing use) shall be fully documented including application program code listings to allow the Employer to maintain the software for the life of the supported system.


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CHAPTER 7

7.0 MATERIALS AND EQUIPMENT

7.1 Materials and Equipment Provided by the Employer

7.1.1 Materials and equipment which are to be provided by the Employer will be as stated in the Contract.

7.1.2 Materials and equipment provided by the Employer shall be collected by the Contractor

from the locations as per contract conditions. The Contractor shall inspect the materials and equipment before taking receipt and shall immediately inform the Engineer of any shortage or damage.

7.1.3 Materials or equipment provided by the Employer which are damaged/lost after collection shall be replaced by the Contractor and offered to the Engineer for approval. In case, the Contractor fails to replace the damaged material, the cost of material with additional costs as per agreement will be recovered from the Bank Guarantees furnished by the Contractor for safe custody of the materials supplied by the Employer as per the Conditions of Contract.

7.1.4 The Contractor shall dispose of crates and containers for materials or equipment provided by the Employer.

7.1.5 Equipment / materials provided by the Employer, surplus to the requirements of the Works shall be returned at the earliest as directed by the Engineer.

7.1.6 The Contractor shall protect and maintain equipment provided by the Employer while it is on the Site and shall provide operatives, fuel and other consumables required to operate the equipment.

7.2 Materials

7.2.1 General

7.2.1.1 Materials for inclusion in the Permanent Works shall be new unless otherwise stated in the

Contract or having been reviewed without objection by the Engineer.

7.2.1.2 Certificates of tests by manufacturers, which are submitted to the Engineer, shall relate to the material delivered to the Site. Certified true copies of certificates may be submitted if the original certificates cannot be obtained from the manufacturer. A letter from the supplier stating that the certificates relate to the material delivered to the Site shall be submitted with the certificates.

7.2.1.3 Materials, which are specified by means of trade or proprietary names, may be substituted by materials from a different manufacturer, provided that the materials are of the same or better quality and comply with the specified requirements and have been reviewed without objection by the Engineer.

7.2.1.4 In addition to any special provisions in the Contract for the sampling and testing of materials, the Contractor shall submit samples of all materials and goods which he proposes to use or employ in or for the Works. Such samples, if having been reviewed without objection, shall be retained by the Engineer and shall not be returned to the Contractor or used in the Permanent Works unless reviewed by the Engineer. No materials or goods of which samples have been submitted shall be used in the Works unless and until the Engineer shall have reviewed such samples without objection.


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7.2.1.5 The Engineer may reject any materials and goods which in his opinion are inferior to the samples previously reviewed and the Contractor shall promptly remove such materials and goods from the Site.

7.2.1.6 If any material required for this Contract is not available in metric specifications from any known sources, at the time the material is required for the Contract, the Engineer may, upon application from the Contractor, give permission to the use of an equivalent material in imperial specifications as a substitute, provided that:

(1) no statutory specification shall be altered except in accordance with relevant legal provision, if any;

(2) the Engineer is satisfied that the Contractor has made every reasonable effort to obtain the material in metric specifications;

(3) in the opinion of the Engineer, the substitute material is suitable for the Works in all respects;

(4) in the opinion of the Engineer, the substitute material complies with all the specifications for the material substituted, allowing minor discrepancies between the specified metric measurements and the corresponding imperial measurements of the substitute, provided that such discrepancies can be effectively and satisfactorily compensated for by the provision of extra quantity of the material; and

(5) the Contractor shall be responsible for all extra quantities of the material required for meeting design and specification requirements of the Works due to the use of the substitute.

7.2.1.7 Hardwood shall not be used for Site hoardings, shoring of trenches and pits, false work or

formwork.

7.2.2 Notice of place of manufacture and/or source of supply

The Contractor shall notify the Engineer of the places of manufacture and/or the source of supply of all goods and materials previously reviewed without objection by the Engineer to be incorporated into the Permanent Works. The Contractor shall give reasonable notice (which shall not in any event be less than 56 days) to the Engineer before the start of any manufacturing and/or the supply of goods and materials.

7.2.3 Certificates for Manufactured Goods or Materials

The Contractor shall obtain certificates for each batch of goods and materials incorporated into the Permanent Works. Each certificate shall certify that the materials comply with the requirements of the Contract and shall include all reports of inspections and/or tests carried out at the place of manufacture.

7.3 Equipment

7.3.1 Identification labels

7.3.1.1 Each and every individual item of equipment forming part of the Permanent Works shall be

fitted with permanent identification labels in accordance with a system based on the contract identification. In this respect, the term “individual item of equipment” refers to a complete assembly of components and to each removable sub-module within the complete assembly.

7.3.1.2 The proposed labelling system shall be submitted for review by the Engineer at least 1

month before the scheduled date for the shipment of the first item of equipment to site.


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7.3.1.3 The identification label whenever possible shall be permanently attached in such a way that it shall not become detached or illegible during the lifetime of the system from any cause including wear and tear, environmental effects (such as rain, direct sunlight, etc.) or any other influence. Preference shall be given to embossed or engraved metallic labels mechanically fastened by riveting or similar means to the item to which they refer.

7.3.1.4 All labels shall be of the type that can be easily cleaned to remove dirt and debris

(including grease and oil) without disturbing the legibility properties.

7.3.1.5 All labels shall incorporate the inscription “Property of MAHA-METRO”.

7.4 Electronic Control Racks & Cabinets

7.4.1 Racks & Cabinets

7.4.1.1 Electronic control equipment shall be housed in 19" racking suitably enclosed in metal cabinets of a type acceptable to the Engineer. A sample of each type of rack or enclosure proposed shall be submitted to the Engineer for inspection.

7.4.1.2 The equipment shall be of modular construction to facilitate maintenance, repair and

replacement of parts. Standard commercial parts shall be utilised to the maximum extent possible.

7.4.1.3 Cubicles, Equipment Racks, cable and wiring Termination Racks shall not be filled to

greater than 80% of their capacity at the completion of the works.

7.4.1.4 There shall be a minimum walkway of 1000mm between equipment racks.

7.4.1.5 The equipment shall be suitable for the environment in which it is to be used and it shall be designed to prevent ingress of all vermin and to minimise the ingress of moisture, dust and dirt.

7.4.1.6 Outdoor equipment shall be sealed against the ingress of dust, moisture and vermin.

7.4.1.7 No item of equipment which is removable as part of routine maintenance procedures shall

be mounted at more than 2.0m above floor level.

7.4.2 Cables

7.4.2.1 No joints or splices shall be permitted in cables or wires except at recognised termination points.

7.4.2.2 All multi-core cables shall allow 20% or 2 cores, whichever is the greater, as spares.

7.4.2.3 All cable cores shall be terminated including all spare conductors.

7.4.2.4 Each cable core shall be uniquely numbered and identified with a label giving details of

the circuit carried.

7.4.2.5 Terminals carrying voltages exceeding 50 volts shall be uniquely identified and protected against accidental contact by persons, test equipment or other unintended physical contact. Similarly all bus bars shall be suitably identified and protected.


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CHAPTER 8

8.0 PACKAGING, STORAGE, SHIPPING AND DELIVERY

8.1 Storage

8.1.1 The Contractor shall provide and maintain acceptable storage facilities for the Permanent Works, equipment and materials of all kinds intended for use in carrying out the Works or for incorporation into the Works.

8.1.2 The Contractor shall prepare, protect and store in an agreed manner all Permanent

Works, Contractor’s Equipment, equipment and materials so as to safeguard them against loss or damage from repeated handling, from climatic influences and from all other hazards arising during shipment or storage on or off the Site.

8.1.3 Secure and covered storage shall be provided by the Contractor for all Permanent Works,

Contractor’s Equipment, equipment and materials which are other than those having been reviewed without objection by the Engineer as suitable for open storage.

8.2 Crating

8.2.1 The Contractor shall provide all packing, crates and markings. In doing so, it shall comply

with the following requirements: (1) Each case, crate or package shall be water proof , rot -proof and insect/rodent-proof,

of robust construction and suitable for the intended purposes. The Contractor shall, in determining the package materials to be used, take cognisance of the climatic conditions likely to occur during the period of transport, shipment and storage.

(2) Each case, crate or package shall be legibly and indelibly marked in large letters with

the Site address, Contract number, "right way up", opening points and other markings as necessary to permit materials to be readily identified and handled during transit and when received at the Site.

(3) Each case, crate or package shall contain a comprehensive packing list showing the

number, mark, size, weight and contents together with any relevant drawings. A second copy of the packing list shall be enclosed in a watertight enclosure on the outside of each case or package. Distribution of additional copies of each packing list shall be in accordance with the Engineer's instructions.

(4) All items heavier than 100 kg shall be marked on the outside of the case to show the

gross and net weights, the points for slinging, and where the weight is bearing. (5) Care shall be taken to prevent movement of items within cases, crates or packages by

the provision of bracing, straps and securing bolts as necessary. Bags of loose items shall be packed in cases, and shall be clearly identified by well-secured metal labels on which the quantity and name of the part and its index or catalogue number have been stamped.

(6) Plug connected electronic circuit boards shall be removed from their racks, packed

and shipped separately. (7) All packing shall be free from sharp edges to prevent injury to persons or other

objects. (8) Each bulky/heavy case, crate or package shall include (a) wedge(s) for easy loading

and unloading by mechanical handling equipment such as forklift truck. (9) Electronic circuit boards, integrated circuits (IC) and the like shall be well protected by

using appropriate packing, e.g. anti-static bubble bag or similar.


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(10) Rubber products and the like shall be suitably packed to avoid damage including but

not limited to hardening, deformation and peel-off.

8.3 General Precautions

8.3.1 Spare parts shall be tropicalised in their packing for prolonged storage in accordance with BS 1133 or other equivalent International /Indian standard and shall be suitably and individually labelled to indicate: (1) shelf life and date of manufacture; (2) type or condition(s) of storage and special handling information; (3) description of item and relevant part number; (4) serial number, if applicable; (5) inspection/test certificate number and batch number; and (6) Contract number, variation order number and item number.

8.3.2 Tubes, cable, conductor and other similar openings shall be properly sealed and blanked

off to prevent ingress of dirt or moisture. Flanged ends shall be protected by adhesive tape or jointing material covered by a properly secured wooden blank not smaller than the flange itself. Plain tube ends shall be closed off with bungs or plugs or suitable materials firmly fixed in position.

8.3.3 Particular care shall be taken to prevent mechanical transport related damage or corrosion

of shafts and journals where they rest on timber or other supports which may contain moisture. At such points, wrappings impregnated with anti–rusting composition and of sufficient strength to resist chafing under the pressures and movements during transit shall be used.

8.3.4 Spare ball and roller bearings and similarly protected items shall not be removed from the

manufacturer’s wrappings or packing.

8.3.5 Fragile materials shall be packed in such a way that they shall not be damaged during transit and when they are properly unpacked for quality inspection. Glass items shall be capable of being easily re-packed without

8.3.6 Appropriate precautions in accordance with the GCC, Contractor’s safety regulations, the

regulations of the Employer, and statutory regulations shall be taken in respect of all hazardous, toxic, inflammable, etc. materials.

8.4 Packaging Procedures

8.4.1 All required inspection / test certificates shall be supplied and packed together with

individual material. All packaging materials and procedures shall be subject to review by the Engineer.

8.4.2 All empty cases, crates or packages, whether or not returnable, shall be removed from the

Site by the Contractor or stored by the Contractor in such a way that they do not interfere with the progress of the work of Project contractors.

8.4.3 Two copies of packing lists and quality certificates shall be attached to each case or

package to be shipped. One copy shall be placed inside the package and the second copy shall be enclosed in a watertight enclosure on the outside of each case or package. A copy of packing lists and quality certificates shall be sent to the Engineer after each package of the Works, the equipment, spare parts and other items to be shipped have been shipped.

8.5 Shipping


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8.5.1 The Contractor shall notify the Engineer ten days in advance of any expected shipment date and give further notification of the actual shipment date and routing when such information is subsequently established. This shall complement the inspection requirements prior to delivery as specified herein.

8.5.2 Two copies of packing lists and quality certificates shall be attached to each case or

package to be shipped. One copy shall be placed inside the package and the second copy shall be enclosed in a watertight enclosure on the outside of each case or package. A copy of packing lists and quality certificates shall be sent to the Engineer after each package of the Works, the equipment, spare parts and other items to be shipped have been shipped.

8.5.3 Without prejudice to any other provisions of the Contract, the Contractor shall be

responsible for all legal requirements, duties, dues, taxes and other requirements and expenditures required for the importation of the Works, the equipment, spare parts and other items to be supplied under the Contract into Pune.

8.5.4 The Contractor shall clear the Works, the equipment, spare parts and other items to be

supplied under the Contract through Maharashtra/other customs / Indian sea port in accordance with all applicable enactments, whether Central or State.

8.6 Delivery

8.6.1 The Contractor shall deliver the Works and all items to be supplied under the Contract to

the Site.

8.6.2 The Contractor shall unload the Works and all items to be supplied under the Contract at the designated delivery point and positioning or storing them.

8.6.3 Any part of the Works or any item to be supplied under the Contract that is damaged in transit shall not be considered as delivered until repairs or replacements have been made and all necessary spare parts or items have been delivered to the Site.

8.6.4 All documents, manuals, drawings and other deliverables shall be delivered to an address in Pune to be designated by the Engineer in writing.

8.6.5 The Contractor shall store and secure the Works, equipment, spare parts and other items until the same have been inspected and are considered delivered at the designated point by the Engineer.

8.6.6 The Contractor shall remove temporary fittings required for shipment and re-assembly of equipment and shall complete this prior to the equipment or parts thereof being inspected and before they are considered delivered.

8.6.7 An item shall be considered delivered when all damage have been repaired and all documentation and post delivery preparation have been completed to the satisfaction of the Engineer.


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CHAPTER 9

9.0 TESTING AND COMMISSIONING Testing and Commissioning shall comply with all the requirements of the GCC supplemented, amplified, modified or superseded as applicable by this Specification and the PS.

9.1 General

9.1.1 The Contractor shall perform all testing and commissioning activities to satisfactorily demonstrate the performance of the Works within the framework of the Completion Management Plan.

9.1.2 The Contractor’s activities shall include but are not limited to the following:

(1) provision of all labour and experienced supervision to perform all inspections and

tests required to demonstrate the performance of the Works; (2) preparation of that portion of the Commissioning Plan that applies to the Works to

a level of detail acceptable to the Engineer; (3) performance of all duties and responsibilities, as specified in the Commissioning

Plan; (4) participation in the Commissioning Team that shall develop, review and implement

the Commissioning Plan. As a participant of the Commissioning Team, the Contractor shall provide personnel and technical support to the Employer and the Engineer in the Commissioning of the Project;

(5) performance of the testing and commissioning for all systems forming part of the

Works in a manner which is fully co-ordinated with other designated Contractors, the Employer and the Engineer;

(6) provision of all required testing and specialised equipment and materials including

consumables required to support the testing and commissioning pre-operations activities; and

(7) removal and appropriate disposal of any toxic or other spoils (e.g. cable drums,

depleted filters, oils, and fluids) created as a result of the Contractor’s construction, testing and commissioning activities.

9.1.3 The Contractor shall provide full access for the Employer and Engineer to witness any test

or inspection.

9.1.4 The Employer and the Engineer will bear their own costs for attendance at witnessed inspections or tests (other than re-tests) scheduled in accordance with the agreed Works Programme and subject to notice in accordance with the Specification.

9.2 Manufacturing Test Plan

9.2.1 The Manufacturing Test Plan is the Contractor’s plan for carrying out the necessary

procedures to ensure that the items presented for acceptance by the Employer and the Engineer are in compliance with the requirements of the Specification.

9.2.2 During the process of procurement and manufacture of the system components the

Contractor shall undertake such testing and inspection as is required by the Quality Plan referred to in Clause 5.5 above.

9.2.3 The Employer and the Engineer will not become involved in the Contractor’s

Manufacturing Tests except in respect of the following:


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Type Tests; and

First Article Inspection

9.2.4 Before shipment of any items to Site the Contractor shall present the items for the first stage of Acceptance according to the Commissioning Plan as detailed in Clause 9.3 below.

9.2.5 Inspection

The Contractor shall be wholly responsible for all inward inspection of items to be incorporated into the system as a whole. Equipment issued by the Employer shall not be subject to Type Tests or First Article Inspection however the Contractor shall undertake Inspection as referenced in Clause 7.1 above. Should the Employer’s issued equipment be subsequently incorporated into another manufactured item then the whole item shall be subject to both Type Tests and First Article Inspection.

9.2.6 Type Tests

9.2.6.1 Type tests will not be required in those cases where the Contractor can produce certified

evidence that the required type tests have been performed successfully on identical equipment or equipment which is, for practical test purposes, similar and produced in the factory where the equipment offered is to be manufactured.

9.2.6.2 Evidence to this effect submitted during the Tender period shall be resubmitted, this and

any further submissions for waiver of Type Testing shall be submitted for review by the Engineer’s Representative no later than two months before the scheduled date for shipment of the item to site.

9.2.6.3 Unless specified to the contrary, equipment type testing shall consist of performing the

tests listed below on at least one sample of the design:

a. Mechanical Tests - Based on the function to be performed as laid down in the PS; b. Environmental Tests - Based on the class of environment into which the item is to be

installed; c. Functional Tests - To comply with the requirements of the PS; d. Electrical Tests - (where appropriate) To demonstrate compliance with electrical

characteristics under conditions of interference and power supply disruption; and e. Fatigue (Soak) Tests - To demonstrate the reliability or longevity of the item.

9.2.6.4 Type tests are not required if previously independently witnessed tests have been

successfully carried out. Where only some of the required tests have been carried out, the Engineer may agree to selected type tests being carried out individually rather than as part of a sequence.

9.2.6.5 The Contractor shall conduct the tests in accordance with the reviewed test procedures,

and shall enter the results in the result sheets. Full use shall be made during the tests of operator manuals and other documentation provided by the Contractor, to provide a series of tests of their accuracy.

9.2.6.6 Various requirements for typical Type Tests are included in Appendix 5 of this

Specification.

9.2.6.7 For each test, the Engineer will determine whether the item under test has passed or failed. In general, the test will be considered to have failed if either:

The result of the test is not in accordance with the expected result described in the test procedure, or


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The result of the test is in accordance with the expected result described in the test procedure, but some other unexpected or unexplained event occurred which the Engineer considers to be a fault.

9.2.6.8 If during Type Tests, any failure occurs or the equipment design is changed, it shall be

reported to the Engineer who may, at his discretion, require repetition of the previous tests at the Contractor's cost.

9.2.7 First Article Inspection

9.2.7.1 FAI shall be performed jointly by the Employer and the Engineer and the Contractor on all

major equipment items or sub-systems identified by the Engineer.

9.2.7.2 Equipment shall be shipped from the point of manufacture only after a FAI has been completed or the requirement waived in writing by the Engineer.

9.2.7.3 The Contractor shall provide a minimum of 15 working days notice to the Engineer before

any FAI. Other than the FAI, the Contractor shall give the Engineer notice of all Quality Control Points and Quality Hold Points involving inspections and/or tests by the Contractor in accordance with Clause 9.8.1 below.

9.2.7.4 At least 15 days prior to each FAI, the latest drawings, inspection and test procedures,

specifications and quality documentation required for adequate inspection of the equipment under inspection shall be submitted to the Engineer. The drawings shall be complete to the lowest level replaceable unit.

9.2.7.5 The Contractor shall ensure that he and his subcontractors are prepared for all FAIs. The

Contractor shall not schedule more than one FAI on the same day without prior notice of No Objection by the Engineer.

9.2.7.6 The FAI shall evaluate component and system maintainability. The FAI shall enable the

Employer and the Engineer and the Contractor to jointly establish the quality of workmanship for the balance of like components.

9.2.7.7 The FAI shall not be conducted until the design drawings of the equipment have been

reviewed. If drawings with outstanding comments are used, the Engineer’s comments shall be satisfied at the FAI and represented by the inspected equipment.

9.2.7.8 FAI shall be performed on a component built using reviewed without objection production

processes, tooling and manpower. All test fixtures, programs and instruments used in FAI shall be those to be used in the routine production testing of subsequent identical items.

9.2.7.9 The Contractor shall be responsible for the cost and scheduling, to the Employer and the

Engineer's convenience, of any repeat testing of items which fail FAI.

9.2.8 Factory Acceptance Test

Before shipment all manufactured items or systems shall undergo FAT in accordance with the requirements of the PS.

9.3 Commissioning Plan

9.3.1 The Commissioning Plan is the Employer and the Engineer’s tool for managing and co-

ordinating the Testing, Commissioning, Training and Service Trial activities. The Commissioning Plan will be divided into the following sub-plans:

(1) Factory Testing Plan (see Clause 3.5.3 above and PS) (2) On-Site Testing and Commissioning Plan

9.3.2 Testing and Commissioning Phases


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9.3.2.1 Testing and Commissioning activities shall be undertaken in the following phases:

(5) Factory Acceptance Test (which requirements are specified in Clause 3.5.3 above); (6) Installation Tests; (7) Partial Acceptance Tests; (8) System Acceptance Tests; (9) Integration Testing & Commissioning; and (10) Service Trial.

9.3.2.2 Items (3), (4), (5) and (6) as required by the PS constitute the Tests on Completion

referred to in the GCC.

9.4 On-Site Testing and Commissioning Plan

9.4.1 The Contractor shall prepare and submit for review by the Engineer the Contractor’s On-Site Testing and Commissioning Plan detailing and explaining how the Contractor will plan, perform and document all tests and inspections that will be conducted to verify and validate the Works on Site. The On -Site Testing and Commissioning Plan shall consist of a narrative description supported by graphics, diagrams and tabulations as required.

9.4.2 The On-Site Testing and Commissioning Plan shall contain, but not be limited to, the

following topics: (1) the Contractor’ s strategy for testing and commissioning all constituent parts of the

Works and how this relates to the sequence of construction and installation;

(2) the sequencing and interrelationships of the inspections and tests including:

(a) all Quality Hold Points; and (b) all Quality Control Points;

(3) the interdependency and interaction with other Contractors and their commissioning

programmes; (4) the type and extent of testing and commissioning to be undertaken and the parts of

the Works to be proven by that testing; (5) the objective of each test, what particular design and operating criteria the test or

inspection will prove and how the success of the test will be demonstrated or measured;

(6) organization chart and CV of key personnel in testing and commissioning team; (7) the plan for the production and submission of t he testing and commissioning

procedures to the Engineer for review including the submission of the testing and commissioning reports and records; and

(8) the On-Site Testing and Commissioning Plan shall be organised and submitted in the

stages described in Clauses 9.3.2 above, 9.4.3 below & 9.4.7 below.

9.4.3 Installation Tests

9.4.3.1 The Installation Tests phase is defined as being the final stage of assembly/installation before the start of Commissioning itself. The Installation Tests are to be performed by the Contractor under the Contract and may be witnessed by the Employer or the Engineer. During this phase, the Contractor shall perform static testing of components and/or systems in preparation for Partial Acceptance Testing.


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9.4.3.2 The particular requirements for Installation Tests are prescribed in the PS. Where performance across interfaces to other Contractors or to other parties is required to be verified, the Contractor shall liaise with the interfacing party to co-ordinate the test procedures and programme in the manner prescribed in Clause 3.3.2 above.

9.4.3.3 The Contractor shall prepare three copies of a test report immediately after the completion

of each test whether or not witnessed by the Employer or the Engineer. If the Employer or the Engineer has witnessed the test, he will countersign the report to indicate his agreement to the information and conclusions (i.e. whether or not the equipment being tested has passed satisfactorily) contained therein. If the Employer or the Engineer has not witnessed the test (i.e. if a written waiver has been granted), the Contractor shall forward three copies of the test report without delay to the Engineer.

9.4.3.4 The Engineer will countersign the report to indicate his agreement to the information and

conclusions (i.e. whether or not the equipment being tested has passed satisfactorily) and return one copy to the Contractor. Where the results of the test do not meet the requirements of the Specification, the Employer or the Engineer may call for a re-test.

9.4.3.5 Test equipment and instrumentation shall be subject to calibration test within a properly

controlled calibration scheme, and signed calibration certificates shall be supplied to the Engineer in duplicate. Such calibration checks shall be undertaken prior to testing and, if required by the Employer or the Engineer, shall be repeated afterwards.

9.4.3.6 The Contractor shall submit to the Engineer a comprehensive schedule of tests as

required by the PS giving full details and procedures for each test to be carried out under the Contract and including the pass / fail criteria (i.e. the standards or limits to be achieved).

9.4.4 Partial Acceptance Tests

9.4.4.1 Partial Acceptance Tests are defined as the performance of functional tests of sections,

areas, or stages of a system. The Partial Acceptance Tests are part of the Tests on Completion to be performed by the Contractor under the Contract in order to achieve Employer’s Taking Over of the Works. During this phase, an energy source shall be introduced to enable functional testing to be performed. On satisfactory completion of the Partial Acceptance Tests, the tested items will be considered available for Systems Acceptance Testing.

9.4.4.2 The particular requirements for Partial Acceptance Tests are prescribed in the PS.

9.4.4.3 The Contractor shall submit to the Engineer a comprehensive Partial Acceptance Tests

Plan including all requirements detailed in the PS. The plan shall be submitted on a logical section-by-section basis, using a “top-down” approach describing the testing and commissioning strategies and processes clearly showing how these serve to provide the full verification of the systems and equipment.

9.4.4.4 The Partial Acceptance Tests Plan shall identify a comprehensive list of specifications,

standards, method statements, procedures, pass/fail criteria, sample records, resources to be made available, drawings and records to be submitted to the Engineer, and a programme showing the dates for testing and for submission of each test procedure.

9.4.4.5 Test procedures shall be carefully planned to ensure that the work can be executed in the

time available. If the available time is restricted, this planning shall include contingency plans to be implemented if testing proceeds slower than anticipated or if defects are discovered that necessitate rectification and subsequent repeat testing, etc.

9.4.4.6 If any working equipment is relocated or altered by the Contractor during the execution of

the Works, thorough re-testing shall be performed to verify that the equipment remains fully functional and operates safely according to its specification. The testing to be


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performed shall be no less rigorous than the procedures used for the original testing and commissioning of the equipment.

9.4.4.7 The Contractor shall submit to the Engineer by the date laid down in the PS (or if none is

given, no later than two months before the commencement of the commissioning work whichever is earlier), 3 copies of its proposed Partial Acceptance Tests records. The records shall be appropriately sub-divided to make provision for the various parts of the systems and equipment covered by the Contract and shall cover all tests (mechanical, electrical or otherwise), positive identification of equipment, assemblies and sub-assemblies by serial number, drawing and specification reference numbers (and issue reference) and any other data to be certified by the Employer or the Engineer during the course of commissioning.

9.4.4.8 The Contractor shall during the execution of the Works prepare such reports and records

of design, manufacture, installation, erection and testing as may be required in order that any relevant licences or approvals (including any statutory approvals) may be issued or granted. Such records shall be adequate to enable the system or its respective part to be commissioned and to meet the requirements of the licensing authority or statutory body.

9.4.4.9 Immediately following the successful Partial Acceptance Testing of the system or any

constituent part, the Contractor shall complete the appropriate Partial Acceptance Tests records in the agreed format and submit 3 signed copies to the Engineer.

9.4.4.10 The Contractor shall include a complete schedule of all Partial Acceptance Tests records

and their current status within the Monthly Progress Report.

9.4.5 System Acceptance Tests

9.4.5.1 System Acceptance Tests are defined as the tests undertaken to demonstrate that the Works in its entirety is capable of functioning in accordance with the specified requirements in the Contract in all respects. The System Acceptance Tests are part of the Tests on Completion to be performed by the Contractor under the Contract in order to achieve Employer’s Taking Over of the Works. The System Acceptance Tests may commence before remote operations capability (if any) is fully functional, however, the system must be satisfactorily tested remotely (if specified to have such capability) before the System Acceptance Tests can be considered to be completed. On satisfactory completion of the System Acceptance Tests, the tested items will be considered available for Integrated Testing & Commissioning.

9.4.5.2 The particular requirements for System Acceptance Tests are prescribed in the PS.

9.4.5.3 The Contractor shall submit to the Engineer a comprehensive System Acceptance Tests

Plan including all requirements detailed in the PS. The plan shall be submitted on a section by section basis to demonstrate how the System Acceptance Tests are to be carried out. The plan shall adopt a top down approach and describe the system completion strategy and process.

9.4.5.4 System Acceptance Tests shall comprise comprehensive testing of the assembled

installation to ensure that it operates in accordance with the requirements of the PS.

9.4.5.5 The tests shall include, but not be limited to, the following: (1) tests of all functional and performance requirements for the system; (2) tests of behaviour under failure conditions, e.g. changeover to redundant hardware;

initiation of re-configuration functions or reverse modes of operation; and recovery of the equipment and system from failure.

9.4.5.6 The System Acceptance Test Plan shall identify a comprehensive list of specifications,

standards, method statements, procedures, pass / fail criteria, sample records, resources


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to be made available, drawings and records to be submitted to the Engineer, and programme showing the dates for testing and for submission of each test procedure.



9.4.5.8 Immediately following the successful acceptance testing of the system, the Contractor

shall complete the appropriate commissioning records in the agreed format and submit 3 signed copies to the Engineer.

9.4.5.9 The Contractor shall include a complete schedule of all System Acceptance Test records

and their current status within the Monthly Progress Report.

9.4.6 Integration Testing & Commissioning

9.4.6.1 Integrated Testing & Commissioning are defined as the final tests to be undertaken before the commencement of Service Trial. The Integrated Testing & Commissioning are part of the Tests on Completion to be performed by the Contractor under the Contract in order to achieve Employer’s Taking Over of the Works. The Integrated Testing & Commissioning shall demonstrate the full compatibility between all interfacing systems. On satisfactory completion of the Integrated Testing & Commissioning, the tested items will be considered available for Service Trial.

9.4.6.2 The particular requirements for Integrated Testing & Commissioning are prescribed in the

PS.

9.4.6.3 The Contractor shall submit to the Engineer a comprehensive Integrated Testing & Commissioning Plan as required by the PS. The plan shall be submitted on a logical section-by-section basis, using a “top-down” approach describing the testing and commissioning strategies and processes clearly showing how these serve to provide the full verification of the systems and equipment in context of the complete railway system.

9.4.6.4 The Contractor shall co-ordinate with the Employer and the Engineer and with all

interfacing parties to ensure that the proposed test programme and schedule truly demonstrate that the full specified performance requirements are achieved.

9.4.6.5 The tests shall include, but shall not be limited to the following:

(1) test of all functional and performance requirements for the system; (2) test to demonstrate compliance with all interface specifications; and (3) test of behaviour under failure conditions (e.g. changeover to redundant hardware,

initiation of re-configuration functions or reversionary modes of operation, recovery of systems and equipment from failure, demonstrations of planned emergency procedures, etc.).

9.4.6.6 The Integrated Testing & Commissioning Plan shall identify a comprehensive list of

specifications, standards, method statements, procedures, pass/fail criteria, sample records, resources to be made available, drawings and records to be submitted to the Engineer, and a programme showing the dates for testing and for submission of each test procedure.




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9.4.6.8 Immediately following the successful Integrated Testing & Commissioning of the system or any constituent part, the Contractor shall complete the appropriate commissioning records in the agreed format and submit 3 signed copies to the Engineer.

9.4.6.9 The Contractor shall include a complete schedule of all Integrated Testing &

Commissioning records and their current status within the Monthly Progress Report.

9.4.7 Service Trial

9.4.7.1 Service Trial is defined as the final test of the fixed equipment, the rolling stock, and the operational procedures including the final elements of the Tests on Completion to demonstrate that the system in its entirety can operate satisfactorily. The Service Trial is performed by the Employer with attendance by the Contractor under the Contract in order to achieve Employer’s Taking Over of the Works. During this phase, the system will be run to the published timetable but without fare-paying passengers. This phase also allows for Validation of the training procedures in a real time environment.

9.4.7.2 The Commissioning Team in conjunction with the Employer will develop the Service Trial

Plan. Operations Department and will serve to organise and co-ordinate all on-Site activities.

9.4.7.3 The particular requirements for tests to be undertaken during the Service Trial are

prescribed in the PS.

9.4.7.4 The Contractor shall provide special and general attendance to the Employer and the Engineer during the Service Trial period as required by the PS.

9.4.7.5 The Contractor shall co-operate with the Employer and the Engineer and with all

interfacing parties to ensure that the proposed Service Trial programme and schedule truly demonstrates that the full, specified performance requirements and operating parameters are achieved.

9.4.7.6 The Contractor shall review and comment on the Engineer’s Service Trial Plan and shall

identify specifications, standards, method statements, procedures, pass / fail criteria, to the Engineer for inclusion in the Plan.

9.4.7.7 The Contractor shall not interfere with the Service Trial tests and Validations in any

manner. Any need for remedial works required to be performed by the Contractor shall be co-ordinated with the Employer and the Engineer in advance.

9.4.7.8 Immediately following the successful tests of the system or any constituent part during

Service Trial the Contractor shall complete the appropriate commissioning records in the agreed format, submit 3 signed copies to the Engineer and may then apply for the Taking Over Certificate in accordance with the requirements of the GCC.

9.4.7.9 The Contractor shall include a complete schedule of all Service Trial records and their

current status within the Monthly Progress Report.

9.5 Activity of the Employer and the Engineer

9.5.1 The Employer and the Engineer will establish a Commissioning Team and a Site Co-ordination Team at appropriate stages of the Project. These teams will comprise representatives of all interested parties including not more than two representatives of the Contractor, subject to review by the Employer and the Engineer. In accordance with the Commissioning Plan, the Commissioning Team shall advise and plan to co-ordinate the activities of the Contractor to ensure the Employer and the Employer’s requirements are met.


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9.5.2 The Contractor shall participate in the activities of the Commissioning Team and Site Co-ordination Team in addition to its own testing and commissioning or as directed by the Employer or the Engineer.

9.6 Records and Reports

9.6.1 The Contractor shall submit to the Engineer for review not less than six (6) months before

commissioning activities commence his proposed format for the commissioning records. The records shall be appropriately sub-divided to make provision for the various parts of the Permanent Works covered by the Contract.

9.6.2 The format of the records shall cover all mechanical and electrical tests, provide positive

identification by serial number for assemblies and sub-assemblies of the Permanent Works and show modifications to Employer’s Drawings and diagrams or "as built" data to be certified by the Employer or the Engineer in the course of installation, testing and setting to work of the Works.

9.6.3 The Contractor shall, during the execution of the Works, prepare such reports and records

of manufacture, installation and testing as may be required in order that a licence may be issued or statutory requirements may be met or approval given. Such reports or records shall be adequate to enable each part of the Permanent Works to be commissioned and to meet the requirements of the licensing authority or any standing statutory regulations, and shall be reviewed by the Employer and the Engineer.

9.6.4 The Contractor shall obtain reports of each inspection and/or test. Such reports shall show

the results of all the inspections and/or tests carried out and shall certify that the work has been inspected and/or tested in accordance with the requirements of the Contract and that the work complies with the requirements of the Contract.

9.6.5 Any analysis of the results required to confirm that the work complies with the

requirements of the Contract shall be compiled and reported to the Engineer in accordance with Chapter 4.

9.6.6 A representative of the Contractor who has been allocated the required authority under the

relevant quality plans shall sign each report of inspection and/or test.

9.6.7 Each report of inspection and/or test shall include the appropriate details of: (1) the description of the item or goods subjected to the test or inspection; (2) if applicable, the batch from which the samples were taken for test, the size and

description of samples and the method of sampling; (3) the place of testing; (4) the date and time of tests; (5) the environmental conditions; (6) the technical personnel supervising or carrying out the test or inspection; (7) the properties tested or inspected; (8) the method of testing or inspection; (9) all relevant checklists and work sheets used during the inspection and/or test,

including the readings and measurements taken during the tests; and (10) the test results, including any calculations and graphs.


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9.6.8 After Commissioning of a part of the Works, the Contractor shall complete each commissioning record in the agreed format and shall forward copies of the record to the Engineer for review.

9.6.9 The Contractor shall submit within its Monthly Progress Report a complete schedule of his

commissioning records showing completion dates, target completion dates and status.

9.6.10 Timing for Reports of Inspection and/or Test

The Contractor shall ensure that a signed copy of each report of inspection and test is filed in his filing system within 3 (three) working days of the date of inspection and test.

9.6.11 Quality Control Register

The Contractor shall provide and maintain at all stages of the work a quality control register or registers to identify the status of inspections, sampling and testing of the work and all certificates in accordance with Quality Control Register in Chapter 5.

9.6.12 Summaries of Inspection and/or Test

The Contractor shall submit to the Engineer for his information summaries based on each quality control register showing the type and amount of certification received and the inspection and/or testing undertaken on each element of the Works. Such summaries shall reach the Engineer’s office before the 7th working day of the month. The summaries shall identify and demonstrate the compliance of such certification, inspection and/or testing with the requirements of the Contract and shall identify any item which does not conform to the requirements of the Contract.

9.7 Test Equipment and Facilities

9.7.1 The Contractor shall provide all equipment and services required for testing, including, but

not limited to: (1) Laboratory test instruments. (2) Special test equipment, emulators, simulators and test software, to permit full testing

of System functions and performance. (3) Other items of the System, specified elsewhere as being part of the Contractor's

supply, even if not part of the Subsystem under test. (4) Consumables.

9.7.2 All test instruments shall be subject to routine inspection, testing and calibration by the

Contractor.

9.7.3 Details of all test instruments shall be submitted for review by the Engineer and, if required by the Employer or the Engineer, shall be calibrated at the expense of the Contractor by an independent standards laboratory.

9.7.4 All test equipment must be capable of operating from the mains supply (230V AC 50Hz).

9.7.5 All test software shall be subject to formal quality assurance requirements stipulated

elsewhere in the Specification.

9.7.6 The Contractor shall ensure that all inspection and test equipment is calibrated in accordance with the specified standards or, if such standards are not applicable to certain test and inspection equipment, with systems and programmes of calibration which have been reviewed without objection by the Engineer.


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9.7.7 The Contractor shall ensure that documented evidence of instrument calibration is maintained and made available to the Employer or the Engineer on request.

9.8 Witnessing by the Employer and the Engineer

9.8.1 Notice for Trial, Inspection and/or Test to the Engineer

9.8.1.1 In relation to all Quality Control Points and Quality Hold Points involving inspection and/or

testing by the Contractor, the Contractor shall give the Engineer notice of when the relevant work will be inspected and/or tested using the form in Appendix 6 of this Specification. The period of notice shall be as stated in the PS or such period as in the opinion of the Engineer is reasonable and notified to the Contractor. In the absence of any such statement or notice, a reasonable period of notice shall be given by the Contractor provided that: (1) in the case of on-Site work, such notice shall be given not less than 72 hours of

normal working time before the work is to be inspected and/or tested;

(2) in the case of work carried out off-Site in Pune, such notice shall be given not less than 5 days before the work is to be inspected and/or tested; and

(3) in the case of work carried out outside Pune, such notice shall be given not less

than 14 working days before the work is to be inspected and/or tested.

9.8.1.2 In relation to all inspection and/or testing notified by the Contractor, the Employer and the Engineer may elect to witness such inspections and/or tests but the Contractor may proceed with the inspections and/or tests notwithstanding the absence of the Employer or the Engineer or of any response to the said notice.

9.8.1.3 If the Contractor is in any doubt whether inspection and/or testing by the Engineer is

required as a Quality Hold Point, the Contractor shall request that the Engineer clarifies his requirements prior to submitting the relevant inspection and testing plan for review, and in any event not later than 30 days.

9.8.2 Timing for Inspection and/or Test by the Employer and the Engineer

9.8.2.1 The Contractor shall allow the Employer and the Engineer a reasonable time to carry out

any inspection and/or testing and to assess the result of any inspection and/or test before proceeding with the Works.

9.8.2.2 Unless the Engineer’s prior review without objection has been obtained, all inspections

and/or tests to be carried out or witnessed by the Employer and the Engineer shall be carried out between 0800 and 1800 hours.

9.8.3 Failure to Notify the Engineer

The Employer or the Engineer may reject the test and test results in question, and require the test to be repeated in the event of any failure by the Contractor to notify the Engineer in accordance with Clause 9.8.1.1 above.

9.9 Failures

9.9.1 The Contractor shall correct all faults found during testing, and shall arrange for the

relevant tests to be repeated. The relevant tests shall only be repeated when the fault has been remedied and the equipment demonstrated to function correctly.

9.9.2 Where remedial measures involve significant modifications that might, in the Engineer's

opinion, affect the validity of earlier tests, the Contractor shall repeat the earlier tests and obtain results satisfactory to the Employer and the Engineer before repeating the test in which the fault was first identified.


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9.9.3 The Employer or the Engineer shall have the right to order the repeat or abandonment of

any test in the event that results demonstrate that the equipment is significantly non-compliant with the Contract.

9.9.4 The Employer or the Engineer shall have the right to suspend any test in the event that

errors or failures have become unacceptable. The Employer or the Engineer shall also have the right to suspend any test if a fault was detected by the Contractor but not reported to the Engineer within 24 hours of the detection. In this event, the suspension shall remain in effect until reporting has been brought up to date to the satisfaction of the Employer and the Engineer.

9.10 Repeat Tests

9.10.1 The Contractor shall correct and re-test every fault detected during the tests.

9.10.2 If the test results of the item under test fail, the provisions of GCC Clause 7.5 shall apply.

9.11 Fault Categories

9.11.1 The Engineer will allocate a category to each fault, which shall determine the future

conduct of tests. Test categories shall be as defined in Table 9-1:

Table 9.1: Fault Categories

Category Description

0 An item recorded as a fault during testing, and subsequently considered as being a normal acceptable occurrence. Testing may continue.

1 Minor fault. An event not affecting the functionality being tested in that session. Testing may continue.

2 Repeatable fault not affecting the functionality being tested in the session. Testing may continue at the discretion of the Engineer.

3 Repeatable fault affecting the functionality being tested in the session. The fault must be rectified before retest of the affected test session or sessions. Testing may proceed on other sessions if permitted by the Engineer.

4 Major fault affecting the functionality being tested in the session. The fault must be rectified before recommencing testing.

5 Non repetitive fault affecting functionality being tested in the session. The action taken will depend on the severity of the fault. Discussion is needed to establish the most appropriate course of action.

6 Documentation error or deficiency. The error will usually be amended during the test and the test will continue. The documentation shall be corrected before the tests are considered complete.

7 Deficiency in the ability of the test or test equipment to demonstrate the functionality being tested in the session. Discussion is needed to establish the most appropriate action.

8 Other fault not covered above, but requiring explanation and, in some cases, correction.

9.12 Fault Log

9.12.1 The Contractor shall maintain a fault log throughout each series of tests. Every fault

detected during the tests will be entered in the log, together with the actions taken to clear and re-test the fault.

9.12.2 The fault log will be retained as part of the permanent quality assurance record for the

system and be subject to regular inspection by the Engineer.

9.13 Hardware Failure Reports


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9.13.1 For each hardware failure that occurs at any stage of testing, the Contractor shall investigate the failure and prepare a report on its cause(s) and design implications, if any, resulting from such failure. The report shall clearly show: (5) the observed symptoms; (6) the most likely cause of the failure; (7) the fault category (from Table 9-1); (8) an analysis of any stress t hat may have been caused to other components of the

equipment being tested as a result of the failure; (9) whether the failure is a result of any component operating outside its design range;

and (10) whether any design changes should be made to avoid further failures.

9.13.2 All such reports will be retained as part of the permanent quality assurance record for the

system, which shall be subject to inspection by the Engineer.

9.14 Software Failure Reports

9.14.1 For each software failure that occurs, once the software has been reviewed without objection for inclusion into the system and is subject to configuration control, the Contractor shall generate a software failure report.

9.14.2 All such reports will be retained as part of the permanent quality assurance record for the

system, which shall be subject to inspection by the Engineer.

9.14.3 The report shall clearly show: (7) the observed symptoms; (8) the likely cause; (9) the fault category (from Table 9.1); and (10) the operator input.

9.14.4 The report shall also clearly show the following information which shall be entered when

the failure has been investigated: (1) the actual cause of the failure; (2) the corrective action taken; and (3) all software modules affected.


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CHAPTER 10

10.0 TRAINING AND TRANSFER OF TECHNOLOGY

10.1 Training Requirements

10.1.1 The Contractor shall provide comprehensive training to the Employer’s staff to enable all of the systems and equipment supplied, installed or modified as part of the Works to be operated and maintained in the designed manner safely and efficiently so as to achieve the maximum reliability and economy, and to meet the requirements of the Employer’s programme.

10.1.2 To achieve the objective, it will be necessary to train the Employer’s staff, including

Employer’s Training Instructors (ETI). The Contractor shall submit to the Engineer for review and critique the range of staff for which training is recommended and Training and Transfer of Technology Plan to be proposed by the Employer and as stated in PS in accordance with Clause 3.7.4 above.

10.1.3 The recommendation shall include details of training equipment necessary and

appropriate to achieve the training objectives.

10.1.4 The Training Plan shall provide a structured training programme to educate and train the personnel of the Employer in all aspect s of the system operation and maintenance and shall include, but not be limited to, the following: (1) schedule of training courses; (2) objective, syllabus, format, class size and duration of each training course; (3) training facilities to be provided by the Employer; (4) list of training materials and documentation to be included with the training course; (5) method of pre- and post- testing to be utilised; (6) qualifications and experience level necessary for the trainees; (7) instructor’ s qualifications; and (8) course evaluation methods.

10.1.5 Courses offered shall be suitable for operations and maintenance staff classified below as

distinct from engineering design staff: (1) first line and second line maintenance staff undertaking recovery/corrective and

routine/preventive maintenance; (2) third line (high skill level) maintenance staff specialised in workshop repair and

overhaul of equipment; and (3) technical support staff specialising in fault analysis and investigation techniques

associated with the particular type of equipment.

10.1.6 Training shall, as a minimum, impart the following techniques to the Employer’s staff of the appropriate grades: (1) all planned maintenance and overhaul of the systems and equipment supplied,

installed or modified under the Contract; (2) fault-finding and rectification techniques for the systems and equipment supplied,

installed or modified under the Contract. These shall be developed from the Contractor’s previous experience with similar equipment and also from the fault tree analysis and other analyses carried out as part of the reliability engineering studies undertaken by the Contractor;

(3) normal and degraded modes of operation of the systems and equipment supplied, installed or modified under the Contract;

(4) all rules, regulations, practices and procedures necessary for the safe and efficient operation of the systems and equipment supplied, installed or modified under the Contract; and


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(5) all contingency plans necessary to recover speedily and safely from any mishaps or emergencies that may arise with the systems and equipment supplied, installed or modified under the Contract.

10.1.7 Training shall be carried out in the medium of the English language and supplemented, if

necessary, in the Hindi language.

10.2 Training Method

10.2.1 Training shall consist of classroom (theory) training; computer based interactive multimedia training (CBT), simulator training, and practical (hands on) training.

10.2.2 The training shall take place in Pune, unless there are prohibitive reason(s), and shall be

related to Permanent Works that are to be or are being installed on the Project.

10.2.3 The training in Pune shall be supplemented, where appropriate, by training at the Contractor’s own premises and the premises of the major sub-contractors during the manufacturing and factory testing phases of the Works. Maximum use shall be made of the opportunities presented during equipment testing phases of the Contract to demonstrate and practise fault finding and diagnostic techniques.

10.2.4 To meet this need, the Contractor shall supply competent trainers/instructors to carry out

training to a high degree of proficiency in areas where the Contractor has the specialised knowledge.

10.2.5 In order to ensure that satisfactory standards are met, the Employer’s relevant Operations

/ Maintenance Department in liaison with the Training Department will monitor all training.

10.2.6 During the Defects Liability Period, when the Contractor is responsible for faultfinding and repair, he shall provide practical hands on training to the Employer’s maintenance staff to facilitate the successful handover of this function.

10.2.7 Where applicable, the Employer will pay all of his staff’s salaries, travelling, subsistence

and other related allowances.

10.3 Employer’s Instructor Training

10.3.1 The Contractor shall provide training courses and training materials to train the Employer’s Training Instructors (ETI) to a level of competence to allow the ETIs to subsequently train the Employer’s staff in all aspects of operation and maintenance of the systems and equipment supplied, installed or modified as part of the Works.

10.3.2 For Maintenance Instructors, this shall include specific training in the use of maintenance

documentation, all faultfinding guides and any special gauges, instrumentation or test equipment required in any maintenance or fault finding and analysis.

10.3.3 For Operations Instructors, this shall include training in the operation of the equipment and

the various systems/sub systems under both normal and fault conditions.

10.4 Training Plant & Equipment

10.4.1 With the prior review of the Engineer, the Contractor may use the Permanent Works being erected, tested or commissioned for the training of the Employer’s staff. In general, the Contractor shall not use Contract Spare parts for this purpose.

10.4.2 Training course notes shall be entirely compatible, and, where appropriate, cross-

referenced to the manuals supplied by the Contractor as part of the Operation and Maintenance documentation.


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10.4.3 The Contractor shall provide such written or printed matter, functional equipment, samples, models, cutaway equipment, slides, films and other instructional materials as may be necessary for training. Such equipment and material shall remain the property of the Employer and shall be sufficient both for the persons trained by the Contractor and for those to be subsequently trained by the ETI.

10.4.4 The Contractor shall provide an instructor’s guide for each training course. The guide shall

include the course agenda, objectives, list of resources and facilities required, detailed lesson plans, presentation notes, discussion guides, training aids and job aids, test papers, criteria and methodology for testing and assessment, and all other things that will enable the ETI to carry out repeat or refresher courses in the future.

10.4.5 All training course notes and instructor’s guides shall be submitted to the Engineer for

review 6 weeks prior to the commencement of the first training session of the course.

10.4.6 All training course notes and instructor’s guides shall be in a form that allows for easy reproduction.

10.4.7 All training course notes and instructor’s guides shall be in a standard format as set out by

the Employer.

10.5 Testing and Assessment

10.5.1 The Contractor shall, at the conclusion of each training course, issue questionnaires to, and/or set practical tests for all trainees directed at determining the level of satisfaction with the course content and to assess the level of knowledge and understanding of the course content by each trainee.

10.5.2 The Contractor shall review the responses to questionnaires and the trainees’ test results

and forward a summary to the Engineer.

10.5.3 If the Engineer considers that the course has not achieved the required objectives, he will advise the Contractor who shall then organise and implement appropriate re-training.

10.6 Training Records

10.6.1 The Contractor shall, at the completion of each training course:

(1) provide the Engineer with a consolidated training record listing the training course title,

date of training, name of all trainees, training result and other relevant information; and

(2) issue an appropriate certificate to each trainee who has successfully completed the course.

10.7 Transfer of Technology

10.7.1 Tenderer shall submit the detailed plan of transfer of technology along with MOU with

suitable Indian companies or company having proven track record and working in related areas for major systems / subsystems.

10.7.2 TOT shall be essential and shall include system assembly, installation, maintenance and

software modification / customisation and training of Employer’s personnel to cover the systems/subsystems:

Overhead collection system

SCADA System

Traction Power Supply equipment

Power supply installations

Earthing & Bonding System


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10.7.3 TOT shall essentially include the following aspects as a minimum:

Engineering or extensions and up gradations of the system.

Re-engineering to suit changed traffic conditions.

Incorporation of optional facilities.

Addition/Modification to depot yards.

Change in parameters of Rolling Stock.

Any other configuration/programmes required for maintenance/ up gradation of hardware/software.

10.7.4 The Transfer of Technology shall require involvement of Employer’s personnel in each of

sub-systems during the contract period. The sponsored engineers shall be under the technical administrative control of the contractor. It is tentatively proposed to deploy two of Employer’s personnel for this purpose.

10.7.5 The Contractor shall undertake to supply or make arrangement with the original

manufacturer to supply additional equipment required for replacement or expansion of the network in future.

10.7.6 The Contractor shall undertake to provide, if required during the life of the equipment

ordered, technical assistance in the form of additional drawings, maintenance practices and technical advice.


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CHAPTER 11

11.0 OPERATION AND MAINTENANCE DOCUMENTATION

11.1 General

11.1.1 The Contractor shall supply Operation and Maintenance documentation in respect of the systems and equipment supplied or installed or modified under the Contract in accordance with the requirements of the following clauses, except where expressly specified otherwise in the Contract.

11.1.2 All Operation and Maintenance Manuals produced by the Contractor shall conform to the

requirements of the Employer. The Contractor shall interface with the Employer for the requisite format.

11.1.3 The Contractor shall supply all documentation, including Operation and Maintenance

Manuals and “as-built” drawings, necessary for operating, maintaining, repairing and modifying the systems and equipment supplied, installed or modified under the Contract.

11.1.4 Except where otherwise stated, the Contractor shall provide one electronic copy, eight

bound copies and one unbound copy of all documentation. The unbound copy will be used by the Employer for reproduction purposes. All documentation shall be in the English language.

11.1.5 The Operation and Maintenance Manuals shall be provided in the English language.

11.1.6 The Contractor shall fully co-ordinate and cross-reference interfaces and areas associated

with interconnecting equipment and systems within the Contract. The Operation and Maintenance Manuals shall fully describe the overall operation of all systems incorporating all equipment.

11.1.7 The Operation and Maintenance Manuals shall contain no irrelevant or ambiguous

information and shall relate specifically to this Contract.

11.1.8 The Contractor may use manufacturer’s data and handbooks for individual items of E&M equipment that are a sub-component of the overall system, including printed circuit boards, providing they meet the intent of the Specification, and are integrated by the Contractor into the description of his equipment, and are indexed accordingly in his own general index. All such documentation shall be contained in similar binders.

11.1.9 Where a sub-assembly item is of such a nature that local repairs in Pune / India cannot be

made and it is necessary to be returned to the manufacturer as a unit for overhaul, the specific information concerning its repair and breakdown into component parts shall be provided.

11.1.10 The document shall be collated and numbered in proper order and correspond to the

contents and index tables. Nomenclature or references to any items of equipment, diagrams, figure numbers or units shall be consistent throughout the text. In order to comprehend the text, diagrams, drawings, sketches and actual photographs shall be added where necessary. All manufacturers’ literature identification codes or stamp markings shall be omitted. Precautions and warnings regarding the safety of life and equipment shall be included where applicable.

11.2 Arrangement and Format of Manuals

11.2.1 The Contractor shall arrange all documentation in accordance with the Employer

requirements.


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11.2.2 The Contractor shall provide documentation for all hardware and software for computer systems and other associated electronic equipment to meet the following requirements. Such documents shall include but not be limited to: (1) manufacturers’ documentation supplied as standard with the equipment; (2) hardware configuration with details of expansion capabilities and options; (3) programme loading instruct ions, including runtime environment configuration; (4) programme listing including comprehensive 'comment statements' in hard copy and

soft format for source code, compilers and development tools necessary to modify and recompile software;

(5) flow charts, data flow diagrams and state diagrams as appropriate; (6) description of software modules including purpose, linkage with other modules, error

routines and any special considerations; (7) memory maps for both internal and peripheral memory showing description of all

programmes, data files, over lay areas, memory available for expansion and the like; (8) loading and operating instructions for diagnostic programmes and specifically

developed debugging tools; and (9) programming manuals relevant to operating systems, languages, development tools,

etc.

11.2.3 The documentation shall in all respects be entirely sufficient to allow any competent software programming organisation to undertake programme and/or system modifications without recourse to the Contractor. These requirements shall apply in respect of microprocessor based equipment and 'firmware'.

11.3 Drawings

11.3.1 The Contractor shall submit such drawings as may be required for the operation and

maintenance and repair of the Permanent Works by the Employer.

11.3.2 Information contained on the drawings shall include but not be limited to: (1) arrangement drawings for all sub-systems and individual items of equipment; (2) installation and fixing drawings for all sub-systems and individual items of equipment; (3) inter face drawings for all sub-systems and individual items of equipment; (4) schematic drawings for all electrical, pneumatic, hydraulic, water and drainage

systems; (5) sizes, material and finish of all fixtures and threads; (6) manufacturer's code, drawing and reference numbers; (7) wiring diagrams to BS EN 60617, BS 3939 and BS 376 including internal wiring of

sealed unit items; (8) setting dimensions and tolerances; and (9) bill of materials.

11.3.3 Where instructed by the Engineer, drawings shall be supplied with Hindi language notation

in addition to English. The Engineer will supply such Hindi notation to the Contractor.

11.4 Submissions

11.4.1 The Contractor shall deliver all documentation to the Engineer by the date stated in the PS, or, if none is given, not later than six (6) months prior to the issue of the Taking Over Certificate for the Works (for the final draft version), and one (1) month prior to the issue of the Taking Over Certificate for the Works (for the final version). The delivery shall include a copy of the software and licence to operate the software to modify the manuals together with one set of CADD drawing files. The final manuals shall incorporate comments made by the Engineer on the draft manual.

11.4.2 Drawings shall be submitted to the Engineer as stated in the PS. The submission shall be

in accordance with stage commissioning requirements specified in the Works Programme and shall include two Compact Discs (CD) for each drawing.


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11.4.3 Following the Engineer’s review, the Contractor shall make a final submission of the

complete Operation and Maintenance Manuals and as–built drawings in a form and in a quantity specified in the PS. The final submission shall be made not later than the date set by the Engineer. The type of binder used to bind the Operation and Maintenance documentation shall be of a design which will permit all changes and additions to the said documentation to be readily collated therein. The Contractor shall make such amendments to his submissions as may prove necessary during commissioning of the Permanent Works and the Defects Liability Period. Amendments found necessary during commissioning shall be completed within two months after the issue of the Taking Over Certificate for the Works. Subsequent amendments shall be completed two months prior to the issue of the Defects Liability Certificate.

11.5 Operation and Maintenance Manuals

The Employer shall have the right to reproduce any part or the whole of any Operation and Maintenance Manual as he wishes for his O & M requirements.


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CHAPTER 12

12.0 SUPERVISION AND PLANNING OF MAINTENANCE

12.1 Scope

12.1.1 The Contractor shall be responsible for the supervision of maintenance of the equipment supplied under the Contract after the Taking Over of the Works or Part of the Works. The maintenance personnel shall be provided by the Employer.

12.1.2 The responsibility for the provision of supervision of maintenance shall be based on the

number of man-months identified during the Tender period and incorporated into the Contract. The actual utilisation of these man-months shall be at the Employer’s discretion and may be at any time up to six months after the Employer s Taking Over of the whole of the Works or the last part of the Works or the date of issuing of the Performance Certificate whichever shall be the later.

12.1.3 The scope of maintenance activities shall include all scheduled and unscheduled

maintenance required including all routine inspections and service overhauls at trackside, on trains and in workshops. Maintenance work shall include faultfinding following report of incidents and repair of items of equipment changed out in the course of fault rectification but excluding any Contractor’s liability for work to be carried out under the requirements of the Defects Liability Period.

12.2 Maintenance Planning & Management Staff

12.2.1 The Contractor shall undertake the necessary tasks in planning the maintenance activities

to ensure that the reliability of the operating railway is upheld including but not limited to: (1) Provide recommendations in respect of philosophy and procedures for repairs of

electronic systems, including PCBs, and the scale of facilities required to be set up in the Depot and Workshops for this purpose.

(2) Preparation of detailed operational plan for the routine servicing of any equipment which requires such service. The plan shall ensure that all items in use receive maintenance within the required time cycle by suitably trained and qualified staff and under the personal safety regime appropriate to the location of the equipment being maintained.

(3) Preparation of a detailed staffing for each and every different inspection, overhaul and repair activity. The plan shall also identify and quantify resources required by staff and groups of staff in terms of tools, tackle, protective clothing, etc.

(4) Preparation of a detailed quality plan, covering all maintenance activities. Based on the plan it shall be possible for the maintenance organisation to obtain ISO-9002 certification.

(5) Preparation of a computer based Stores management Plan, which shall assist the management, ensuring a timely availability of spares, tools and consumable materials with a low level of inventory.

(6) Setting in position a computerised defects and failure analysis and documentation system, based on FMEA principles for all systems, subsystems and components including individual PCBs.

(7) Efficient supervision of the maintenance, overhaul and repair activities of maintenance staff to ensure high quality work and productivity. This shall also include planning and supervision of ongoing training and retraining as required in the correct procedures using the t raining materials and courses supplied under the Contract. Where the supplied training courses are insufficient the Contractor shall develop additional


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training courses, manuals and materials to make good the deficiency as part of his Defects Liability responsibilities.

12.3 Supervisory Staff

12.3.1 The Contractor shall provide supervisory maintenance staff who are experts in the first

and third line faultfinding, maintenance and repair of the various systems supplied under the Contract covering at least the following:

(1) OCS Equipment System; (2) SCADA System; (3) Cabling Work; (4) Circuit Breakers; (5) Protection and measuring transformers; (6) Bonding and Earthing System; (7) Batteries

12.3.2 The experts provided for supervision of maintenance shall have adequate qualifications

and experience in the relevant discipline in the maintenance depots / workshops of existing metro type undertakings.

12.3.3 The deployment of the experts may not be continuous and they may be required to

supervise the maintenance in short periods at the discretion of the Employer.

12.3.4 The experts shall be available in Pune at short notice to supervise the Employer’s staff at any time during the Normal Operating hours and by arrangement to undertake extended investigations during Non-Revenue hours.


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CHAPTER 13

13.0 SUPPLY OF SPARE PARTS, SPECIAL TOOLS AND TEST EQUIPMENT

13.1 Details of supply

13.1.1 The Contractor shall supply to the Employer for the Permanent Works, in accordance with the provisions of this Chapter, as part of the Works: (1) spare parts including (but not limited) sub-assemblies and those to be supplied by its

subcontractors of any tier ("Spare Parts"); (2) special tools, jigs, fixtures and gauges and test equipment, including those to be

supplied by its subcontractors of any tier ("Special Tools and Test Equipment"),

13.1.2 The Spare Parts to be supplied by the Contractor shall consist of: (1) Contract Spares (as hereinafter defined); (2) Commissioning Spares (as hereinafter defined); and (3) Defects Liability Spares (as hereinafter defined).

13.1.3 The Contractor shall submit to the Engineer for review, in the format of a contract spares

schedule, in accordance with Chapter 4 above, a list of: (1) the Spare Parts to be supplied by the Contractor as part of the Works to suit stage,

categorised into individual parts or sealed units; and (2) the Special Tools and Test Equipment to be supplied by the Contractor as part of the

Works to suit stage. Such list shall be an amplification and confirmation of the list supplied with the Tender, as may have been subsequently modified during the Tender period, and shall be amended as necessary to reflect changes in design that may have occurred since the date of the Letter of Acceptance.

13.1.4 The Contractor shall use separate sets of contract spares schedules for different

subassemblies of the main assembly / equipment.

13.1.5 The information supplied in respect of each spare part or special tool shall include, but not be limited to, the following:

13.1.5.1 Core data - main assembly/equipment

(1) manufacturer / brand name (2) manufacturer's type/model number (3) rating (4) serial number if applicable (5) total number of the main assembly/ equipment supplied under the Contract

13.1.5.2 Core data - sub-assembly of main assembly/equipment

(1) manufacturer / brand name (2) manufacturer's type/model number (3) rating (4) serial number, if applicable

(if items (i) to (iv) above are different from those of the main assembly/equipment) (5) total number of sub-assembly in the main assembly/equipment supplied under the

Contract

13.1.5.3 Individual item of main/sub assembly/equipment (1) manufacturer order number


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(2) parts description - a full description of the Spare Part, including a note as to whether it is a sealed unit or whether it is an assembly or subassembly which can be broken-down into component parts

(3) manufacturer / brand name (4) the manufacturer's part number (if different from the ordering number) (5) the sub-contractor's ordering part number/reference, if applicable (6) recommended quantity (7) unit of measurement (8) unit price CIF to Pune including delivery to designated location amount (quantity

multiplied by unit price) (9) total number of the Spare Part in the sub-assembly of the main assembly/equipment

supplied under the Contract (10) total number of the Spare Part in all the sub-assemblies of all the main assemblies/

different equipment supplied under the Contract The Contractor shall ensure that the ordering part numbers specified shall enable the Employer to procure the exact item in future without reference to the Contractor.

13.1.5.4 Primary data

(1) parts catalogue number/cross reference (illustrated parts catalogues to be submitted

together with the contract spares schedules to the Engineer) (2) drawing number

13.1.5.5 Secondary data

(1) lead times stating whether for ex-stock or for product manufactured upon receipt of

order. (2) delivery schedule(s). (3) supplementary information:

a. special handling instruction, e.g. for fragile materials, hazardous substances, radioactive materials, etc.

b. storage requirement, e.g. overall dimensions including special packing (if any) for bulky materials, materials with limited shelf life, etc.

c. statutory requirements, e.g. licences, test certificates, etc. d. interchangeability information e. tailor-made product for the Contract or a standard bought-in product f. the source of the Spare Part or Special Tool and Test Equipment, including

the manufacturer’s name and address together with that of his Pune agent g. supplementary sheets to be used for detailed information that is important to

the Employer's future procurement.

13.2 Manufacture and delivery of Spare Parts

13.2.1 The Spare Parts to be supplied under the Contract shall be manufactured at the same time as the Permanent Works. All Spare Parts shall be manufactured, works tested and inspected in accordance with the relevant quality system, suitably packed and labelled in accordance with Chapter 8 above, and delivered to the Employer by the Contractor. Before the Spare Parts are delivered to the Employer, the Contractor shall submit to the Engineer a shipment advice notifying details such as date of despatch, date of arrival, vessel name, etc. as well as a packing list to indicate the contract number, variation order number, the lot size, quantity and weight. The Spare Parts shall be consigned to the Employer and delivered in accordance with The Engineer's instructions to a programme which shall ensure that sufficient Spare Parts are delivered to facilitate normal routine maintenance of the Permanent Works by the Employer at all stages of completion. The Spare Parts shall be supplied in total not later than the date set out for stage commissioning of the system.

13.2.2 Spare Parts shall be fully interchangeable with their corresponding part. All Spare Parts

shall be configured to the latest revision during the Defects Liability Period. For Spare


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Parts such as electronic components, lamps, fuses and other consumable and high-use items, the Contractor shall ensure that a minimum of two alternative sources of supply are available.

13.2.3 An adequate supply of Spare Parts shall be available throughout the design life of the

Works, from the date of the Taking Over of the Works. The Contractor undertakes to notify the Employer at least 6 months prior to deleting any item used in the Works from general availability.

13.2.4 For any Spare Parts that the Contractor is unable to supply throughout the design life of

the Works, or where the Contractor ceases availability support of that item before the end of such design life or if the Contractor ceases trading, the Contractor undertakes to transfer the relevant intellectual property rights, design rights and technology to the Employer and the Employer shall have the full right to manufacturing drawings, schedules, software and any other information needed to manufacture the relevant item. Such rights shall give the Employer complete freedom to manufacture the item in Pune or anywhere else world-wide. The Contractor shall also undertake to notify the Employer two years in advance of the intended cessation of spares availability of any item.

13.2.5 If any Spare Part is rendered obsolete by a design change or material change during the

design life of the Works supplied under the Contract, the Contractor shall design a replacement item to match the identical mechanical and electrical interfaces as the former item.

13.2.6 If, as a result of changes in technology, any Spare Part is not completely interchangeable

with the original item, or the performance of any Spare Part is different from the original item, then the Contractor shall purchase the same from the Employer, at a price agreed between the parties, such quantities of the obsolete Spare Part as the Employer may possess.

13.3 Contract Spares

13.3.1 Notwithstanding the quantities defined in the PS the quantity of Spare Parts shall be

sufficient for the full operation of the Permanent Works for the first 5 years following the expiry of the Defects Liability Period for the works (“Contract Spares’).

13.3.2 The Contractor shall supply and deliver the Contract Spares on or before completion of

the Systems Acceptance Test.

13.4 Commissioning Spares

13.4.1 In addition to the Contract Spares, the Contractor shall keep on the Site under his own custody throughout the installation, erection and commissioning periods, sufficient stocks of Spare Parts to enable immediate replacement of any item in the Permanent Works found to be defective or in any way in non-conformance with the Specification during the installation, erection and commissioning period ("Commissioning Spares").

13.4.2 The Contractor shall supply and deliver the Commissioning Spares on or before the

commencement of any Partial Acceptance Tests (PAT) or as defined in the PS.

13.4.3 The Contractor shall submit to the Engineer for review a list of all Commissioning Spares that shall be made available during the installation, erection and commissioning period.

13.4.4 The Contractor shall not be entitled to use any of the Contract Spares to replace any item

in the Permanent Works during the installation, erection and commissioning periods.

13.5 Defects Liability Spares

13.5.1 In addition to the Contract Spares, the Contractor shall keep sufficient stocks of Spare Parts in an off-site location in Pune throughout the Defects Liability Periods to enable rapid


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replacement of any item in the Permanent Works found to require replacement as part of the Contractor's obligations during the Defects Liability Periods ('Defects Liability Spares”).

13.5.2 The Contractor shall supply and deliver the Defects Liability Spares on or before the

commencement of the Service Trial.

13.5.3 The Contractor shall submit to the Engineer for review a list of all Defects Liability Spares that shall be maintained by the Contractor during the Defects Liability Periods.

13.5.4 The Contractor shall not be entitled to use any of the Contract Spares to replace any item

in the Permanent Works during the Defects Liability Periods.

13.6 Special Tools and Test Equipment

13.6.1 The Special Tools and Test Equipment (together with the relevant calibration certificates) required to carry out all the functions described in the Operation and Maintenance Manual or as required by the PS shall be suitably packed and identified in accordance with Chapter 8 above, consigned to the Employer by the Contractor and delivered to the Employer in accordance with the Engineer's instructions not later than the date scheduled for stage commissioning. The extent of supply shall include protective carrying cases as may be appropriate for the storage and use of each item.

13.6.2 All Special Tools and Test Equipment shall be supplied with Operation and Maintenance

Manuals, complete diagrams, schematics, assembly and connection drawings, calibration instructions and circuit diagrams/descriptions for future maintenance.

13.6.3 Where the Contractor has used the Special Tools and Test Equipment for installation and

commissioning of the Permanent Works, he shall refurbish and re-calibrate each item to the satisfaction of the Engineer prior to handover to the Employer, accompanied by the Certificate of Calibration traceable to a recognised International or National standard.

13.6.4 Where any item of Special Tools and Test Equipment is provided by the Contractor, it

shall be accompanied by drawings, manuals and full operating instructions to enable them to be used by suitably skilled (but not necessarily specially trained) personnel in a non-hazardous manner and to achieve the desired result in terms of accuracy and quality.

13.6.5 The Contractor shall provide the means and instructions which describe the parameters of

each item of Special Tools and Test Equipment that are critical to their proper methods of use and which enable the Employer's staff using the Special Tools and Test Equipment to achieve the proper performance and operation. Such means and instructions shall include, but not be limited to, any routine checking or recalibration needs for the Special Tool and Test Equipment itself.

13.7 Coding and Tagging of Spare Parts and Special Tools and Test Equipment

13.7.1 All Spare Parts and Special Tools and Test Equipment to be delivered to the Employer

shall each carry a tag suitably marked, bar-coded (as directed by the Engineer) and numbered.

13.7.2 The numbers on the tags shall correspond with those on the coding system developed by

the Contractor for all E&M components, parts and equipment's. See also Clause 7.3.1 above.


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CHAPTER 14

14.0 THE WORKS AND CARE OF THE WORKS

14.1 Methods of Construction

The Contractor shall, submit the Construction and Installation Plan as stated in the PS or if none is given within 20 days of the Commencement Date of Works and in any case not less than 5 weeks before starting the construction of the Works on Site, submit to the Engineer the Construction and Installation Plan as specified in Chapter 3.0 above.

14.2 Temporary Works

Upon receiving a written application from the Contractor, the Engineer may at his absolute discretion consent to certain Temporary Works of a minor nature being exempted from the requirements of this Chapter. Such exemption shall not relieve the Contractor of any of his obligations under the Contract.

14.3 Normal Working Hours

14.3.1 Normal working hours shall be defined as the period between 0700 hours and 1900 hours

on all days excluding general holidays. Work outside normal working hours shall not be carried out unless reviewed without objection by the Engineer and unless the Contractor has obtained any necessary permission or approval from relevant authorities.

14.3.2 The Contractor shall inform the Engineer 24 hours, or such shorter period reviewed

without objection by the Engineer, in advance of any occasion when work outside normal working hours is proposed.

14.3.3 Work in the vicinity of existing Indian Railway tracks shall only be possible in non-traffic

hours. Non-traffic hours are from the time of passage of the last train at the close of traffic, to the commencement time of running of the next first train.

14.4 Drawings and Schedules

Detailed manufacturing drawings for the Permanent Works shall be submitted to the Engineer for review. Moreover, these drawings shall be available on the Contractor’s or his sub-contractor’s premises if required. The Contractor shall also maintain at the Site a comprehensive and up-to-date set of drawings properly indexed and catalogued, which shall include complete sets of detailed working and, where applicable, manufacturing drawings and shall permit free access to such drawings by the Engineer at any reasonable time.

14.5 Notification and Inspection of Works

14.5.1 The Works will be subject to a formalised system of written applications for inspection.

14.5.2 Work that is carried out without being appropriately sanctioned by the Engineer could be

classified as defective work.

14.6 Construction Restraints

14.6.1 The Contractor shall design and implement Temporary Traffic Management (TTM) in accordance with the provisions of the applicable enactments.

14.6.2 The Contractor shall ensure that the design, construction and performance of all

Temporary Works and the design and construction of all Permanent Works shall be such that any ground movements in and around the Site will not result in settlement and/or subsidence of the ground that will cause damage to any buildings, structures, rail, roads, footpaths, slopes or utilities.


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14.7 Protection from Water

14.7.1 Unless otherwise reviewed by the Engineer, all work shall be carried out, as near as may

be practicable in the circumstances, in dry conditions, except where the work is required to be carried out in or with water or other fluids.

14.7.2 The Permanent Works, including materials for use in the Permanent Works, shall, where

necessary and as near as may be practicable, be kept free of water and protected from damage due to water. Water on the Site and water entering the Site shall be disposed of by temporary drainage or pumping systems or by other methods capable of keeping the Works free of water and protected from damage due to water. Traps shall be provided by the Contractor to intercept silt and debris before water is discharged from the Site.

14.7.3 The discharge points of the temporary drainage and pumping systems shall be as those

having been reviewed without objection by the Engineer. The Contractor shall make all arrangements with and obtain the necessary approvals and inspections from the relevant authorities for discharging water to drains, watercourses etc. The relevant work shall not start until the arrangements for disposal of the water previously reviewed without objection by the Engineer have been implemented.

14.7.4 Measures shall be taken to prevent flotation of new and existing structures.

14.8 Protection from Weather

14.8.1 Work shall not be carried out in weather conditions that may adversely affect the work

unless protection by methods reviewed without objection by the Engineer is provided.

14.8.2 The Permanent Works, including materials for the Permanent Works, shall be protected by methods reviewed without objection by the Engineer from exposure to weather conditions which may adversely affect the Permanent Works.

14.9 Protection of Work

Finished work shall be protected by methods reviewed without objection by the Engineer from damage that could arise from the execution of adjacent work. Work shall be carried out in such a manner that work carried out by others, including Government departments, utility undertakings, relevant authorities and Project Designated Contractors, is not damaged.


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CHAPTER 15

15.0 SITE ESTABLISHMENT AND ATTENDANCE

15.1 Use of the Site

15.1.1 The Site shall not be used by the Contractor for any purpose other than for executing the Works or carrying out other work which is associated with the Works and having been reviewed without objection by the Engineer.

15.1.2 Entry to and exit from the Site shall be obtained only at the locations stated in the Contract

or other locations having been reviewed without objection by the Engineer.

15.1.3 All materials and equipment stored on Site shall be adequately protected against loss or damage due to any cause such as climatic effects, vandalism, shock and vibration, etc. according to the nature of the articles stored and the local Site condition.

15.1.4 The particular use to which the Site is put shall be submitted to the Engineer for review

with the following particulars: (1) drawings showing the layout within the Site of the Engineer’s and Contractor’s

accommodation, access roads and major facilities required early in the Contract; (2) drawings showing the layout and the construction details of the Engineer’s

accommodation; and (3) proposals for the Contractor’s Site accommodation (if applicable) as defined by

Clause 15.4 below.

15.2 Survey of the Site

On or before the Contractor is granted access to a certain portion of the Site, the Contractor shall carry out a survey jointly with the other contractors executing works on that portion of the Site. The Contractor shall advise the Engineer of the date of the joint survey at least 1 week in advance of the date.

15.3 Fences and Signs on the Site

15.3.1 Hoardings, fences, gates and signs on and at the Site shall be maintained in a clean,

stable and secure condition.

15.3.2 Project signboards stated in the Contract shall be erected not more than 28 days, or such other period reviewed without objection by the Engineer, after the Commencement Date of the Works. Other advertising signs shall not be erected on the Site unless reviewed by the Engineer.

15.3.3 The permission of the Engineer shall be obtained before hoardings, fences, gates or signs

are removed. Hoardings, fences, gates and signs which are to be left in position after Employer’s Taking Over of the Works shall be repaired and repainted as instructed by the Engineer.

15.4 The Contractor’s Site Accommodation

15.4.1 The Contractor’s offices, sheds, stores, mess rooms, latrines and other accommodation

on the Site shall be maintained in a clean, stable and secure condition. Living accommodation shall not be provided on the Site unless stated in the Contract or having been reviewed without objection by the Engineer. The Contractor's personnel shall not be allowed to live on the Site.


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15.4.2 The Contractor shall provide and maintain all necessary offices, sheds, stores, mess rooms, latrines and other accommodation and remove the same from the Site on the Employer’s Taking Over of the Works. These shall be to the satisfaction of the Engineer and shall be kept in a clean and sanitary condition. No structure shall be erected by the Contractor within the Site without the written consent of the Engineer and such consent will not relieve the Contractor of the responsibility of siting temporary structures clear of the Works.

15.4.3 A copy of the plan showing the extent and position of all offices, stores, sheds, etc. shall

be prepared by the Contractor and retained for inspection in the Site office.

15.4.4 The works area for Contractor’s accommodation will be available to the Contractor on dates set out in the PS.

15.4.5 The Contractor shall not erect or operate canteen and kitchen facilities on the Site except

with the consent of the Engineer and, where appropriate, the relevant authorities. Any such facilities shall, in particular but without limitation, conform to all regulations and standards to the extent required by the concerned city authorities.

15.5 Site Utilities and Access

15.5.1 Temporary water, electricity, telephone, sewerage and drainage facilities shall be provided

for the Engineer’s accommodation and for the Contractor’s use in carrying out the Works. The Contractor shall make all arrangements with and obtain the necessary approvals from the relevant authorities for the facilities.

15.5.2 If, under the Contract, the Contractor is provided with Site utilities and access by any other

Designated Contractor under the attendance of the same or another contractor, the Contractor shall ensure that all requirements in terms of use of such facilities, their upkeep and maintenance, etc. are properly observed. If the facilities provided under such attendance are insufficient for the Contractor’s bona fide needs, the Contractor shall be solely responsible for providing such additional facilities he may require for the execution of the Works.

15.5.3 Access roads and parking areas shall be provided within the Site as required and shall be

maintained in a clean, passable and stable condition.

15.6 Site Facilities for the Engineer

15.6.1 Details of office accommodation, office facilities, equipment transport etc required are given in the PS.

15.6.2 Accommodation & Equipment

15.6.2.1 If required under the Contract, the accommodation to be provided on the Site for the

Engineer shall be in accordance with the Contract.

15.6.2.2 The accommodation shall be maintained in a clean, stable and secure condition and shall be cleaned at least daily. The services of a full-time attendant shall be provided for the Engineer.

15.6.2.3 Office facilities and equipment provided for the use of the Engineer shall be maintained in

a clean and serviceable condition including refreshments, stationeries, printer & cartridges, etc, all consumables shall be replenished when required. Measuring and testing equipment shall be calibrated before it is used and at regular intervals reviewed by the Engineer. Survey equipment shall be maintained by the service agent and shall be regularly checked. Equivalent replacements shall be provided for equipment that is out of service.


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15.6.2.4 The permission of the Engineer shall be obtained before accommodation or equipment is removed. Portable accommodation shall be moved at the times instructed by the Engineer.

15.6.2.5 The accommodation to be provided for the Engineer is for the exclusive use of the

Engineer’s staff associated with the Project.

15.6.2.6 All accommodation and equipment for the Engineer shall be provided throughout the course of the Works and for so long a period of time during the Defects Liability Period as the Engineer may require.

15.6.2.7 The Contractor’s proposals for the construction of the offices shall be submitted for review

by the Engineer within 14 days of the Commencement Date of the Works and erected within 42 days of the Commencement Date of the Works.

15.6.2.8 The Contractor’s attention is drawn to the fact that if directed by the Engineer, resident site

staff for the Project shall be allowed use of the Engineer’s Site accommodation including the extension of servicing to these resident site staff.

15.6.3 Transport

15.6.3.1 The Contractor shall provide transport for the Employer and Engineer from the

Commencement Date of the Works.

15.6.3.2 The transport shall be for the exclusive use of the Employer or the Engineer and persons authorised by the Employer or the Engineer and shall be available at all times during normal working hours and at other times when the Contractor is working or when instructed by the Employer or the Engineer. The transport shall not be used by the Contractor or other persons.

15.6.3.3 The transport shall be maintained in a clean and serviceable condition and shall be

serviced regularly. The Contractor shall provide toll charges, parking fees, taxes, licenses, insurance, fuel, oil and other consumables. All transport shall be covered by fully comprehensive insurance, which includes passenger liability and which allows the vehicle to be driven by any driver.

15.6.3.4 A competent driver shall be appointed and shall be available to drive the land transport

when required by the Employer or the Engineer.

15.6.3.5 Records of journeys shall be kept in logbooks provided by the Engineer.

15.6.3.6 Equivalent alternative transport shall be provided when the designated transport is unavailable.

15.6.3.7 The transport shall be provided until the end of the Defects Liability Period or such earlier

date as instructed by the Engineer.

15.7 Clearance of the Site

Temporary Works, which are not to remain on the Site after the Employer’s Taking Over of the Works, shall be removed on the Employer’s Taking Over of the Works or at such other time(s) as instructed by the Engineer. The Site shall be cleared and reinstated to the lines and levels and to the same condition as existed before the Works started except as otherwise stated in the Contract.

15.8 Attendance

15.8.1 Offices for the Employer or the Engineer


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Unless otherwise stated in the Contract, the Employer or the Engineer may arrange his own temporary accommodation on the Site at locations indicated in the Contract or as advised in writing. The Contractor shall afford, provide and maintain free and unhindered access to such Employer or the Engineer’s Site offices and parking areas and for the Employer or the Engineer’s Site officers, contractors and workmen as may be necessary for installation, inspection, maintenance, repair and removal of the aforesaid Employer or the Engineer’s Site offices and the services thereto.

15.8.2 Attendance on the Employer or the Engineer

The Contractor shall provide all necessary assistance to the Employer or the Engineer, including adequate and safe means of access to all parts of the Site to assist him in carrying out his duties and responsibilities under the Contract. Such assistance shall not include the provision of full-time attendance upon the Employer or the Engineer.

15.8.3 Attendance on the Commissioner of Rail Safety or other inspecting authorities

15.8.3.1 The Contractor shall afford all necessary attendance upon the Commissioner of Rail

Safety or other inspecting authorities / Inspectorate during their inspections including adequate and safe means of access to appropriate parts of the Site.

15.8.3.2 The Contractor shall provide all documents necessary for inspection as are requested by

the above authorities.

15.8.4 Attendance on the Fire Services Department

The Contractor shall afford all necessary attendance upon the Fire Services Department to enable them to carry out such tests and inspections as are required by the City fire service of Practice for Inspection and Testing of Installations and Equipment and the requirements of any Other Contractors. Such attendance shall include adequate and safe means of access to all parts of the Site.

15.8.5 Attendance on Other Contractors

15.8.5.1 The Contractor shall provide general and special attendance on Other Designated

Contractors who will be carrying out the execution of electrical and mechanical and other works on the Site. Reference shall be made to the PS to determine the full extent of such attendance.

15.8.5.2 General attendance shall include but not be limited to providing for accepting deliveries,

unloading and storing materials for the Other Contractors on the Site and allowing the Other Contractors space for their site offices, and all reasonable access and facilities for the proper execution of their work including the free use of access roads, craneage, scaffolding, ladders, stores, messrooms, sanitary and welfare facilities provided that these facilities are normally available on the Site at the time.

15.8.5.3 The Contractor shall allow the use of his Site services including ventilation, temporary

water supply, temporary electricity supply, background lighting, pumping, watchmen, etc. by the other contractors. The Contractor shall ensure that his Site services referred to above shall be available for use by the other contractors until the commissioning of the relevant permanent installations or until the issue of the Taking-Over Certificate for the Works, whichever is the later.

15.8.5.4 Special attendance shall include but not be limited to cutting of holes and other openings,

forming chases, providing built-in sleeves, grouting in bolts, anchors, brackets, base plates, frames and the like, including making good to the disturbed work and cleaning after completion of the disturbed work.

15.8.6 Attendance by Other Contractors


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Where provided for under the Contract, the Contractor shall receive attendance from other contractors. The Contractor shall ensure that by receiving such attendance, it does not hinder, obstruct or otherwise frustrate the other contractor that is providing the attendance in any way.

15.9 Contractor’s Equipment

The Engineer reserves the right to order the immediate removal and replacement of any Contractor’s Equipment that, in his opinion, is unsatisfactory for its purpose.

15.10 Security

15.10.1 The Contractor shall be responsible for the security of the works area for Contractor’s

accommodation and shall provide and maintain fencing to all works areas with designated entry /exit parts. The fencing shall be metal panels minimum 2m heights and painted as directed by the Engineer. Each entry / exit point shall be guarded by security staff on a 24 hrs basis and fixed with a lockable gate.

15.10.2 The Contractor shall provide adequate training to its security staff to ensure that they are

able to discharge their security duties properly.

15.10.3 The Contractor shall establish and maintain contingency plans to cope with emergency situations such as fire, flooding, serious damage to the Works, etc.

15.10.4 The Employer’s security staff will conduct inspections and security audits on the Site and

the works area for Contractor’s accommodation from time to time. The Engineer will give recommendations for improvement arising from the inspections and security audits to the Contractor. However, managing the security of the Site and the works area for Contractor’s accommodation remain the Contractor’s responsibility.


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CHAPTER 16

16.0 LIAISON WITH OTHERS

16.1 Liaison with others

16.1.1 The Contractor shall make all necessary arrangements with and obtain the necessary approvals from Government departments, utility undertakings and other duly constituted authorities for the execution of the Works.

16.1.2 The Contractor shall maintain close liaison with other contractors including Designated

Contractors employed by the Employer or otherwise, utility undertakings or other authorities who are carrying out work on or adjacent to the Site. The Contractor shall ensure as far as possible that the progress of the Works is not adversely affected by the activities of such other entities.

16.2 Work by Other Contractors

16.2.1 The contractor shall keep note of the works which may be proceeding on various adjacent

areas by others include, but is not limited to, those listed in the PS. The Engineer will keep the Contractor informed of forthcoming work by other contractors in the proximity of the Site.

16.2.2 The Contractor shall provide reasonable access to such contractors and any other

adjacent contractors and shall where necessary liaise with the appropriate contractors, utility undertakings and other duly constituted authorities on details of interdependent phasing. The Contractor shall notify the Engineer and other concerned entities at least 14 days in advance should he wish to alter these access arrangements during the course of the Works.

16.3 Interface Management

16.3.1 The Contractor shall co-ordinate with relevant authorities and other contractors in the

execution of the Works.

16.3.2 The Contractor shall interface and liaise with other contractors to ensure the effective and compatible co-ordination of all aspects of the design, installation and testing of the Works. The Engineer shall be kept fully informed at all stages of the Works.

16.3.3 The Contractor shall assign a person as the interface contact for each other contractor to

actively manage the progress of each interface to ensure adherence to the jointly developed Interface Management Plan.

16.3.4 Throughout the design process, the Contractor shall liase with Other Contractors to

develop interface designs in conjunction and co-operation with the designers of interfacing systems. Interfacing systems include, but are not limited to, those listed in the PS. These interface designs will be monitored and reviewed by the Engineer but the Contractor shall work directly with the Other interfacing Contractors to develop designs which are mutually acceptable to all parties. The Engineer will provide details of the Other Contractors as contracts are awarded.

16.3.5 The Engineer may, at his discretion, attend the Contractor’s meetings with other

Interfacing Contractors. The Contractor shall give the Engineer a minimum of 7 days notice of all meetings to be held with any Other Interfacing Contractors, or 14 days notice if the meeting is to be held outside Pune. If insufficient notice is given to the Engineer, he may require the meeting to be postponed to a later date to enable him to attend.

16.3.6 The Contractor shall provide the Engineer with two copies of the minutes of all meetings

within 14 days of each meeting and also two copies of all correspondence with any other contractor.


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16.3.7 The Contractor shall attend co-ordination meetings chaired by the Engineer at no greater

than monthly intervals to discuss and ensure that designs are correct and that conflicts in E&M services requirements between the Contractor and other contractors are identified and resolved.

16.3.8 The Contractor shall co-ordinate his installation activities with the other contractors. The

Contractor shall ensure that there is no interference to the work of the other contractors and shall maintain close co-ordination with other contractors working on or adjacent to the Works to ensure that their work can progress in a smooth and orderly manner.

16.3.9 The Contractor shall be given access to the various parts of the Site by the dates relative

to the Works Programme defined in the ITT and the PS as Access Dates. The ITT and the PS specify certain Key Dates by which the Contractor shall complete certain parts of his Works to enable work to be undertaken by the other contractors. These dates may be subject to adjustment by the Engineer in consultation with the Contractor and the Other Contractors to ensure the progress of the Project.

16.3.10 The Contractor's responsibility shall include provision of and receipt from other contractors

or the Engineer of information required for construction of the Works and the installation of the Works and Contractor's Equipment, insofar as that requirement is specified in or can reasonably be inferred from the Contract. Where the execution of work by another contractor depends upon the Contractor’s Site management or upon information to be given by the Contractor, the Contractor shall provide the other contractor with either the required services or the correct and accurate information required to enable the other contractor to meet his programme for the construction or installation of his works.

16.3.11 In the event of any disagreement as to the extent of services or information required to be

exchanged between the Contractor and another contractor, the Engineer shall determine the requirements and this determination shall be final and binding on the Contractor and the other contractor.

16.3.12 The Contractor shall co-ordinate his testing and commissioning activities with the other

contractors. The Contractor shall ensure that there is no interference to the work of the other contractors and shall maintain close co-ordination with other contractors working on or adjacent to the Works to ensure that their testing and commissioning work can progress in a smooth and orderly manner.


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CHAPTER 17

17.0 THE SITE

17.1 Access to Site

The Contractor will be given access to the Site in accordance with following conditions.

17.2 Site Restrictions

17.2.1 The particular use to which the Site is put shall be submitted to the Engineer for review within 14 days of the Commencement Date of the Works and the Contractor shall: (1) confine his use of the areas of the Site to purposes having been reviewed without

objection by the Engineer who reserves the right to extend, amend or restrict the uses to which areas of the Site will be put;

(2) where required under the Contract, provide and maintain fencing and lighting around

and within the areas of the Site when or where necessary for the safety and convenience of the public or others or as directed;

(3) refrain from depositing rubbish or causing nuisance or permitting nuisance to be

caused and, except where reviewed without objection by the Engineer, depositing earth on or removing earth from areas of the Site;

(4) on the Employer’s Taking Over of the Works, or earlier if so instructed by the

Engineer, remove all Temporary Works except where permitted and reinstate the areas of the Site to the extent, standards and details indicated in the Contract or as directed by the Engineer;

(5) refrain from obstructing manholes, utility access points and the like; and (6) refrain from felling trees, other than those specifically identified in the Contract to be

felled, and refrain from depositing earth around the trunks of trees and protect all trees remaining on Site to the satisfaction of the Engineer.

17.2.2 Work other than that necessary for completion of the Works shall not be carried out on the

Site.

17.2.3 While the Contractor is being given access to the Site, he shall provide means of distributing loads imposed by Contractor’s Equipment and prevent damage to utility services.

17.2.4 Except where otherwise provided, the Contractor shall not permit any person to reside on

the Site.

17.2.5 Unless otherwise stated, the Contractor shall pay all rates and charges of any nature whatsoever arising out of his use of the Site and all work areas provided therein under the Contract.

17.2.6 The location and size of stockpile material, including excavated material within the Site,

shall be submitted to the Engineer for review. All stockpiles shall be maintained at all times in a stable condition.

17.2.7 The Contractor shall not allow animals to be brought onto or kept on the Site.

17.2.8 The Contractor’s attention is drawn to the Waste Disposal Regulation currently prevalent

in Pune, regarding storage, transportation and disposal of chemical waste. The Contractor’s proposed methods and chemicals to be used in cleaning shall be submitted for review by the Engineer.


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17.2.9 No rock crushing or screening facilities shall be set up on Site unless reviewed by the

relevant authorities and reviewed without objection by the Engineer.

17.3 Site Services

17.3.1 Where required under the Contract, the Contractor shall provide all Site services as necessary and appropriate for the construction of the Works, which shall include, but not necessarily be limited to: (1) electricity; (see Chapter 22 below) (2) water; (3) compressed air; (4) Site communication facilities; and (5) temporary drainage and sewage disposal.

17.3.2 The Contractor shall provide such services for use solely in connection with the proper

execution of the Works. The Contractor shall comply with all regulations of the utility companies and Government departments concerned. The Contractor shall provide and maintain installations associated with such services and in relation thereto and shall take all reasonable precautions to safeguard the safety and health of all persons and the security of the Site. The Engineer may demand the immediate disconnection or alteration of such installations or portions thereof which he considers as being prejudicial to safety, health or security. As soon as any or all of the Contractor’s installations are no longer required for the execution of the Works, they shall be entirely removed to the satisfaction of the Engineer.

17.3.3 All installations shall comply fully with all appropriate statutory requirements. Pipes, tubes,

ducts or cables crossing highways, footpaths or rights of way shall be ramped over or recessed below the surface. Specific services shall comply with the following: (1) Electricity

The electricity supply shall comply with the requirements of Chapter 22 below. (2) Water

An adequate supply of potable water shall be provided at the Site, including provision to the satisfaction of the water authority of any storage tanks so that sufficient potable water is always available for the execution of the Works. Suitable provision shall be made where the water authority requires the use of salt water for flushing purposes.

(3) Compressed Air Except in pressurised workings, the compressed air supply for pneumatic tools and equipment shall be at a pressure of not more than 0.9MN/m2. The Contractor shall submit for review by the Engineer details of proposed air supply for use in pressurised workings

(4) Site Communication Facilities Where required under the Contract, the Contractor shall install efficient means of Site communications including messenger, telephone and, where appropriate, two-way radio to the satisfaction of the Engineer.

(5) Temporary Drainage & Sewage Disposal Where required under the Contract, adequate provision shall be made for the discharge or disposal from the Site of all water, surplus fluid sewage and waste products and the method of disposal shall be submitted to the Engineer for review.


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The Site shall be kept well drained and free from standing water. Where existing channels and gullies cannot be maintained, temporary drainage arrangements shall be provided.

17.3.4 The Engineer will instruct the Contractor as to the requirements for Site services to be

connected to the Engineer’s portable Site accommodation at any given location and the Contractor shall provide and maintain these services during his use of the Site.

17.4 Site Cleanliness

17.4.1 The Site shall be maintained in a clean and tidy condition. Materials, including materials

required for Temporary Works shall be stored in an orderly manner. Rubbish, debris, cement bags, disused formwork and the like shall be disposed of at least once a day and the work area cleaned by flushing with water as necessary so that the Site is kept constantly clean and tidy. Notwithstanding the above, the Contractor shall place rubbish bins at strategic locations about the Site. The Contractor shall throughout the period of the Contract provide a central collection point on Site, as reviewed without objection by the Engineer, for collecting all empty cans, drums, packing and other receptacles capable of holding water. The Contractor shall procure the regular collection and removal of such debris from the Site. After every shift of works, all work areas shall be cleaned and made tidy to the satisfaction of the Engineer.

17.4.2 The Contractor shall ensure that no earth, debris, rock or empty cable drums are

deposited on public or private rights of way as a result of the Works, including any deposits arising from the movement of Contractor’s Equipment. All roads, both within and external to the Site which are affected by the Works shall be kept in a clean condition by the Contractor. All haul roads shall be regularly graded and watered, as necessary to minimise dust nuisance.

17.4.3 Where required under the Contract, the Contractor shall provide and maintain a patrol unit

for the duration of the Contract. The unit shall comprise 1 foreman and 2 labourers whose services shall be allocated full-time to the unit. The main duties of the patrol unit shall include the upkeep of lighting, signage and security as well as other related duties as instructed from time to time by the Engineer.

17.4.4 The patrol unit shall be required to work outside the Contractor’ s normal working hours if

so required by the Engineer. 17.4.5 The Contractor shall provide all necessary protective clothing, safety equipment, hand

tools, ladders, trestles, power supply, replacement equipment and the like for the exclusive use of the patrol unit.

17.5 Prevention of Mosquito Breeding

17.5.1 Measures shall be taken to prevent mosquito breeding on the Site. The measures to be

taken shall include the following: (1) empty cans, oil drums, packing and other receptacles which may retain water shall be

deposited at a central collection point and those not required for future use shall be removed from the Site regularly;

(2) standing water shall be treated at least once every week with an environmental

acceptable oil which will prevent mosquito breeding; and (3) Contractor’s Equipment and other items on the Site that may retain water shall be

stored, covered or treated in such a manner that water will not be retained.

17.5.2 Posters in English, Hindi and Marathi drawing attention to the dangers of permitting mosquito breeding shall be obtained from the Maharashtra Government and displayed


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prominently on the Site, to the requirement of the applicable enactments. These posters shall be removed on Employer’s Taking Over of the Works.

17.6 Prevention of Dust

Work shall be carried out in such a manner that avoidable dust is not generated. Areas of the Site in which dust is likely to be generated shall be sprayed with water regularly. Screens, dust sheets, tarpaulins or other methods reviewed by the Engineer shall be used to prevent generation of dust. Materials, including earthworks material, from which dust may be generated when being transported to or from the Site shall be sprayed with water or covered. The location and size of material stockpiles, including excavated materials within the Site, shall be subject to review by the Engineer. All stockpiles shall be maintained at all times in a safe manner.

17.7 Engineering Conditions for Temporary Land Allocation

The Contractor shall comply with the obligations, requirements and restrictions described in the PS in respect of the Contractor’s work areas, if any.

17.8 Attendance by Civil Works Project Contractor

17.8.1 Where supplies of electricity, water, compressed air, temporary ventilation, temporary

lighting, etc. are installed by the Civil Works Project Contractor (“Civil Works Project Contractor”) for use during construction of the structural components of the Project, these services may be made available to the Contractor for his own use during erection, installation and testing of the Works in accordance with Chapter 22 below.

17.8.2 The Contractor shall supply the Engineer with its requirements (if any) for such services

within 90 days of the Commencement Date of the Works. Upon receipt of the Contractor’s declaration, the Engineer will ascertain whether any of these requirements can be satisfied by the installations installed by the Civil Works Project Contractor. The Engineer will subsequently notify the Contractor of the result of these investigations.

17.8.3 Where services are required and are not available from the Civil Works Project Contractor,

the Contractor shall provide, test, maintain and subsequently remove the services.

17.8.4 Background lighting to an average level of 50 lux at the walkway level will be provided in the tunnels by the Civil Works Project Contractor. The Contractor shall provide any additional lighting he may require to facilitate his own work or for reasons of safety.

17.9 Access to the Site by Other Contractors 17.9.1 Due to the multi-discipline nature of the Project, several different parties may require

access to the same portion of the Site during the construction phase for the installation, erection and testing of the Works. To facilitate the organisation and coordination of access and occupation requirements, including the use of Works Trains, if any, the Engineer will issue and maintain a TRIP as referred to in Clause 2.12 above.

17.9.2 The TRIP will be developed from the declared requirements of all Project Contractors and

others having need of access and occupancy, at the weekly Works Train Meeting. The TRIP will be subject to revision and updating to reflect changing circumstances during the progress of the Project.

17.9.3 The Contractor shall work in accordance with the arrangements prescribed by the TRIP. 17.9.4 The Contractor shall ensure that his working arrangements on the Site conform to the

agreements made with the Engineer during establishment of the TRIP requirements. In particular, the Contractor shall ensure that his occupancy does not extend either physically or chronologically beyond the agreed boundaries.


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17.10 Transportation to Site

17.10.1 The Contractor shall use such routes and rights of entry to the Site as may be decided by the Engineer from time to time. Routes for very large or very heavy loads shall be discussed with the Engineer in advance of the need arising and all arrangements therefore shall be submitted for review by the Engineer.

17.10.2 In this context, the definition of the terms “very large” and “very heavy” refer to articles that

cannot be transported by normal road vehicles or be handled by readily available methods. Where doubt exists, it shall be the responsibility of the Contractor to notify and discuss the nature of the load in question with the Engineer in accordance with Clause 17.9.1 above.

17.10.3 The Contractor shall comply with the requirements of the Commissioner of Transport and

/or the Commissioner of Police and / or any other relevant authority regarding any special traffic arrangements that may be necessary. The Contractor’s attention is drawn to the Road Traffic (Regulation and Licensing of Vehicles) Regulations and the Road Traffic (Construction and Use) Regulations currently in use at Pune.

17.10.4 Extraordinary traffic may be moved from docks and between areas of the Site over public

highways only by police escort and on a route and at a time determined by the relevant authority. The Contractor shall be responsible for obtaining permission from the relevant authorities to move extraordinary loads and traffic and for arranging police escorts as necessary.

17.10.5 The Contractor shall make all arrangements and assume full responsibility for

transportation to the Site of all Contractor’s Equipment, materials and supplies needed for the proper execution of the Works.

17.10.6 While travelling to and from the Site, the Contractor shall observe all posted speed limits,

traffic regulations, stop signs, etc., and adherence to the access route indicated on the Employer’s Drawings or as instructed by the Engineer. No employee of the Contractor shall trespass into any part of the Employer's premises other than the Site or the designated route of access.

17.10.7 The Contractor shall ensure that all roads and pavements, etc. leading to and around the

Site are kept free from obstructions and shall not cause inconvenience or hindrance to traffic or persons either by its vehicles or by its workmen, scaffolding, plant, materials, equipment, etc.

17.10.8 The Contractor shall repair damage to existing roads, footpaths, steps, cables, sewers,

live drains, etc. and shall reinstate any damage caused by the Contractor’s actions.

17.11 Contractor’s Own Rolling Stock

17.11.1 Where the Contractor is to provide rolling stock (either self-propelled or trailing) for use during the installation and testing of the Works, the requirements of Clause 17.12 below shall apply. All the Contractor’s own rolling stock shall not cause any infringement anywhere.

17.11.2 The Contractor shall submit full details of any rolling stock that is to be used during the

installation and testing of the Works to the Engineer for review within 90 days of the Commencement Date of the Works. Such details shall include a full description and drawings of the rolling stock, details of axle load, stopping distance, fail-safe braking system, kinematic envelope, and operating and maintenance instructions.

17.11.3 If required, the Contractor shall maintain its own rolling stock during the installation and

testing of the Works. The maintenance work shall be carried out by qualified and experienced personnel, whose qualifications have been reviewed without objection by the


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Engineer, in accordance with the maintenance procedures that shall have been reviewed without objection by the Engineer.

17.11.4 Prior to use, and following each maintenance examination, the Contractor’s qualified

engineer shall certify the Contractor’s own rolling stock as fit-to-run. Thereafter, the Contractor’s qualified engineer shall issue a registration tag. The expiry date, i.e. the date of the next inspection, shall be shown on the registration tag. The Contractor’s own rolling stock shall not be used without a valid registration tag.

17.11.5 The Contractor shall establish a maintenance programme for his own rolling stock and

shall submit the maintenance programme for review by the Engineer prior to the delivery of his own rolling stock to the Site. The Engineer will periodically inspect the Contractor’s own rolling stock to ensure it is properly maintained to the standards set out in the maintenance programme.

17.11.6 If the Contractor’s own rolling stock is found to be operating in an unsatisfactory or unsafe

condition, it shall be immediately removed until it has been restored to an acceptable condition to the satisfaction of the Engineer.

17.12 Defined Area Working and Works Train Operations

17.12.1 When the Project under construction has been made available for track related electrical

and mechanical installation works, the area will be classified as a Defined Area within which Works Trains will be operated.

17.12.2 All persons whose duties require them to work within a Defined Area must observe safety

rules and procedures to be provided by the Contractor and reviewed without objection by the Engineer. It shall provide procedures and guidance for the safety of all persons in the Defined Area.

17.12.3 The Contractor shall communicate the rules and procedures, which shall be published

from time to time, to their workers and/or agents on Site, and to ensure all such rules and procedures are being observed in the course of all works and construction activities.

17.12.4 Persons working on or near tracks in a Defined Area, either by themselves or supervising

a working party, must be suitably trained and qualified by the Contractor or his delegates in the requisite safety provisions. Persons who are not qualified shall not attempt to gain access to the railway tracks unless accompanied by a qualified person.

17.12.5 When contact lines are energised, EMUs may be running at high speed for testing. No

work may be undertaken on either the UP or DOWN tracks when test trains are running. Procedures for gaining access to the energised track will be detailed in the Works Train Manual. The Contractor shall make requests for gaining access to the energised track at the weekly Works Train Meetings.

17.13 Work in Vicinity of Operating Tracks

17.13.1 This Paragraph shall apply to works in the vicinity of the existing Indian Railway tracks

after the commencement of revenue operations and all ancillary areas which form a part of the operating system, including all depots and sidings.

17.13.2 The following words and expressions shall have the meaning hereby assigned to them in

this Paragraph: (1) “Railway” means the existing rail tracks of the MAHA-METRO and Indian Railway

after the commencement of revenue operations and any ancillary areas such as the depots, sidings, stations, terminus and traction power stations.

(2) “Railway Representative” means a person, or persons, nominated by the Engineer to liase with the Contractor and the Engineer on matters affecting the operation of the Railway.


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(3) “Restriction” means speed restriction, which is a limitation of the normal permitted speed of rail traffic over a specified length of the Railway.

(4) “Possession” means possession of the Railway, which is the closing of a specified length of the Railway to rail traffic.

(5) “Isolation” means isolation and earthing of the electrical equipment, which is the disconnection of a section of such equipment from all sources of electricity supply and the connection of it to the Railway.

17.13.3 The Contractor shall have regard to the Specification for work within the vicinity of the

Railway and shall comply strictly with the requirements as set out therein. The Contractor shall comply with any instructions given by the Employer or the Railway Representative through the Engineer with regard to planning, methods of working, safety requirements and on any other matters which may affect the operation of the Railway, and also shall comply with all rules, regulations, procedures, manuals and notices which may be published from time to time by the Employer or the Railway Representative. Provided that if a situation occurs which in the opinion of either the Contractor or the Employer or the Railway Representative may give rise to or actually constitute an emergency and either the Contractor or the Employer or the Railway Representative considers that it is not practicable to communicate through the Engineer then the Contractor and the Employer or the Railway Representative may communicate directly and the Employer or the Railway Representative may give a direct instruction to the Contractor and such instruction shall be regarded for the purposes of this Contract as an instruction from the Engineer.

17.13.4 Should the Contractor be unwilling or unable at once to conform with a direct instruction

from the Employer or the Railway Representative under the provisions of the paragraph above or to carry out any remedial or other work or repair, the Employer or the Engineer may by written order to the Contractor suspend the execution of the Works or of any part thereof or authorise the carrying out of such remedial work or other work or repair by a person other than the Contractor.

17.13.5 The Contractor shall notify the Engineer as soon as possible of any direct instruction

received from the Employer under the provisions of this Paragraph.

17.13.6 Where any part of the Works has to be carried out during the period of a Restriction and/or Possession and/or Isolation and the period of such Restriction and/or Possession and/or Isolation is prescribed in the Contract, the Contractor shall plan and execute that part of the Works so that such period is not exceeded and so that no further periods are required.

17.13.7 If no such period is prescribed, the Contractor shall before commencing any work hold

discussions through the Engineer with the Employer who will decide whether any part of the Works is to be carried out during a period of a Restriction and/or Possession and/or Isolation and the Engineer will notify the Contractor accordingly.

17.13.8 After the method of carrying out the work has been agreed with the Employer (and taking

into account any provisional arrangements which have been made) the Contractor shall in all cases other than for emergency works submit written notice of his programme of work, which shall include details of any Restriction and/or Possession and/or Isolation previously notified by the Employer as being necessary, to the Employer at least 10 (ten) weeks in advance of the proposed commencement of work on or near the Railway and shall at the same time submit a copy thereof to the Engineer.

17.13.9 Where a Restriction and/or Possession and/or Isolation is necessary, the Contractor shall

initiate the necessary action to obtain the requisite approval for such Restriction and/or Possession and/or Isolation from the Employer. The Contractor shall be solely responsible for all delays caused through failure to submit the necessary application for approval, late submission of any such application or submission of inadequate information.

17.13.10 The Contractor shall so organise the execution of the work during any period of Restriction

and/or Possession and/or Isolation that he will be able to give up such Restriction and/or Possession and/or Isolation at the time prescribed in the Contract or agreed by the


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Employer. Should the Contractor in the opinion of the Employer or the Engineer not make sufficient or adequate arrangements (including the provision of standby plant) for completing the whole or any stage of the work within the time allowed in the programme or agreed with the Employer, the Employer may in his discretion cancel the Restriction and/or Possession and/or Isolation, or the Employer may employ labour, plant and materials to assist the Contractor to finish the work or to carry out such work as is necessary, or may himself carry out such work as is necessary, to enable the Restriction and/or Possession and/or Isolation to end at the earliest possible moment.

17.13.11 A period of Restriction and/or Possession and/or Isolation cannot normally be extended. If

the Contractor fails to carry out the work during any such period, then Contractor shall be required to re-apply to the Employer for a further period of Restriction and/or Possession and/or Isolation.

17.13.12 All expenses which in the opinion of the Engineer are properly incurred by the Employer

as a result of the Employer making necessary arrangements to assist the Contractor or carrying out any necessary work in accordance with Clause 17.13.10 above shall be a debt due from the Contractor to the Employer.

17.13.13 The Contractor shall on demand pay to the Employer any loss of revenue and additional

expenditure which in the opinion of the Engineer has been incurred by the Employer by reason of the rescheduling of services by the Employer due to the Contractor obstructing the Railway or interfering with the control or train control system or electrical equipment other than for a period for which a Restriction and/or Possession and/or Isolation has been given.

17.13.14 In the event that damage is caused by the Contractor to the Railway such that

rescheduling/suspension of services by the Employer has to be made, then the Contractor shall on demand pay to the Employer any loss of revenue and additional expenditure which in the opinion of the Engineer has been incurred by the Employer in making good the damage and in rescheduling/suspending the services.

17.13.15 The Employer shall have the right to cancel or alter the date and the timing of any agreed

period of Restriction and/or Possession and/or Isolation if this proves necessary for the safety or uninterrupted running of rail traffic by notice to the Contractor which shall be deemed to be an instruction issued by the Engineer, but in such an event the Engineer shall make alternative arrangements as soon as practicable.

17.14 Rodent Control

The Contractor shall at all times take effective measures to prevent damage by rodents to the Permanent Works and constituent parts thereof, such as cables, electronic cards, etc., during the execution of the Works and shall advise the Engineer of such measures taken accordingly.


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CHAPTER 18

18.0 HEALTH AND SAFETY

18.1 Health and Safety Philosophy

18.1.1 The health, safety and welfare of all personnel working on the Project, the general public and the avoidance of damage to property are of paramount importance to the Employer. Prime consideration shall be paid to construction activities to ensure that all operations shall be conducted in such a manner as to eliminate the risks to persons and property. The Contractor shall treat safety measures as the first priority in all his activities with respect to executing the Works.

18.1.2 The Contractor will be issued with the following MAHA-METRO documents: Corporate

Safety Standards, Safety Policy, Safety Plan, SHE Manual etc. as they become available. These documents set out the minimum standards to be achieved by the Contractor but do not relieve the Contractor of his liabilities and obligations under the concerned enactment. Where there is a discrepancy in the documents, the higher or stricter standards shall be applied.

18.1.3 The Engineer will issue to the Contractor the Employer’s SHE Manual and any revised

version thereof as may from time to time be produced by the Employer. The Contractor shall comply with the requirements of the SHE Manual, provided the standards set out in the SHE Manual shall be regarded as the minimum to be achieved an shall not relieve the Contractor of any of his statutory duties of his responsibilities under the Contract.

18.1.4 The provisions of the Contract regarding safety shall apply and to be binding upon the

Contractor for any part of the Works and the person employed as sub-contractor of any tier. The Contractor shall ensure that the requirements of the Contract in respect of safety are included in all sub-contracts placed by him.

18.1.5 The Engineer reserves the right to order the immediate removal and replacement of any

item of Contractor’s Equipment or Temporary Works which in his opinion, is unsatisfactory for its purpose or is in unsafe condition.

18.2 Health and Safety Management

18.2.1 The Contractor shall be fully responsible for safety on the Site, for the Works, his

personnel, sub-contractors' personnel, the public domain and all persons directly or indirectly associated with the Works, on or in the vicinity of the Site.

18.2.2 The Contractor shall submit reports, notices and information to Government bodies where

there is a statutory requirement to do so.

18.2.3 The Contractor shall and will ensure that, his sub-contractors of any level, all persons employed by him on the Site and any person authorised by him to be on the Site shall comply in every respect with the provisions of relevant statutory requirements and the Employer’s safety documents as listed in Clause 18.1.2 above.

18.2.4 The provisions of the GS regarding health and safety shall apply to the Contractor and his

sub-contractors of any level for any part of the Works.

18.2.5 The Contractor shall ensure that proper and adequate provisions to ensure compliance are included in all sub-contracts placed by him and into all sub-contract documentation.

18.2.6 The safety standards of the sub-contractors are to be properly assessed prior to the

placing of contracts and the Contractor shall employ only sub-contractors with a track record of maintaining the highest safety standards.


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18.2.7 The Engineer reserves the right to order the immediate removal and replacement of any item of Contractors equipment or Temporary Works which in his opinion, is unsatisfactory for its purpose or is in an unsafe condition.

18.3 Legislation, Codes of Practice, Standards, etc.

18.3.1 The Contractor shall comply with all current and future enactments, Codes of Practice and

Safety Guides approved by the Government of Maharashtra and National Government relating to the Works.

18.3.2 Where identified specifically in the GS and SHE Manual, Indian Standards are also to be

complied with.

18.4 Breach of Health and Safety Obligations

18.4.1 Serious or repeated breaches of the Employer’s safety documents as listed in Clause 18.1.2, statutory regulations, or other disregard for the health and safety of any person, may be the reasons for the Engineer to exercise his authority to require the removal from the Site of any employee of the Contractor or a sub-contractor of any level.

18.4.2 Once removed from the Site at the request of the Engineer, that person shall not be re-

employed on the Contract, allowed on the Site or on any other MAHA-METRO related project.

18.4.3 The Engineer shall have the right to order the suspension of any or all of the Contractor's

activities where the Engineer considers that to continue such activity or activities may pose a hazard to the safety of persons or property or the Works.

18.4.4 Where the Engineer orders such suspension as described in Clause 18.4.1 above, such

suspension shall continue until the Contractor has satisfied the Engineer that satisfactory corrective action has been taken to eliminate the hazard, the subject of the suspension.

18.5 Contractor’s Health and Safety Documentation

18.5.1 Outline Safety Plan

For the purpose of this clause “Outline Safety Plan” means the Contract specific safety plan forming part of the Tender setting out in summary from the Contractor’s proposed means of complying with its obligation in relation to safety and industrial health, and “Site Safety Plan” means the site safety plan including all the supplements thereto, or any amended or varied version thereto, as submitted by the Contractor in accordance with this clause and consented by the Engineer.

18.5.2 Site Safety Plan

18.5.2.1 The Contractor shall devise and implement a Site Safety Plan developed from the Outline

Safety Plan submitted and developed during the Tender period.

18.5.2.2 The Site Safety Plan shall fully comply with the Health and Safety requirements of the Project conditions and proposed work activities, the GS, the Employer’s Safety documents as listed in Clause 18.1.2 above and all relevant enactment, regulations, Codes of Practice, Safety Guides and relevant Indian Standards. The plan shall be prepared and submitted to the Engineer for review within 30 days of the date of Notice to Proceed.

18.5.2.3 The Site Safety Plan should contain as a minimum those items set out in the following

clauses of the GS.

18.5.2.4 The Site Safety Plan shall include detailed policies, procedures and regulations which, when implemented, will ensure compliance with this Clause 18.5.2. The Site Safety Plan shall include but not be restricted to:


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(a) A statement of the Contractor’s policy, organisation and arrangements for safety,

health and welfare; (b) The names and experience of persons within the Contractor’s proposed management

who would be responsible for co-ordinating and monitoring the Contractor’s safety performance;

(c) The number of safety staff who would be employed on the works, their responsibilities,

authority and line of communication with the proposed Contractor’s agent. (d) A statement of the Contractor’s policy and procedures for identifying and estimating

hazards, and the measures for addressing the same; (e) A list of safety hazards and health hazards anticipated for this Contract and sufficient

information to demonstrate the Contractor’s proposals for achieving effective and efficient health and safety procedures;

(f) A description of the training courses and emergency drills which would be provided by

the Contractor, with an outline of the syllabus to be followed; (g) Details of the safety equipments which would be provided by the Contractor, including

personal protective equipment; (h) A statement of the Contractor’s policy and procedures for ensuring that contractors

equipment used on the project site are maintained in a safe condition and are operated in a safe manner;

(i) A statement of the Contractor’s disciplinary procedures for ensuring that sub-

contractors comply with the Contractor’s safety plan. (j) A statement of the Contractor’s disciplinary procedures with respect to safety related

matters, and (k) A statement of the Contractor’s procedures for reporting and investigating accidents,

dangerous occurrences or occupational illness.

18.5.2.5 The Contractor shall from time to time as necessary or required by the Engineer produce supplements to the Site Safety Plan such that it is at all times a detailed, comprehensive and contemporaneous statement by the Contractor or its site safety and industrial health obligations, responsibilities, policies and procedures (under the laws of India or as stated in this clause or elsewhere in the Contract) relating to the work on site. Any and all submissions to the Engineer of supplements to the Site Safety Plan shall be made in accordance with the agreed procedures.

18.5.2.6 If at any time the Site Safety Plan is, in Engineer’s opinion insufficient or requires revision

or modification to ensure the security of the Works and the safety of all workmen upon and visitors to the Site, the Employer’s Representative may instruct the Contractor to revise the Site Safety Plan and the Contractor shall within fourteen days submit the revised plan to Engineer for review.

18.5.2.7 Any omission and errors in the Site Safety Plan or the Engineer’s acceptance or rejection

of the Site Safety Plan and/or supplements thereto shall be without prejudice to the Contractor’s obligations with respect to the Site safety and industrial health and shall not excuse any failure by the Contractor to adopt proper and recognised safety practices throughout the execution of the Works.

18.5.2.8 The Contractor shall adhere to the Site Safety Plan and shall ensure, as far as practically

possible, the all sub-contractors of all tiers each shall have a copy of the Site Safety Plan and comply with its provisions.


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18.5.2.9 The Contractor shall provide all necessary access, assistance and facilities to enable the

Employer’s Representative and the Employer to carry out surveillance to verify that the Site Safety Plan is being properly and fully implemented.

18.5.2.10 The Contractor shall provide its sub-contractors with copies of the Site Safety Plan and

shall incorporate into all sub-contract documentations provisions to ensure the compliance with such plan at all tiers of the sub-contracting.

18.5.2.11 The Contractor shall, unless the Engineer consent in writing is given, require all sub-

contractors to appoint a safety representative who shall be available on the Site throughout the operational period of the respective sub-contract. In the event of the Engineer’s consent being given, the Safety Officer or Safety Staff, without prejudice to their duties and responsibilities, shall ensure, as far as is practically possible, that the employees of sub-contractors of all tiers are conversant with appropriate parts of the Site Safety Plan and the statutory regulations.

18.5.3 Sub-contractors documentation

18.5.3.1 The Contractor’s and his Sub-Contractors’ health and safety documentation shall be

consistent. As new sub-contractors are mobilised on Site the Contractor shall ensure that each is issued with copies of the Corporate Safety Documents and each sub-contractor complies with the established health and safety documentation procedures.

18.5.3.2 The Contractor shall submit to the Engineer for review a Works specific copy of his Health

and Safety Manual and his Health and Safety Plan for review within 30 days of the Commencement Date of the Works.

18.5.3.3 The Contractor shall provide his sub-contractors with copies of the Health and Safety

Manual and the Health and Safety Plan, risk assessments and method statements.

18.5.4 Health and Safety Manual

The Contractor’s Health and Safety Manual shall contain the procedures required for carrying out the work activities on the Project and is to be regularly reviewed and up-dated to reflect changes to work practice and changes to concerned enactment. Copies of proposed changes are to be submitted to the Engineer for review prior to inclusion and implementation.

18.5.5 Risk Assessments

18.5.5.1 The Contractor shall carry out a detailed risk assessment covering the occupational health

and safety aspects of the Works.

18.5.5.2 The documentation arising from this exercise shall contain a comprehensive schedule of all perceived risks and the proposed resolution or mitigation measures necessary to reduce these risks to a minimum.

18.5.5.3 The results of such assessments shall be recorded and the records kept for inspection by

the Engineer.

18.5.6 Method Statements

18.5.6.1 In order to ensure that health and safety has been properly considered at the planning stage, the Contractor shall submit to the Engineer for review, detailed method statements for each construction task as the Engineer requires.

18.5.6.2 The Contractor shall produce and implement a permit to work system for all high risk

operations. The permit to work system shall be submitted to the Engineer for consent before application.


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18.5.6.3 Method statements shall be logical construction guides designed for the use by the

Engineer on Site. They shall contain a detailed risk assessment, which shall include the task or operation, a hazard analysis and methods for preventing injury, including personal protective equipment and any pertinent safety measures to be adopted.

18.5.6.4 Detailed programme showing what method statements will be written and when they will

be submitted shall be produced and submitted to the Engineer within 30 calendar days of the Commencement Date of the Works or at a date reviewed by the Engineer.

18.5.6.5 Method statements shall be reviewed by the Engineer prior to any work commencing on

the task described. Accordingly, the Contractor shall ensure that such statements are prepared in sufficient time to allow a review before the proposed programmed start date for the relevant task.

18.5.6.6 Before formal issue to the Engineer, the engineer in charge of the described works and

the Contractor’s authorised representative shall sign the method statement.

18.5.6.7 After review by the Engineer, a copy will be held in the safety office to facilitate monitoring of the work and a further copy shall be given to the engineer supervising the work. The original shall be retained in the Contractor’s files for audit purposes.

18.6 Contractor’s Safety Arrangements

18.6.1 Co-ordination of work activities

18.6.1.1 The Contractor shall ensure that work is to be co-ordinated throughout the Project to

ensure that the activities of one group of workers does not affect the safety of another group, e.g., scaffolders working above cable layers, etc.

18.6.1.2 Daily meetings are to be held to co-ordinate the work activities and permits to work are to

be issued as and when required.

18.6.2 Safety inspections

18.6.2.1 The Contractor shall conduct formal, documented Site safety inspections (at least once a month) which are to be attended by the Contractor’s most senior Site staff and safety staff.

18.6.2.2 A report of each safety inspection shall be made and shall include the actions taken to

resolve any problems or shortcoming discovered during the inspection. The report shall be made available for audit purposes and be discussed at the relevant meetings.

18.6.2.3 A comprehensive health and safety inspection check-list for the use of the Contractor’s

Site staff when inspecting the Site is to be formulated and submitted for review by the Engineer.

18.6.2.4 The checklist shall indicate the standard to be achieved on any particular aspect of health

and safety and be compiled in such a way that allows the inspector to enter his or her actual findings for comparison against the said statement and subsequent rectification.

18.6.2.5 When completed, the checklist shall be kept for record purposes and be made available to

the Engineer for audit purposes.

18.6.2.6 A grading system is to be established which grades the area inspected as either "Very Good", "Good", "Acceptable", "Poor" or "Un-acceptable".

18.6.2.7 Where an area receives a grading below “Acceptable”, immediate action is to be taken to

rectify the problems raised and a further audit shall be conducted after 7 days to assess the conditions.


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18.6.2.8 The Contractor is to advise the Engineer of the date of the monthly inspection. The Engineer may send a representative to assess the thoroughness of the inspection.

18.6.3 Safety audits

18.6.3.1 The Contractor will be subject to the Employer’s Safety Performance Measurement

Scheme, which will be based upon a series of audits carried out or to be carried out, the extent, scope and at a frequency determined by the Engineer, to measure the Contractor’s compliance with the provisions of the Employer’s safety documents as listed in Clause 18.1.2 above, the enactments, Contractor’s Health and Safety Manual and Site Plan.

18.6.3.2 The Employer’s audit will be graded as follows: "Very Good", "Good", "Acceptable" or "Un-

acceptable".

18.6.3.3 Where the Contractor receives a grading of “Un-acceptable”, immediate action shall be taken to rectify the problems raised and a follow up audit shall be conducted within 30 days to assess conditions and ensure that remedial action has been taken.

18.6.3.4 The Contractor shall continue to be audited, every 30 days, until such time as a grade of

“Acceptable” or above has been achieved.

18.6.3.5 The Employer’s auditors shall be used for the follow up audit(s) and the Contractor shall be liable for the full costs incurred of all additional follow up audits.

18.6.3.6 The Contractor shall conduct regular (at least every 3 months) internal safety audits on

both the safety management system and the physical Site conditions. The internal safety audits shall be performed to the same criteria and using the same grading and benchmarking as the Employer’s audits.

18.6.3.7 The internal safety audits shall be conducted by person(s) reviewed without objection by

the Engineer, who are qualified and competent to carry out safety audits. The documentation generated by the audit process, including score sheets, shall be made available to the Engineer for audit purposes.

18.6.3.8 The internal safety audits shall include the work of sub-contractors of all levels.

18.6.3.9 The Contractor shall advise the Engineer of the date of the internal safety audit. The

Engineer may send a representative to assess the thoroughness of the internal safety audit.

18.6.4 Reporting of accidents, incidents and dangerous occurrence

The Contractor shall notify the Engineer immediately of any dangerous occurrences or accidents, which result in death, serious bodily injury or incapacity for more than 3 days. Such initial notification may be verbal but shall in any event be followed by a preliminary written report, in a format reviewed without objection by the Engineer, within 24 hours of the occurrence/accident and a detailed written report shall be submitted within 7 days. Copies of all accident, incident and dangerous occurrence reports shall be kept on file and made available for audit purposes.

18.6.5 Monthly reports

18.6.5.1 The Contractor shall, as part one of each Monthly Progress Report, submit a Site Safety

Report duly signed by the Contractor’s director responsible for the Contract.

18.6.5.2 The Site Safety Report shall comprehensively address all relevant aspects of occupational safety and health and shall contain certain standard forms and information, as directed by the Engineer, for statistical analysis.


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18.6.5.3 The Contractor shall submit reports or accident analysis, in a format reviewed without objection by the Engineer, as and when required by the Engineer.

18.6.6 Safety staff

18.6.6.1 The Contractor shall appoint a safety officer whose duties throughout the period of the

Contract shall be entirely connected with the safety and industrial health aspects of the Contractor’s activities on the Site. The safety officer shall be suitably qualified and experienced person who shall supervise and monitor compliance with the Site Safety Plan. The safety officer shall, in particular but without limitation, carry out audit of the operation of the Site Safety Plan in accordance with a rolling program to be submitted, from time to time, to the Engineer for his consent. The safety officer’s appointment shall be within twenty eight (28) days of the date of acceptance of Tender and shall be subject to the Engineer written consent.

18.6.6.2 The Contractor shall not undertake any work on the Site until the safety officer has

commended duties in Pune unless the Engineer has specifically consented in writing.

18.6.6.3 Without prejudice to the generality under clause of the General Conditions of Contract, the Contractor shall not remove the safety officer from the Site without the express permission of the Engineer within fourteen (14) days of any such removal or notice of intent of removal, and the Contractor shall nominate a replacement safety officer for the Engineer consent.

18.6.6.4 The Contractor shall provide the safety officer with supporting staff in accordance with the

staffing levels set out in the Site Safety Plan. The supporting staff shall include at least one (1) deputy safety officer whose appointments shall be subject to the Engineer consent under similar criteria to those contained under Clause 18.6.6.1 above.

18.6.6.5 The Contractor shall empower the safety officer and safety staff to instruct employees of

the Contractor or of its sub-contractors of any tiers to cease operations and take urgent and appropriate action to make safe the Site and prevent unsafe working practices or other infringements of the Site Safety Plan or the statutory regulations.

18.6.6.6 The Contractor shall ensure that the safety officer maintains a daily site safety diary, such

diary comprehensive recording all relevant matters concerning site safety, safety inspections and audits, safety related incidents and the like. The site safety diary shall be reviewed and signed on a weekly basis by the site agent and shall be available at all times for inspection by the Engineer.

18.6.6.7 The Contractor staff organisation plan shall show direct lines of communication and

reporting between the safety officer and the site agent and between the safety officer and the project director responsible for the Contract. The Contractor shall instruct and require the site agent and the project director responsible to be directly accountable in all matters concerning Site safety.

18.6.7 Safety promotion and incentive schemes

The Contractor shall actively promote and encourage the standards of health and safety on the Site and implement safety incentives and award schemes at all levels of management, supervisors, foremen, workers, etc. The Contractor shall be able to demonstrate to the Engineer that this requirement is being carried out to the Engineer's satisfaction.

18.6.8 Safety information

18.6.8.1 The Contractor shall display in each of his Site offices, workshops and canteens a copy of

the document on “A Guide to the Construction Site’s Safety Regulations” published by the Government or a similar approved document. This document shall be translated into languages, which are understood by labour engaged by the Contractor or sub-contractors.


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18.6.8.2 The Contractor shall ensure that safety, rescue and occupational health matters are given

a high degree of publicity to all persons, regularly or occasionally on Site. Posters in English, Hindi and other languages understood by the workers, drawing attention to Site safety, rescue and occupational health, shall be made or obtained from appropriate sources and shall be displayed prominently in relevant areas of the Site.

18.6.8.3 Posters in English, Hindi and Marathi drawing attention to safety shall be obtained from

the National Safety Council and displayed prominently throughout the Site.

18.6.8.4 The Contractor shall keep on Site a complete and up-to-date set of all relevant occupational health and safety legislation, relevant Codes of Practice and any relevant guides and safety pamphlets published by the National Safety Council.

18.6.9 Safety meetings

18.6.9.1 The Contractor shall establish a ‘Site Safety Management Committee’ to formally review

on monthly basis the safety management on the Project and monitor the implementation of the Site Safety Plan. The most senior site manager shall act as chairman of this committee with members of the Engineer’s staff attending as appropriate.

18.6.9.2 Attendance from the Contractor shall include, but not be limited to, the senior manager on

Site and the safety manager/officer/supervisor and representatives from all sub-contractors.

18.6.9.3 The Contractor shall act without delay upon such decisions or recommendations as may

be made by the committee on matters of health and safety.

18.6.9.4 The Engineer as appropriate may invite representatives from third parties.

18.6.9.5 The Contractor shall establish a tier of monthly safety meetings and shall ensure that all level of staff, all disciplines and all work areas are covered so that the dissemination of information is carried through to all levels of staff and workers.

18.6.9.6 Minutes of all tiers of Contractor’s safety meetings shall be issued to the Engineer for

information.

18.6.10 Safety training

18.6.10.1 The Contractor shall ensure that induction training courses shall be provided for construction site workers or equivalent.

18.6.10.2 The induction course shall be conducted by suitably qualified persons and repeated at six-

month intervals.

18.6.10.3 All workers must receive induction training before they are allowed to commence work on the Site.

18.6.10.4 The Contractor is to issue all Site workers with a Site pass once they have attended the

induction course. The pass is to include the worker’s name, photograph, types of courses attended and expiry date of the card (maximum 6 months). The pass is to be carried at all times when on the Site.

18.6.10.5 The Contractor shall keep records of such training for health and safety audit purposes.

Upon completion of their training, the Contractor’s Site staff shall sign a copy of their assigned safety responsibility statement, which shall be kept by the Contractor for audit purposes.


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18.6.10.6 The Contractor is to report the number of training sessions and employees trained each month, at the Site Safety Management Committee meeting and in the Monthly Progress Report.

18.6.11 Alcohol and drugs

18.6.11.1 The Contractor shall ensure that alcoholic drinks, drugs and other substances, which may

impair judgement, are not sold, introduced or consumed on the Site.

18.6.11.2 The Contractor shall ensure that his personnel and those of his sub-contractors of any tier are not under the influence of alcohol or any substance which may impair judgement whilst on the Site or otherwise engaged in the execution of the Works.

18.6.11.3 The Contractor shall immediately remove or cause to be removed from the Site any

person employed by the Contractor or his sub-contractors of any tier who is found to be under the influence of alcohol, drugs or any other substance which may impair judgement. Such person shall not be employed again in connection with the Works or on the Project without the prior consent of the Engineer.

18.7 Site Conditions

18.7.1 Emergency procedures and facilities

The Contractor shall establish and implement emergency procedures which detail the organisation of rescue and/or damage limitation teams to deal with emergency situations on the Site such as, but not limited to, fire, loss of power, monsoon, flooding, stranding or the evacuation of a seriously injured person(s) from a remote or difficult Site location, etc. The emergency procedures shall specify what equipment is needed, where it will be located and who is responsible for its maintenance.

18.7.2 First aid facilities

18.7.2.1 The Contractor shall provide, or have access to, sufficient first aid provisions, including

trained personnel and facilities appropriate to the Site conditions as elaborated in Appendix 8. Arrangements for transporting the injured (ambulance, stretcher, etc.) shall be provided.

18.7.2.2 A Nurse or trained First-Aider is required at all times at the Site of working.

18.7.2.3 The Contractor shall maintain a register of all persons attending the clinic or receiving first

aid treatment. Records are to be in a comprehensive format and shall be kept for audit purposes.

18.7.2.4 First aid kits, up to the standards required by the appropriate authority shall be carried in

supervisor’s vehicles and made available where work is in remote areas.

18.7.3 Lifting appliances and lifting gear

18.7.3.1 The Contractor shall provide and maintain safe mechanical cranes. Hoists and conveying facilities for the lifting and transport of materials and shall comply with all relevant requirements of IS 807 code of practice for the design and manufacturing testing and commissioning of cranes. All cranes, hoists and the like shall be fitted with audible overload warning devices. All such equipments shall be regularly maintained in accordance with manufactures’ recommendations and standards having regard to local legislation and recommendations from the appropriate statutory authority.

18.7.3.2 Prior to use on Site, all lifting appliances and lifting gear shall be tested to an approved

safety margin and suitably identified in accordance with the requirements of the current legislation. The test certificates shall be submitted to the Engineer for review prior to the use of such equipment on Site.


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18.7.3.3 The safe working load shall be clearly and indelibly marked on all lifting appliances and

lifting gear either by stamping or by the addition of permanently secured tag labels.

18.7.3.4 The Contractor shall prepare and maintain an up-to-date register containing test certificates of all lifting and hoisting equipment used on the works. The Contractor shall notify the Engineer the person responsible for maintaining this register. The register shall, form the commencement of construction, be available on Site for inspection by the Engineer and relevant authorities.

18.7.3.5 Competent operators with certificates certifying that the proposed operator has received

training in the general principles of carne operation and specific training in the type of lifting of hoisting equipment he is required to operate shall be provided for the control of all lifting and hoisting equipment.

18.7.3.6 A system is to be devised and implemented, such as colour coding, to identify the expiry

of the certification of lifting appliances and lifting gear. This system is to be displayed in the cabs of all lifting appliances.

18.7.3.7 A trained banksman shall be in attendance at each lifting appliance or hoisting operation.

18.7.3.8 The banksman shall be equipped with a radio link to the crane or hoist operator and shall

be easily identifiable from other workers.

18.7.3.9 The operators of shaft hoisting gear shall be in communication with the top and bottom of the shaft and each intermediate landing.

18.7.3.10 All crane hooks and other lifting devices used on or around the Site shall be fitted with a

safety catch or other device to stop the lifting gear being detached.

18.7.3.11 The safe working load shall be clearly and indelibly marked on all lifting equipment, either by stamping or by the addition of permanently secured tag labels. Stamping shall not be permitted on any stress bearing part.

18.7.3.12 Slings, shackles and such-like equipment used in lifting shall be colour coded for

identifying lifting gear which requires re-inspection or disposal.

18.7.4 Fire precautions

18.7.4.1 The local fire safety rules / guidelines and any relevant regulations made thereunder and other requirements laid down in the Specification or as laid down from time to time by the Engineer shall be observed at all times.

18.7.4.2 The Contractor shall thoroughly assess the risk of fire throughout the Site and shall

develop a comprehensive fire control strategy as a part of the Site Safety Plan, which will extend to all aspects of the Works. The fire control strategy shall be discussed regularly and reviewed with the Engineer.

18.7.4.3 Adequate and suitable fire extinguishers are to be positioned throughout the Site, with

particular attention paid to offices, flammable storage areas, workshops, etc.

18.7.4.4 Adequate and suitable fire extinguishers are to be provided at all hot work locations.

18.7.4.5 The Contractor shall ensure that all persons on the Site are trained in and undergo regularly refresher courses in the use of fire extinguishers.

18.7.4.6 Fire points are to be clearly designated.

18.7.5 Dangerous goods, hazardous substances


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18.7.5.1 The Contractor shall obtain the requisite licenses for the manufacture, storage, handling and use of all dangerous goods.

18.7.5.2 The Contractor shall ensure that all explosives, compressed gases, petrol and other

dangerous substances, shall be stored and handled in accordance with the relevant legislation.

18.7.5.3 Before being brought on to Site, any materials proposed by the Contractor shall be

assessed by the Contractor for their occupational health and environmental compatibility. Any material that is toxic, explosive or inflammable or may otherwise create a hazard shall, whenever possible, be replaced by a less hazardous product. Where this cannot be done, the Contractor shall conduct a risk analysis and produce a method statement specifying the safe method of use and all associated precautions including personal protective equipment.

18.7.5.4 All hazardous substances and dangerous goods brought onto the Site shall be entered

into a Site register.

18.7.5.5 The Contractor shall ensure that material safety data sheets are available and issued to workers, for all hazardous substances brought onto the Site.

18.7.5.6 The Contractor shall make adequate provision for the storage and disposal of waste oils,

de-greasing agents, etc.

18.7.5.7 Flash back arrestors and pressure gauges shall be fitted to all oxygen and acetylene cylinders.

18.7.5.8 Oxygen and acetylene cylinders shall be stored and used in a vertical position and be

transported upon a trolley or in cage.

18.7.6 Radiation protection

18.7.6.1 The use of radioactive substances and radiating apparatus shall comply with the government regulatory requirements and all subsidiary legislation.

18.7.6.2 Operations involving ionising radiation shall only be carried out after having been reviewed

without objection by the Engineer and shall be carried out in accordance with a method statement.

18.7.6.3 Each area containing irradiating apparatus shall have warning notices and barriers, as

required by the regulations, conspicuously posted at or near the area.

18.7.6.4 Radioactive substances will be stored, used or disposed shall be strictly in accordance with the applicable enactments.

18.7.6.5 The Contractor shall ensure that all Site personnel and members of the public are not

exposed to radiation.

18.7.7 Excavations and floor openings

18.7.7.1 Before the commencement of any excavation work, sufficient information shall be obtained from the utility companies to identify the locations of buried services. Buried services are to be located using a cable detector, digging hand dug trial pits and by reference to the relevant drawings, before mechanical digging takes place.

18.7.7.2 Excavations shall be carried out by trained and experienced workers who shall be fully

instructed on the possible dangers and safety precaution to be taken, before work is commenced.

18.7.7.3 The Engineer shall be notified immediately of any damage or interruption to a utility.


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18.7.7.4 A Permit to dig system shall be established and implemented prior to excavation starting.

18.7.7.5 The Contractor shall ensure that all temporary covers/decking to the trenches and barriers

at the edges of excavations are safe and securely installed at all times, especially during adverse weather conditions.

18.7.7.6 Where there is a danger to the public, extra care must be taken to properly cover all

temporary openings and adequately barrier and sign the excavation. Flashing warning lights, signs and adequate lighting is to be installed where required.

18.7.8 Site transport

18.7.8.1 The Contractor shall ensure that all Site vehicles are regularly maintained and kept in a

safe condition with fully working brakes, lights, exhaust, windscreen, windows and doors, etc.

18.7.8.2 Each vehicle, piece of plant or machinery shall be uniquely and clearly identified and

registered for maintenance purposes.

18.7.8.3 When instructed by the Employer or the Engineer, the Contractor will remove any vehicle from the Site that is not up to the standards required.

18.7.8.4 The Contractor will remove from the Site immediately any vehicle that is beyond repair.

The Site shall not to be used as a scrap yard.

18.7.8.5 The Contractor is to ensure that only vehicles fitted with seats with backrests and seat belts are used as Site transport. If required by law the carrying of passengers in vehicles that have not been fitted with seat belts is strictly prohibited. No person shall ride in the back of vehicles not legally authorised to carry passengers. Drivers of vehicles permitting this practice are to be warned for a first offence then removed from the Site for the second offence.

18.7.8.6 The speed limit on the Site is to be restricted to 5 ppm and signs displayed advising

drivers of the limits imposed.

18.7.8.7 Speed bumps are to be located at strategic points throughout the Site to enforce the speed limits.

18.7.9 Driving/operator’s licenses

Drivers of vehicles and operators of the Contractor’s Equipment shall hold the necessary license group for the vehicle or plant they are driving/operating. Where no such license group exists, drivers/operators shall have an equivalent group and undertake training in the vehicle/plant given by the Contractor’s plant department. Records of the training given are to be retained.

18.7.10 Personal protective equipment (PPE)

18.7.10.1 The Contractor shall make available on Site at all times adequate provision of safety

equipment including, but not limited to, safety helmets, goggles, ear protectors, safety belts, respiratory protection, safety equipment for working in sewers, drains and enclosed spaces, equipment for rescue from drowning, fire extinguishers, first aid equipment and other necessary safety equipment.

18.7.10.2 The Contractor shall ensure that safety footwear and safety helmets are worn at all times

by all persons on site.

18.7.10.3 High visibility vests shall be worn at all times when in the tunnels.


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18.7.10.4 Persons shall sign for all PPE being issued and a register shall be kept recording the issue.

18.7.10.5 A suitable dry, clean and well-ventilated area shall be provided for the storage of the PPE.

18.7.11 Tunnel and underground work

18.7.11.1 The Contractor shall establish and implement a tagging system, which shall clearly and

accurately record the number of persons entering and leaving the tunnel, their name, company and ID card no.

18.7.11.2 All work associated with tunnels shall be performed in accordance with BS6164

18.7.11.3 The Contractor shall ensure that there is sufficient clean airflow, as per the requirements

of BS6164, at all times.

18.7.11.4 Before entry into such areas, remote atmosphere monitoring shall be carried out to ensure that adequate ventilation and a breathable atmosphere exist.

18.7.11.5 No person shall enter such areas unaccompanied and without adequate ventilation being

in operation.

18.7.11.6 All diesel-driven plant used underground shall be provided with efficient and properly maintained catalytic converters.

18.7.11.7 Petrol driven plant or machinery shall not be used in any underground working.

18.7.11.8 No person under the age of 18 years shall enter or work in the tunnels or confined spaces.

Hot work will only be carried out under the control of a hot work permit

18.7.11.9 Paint, thinners or flammable gasses shall not be stored in the tunnels or in confined spaces.

18.7.12 Ladders, temporary access

18.7.12.1 The Contractor shall provide, register, maintain and use only ladders, which are

purchased as proprietary products, on the Site. Site made ladders are not to be used under any circumstances.

18.7.12.2 All ladders shall be free from patent defects, secured against movement and installed in

accordance with the relevant Codes of Practice.

18.7.12.3 Wooden access steps with handrails are to be installed and maintained as access where the use of mobile access staircases is impractical.

18.7.13 Temporary Works

18.7.13.1 The Contractor shall appoint an engineer as a Temporary Works Co-ordinator. His duties

shall include, but not limited to, checking and certifying the design of all Temporary Works prior to erection and loading, ensuring that the erection work is carried out in accordance with the design, compiling a Temporary Works register, completing a suitably designed form or certificate which is to be displayed on the Temporary Works to say that it has been inspected and is safe to load.

18.7.13.2 The Temporary Works Co-ordinator shall not be the same person who designed the

Temporary Works.

18.7.13.3 Suspended, cantilever, bracket type scaffolding or working platforms are to be designed, certified and inspected by an independent engineer, who may be the Temporary Works Co-ordinator, prior to loading.


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18.7.14 Temporary buildings, sheds, workshops, etc.

18.7.14.1 No temporary structure is to be erected without the consent of the Engineer.

18.7.14.2 Except where consent is obtained from the Engineer, no person shall reside on the Site.

18.7.15 Temporary electricity

18.7.15.1 Temporary electricity supplies shall comply with Chapter 22 below.

18.7.15.2 Switchbox / distribution box construction shall be robust, corrosion proof, water proof and

be of coated metal and shall be mounted on an integral frame at least 1000mm off the ground. In coming cables shall be secured by a waterproof gland.

18.7.16 Housekeeping

18.7.16.1 The Contractor shall clean the Site area on a daily basis and maintain it in a safe, tidy and

sanitary condition.

18.7.16.2 Sufficient waste bins are to be provided throughout the area of work and a daily disposal regime is to be established and implemented.

18.7.16.3 The Contractor is responsible for enforcing the standards of housekeeping of its sub-

contractors and their areas of work.

18.7.17 Site services

18.7.17.1 The Contractor shall provide, maintain and ensure the installation to the required standards, of all services entering and being used on Site.

18.7.17.2 All Government and utility company regulations and requirements shall be complied with.

18.7.17.3 The Engineer may require the immediate termination or alteration to an installation if he

considers that they are prejudicial to safety or health.

18.7.17.4 The Contractor shall ensure that services used on the Site are designed so that there is no possibility of the users of such services surrounding the Site, being affected by loss of supply, contamination, power surges, etc.

18.7.18 Contractors Equipment

The Contractor shall produce policy and procedures for ensuring that all his plant and equipment used on the Site is maintained in a safe condition and is operated in a safe manner.


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CHAPTER 19

19.0 DAMAGE AND INTERFERENCE

19.1 Damage and Interference

19.1.1 Work shall be carried out in such a manner that, as far as is practicable, there is no damage to or interference with the following, other than such damage as is necessitated to enable the execution of the Works:

(1) watercourses or drainage systems; (2) utilities; (3) structures, roads including street furniture, or other property; (4) public or private vehicular or pedestrian accesses; (5) trees, graves or burial urns; and (6) existing railways and railway systems. The Contractor shall obtain prior approval of the concerned authority or party, if so required, for any work near properties under their ownership or management. The Contractor shall inform the Engineer as soon as practicable of any item, utility or thing which is not stated in the Contract as requiring diversion, removal or relocation but which the Contractor considers as requiring diversion, removal or relocation to enable the Works to be executed. The Contractor shall not divert, remove or relocate any such item, utility or thing without such diversion, removal or relocation having been reviewed without objection by the Engineer.

19.1.2 Items which are damaged or interfered with as a result of the Works being carried out and

items which are diverted, removed or relocated to enable the Works to be carried out, shall be reinstated to the same condition as existed before the Works started or to such condition as may be reviewed without objection or instructed by the Engineer.

19.1.3 The Contractor shall excavate by hand where damage may be caused by the operation of

mechanical plant adjacent to any utilities.

19.1.4 Except with the prior approval of the Fire Service Department of Maharashtra / Chief Fire Officer, Pune, no damage or interference with existing fire hydrants and valves shall be caused.

19.1.5 Prior to trench excavation, the Contractor shall carry out investigations to locate utilities by

means of hand-dug inspection pits. The locations and number of inspection pits required in meeting the Contractor’s obligations to establish the location of existing utilities and underground features shall be determined by the Contractor. The Contractor shall note that many existing pipes/ducts/cables may not be shown in the records kept by the utility undertakings, and may only be exposed as the excavation proceeds. The trench excavation shall be carried out by hand where there are utilities adjacent to or within the excavation works and the Contractor shall have allowed in his programme the time required for the exposing, temporary support and diversion of these recorded or unrecorded utilities. Should any pipes/ducts/cables or cover tiles be exposed, the respective utility undertaking shall be contacted to determine if all the utilities have been located. Cover tiles and utilities shall only be removed by the utility undertakings concerned.

19.1.6 Where the Engineer has conducted utility and ground investigation on behalf of the

Employer, the Contractor may obtain the data obtained from the investigations from the Engineer in accordance with Clause 1.7.2 above and subject to the condition of Clause 19.3 below.

19.2 Watercourses and Drainage Systems


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19.2.1 Existing watercourses and drainage systems shall be temporarily diverted as required to enable the Works to be carried out. Particulars of the proposed diversions shall be submitted to the Engineer for review at least 14 days before the relevant work starts. Diversions shall be constructed to the satisfaction of the Engineer with such alignment and in such manner that the flow is discharged adequately and effectively without causing flooding or erosion to the adjacent area. The diversions shall be maintained while the work is being carried out and shall be reinstated, including the removal of any obstructions to flow, as soon as practicable after the work is complete.

19.2.2 Measures shall be taken to prevent excavated material, silt or debris from being deposited

in existing drainage systems, watercourses or the river.

19.2.3 Under no circumstances shall foul sewage flow be diverted into existing storm-water drains and vice versa.

19.2.4 The Contractor shall adequately maintain the existing drainage and sewerage systems at

all times including removal of solids in sand traps, manholes, gullies and streambeds.

19.2.5 The Contractor shall discharge water surface run-off from the Site into storm drains via adequately designed sand/silt removal facilities such as sand traps, silt traps and sediment basins. Channels or sandbag barriers shall be provided on Site to properly direct the storm water to such silt removal facilities. The Contractor shall remove all silt, which may have accumulated in the drainage or sewerage systems whether within the Site, or not. If at any time such provisions prove to be ineffective, the Contractor shall take such additional measures as the Engineer deems necessary.

19.2.6 Water pumped out of the trenches under construction shall be discharged into storm

drains after the removal of silt in silt removal facilities.

19.2.7 The Contractor shall maintain the silt removal facilities, channels and manholes and remove the deposited silt and grit regularly, at the onset and after each rainstorm to ensure that these facilities are functioning properly at all times.

19.2.8 No obstruction to flow is to be left in position longer than is necessary for carrying out the

Works. The Contractor shall ensure that adequate provisions are made for dealing with increased flow of water during the wet season.

19.2.9 The Contractor shall keep interruption or disturbance to the public due to the diversion

works to a minimum.

19.2.10 If any mechanical equipment is required for the foul sewage diversion work, the Contractor shall suggest and provide precautionary measures to mitigate against consequences of breakdown of the equipment.

19.2.11 The Contractor shall at all times ensure that all existing stream courses and drains within

and adjacent to the Site are kept safe and free from any debris and any excavated materials arising from the Works. The Contractor shall ensure that chemicals and concrete agitator washings are not deposited in watercourses.

19.2.12 The Contractor shall be responsible for the Temporary Works involved in training,

diverting, or conducting of open streams or drains intercepted by the Works and the Site, for the maintenance of the Temporary Works and waterways as required by the Engineer, and for reinstating these to their original courses on Employer’s Taking Over of the Works, when and where in the opinion of the Engineer such action is desirable.

19.2.13 The Contractor shall take all necessary precautions to prevent water entering upon or

being discharged from the Site, from entering upon the works of adjacent contractors or adjacent properties.


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19.2.14 The Contractor shall provide where necessary temporary water courses, floodwalls, flood gates, ditches, drains, pumping or other means of maintaining the Works and the Site free of water.

19.3 Utilities

19.3.1 The details of existing utilities are given by the Employer for information only and the

accuracy of the details is not guaranteed. The Contractor shall make his own enquiries and shall carefully excavate trial holes to locate accurately the utilities indicated to him by the utility undertakings.

19.3.2 Temporary supports and protection to utilities shall be provided by methods reviewed

without objection by the Engineer. Permanent supports and protection shall be provided if instructed by the Engineer.

19.3.3 The Contractor shall inform the Engineer and the utility undertakings without delay of the

following:

(1) damage to utilities; (2) leakage of utilities; (3) discovery of utilities not shown on any drawings; and (4) diversion, removal, repositioning or re-erection of utilities which is required to enable

the execution of the Works.

19.3.4 The Contractor shall take all steps necessary to enable the utility undertakings to proceed in accordance with the programme agreed between the Contractor and the utility undertakings under Clause 2.2.2 above. The Contractor shall maintain close liaison with the utility undertakings and shall inform the Engineer of any delays in works by the utility undertakings.

19.3.5 The Contractor shall keep records of existing utilities encountered on the Site and a copy

provided for the Engineer. The records shall be submitted for review by the Engineer and shall contain the following details:

(1) location of utility; (2) date on which utility was encountered; (3) nature and size of utility; (4) condition of utility; and (5) temporary or permanent supports provided.

19.3.6 The Contractor shall co-ordinate the activities of the utility undertakings in connection with

the diversion of utility services necessary for the execution of the Works.

19.3.7 The Contractor shall set up and manage a Utilities Liaison Group for the duration of the Contract. The Group shall meet at a frequency to be instructed by the Engineer but at least once a month, and shall discuss and resolve matters associated with utility undertakings on programming, co-ordination and action. The Contractor shall ensure that all relevant utility undertakings and the Engineer are represented at the meetings.

19.3.8 The Contractor shall inform the Engineer of the date, time and place of every meeting with

utility undertakings and he shall copy all correspondence and minutes of meetings to the Engineer.

19.3.9 The programme for any section of work to be carried out by a utility undertaking shall be

confirmed in writing by the Contractor to the utility undertaking no more than four weeks and no less than one week before the agreed scheduled start date for that section of Works, such confirmation to be notified to the Engineer.

19.3.10 The Contractor shall monitor the progress of utility undertakings against the agreed

programmes and shall notify the Engineer of any slippage to these programmes. The


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agreed programmes shall mean those programmes agreed in writing by the Contractor and the various utility undertakings described in Clause 19.3.9 above.

19.3.11 In the event of any such slippage, the Contractor shall prepare and execute a plan of

action with the relevant utility undertaking to redress the slippage. Such a plan may, if necessary, include provision of Contractor’s labour resources, materials and/or plant to the utility undertaking.

19.3.12 The Contractor shall ensure that the peak particle velocity and amplitude of ground

movement due to temporary sheet pile driving for trench excavation or any other construction activities, as measured by a vibrograph at all water mains within or adjacent to the Site shall not exceed the values specified in this GS.

Type of Structure or Installation Peak Particle Velocity (mm/s)

Vibration amplitude (mm)

Water retaining structures Water tunnels

13 0.1

Water mains Other structures and pipes

25 0.2

19.3.13 Hand digging method shall always be employed where there are utilities adjacent to or

within the trench excavation works. Portable mechanical tools may be used but shall be restricted to the breaking of the pavement surface. Due care shall be exercised to prevent damage to the underground cables, water pipes, gas pipes or other utility installations.

19.3.14 Exposed utility installations shall be adequately supported and protected from accidental

damage.

19.3.15 Smoking and use of naked flames shall be prohibited if gas pipes are present, or pipes the uses of which are not identified are present.

19.4 Structures, Roads and Other Property

19.4.1 The Contractor shall immediately inform the Engineer of any damage to structures, roads

or other property that is not required for the execution of the Works.

19.4.2 The Contractor shall use every reasonable means to prevent any of the highways or bridges connecting with, or on the routes to, the Site from being damaged by any traffic of the Contractor or any of his sub-contractors of any tier and the Contractor shall, in particular, select routes, choose and use vehicles and restrict and distribute loads so that the moving of Temporary Works, Permanent Works and Contractor's Equipment from and to the Site shall be organised as far as reasonably possible so that no unnecessary damage or injury may be occasioned to such highways and bridges. The Contractor shall in selecting such routes take advice from and follow the instructions of the Commissioner for Transport and other relevant authorities of Government of Maharashtra and GOI.

19.4.3 Should the Commissioner for Transport or any other relevant authority or the Contractor

be of the opinion that it should be necessary to move one or more loads of Temporary Works, Permanent Works or Contractor's Equipment over a highway or bridge the moving of which is likely to damage any highway or bridge unless special protection or strengthening is carried out then the Contractor shall, before moving the load on to such highway or bridge, give notice to the Engineer of the weight and other particulars of the load to be moved and request the protection or strengthening of the said highway or bridge. If within 14 (fourteen) days of receipt of such notice the Engineer directs in writing that such protection or strengthening is unnecessary then the Contractor may move the said load or loads over the said highway or bridge but otherwise the Contractor shall not move the said load or loads until notified by the Engineer of the route which he may use.

19.4.4 If during the execution of the Works or at any time thereafter the Contractor shall receive

any claim arising out of the execution of the Works in respect of damage or injury to


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highways or bridges he shall immediately report the same to the Engineer and thereafter the Employer shall negotiate the settlement of and pay all sums due in respect of each claim and shall indemnify the Contractor in respect thereof and in respect of all claims, demands, proceedings, damages, costs, charges and expenses whatsoever in relation thereto. Provided always that if and so far any such claim or part thereof shall in the opinion of the Engineer be due to any failure on the part of the Contractor to observe and perform his obligations under Clauses 19.4.2 and 19.4.3 above, the amount certified by the Engineer to be due to such failure shall be paid by the Contractor to the Employer

19.4.5 Where the nature of the Works is such as to require the use by the Contractor of water-

borne transport, the foregoing provisions of this Clause shall be construed as though "highway" includes any river or other structure related to, on or beneath a waterway, and "vehicle" includes craft, vessels or platforms and shall be read and construed accordingly.

19.4.6 If in the course of or for the purposes of the execution of the Works or any part thereof any

highway or roadway shall have been damaged, broken then notwithstanding anything herein contained:

(1) If the permanent reinstatement of such highway or road or way is to be carried out by

the appropriate relevant authority or by some person other than the Contractor or any sub-contractor of any tier to him, the Contractor shall:

a. at his own cost and independently of any requirement of or notice from the

Engineer be responsible for the temporary reinstatement of such highway, road or way and the making good of any subsidence or shrinkage or other defect, imperfection, settlement or fault in the temporary reinstatement of such highway, road or way and for the execution of any necessary repair or amendment thereof from whatever cause the necessity arises until the end of the Defects Liability Period in respect of the part of the Permanent Works beneath or over such highway, road or way or until the relevant authority or such other person as aforesaid shall have taken possession of the highway, road or way for the purpose of carrying out permanent reinstatement, whichever is the earlier; and

b. indemnify and save harmless the Employer against and from any damage or

injury to the Employer or claims by third parties arising out of or in consequence of any neglect or failure of the Contractor to comply with the foregoing obligations or any of them, and against and from all claims, demands, proceedings, damages, costs, charges and expenses whatsoever in respect thereof or in relation thereto; and

(2) as from the end of such Defects Liability Period or the taking of possession of such

highway or road way referred to in Clause 19.4.6 (1)(a) above whichever shall first happen, the Employer shall indemnify and save harmless the Contractor against and from any damage or injury to the Contractor arising out of or in consequence of or in connection with the said permanent reinstatement or any defect, imperfection or failure of or in such permanent reinstatement and against and from all claims, demands, proceedings, damages, costs, charges and expenses whatsoever in respect thereof or in relation thereto.

19.4.7 Where the relevant authority or other person referred to in Clause 19.4.6 above shall take

possession of the highway or roadway as aforesaid in sections or lengths, the responsibility of the Contractor under Clause 19.4.6 above shall cease in regard to any such section or length at the time at which possession thereof is so taken, but shall during the continuance of the said Defects Liability Period continue to be responsible for any section or length of which possession has not been taken and the indemnities given by the Contractor and Employer respectively under Clause 19.4.6 above shall be construed and have effect accordingly.

19.5 Access


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Alternative access shall be provided if interference with existing public or private vehicular or pedestrian access is necessary to enable the execution of the Works. The arrangements for the alternative access shall be as reviewed without objection by the Engineer. The permanent access shall be reinstated as soon as practicable after the work is complete and the alternative access shall be removed as soon as practicable after it is no longer required.

19.6 Trees and Other Similar Obstructions

19.6.1 Trees which are to be retained or which are not required to be removed in order to carry

out the Works, shall be protected from damage at all times by methods reviewed without objection by the Engineer. Materials, including excavated materials, shall not be banked around such trees and they shall not be trimmed or cut without having been reviewed without objection by the Engineer.

19.6.2 If any trees or other obstructions are required to be removed during the execution of the

Works which are not specifically required to be removed or otherwise catered for, the Contractor shall draw the attention of the Engineer to them and shall not remove them without having received a notice of no objection from the Engineer.

19.7 Noise Control on Works Site

19.7.1 All Contractor’s Equipment shall be effectively “sound-reduced” by means of silencers,

mufflers, acoustics linings or shields or acoustic sheds or screens to levels prescribed in the relevant Noise Control Ordinance and measured outside the nearest occupied property or to the satisfaction of the Engineer. The Contractor shall provide details of proposed noise control measures to the Engineer for review prior to the use of any Contractor’s Equipment on the Site.

19.7.2 Provided that the provisions of this Paragraph shall not be applicable in the case of

emergency work necessary to save life or property or for the safety of the Works or in the case of blasting operations necessitated by urgency and reviewed by the Engineer.

19.7.3 The Contractor shall provide a sound level meter (as specified in Appendix 7 of this

Specification), reviewed without objection by the Engineer, for the exclusive use of the Engineer at all times during the continuance of the Contract.

19.8 Spoil Disposal

19.8.1 The Contractor shall make his own enquiries and arrangements regarding the location and

the availability of spoil disposal areas and reclamation and shall pay all costs of complying with all regulations and requirements of relevant authorities in connection with the use of such areas. These areas are not within the control of the Employer and no claims will be entertained in respect of non-availability of a particular areas or changes in the costs of arrangements for the use thereof.

19.8.2 The Contractor shall be responsible for all necessary liaison to ensure compliance with the

requirements of unproductive disposal of any surplus excavated rock or soft material which is suitable for filling.

19.8.3 The Contractor shall conform to all pertinent environmental protection laws/regulations

and be liable for any breach of such laws/regulations committed by himself and/or his sub-contractors during the disposal of surplus excavated material and water from the Site.


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CHAPTER 20

20.0 ENVIRONMENTAL PROTECTION REQUIREMENTS

20.1 General

20.1.1 The Contractor shall conform to the Indian Environmental Laws and codes as applicable. The current national standards established by the Ministry of Environment and Forest, Government of India and other government agencies for control of environmental pollutants such as air, water, noise and visual impacts/aesthetics shall be followed for compliance during project construction.

20.1.2 The Contractor shall comply with all enactments and their amendments, which shall

include but are not limited to:

(1) Environment Protection Act,1986 and Rules 1986 (2) Air (Prevention and Control of Pollution) Act, 1981 (3) Water (Prevention and Control of Pollution) Act, 1974 (4) Notification on Control of noise from DG sets, 2002 (5) The Noise Pollution (Regulation & Control) Rules, 2000 (6) The Hazardous Waste (Management, Handling & Trans-boundary Movement)

Rules, 2008 (7) Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 (8) Regulation on recycling of Waste Hazardous Materials (9) The Batteries (Management & Handling) Rules, 2001 (10) Guidelines of Pune Urban Development Authority (11) Guidelines of Maharashtra Pollution Control Board

20.1.3 The provisions listed herein regarding environmental protection shall apply to and be

binding upon the Contractor for any works on the Site and the persons employed by sub-Contractors. The Contractor shall ensure that proper and adequate provisions to this end are included in all sub-contracts placed by him.

20.1.4 These provisions however, shall not be applicable in the case of emergency works

necessary for saving of life and property or safety of the Works.

20.1.5 The Contractor has been issued with the Employer’s SHE Manual. Within 20 weeks of notification of acceptance of the Tender, the Contractor shall submit for review by the Employer’s Representative, a draft of his own contract specific Site Environmental Plan based on the environmental protection requirements contained in this chapter and on the Employer’s SHE Manual and his construction methodology. He shall submit a final version prior to the commencement of the Works.

20.1.6 This contract specific Site Environmental Plan of the Contractor, as referred to in Chapter

3 above, shall be consistent with the provisions of the Environmental Management Plan outline, as given in the Employer’s SHE Manual.

20.1.7 On account payment to be made after three months of issuance of Letter of Acceptance,

shall be released, if Site Environmental Plan has been submitted by the Contractor and approved by Employer’s Representative. Otherwise Rs1,50,000 (Rupees one lakh fifty


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thousand) as lump sum amount shall be withheld from running bill till compliance of the above.

20.1.8 The Contractor shall ensure that audits of all the activities detailed in his Site

Environmental Plan are carried out at weekly intervals or at such intervals as the Employer's Representative may require to ensure the continuing effectiveness and compliance with the Site Environmental Plan. The Contractor shall make available on request any document, which relates to his recent internal audits.

20.1.9 For closure of Non Conformance Report, expeditious action shall be taken by the

Contractor for compliance and the Contractor shall ensure closure of Non-Conformance Report within 15 days of its issue. In case of non-closure of report, an amount of Rs 20,000/- (Rupees Twenty thousand only) shall be withheld from running on account bill for every non-closure of report till the same is closed satisfactorily.

20.1.10 The Employer’s Representative may conduct quarterly audits of the Contractor’s Site

Environmental Plan and its effective implementation on the Site. One-week notice will be given by the Employer’s Representative before proceeding with the audit. During the audit by the Employer’s Representative, the Contractor shall provide suitably qualified staff to accompany the auditor.

20.1.11 Milestone / Interim payments will be achieved for successful quarterly audits for which the

Employer’s Representative has issued a “Notice of No Objection” or a “Notice of No Objection subject to….”

20.1.12 The Contractor shall carry out its own environmental audits after four months of issuance

of Letter of Acceptance and every three months thereafter. Submission of environmental audit report duly reviewed and accepted by Employer’s Representative along with action taken shall be ensured within one month of due date of such audits. Otherwise a lump sum amount of Rs 1.00 lakh (Rupees one lakh) shall be recovered for each failure from running bill and this shall not be refunded.

20.2 Housekeeping

20.2.1 The Contractor shall take all precautions to avoid any nuisance arising from his

operations. This shall be accomplished, wherever possible by suppression of nuisance at source rather than abatement of the nuisance once generated.

20.2.2 Following site clearing and before construction of its contracted activities, the Contractor

shall remove all trash and debris.

20.2.3 The Contractor shall ensure that the work place is as far as practicable, maintained in a neat and tidy manner. The materials for use and tools and tackles shall be stacked and stored in a manner that is safe and does not cause obstruction to movement of men and machines at Site.

20.2.4 The Contractor shall maintain the worksite free of trash, garbage and debris. He shall

provide and ensure proper uses of refuse containers to ensure that rodents, flee and other pests are not harboured and attracted.

20.2.5 These may be metal or heavy-duty plastic ‘Refuse Containers’ with tight fitting lids for

disposal of all garbage or trash associated with food. The containers shall not have openings that allow access by rodents. The refuse containers shall be kept upright with their lids shut tight. These containers shall be emptied at-least once daily by the Contractor to maintain site sanitation.

20.2.6 To keep the area free of litter and garbage, specific locations shall be designated for

consuming food and snacks to prevent random disposal of waste. All waste shall be deposited in the refuse containers described in Clause 20.2.5 above. Suitable notice shall be deployed prominently for strict compliance of these requirements.


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20.2.7 Separate containers shall be used for non-biodegradable and reusable / recyclable wastes

and properly labelled.

20.2.8 Measures shall be taken to prevent mosquito breeding at Site. The measures to be taken shall include:

(a) empty cans, oil drums, packing and other receptacles which may retain water shall be

deposited at a central collection point and shall be removed from the Site regularly; (b) still waters shall be treated at least once every week with oil in order to prevent

mosquito breeding; (c) Contractor’s Equipment and other items on the Site which may retain water shall be

stored, covered or treated in such a manner that water could not be retained. (d) Water storage tanks shall be suitably provided. (e) Posters in both Hindi and English, which draw attention to the dangers of permitting

mosquito breeding, shall be displayed prominently on the Site.

20.3 Air Quality

20.3.1 The Contractor shall take all necessary precautions to minimise fugitive dust emissions from operations involving excavation, grading, clearing of land and disposal of waste. He shall not allow emissions of fugitive dust from any transport, handling, construction or storage activity to remain visible in atmosphere beyond the property line of emission source for any prolonged period of time without notification to the Employer's Representative.

20.3.2 The Contractor shall use construction equipment designed and equipped to minimise or

control air pollution. He shall maintain evidence of such design and equipment and make these available for inspection by Employer’s Representative.

20.3.3 If after commencement of construction activity, Employer’s Representative believes that

the Contractor’s equipment or methods of working are causing unacceptable air pollution impacts then these shall be inspected and remedial proposals shall be drawn up by the Contractor, submitted for review to the Employer’s Representative and implemented.

20.3.4 In developing these remedial measures, the Contractor shall inspect and review all dust

sources that may be contributing to air pollution. Remedial measures include use of additional / alternative equipment by the Contractor or maintenance / modification of existing equipment of the Contractor.

20.3.5 Dust generating materials shall be:

(1) Transported in closed containers or covered trucks. (2) Loaded and unloaded in closed systems or wind protected areas. (3) Watered as appropriate to minimise dust production.

20.3.6 Contractor’s transport vehicles and other equipment shall conform to emission standards

fixed by statutory agencies of Government of India and Government of Maharashtra from time to time. The Contractor shall carry out periodical checks and undertake remedial measures including replacement, if required, so as to operate within permissible norms.

20.3.7 In the event that approved remedial measures are not being implemented and serious

impacts persist, the Employer’s Representative may direct the Contractor to suspend work until the measures are implemented, as required under the Contract.


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20.3.8 The Contractor shall cover loads of materials, debris and soil transported from construction sites. All trucks carrying loose material should be covered and loaded with sufficient free- board to avoid spills through the tailboard or sideboards.

20.3.9 The Contractor shall be responsible for ensuring that no earth, rock or debris is deposited

on public or private right of way as a result of his operations, including any deposits arising from the movement of loaded / unloaded trucks and/or other construction vehicles. In the event of it happening, the Contractor shall clean the public/private right of way to the satisfaction of Employer’s Representative.

20.3.10 The Contractor shall make his own arrangements for water for purposes stated in above

clauses and wherever it may be required to control air pollution, dust and debris.

20.3.11 The Contractor shall establish and maintain records of routine maintenance program for internal combustion engine powered vehicles and equipment used on this project. He shall keep records available for inspection by Employer’s Representative.

20.3.12 The Contractor shall promptly transport all excavation disposal materials of whatever kind

so as not to delay work on the project. Stockpiling of materials will only be allowed at sites designated by the Employer’s Representative.

20.3.13 The Contractor shall protect structures, utilities, pavements, public and private right of way

and other facilities from disfiguration and damage due to Contractor’s activities including movement of construction equipment and machinery. Should this happen, he shall make good the damage and remedy the situation to the satisfaction of the Employer’s Representative.

20.3.14 The Contractor shall place excavation materials in the dumping/disposal areas designated

in the plans as given in the specifications.

20.3.15 The temporary dumping areas shall be maintained by the Contractor at all times until the excavate is re-utilised for backfilling or as directed by Employer’s Representative.

20.3.16 The Contractor shall place material in a manner that will minimise dust production. The

materials shall be stabilised each day and wetted, to minimise dust production.

20.3.17 During dry weather, dust control methods must be used daily especially on windy, dry days to prevent any dust from blowing across the site perimeter.

20.3.18 The Contractor will make water sprinklers, water supply and water delivering equipment

available at any time that it is required for dust control use.

20.3.19 Dust control activities shall continue even during any work stoppage.

20.3.20 At each construction site, the Contractor shall provide storage facilities for dust generating materials and shall be:

a. Closed containers/bins or; b. Wind protected shelters or; c. Mat covering or; d. Walled

Or any combination of the above to the satisfaction of the Employer’s Representative

20.3.21 The Contractor shall submit to the Employer’s Representative an Air Monitoring and

Control Plan (AMCP) under contract specific Site Environmental Plan to guide construction activity at work sites insofar as it relates to monitoring, controlling and mitigating air pollution. Air monitoring devices used for such monitoring shall be inspected, calibrated, maintained and used in accordance with the manufacturer’s instructions.


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20.3.22 For the above tunnel works, Suspended Particulate Matter (SPM) shall be monitored, at three locations for two 24-hour samples, every fifteen days. Number of locations can be increased or decreased by the Employer’s Representative depending on the extent of construction activity and its proximity to air sensitive receptors. Permissible values for SPM shall be the recorded base line values or national standards, whichever is higher.

20.3.23 For its activities within the confined spaces, the Contractor shall monitor flammable gases,

oxygen, carbon monoxide, carbon dioxide, hydrogen sulphide, oxides of nitrogen, and aldehyde. The Contractor shall also monitor for any other poisonous gas that the Employer’s Representative shall deem appropriate and necessary.

20.3.24 Air monitoring in confined spaces shall be carried out as often as necessary, however, the

duration between two sets of readings shall not be more than 4 hours.

20.3.25 Within the confined spaces, air shall be considered unfit for workmen to breathe if it contains any of the following:

a. Less than 19.5% and more than 22% oxygen by volume. b. More than 0.5% carbon dioxide by volume. c. More than 0.01% carbon monoxide by volume. d. More than 0.001% hydrogen sulphide by volume. e. More than 0.003% oxides of nitrogen. f. More than 0.5% of methane at any place in the tunnel. g. More than 0.0005% of aldehyde

Any other poisonous gas in harmful amounts

20.3.26 A record of all air quality monitoring containing location, date, time, substance, monitoring

results and name of person conducting the tests shall be maintained by the Contractor and made available for inspection by the Employer’s Representative.

20.4 Water Quality

20.4.1 The Contractor shall comply with the Indian Government legislation and other State

regulations in existence in Maharashtra / Pune insofar as they relate to water pollution control and monitoring.

20.4.2 The Contractor shall provide adequate precautions to ensure that no spoil or debris of any

kind is pushed, washed, falls or deposited on land adjacent to the site perimeter.

20.4.3 In the event of any spoil or debris from construction works being deposited on adjacent land any silt washed down to any area, then all such spoil, debris or material and silt shall be immediately removed and the affected land and areas restored to their natural state by the Contractor to the satisfaction of the Employer’s Representative.

20.4.4 Due to lowering of potable water supplies in Pune and subsequent contamination of

ground water, the Contractor is not allowed to discharge water from the Site without the approval of the Employer’s Representative. The Contractor must comply with the requirements of the Central Ground Water Board for discharge of water arising from dewatering. Any water obtained from dewatering systems installed in the works must be either re-used for construction purposes and this water may subsequently be discharged to the drainage system or, if not re-used, recharged to the ground water at suitable acquifer levels. The Contractor must submit his proposals for approval of Employer’s Representative, on his proposed locations of dewatering of excavation and collection of water for either construction re-use or recharge directly to acquifers. The Contractor’s recharge proposals must be sufficient for recharging of the quantity of water remaining after deduction of water re-used for construction.

20.4.5 The Contractor shall at all times ensure that all existing stream courses and drains within,

and adjacent to the Site are kept safe and free from any debris and any excavated


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materials arising from the Works. The Contractor shall ensure that earth, bentonite, chemicals, any mud slurry from drilling or grouting and concrete agitator washings etc. are not deposited in the watercourses and not discharged into the drainage system unless treatment is carried out that will remove silt, mud particles, bentonite etc. but are suitably treated and effluents and residue disposed off in a manner approved by local authorities.

20.4.6 All water and waste products (surface runoff and wastewater) arising on the Site shall be

collected and removed from the Site via a suitable and properly designed temporary drainage system and disposed off at a location and in a manner that will cause neither pollution nor nuisance.

20.4.7 The Contractor shall discharge wastewater arising out of site office, canteen or toilet

facilities constructed by him into sewers after obtaining prior approval of agency controlling the system. A wastewater drainage system shall be provided to drain wastewater into the sewerage system.

20.4.8 The Contractor shall take measures to prevent discharge of oil and grease during spillage

from reaching drainage system or any water body. Drips pans, placed on hard surface shall be used to store oil/grease drums.

20.5 Noise

20.5.1 General

(1) The Contractor shall consider noise as an environmental constraint in his design,

planning and execution of the Works. The Contractor shall, at his own expense, take all appropriate measures to ensure that work carried out by the Contractor and by his sub-Contractors, whether on or off the Site, will not cause any unnecessary or excessive noise which may disturb the occupants of any nearby dwellings, schools, hospitals, or premises with similar sensitivity to noise.

(2) Without prejudice to the generality of the foregoing, noise level reduction measures

shall include the following:

a. the Contractor shall ensure that all powered mechanical equipment used in the Works shall be effectively sound reduced using the most modern techniques available including but not limited to silencers and mufflers.

b. the Contractor shall construct acoustic screens or enclosures around any

parts of the Works from which excessive noise may be generated. (3) The Contractor shall ensure that, as far as ambient noise is concerned, noise

generated by work carried out by the Contractor and his sub-Contractors during day time and night time shall not exceed the background noise levels by 10dB(A) or more when measured at a point outside the premises of the location of the source. When background noise levels are not available, the permissible noise levels shall meet the requirements as given in the Environmental Quality Management Manual. The same may be varied from time to time by and at the sole discretion of the Employer’s Representative. In the event of a breach of this requirement, the Contractor shall immediately re-deploy or adjust the relevant equipment or take other appropriate measures to reduce the noise levels and thereafter maintain them at levels which do not exceed the said limits. Such measures may include without limitation the temporary or permanent cessation of use of certain items of equipment.

(4) For ambient noise level compliance, number of monitoring locations shall be atleast

four. Number of locations can be increased or decreased by the Employer’s Representative depending on the extent of construction activity and its proximity to noise sensitive receptors. The other noise monitoring requirements shall be as given in the Employer’s Environment Quality Management Manual.


Feb 2018 Page 140 of 170

(5) For noise emanating from generators run with diesel, notification dated 17th May 2002 under Environmental (Protection) Act,1986 shall apply which require acoustic treatment or acoustic enclosure such that insertion loss of 25dB(A) is obtained or ambient noise standards are met, whichever is on the higher side.

20.5.2 Protection against the effects of occupational noise exposure shall be provided when the

sound levels exceed those shown in Table of this section when measured on the A-scale of a standard sound level meter at slow response.

20.5.3 When employees are subjected to sound levels exceeding those listed in Table of this

section, feasible administrative or engineering controls shall be utilized. If such controls fail to reduce sound levels within the levels of the table, personal protective equipment shall be provided and used to reduce sound levels within the levels of the table.

Table: Permissible Noise Exposures

SN Duration per Day (hours) Sound Level (Slow Response) dBA

1 8 90

2 6 92

3 4 95

4 3 97

5 2 100

6 1.5 102

7 1 105

8 0.5 110

9 0.25 or less 115

20.5.4 If the variations in noise level involve maxima at intervals of 1 second or less, it is to be

considered continuous. In all cases where the sound levels exceed the values shown herein, a continuing, effective hearing conservation program shall be administered.

20.5.5 When the daily noise exposure is composed of two or more periods of noise exposure of

different levels, their combined effect should be considered, rather than the individual effect of each. Exposure to different levels for various periods of time shall be computed according to the formula as given below

𝐹𝑒 =𝑇1𝐿1+𝑇2𝐿2

+⋯+𝑇𝑛𝐿𝑛

Where: Fe The equivalent noise exposure factor T The period of noise exposure at any essentially constant level L The duration of the permissible noise exposure at the constant level (from Table) If the value of Fe exceeds unity (1) the exposure exceeds permissible levels.

20.5.6 A sample computation showing an application of the above formula is as follows. An

employee is exposed at these levels for these periods:

110 dBA 1/4 hour 100 dBA 1/2 hour 90 dBA 1 1/2 hours

Then,

𝐹𝑒 =1/4

0.5+1/2

2+1.5

8= 0.5 + 0.25 + 0.188 = 0.938

Since the value of Fe does not exceed unity, the exposure is within permissible limits.


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20.5.7 Construction material should be handled and transported in such a manner as not to create unnecessary noise as outlined below.

20.5.8 Under the Contract, the Contractor shall:

(1) perform work within the procedures outlined herein and comply with applicable codes,

regulations, and standards established by the Central and State Government and their agencies.

(2) Keep noise to the lowest reasonably practicable level. Appropriate measures will be

taken to ensure that construction works will not cause any unnecessary or excessive noise, which may disturb the occupants of any nearby dwellings, schools, hospitals, or premises with similar sensitivity to noise. Use equipment with effective noise-suppression devices and employ other noise control measures as to protect the public.

(3) Schedule and conduct operations in a manner that will minimize, to the greatest extent

feasible, the disturbance to the public in areas adjacent to the construction activities and to occupants of buildings in the vicinity of the construction activities.

(4) The Contractor shall submit to the Employer’s Representative a Noise Monitoring and

Control Plan (NMCP) under contract specific Site Environmental Plan. It shall include full and comprehensive details of all powered mechanical equipment, which he proposes to use during daytime and night-time and of his proposed working methods and noise level reduction measures. The NMCP shall include detailed noise calculations to demonstrate the anticipated noise generation by the Contractor.

(5) The NMCP prepared by the Contractor shall guide the implementation of construction

activity. The NMCP will be reviewed on a regular basis and updated as necessary to assure that current construction activities are addressed. It shall appear as a regular agenda item in project coordination meetings.

20.5.9 Vibration Level Limits

The vibration level limits at historical sites adjacent to the alignment shall conform to revised version of the German Standard (DIN 4150). The scheme for monitoring vibration level at these historical sites shall be submitted to Employer’s Representative for his approval. The scheme shall include: (1) monitoring requirements for vibrations at regular intervals throughout the construction

period. (2) pre-construction structural integrity inspections of historic and sensitive structures in

project activity. (3) Information dissemination about the construction method, probable effects, quality

control measures and precautions to be used

20.6 Waste

20.6.1 The Contractor shall handle waste in a manner that ensures they are held securely without loss or leakage thus minimising potential for pollution.

20.6.2 The Contractor shall remove waste in a timely manner. Scrap and waste material shall be

removed and disposed off at landfill sites after obtaining approval of concerned department of Municipal Corporation of Pune for its disposal.

20.6.3 Burning of wastes is prohibited. The Contractor shall not burn debris or vegetation or

construction waste on the Site but remove it in accordance with Clause 20.6.2 above.


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20.6.4 The Contractor shall maintain and clean waste storage areas regularly.

20.6.5 If encountered or generated as a result of Contractor’s activity, then waste classified as hazardous under the “Hazardous Wastes (Management, Handling & Trans-boundary Movement) Rules, 2008” and chemicals classified as hazardous chemicals under “The Manufacture, Storage and Import of Hazardous Chemical Rules, 1989 and Environment (Protection) Act, 1986 shall be disposed off in a manner in compliance with the procedure given in the rules under the aforesaid rules / act.

20.6.6 The Contractor shall ensure that oily waste including oil soaked rags/cotton is disposed off

to agency authorised to dispose such waste. The Contractor shall sell discarded batteries to the authorised recycler of such items.

20.7 Prevention of Mosquito Breeding

20.7.1 Measures shall be taken to prevent mosquito breeding at site. The measures to be taken

shall include:

(1) empty cans, oil drums, packing and other receptacles which may retain water shall be deposited at a central collection point and shall be removed from the Site regularly;

(2) still waters shall be treated at least once every week with oil in order to prevent

mosquito breeding; (3) Contractor’s Equipment and other items on the Site which may retain water shall be

stored, covered or treated in such a manner that water could not be retained. (4) Water storage tanks shall be suitably provided.

20.7.2 Posters in Hindi, English and Marathi which draw attention to the dangers of permitting

mosquito breeding shall be displayed prominently on the Site.


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CHAPTER 21

21.0 PHOTOGRAPHS

21.1 Photographs

21.1.1 Colour progress photographs showing the progress of the Works and the quality of the materials and workmanship shall be taken by the Contractor. The photographs shall be taken by a professional photographer, nominated by the Contractor and reviewed without objection by the Engineer. Processing shall be carried out by a competent processing firm, nominated by the Contractor and reviewed without objection by the Engineer. The photographs shall be taken under the direction of the Employer or the Engineer at locations selected by the Employer or the Engineer. Photographs shall be taken once every month and at other times instructed by the Employer or the Engineer.

21.1.2 Digital camera shall be used for photography. One colour print of each progress

photograph shall be provided to the Engineer not more than 2 days after the photographs are taken. The Engineer shall select the sets of progress photographs to be provided. The selected sets shall be provided not more than 2 days after the Engineer has selected the sets. The following shall be provided for the Engineer:

(1) one set of each selected progress photograph comprising three colour prints; (2) albums for the photographs; and (3) CD/DVD/ USB Drive containing the photographs.

21.1.3 The Contractor may propose to hand over a digital camera to the Engineer for such

purposes to meet the requirements of this Chapter. The Engineer shall at his discretion, review the proposed system for practical and technical compliance.

21.1.4 Colour progress photographs shall provide a fair representation of the Works. A minimum

of 24 photographs per month shall be submitted to the Engineer.


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CHAPTER 22

22.0 TEMPORARY WATER AND ELECTRICITY SUPPLY

22.1 Water and Electricity Supply for the Contractor by the Project Civil Works Contractors

22.1.1 The Contractor, during construction phase, may use the following water and power supply

provided by the Project Civil Works Contractors.

(1) at the ends of each station, a mains water supply of 25mm diameter complete with stopcock; and

(2) provided at the ends and at the midpoint of each station, and at agreed locations

along the tunnel (at a maximum distance of 150m), 415V three phase / 230 V single phase power supply, suitably earthed and each with sockets capable of receiving three (3) electric plugs of the size and type used for hand-held construction equipment.

22.1.2 Such provisions shall be available to the Contractor from the commencement of the first

installation interfacing and co-ordination period until the permanent water and power supplies are connected and commissioned within the respective stations. The Contractor will be responsible for reimbursement to the Project Civil Works Contractor of the utility charges for consumption of mains, water and electricity by the Contractor from such provisions, which will be individually metered for each systemwide contractor. The Contractor will charge the systemwide contractors for consumption of mains, water and electricity at the same unit rates as paid by the Project Civil Works Contractor to the water and electricity authorities for such utilities.

22.2 Applicability

22.2.1 Where the Contractor is required to provide temporary electrical supplies, or to use,

extend or expand on temporary supplies installed by others, all such activity shall be executed in accordance with Clauses 22.3 to 22.18 inclusive.

22.2.2 When the Contractor makes use of temporary electrical supplies provided by other, viz.

Project Civil Works Contractors, he will observe and comply with the requirements of this Chapter.

22.3 Work on Site

22.3.1 The Contractor shall nominate a representative whose name and qualifications shall be

submitted in writing to the Engineer for review not later than 4 weeks before the appointment and who shall be solely responsible for ensuring the safety of all temporary electrical equipment on Site. The Contractor shall not install or operate any temporary Site electrical systems until this representative is appointed and has commenced duties.

22.3.2 The name and contact telephone number of the representative having been reviewed

without objection by the Engineer shall be displayed at the main distribution board for the temporary electrical supply so that he can be contacted in case of an emergency.

22.3.3 The Contractor shall submit schematic diagrams and the details of the equipment for all

temporary electrical installations, and these diagrams together with the temporary electrical equipment shall be submitted to the Engineer for review.

22.3.4 All electrical installation work on Site shall be carried out in accordance with the

requirements laid down in BS 7375 and the Specification. All work shall be supervised or executed by qualified and suitably categorised electricians, who are registered as such under the Electricity Act 2003 and concerned regulations.


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22.4 Electrical General

22.4.1 Temporary electrical Site installations and distribution systems shall be in accordance with: (1) Indian Electricity Rule 2005 (with latest amendments); (2) The Power Companies’ Supply Rules; (3) Electricity and its subsidiary regulations; (4) IEE Wiring Regulations (16th Edition); (5) BS 7375 Distribution of Electricity on Construction and Building Sites; (6) BS 4363 Distribution Assemblies for Electricity Supplies for Construction and Building

Sites; and (7) BS 6164 Safety in Tunnelling in the Construction Industry. (8) Any other applicable national standards

22.4.2 Materials, Appliances and Components

All materials, appliances and components used within the distribution system shall comply with BS 4363 and BS 7375 Appendix A.

22.4.3 Design Considerations

22.4.3.1 Distribution equipment utilised within the temporary electrical distribution system shall

incorporate the following features:

(1) flexibility in application for repeated use; (2) suitability for transport and storage; (3) robust construction to resist moisture and damage; and (4) safety in use.

22.4.3.2 All cabling shall be run at high level whenever possible and firmly secured to ensure they

do not present a hazard or obstruction to people and equipment.

22.4.3.3 The installation on Site shall allow convenient access to authorised and competent operatives to work on the apparatus contained within.

22.5 Mains Voltage

22.5.1 The Site mains voltage shall be as the Electricity Companies’ Utility supplies, 415V 3-

phase 4 wire system.

22.5.2 Single-phase voltage shall be as the Electricity Companies' Utility supplies, 230V supply.

22.5.3 Reduced voltages shall conform to BS 7375.

22.6 Types of Distribution Supply

22.6.1 The following voltages shall be adhered to for typical applications throughout the distribution systems:

(1) fixed plant - 415V 3 phase; (2) movable plant fed by trailing cable - 415V 3 phase; (3) installations in Site buildings - 230V 1 phase; (4) fixed flood lighting - 230V 1 phase; (5) portable and hand held tools - 115V 1 phase; (6) Site lighting (other than flood lighting) - 115V 1 phase; and (7) portable hand-lamps (general use) - 115V 1 phase.


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22.6.2 When the low voltage supply is energised via the Employer's transformer, any power utilised from that source shall be either 415V 3 phase or 230V single phase as appropriate. The Contractor shall carry out any conversion that may be necessary to enable him to use power from that source.

22.7 Protection of Circuits

22.7.1 Protection shall be provided for all main and sub-circuits against excess current, residual

current and earth faults. The protective devices shall be capable of interrupting (without damage to any equipment or the mains or sub-circuits) any short circuit current that may occur.

22.7.2 Discrimination between circuit breakers, circuit breakers and fuses shall be in accordance

with:

(1) BS 88; (2) BS EN 60898; and (3) BS 7375; (4) Relevant Indian Standards

22.8 Earthing

22.8.1 Earthing and bonding shall be provided for all electrical installations and equipment to

prevent the possibility of dangerous voltage rises and to ensure that faults are rapidly cleared by installed circuit protection.

22.8.2 Earthing systems shall conform to the following standards:

(1) IS 3043 (2) Indian Electricity Rule 2005 (as amended) (3) IEE Wiring Regulations (16th Edition); (4) BS 7430; (5) BS 7375; and (6) IEEE Standard 80 Guide for Safety in AC Substation Grounding

22.9 Plugs, Socket Outlets and Couplers

Low voltage plugs, sockets and couplers shall be colour coded in accordance with BS 7375, and constructed to conform to BS EN 60309. High voltage couplers and 'T' connections shall be in accordance with BS 3905.

22.10 Cables

22.10.1 Cables shall be selected after full consideration of the conditions to which they will be

exposed and the duties for which they are required. Supply cables up to 3.3KV shall be in accordance with BS 6346. The cable armouring shall be used as the earth return in conditions where the cable is continuously extended and not subject to continuous movement after installation.

22.10.2 For supplies to mobile or transportable equipment where operation of the equipment

subjects the cable to flexing, the cable shall conform to one of the following standards appropriate to the duties imposed on it:

(1) BS 6708 flexible cables for use at mines and quarries; (2) BS 6007 rubber insulated cables for electric power and lighting; and (3) BS 6500 insulated flexible cords and cables

22.10.3 Where low voltage cables are to be used, reference shall be made to BS 7375. The

following standards shall also be referred to particularly for underground cables:


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(1) BS 6346 for armoured PVC insulated cables; and (2) BS 6708 Flexible cables for use at mines and quarries

22.10.4 All cables which have a voltage to earth exceeding 65 V (except for supplies from welding

transformers to welding electrodes) shall be of a type having a metal sheath and/or armour which shall be continuous and effectively earthed. In the case of flexible or trailing cables, such earthed metal sheath and/or armour shall be in addition to the earth core in the cable and shall not be used as the sole earth conductor.

22.10.5 Armoured cables having an over-sheath of polyvinyl chloride (PVC) or an oil resisting and

flame retardant compound shall be used whenever there is a risk of mechanical damage occurring.

22.10.6 For resistance to the effects of sunlight, overall non-metallic covering of cables shall be

black in colour.

22.10.7 Cables which have applied to them a voltage to earth exceeding 12V but not normally exceeding 65 V shall be either one of the type as described in Clause 22.10.5 above or alternatively of a type insulated and sheathed with a general purpose or heat resisting elastomer.

22.10.8 All cables that are likely to be frequently moved in normal use shall be flexible cables.

22.10.9 Flexible cables shall be in accordance with BS 6500 and BS 7375.

22.11 Lighting Installation

22.11.1 Lighting circuits shall be run separate from other sub-circuits and shall be in accordance

with BS 7375 and BS 4363.

22.11.2 Voltage shall not exceed 55 V to earth except when the supply is to a fixed point and where the lighting fixture is fixed in position.

22.11.3 Luminaries shall have a degree of protection not less than IP 54. In particularly bad

environments where the luminaries are exposed to excesses of dust and water, a degree of protection to IP 65 shall be employed.

22.11.4 Where the Engineer requires Site inspection of the Works, the Contractor shall upgrade

the lighting level to a minimum of 200 lux by localised lighting in all areas.

22.11.5 Use of wire guards or other such devices shall provide mechanical protection of luminaries against damage by impact whenever risk of damage occurs.

22.12 Electrical Motors

22.12.1 Totally enclosed fan cooled motors to BS 4999: Part 105 shall be used.

22.12.2 Motor control and protection circuits shall be as stipulated in BS 6164. Emergency stops

for machinery shall be provided.

22.13 Inspection and Testing

22.13.1 Electrical installations on Site shall be inspected and tested in accordance with the requirements of the Indian Electricity Rules 2005 (as amended) and IEE Wiring Regulations (16th Edition).

22.14 Identification


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Identification labels of a type reviewed without objection by the Engineer shall be affixed to all electrical switches, circuit breakers and motors to specify their purpose.

22.15 Maintenance

Strict maintenance and regular checks of control apparatus and wiring distribution systems shall be carried out by an electrician (duly qualified to carry out the said checks) to ensure safe and efficient operation of the systems. The Contractor shall submit for review by the Engineer details of his maintenance schedule and maintenance works record.

22.16 Maintenance Record

All portable electrical appliances shall be permanently numbered (scarf tag labels or similar) and a record kept of the date of issue, date of the last inspection carried out and the recommended inspection period.

22.17 Metering

22.17.1 The Contractor shall install a separately metered and invoiced supply or supplies of

electricity for: (1) Site fabrication facilities; (2) Site workshops and work-yards; and (3) Site offices and stores

22.18 Inability to Supply

Wherever, the Project Civil Works Contractor is not in a position to supply construction power and water supply to the systemwide contractor, he (the systemwide contractor) shall arrange for his own separate construction power and water supply.


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CHAPTER 23

23.0 MOCK-UPS, PROTOTYPES AND SAMPLES

23.1 Requirements

23.1.1 The Contractor shall produce mock-ups, prototypes and samples as specified in the PS.

23.1.2 Samples may be subject to testing and investigation by the Employer and shall in no way be incorporated into the Permanent Works.

23.1.3 Samples shall become the property of the Employer.

23.2 Purpose

23.2.1 The mock-ups, samples and prototypes shall demonstrate the proposed design and/or

design options. Any mock-ups shall increase in levels of detail and finish as the design progresses.

23.2.2 Mock-ups and prototypes may generally be produced initially with “dummy” equipment

items unless otherwise specified, so long as there is sufficient detail to evaluate the operability and/or maintainability aspects of the proposed layout.

23.2.3 The mock-ups and prototypes shall be constructed at the Contractor's premises unless

otherwise specified in the PS.

23.3 Review

23.3.1 The Engineer will conduct a minimum of three formal reviews initially at the place of manufacture.

23.3.2 The complete and agreed mock-ups and prototypes shall be suitable for transportation to,

and display in Pune for final review by the Engineer and the Employer.

23.3.3 The Contractor shall transport and set up such mock-ups and prototypes at a nominated site in Pune. After each review, the Contractor shall incorporate the Engineer's review comments into the mock-ups and prototypes prior to the next scheduled review.


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Appendix 1

1.0 MONTHLY PROGRESS REPORT Note: Contractor shall refer to Para 2.3 of General Specifications regarding Employer’s IT Requirements. The requirements pursuant to this Appendix shall be effected through the ‘Integrated Project Management Platform’.

1.1 Topics

1.1.1 The Monthly Progress Report required under Clause 2.16 of the GS shall include as a minimum the following sections and topics: (1) Executive summary, highlighting any matters of concern and explaining corrective

action to be taken (2) Safety and quality issues (including any necessary corrective action taken or

proposed to prevent the re-occurrence of the non-conformities) (3) Programme and overall progress (4) Physical progress report (see Clause 2.19 of GS) (5) Achievement of Key Dates and Milestone Dates (6) Design Status (7) Design and design coordination progress (8) Design submission and Engineer’s response status (list of all design submissions

showing current status to be appended) (9) Manufacturing status (10) Materials ordered / in process (11) Equipment manufactured / procured (12) Factory Acceptance Test status (13) Delivery status (14) Shipping / transportation activity (15) Deliveries to MAHA-METRO (including release certificate reference) (16) Free issue items (where applicable) (17) Installation / erection on Site (18) Site surveys (where applicable) (19) Equipment installation and erection (20) Completion of remedial works / Site acceptance (21) Safety audit and safety report (22) Test and Commissioning (23) Commissioning activity (24) Planned vs. Actual Table (25) Remedial works (26) System Integration tests (27) Documentation (28) Functional design (29) Operation Manuals (30) Maintenance Manuals (31) Training Manuals (32) As-built drawings (33) Spares / special tools / test equipment (34) Training (35) Employer’s Taking Over of Works (part or whole of Works) (36) Taking Over Certificate (37) Maintenance issues (38) Defects Liability (39) Contractual / Commercial (40) Payments / invoices (41) Engineer’s instructions and variation orders (42) Claims / potential claims (43) Contractor’s resources (details of all staff and sub-contractors engaged on the Works) (44) Progress photographs


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1.2 Progress Reports

1.2.1 The Monthly Progress Reports shall be accompanied by:

(1) the Works Programme, marked to show the status of progress to date; (2) control schedules for document submissions and issues of a repetitive or multiple

nature; (3) where appropriate, exception reports to highlight any problem areas including any

submissions and design information which are overdue; (4) the Key Date and Milestone report, in accordance with Clause 2.18 of the General

Specification; (5) the programme analysis report, in accordance with Clause 2.17 of the General

Specification; (6) the physical progress (earned value) report, in accordance with Clause 2.19 of the

General Specification; (7) “S” curve showing current status of the Contract; (8) a full list of all submissions and their current status in comparison to the Submissions

Programme. Special commentary shall be provided for each item that is late to this programme giving the reasons for the delay and the proposed corrective action that will ensure that the delay does not affect any overall or stage completion dates, particularly those that interface with other parties;

(9) identification and discussion of significant accomplishments, problem areas

encountered, actions taken or planned to resolve actual or potential problems and conflicts, and other comments or proposals on matters (including the interfacing works) affecting or likely to affect the Works; and

(10) a critical items action list which identifies outstanding problems associated with the

timely completion of the Works including anticipated actions for their resolution.

1.2.2 The programmes shall show current status to provide a comparison between the Works Programme and reported progress.

1.2.3 Actual progress shall be reported for each activity in the Works Programme in the following terms:

a. the percentage of the work which is complete; b. the remaining duration of the work; c. the actual start date; and d. the actual completion date.

1.2.4 Actual progress shall reflect the physical scope of the work that has been completed and shall

not be calculated based on elapsed time or hours worked. Any automatic statistical indications in the Contractor’s software that is based on this principle shall be disabled.

1.2.5 Each Monthly Progress Report shall include a programme activity listing and an analysis report. All activities that have negative float shall be analysed by the Contractor to identify the impact on the achievement of Key Dates.

1.3 Copies


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1.3.1 The Contractor shall submit 1 unbound original and 4 bound hard copies of Monthly Progress Reports and of the accompanying documents plus one copy in electronic format.


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Appendix 2

2.0 Not Used


Feb 2018 Page 154 of 170

Appendix 3

3.0 SUBMISSION FOR REVIEW REQUEST FORM

Submission for Review Request

Reference No. (see Paragraph 4.3.2)

Date:

Programme reference and scheduled date:

Submission Stage: (see Paragraph 3.5.1.1)

Title:

We hereby submit for review by the Engineer the documents or articles listed below: (Introduction and list of items submitted – see Paragraph 4.3.5.2 – continue on separate sheet if necessary) ......... .......... ........... I confirm that the material submitted is in full compliance with the Contract.

Signed: (Contractor’s responsible engineer)

Engineer’s Response:

Dated:

The material submitted has been reviewed and the following decision is given:

“No Objection” / “No Objection Subject To” (see below) / “Rejected” (see below)

The following comments are made and a re-submission is to be made by the Contractor within 10 working days demonstrating fully how all of these are taken into account: ................. ................. ................. (Engineer’s comments)

Signed: (Engineer)


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Appendix 4

4.0 SCHEDULE OF ITEMS TO BE SUBMITTED BY CONTRACTOR This Appendix lists the principal items to be submitted by the Contractor for review by the Engineer. This list is not exhaustive and the Contractor is reminded to satisfy itself of the requirements for all submissions whether or not they are included within this Appendix.

Article Ref Para To be submitted

Availability, Reliability and Maintainability deliverables

1.10 In accordance with RAM deliverables described in EN50126

Initial version of the Works Programme

2.5.1.1 Within 7 days of the Commencement Date of the Works

Works Programme 2.5.1.2 Within 60 days of the Commencement Date of the Works

Design Submissions Programme

2.6.1 Within 30 days of the Commencement Date of the Works

Design, Procurement and Manufacturing Programme


Material Control Schedule

2.7.5 As stated in the PS, or if none is given, within 60 days of the Commencement Date of the Works

Factory Testing Programme


Installation Programme 2.8.1 Preliminary version within 60 days of the Commencement Date of the Works. Full version as stated in the PS or as directed by the Engineer

Testing & Commissioning Programme

2.9.1 Preliminary version within 60 days of the Commencement Date of the Works. Full version as stated in the PS or as directed by the Engineer

Time Chainage Programme

2.12.1 60 days before the start of Site works

Monthly Progress Report and supporting documentation

2.16.1 The 5th day of each month.

Physical Progress Report (baseline)


Contractor’s Project Plan


Particulars of Contractor’s Representative

3.3.1.6 (6) 30 days before the Commencement Date of the Works

Interface Management Plan

3.3.2.2 Within 60 days of notification from the Engineer of the identity of each Project Contractor

Detailed Interface Document

3.3.2.4 Within 90 days of notification from the Engineer of the identity of each Project Contractor

EMC Management Plan 3.4.7 As stated in the PS, or if none is given, within 60 days of the Commencement Date of the Works

Software Quality Assurance Plan


Design Plan 3.5.1 As stated in the PS, or if none is given, within 60 days of the Commencement Date of the Works

Design Verification and Validation Plan


Contractor’s Factory Testing Plan


Test Reports 3.5.3.7 Immediately after the completion of Factory Testing

Procurement, 3.5.4 As stated in the PS, or if none is given, within 60


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Manufacturing and Delivery Plan

days of the Commencement Date of the Works

Contractor’s Health and Safety Documentation

3.6.2.2 Within 30 days of the Commencement Date of the Works

Environmental Management Plan

3.6.3.3 (3) 30 days prior to the commencement of construction activities

Environmental Mitigation Implementation Schedule (EMIS)

3.6.3.4 (2) 30 days prior to the commencement of construction activities

Traffic Management Submissions

3.6.3.5 60 days before implementation proving all relevant details and implications

Commissioning Plan 3.7.2.1 First draft within 180 days of the Commencement Date of the Works

Installation Test Schedule

3.7.2.2 (2) As stated in the PS or if not given, not later than two months in advance of the Date scheduled for commencement of respective tests

Partial Acceptance Tests Plan

3.7.2.2 (2) As stated in the PS or if not given, not later than four months in advance of the Date scheduled for commencement of respective tests

System Acceptance Tests Plan

3.7.2.2 (2) As stated in the PS or if not given, not later than four months in advance of the Date scheduled for commencement of respective tests

Integration Tests & Commissioning Plan

3.7.2.2 (2) As stated in the PS or if not given, not later than three months in advance of the Date scheduled for commencement of Tests on Completion

Operation and Maintenance Manuals Plan

3.7.3.2 As stated in the PS or if not given, not later than nine months prior to the issue of the Taking Over Certificate for the Works

Training and TOT Plan 3.7.4.2 As stated in the PS or if not given, not later than six months prior to the issue of the Taking Over Certificate for the Works

Spare Management Plan

3.7.5.2 As stated in the PS or if not given, not later than six months prior to the issue of the Taking Over Certificate for the Works

Defects Liability Management Plans

3.7.6 Upon issuance of the Taking Over Certificate

Project Document Control Procedure


Quality Manual 5.2.3 Within 30 days of the Commencement Date of the Works

Quality System Procedures


Details of Quality Manager


Proposed Corrective & Preventive Action Plan

5.2.7 Within 14 days of issue of CAR

Management Quality Plan

5.3 Within 30 days of the Commencement Date of the Works

Design Quality Plan 5.4 Within 30 days of the Commencement Date of the Works

Manufacturing Quality Plan

5.5 60 days prior to the commencement of the manufacturing works

Site Quality Plan 5.6 60 days prior to the commencement of the construction works

Reports of Quarterly Quality Audits

5.8.2 Every Three months

Quality Control Register 5.9 7th working day of every month


Feb 2018 Page 157 of 170


Software deliverable 6.1 As stated in PS, or if none is given, in accordance with the requirements of EN 50128

Operational Safety Report (Software)

6.6 Within 30 days of completion of design and within 30 days of completion of Commissioning

Packaging Materials & Procedures


Latest drawings, test procedures, specifications and quality documentation for inspection of equipment

9.2.7.4 At least 15 days prior to each First Article Inspections ( FAI )

Installation Tests Reports

9.4.3.3 Immediately after the completion of each test

Proposed Partial Acceptance Test Records

9.4.4.7 As stated in the PS or if not given, not later than two months in advance of the Date scheduled for commencement of tests

Partial Acceptance Tests Records

9.4.4.9 Immediately following the successful Partial Acceptance Tests

System Acceptance Tests Records

9.4.5.8 Immediately following the successful System Acceptance Tests

Integration Tests & Commissioning Records

9.4.6.8 Immediately following the successful Tests on Completion of the system

Service Trial Records 9.4.7.8 Immediately following the successful Service Trial of the system

Summaries of Inspection and/or Test

9.6.12 7th day of the following month

Operation & Maintenance Documentation (Draft Version)

11.4.1 As stated in the PS or if not given, not later than 6 months prior to the issue of the Taking Over Certificate for the Works

Operation & Maintenance Documentation (Final Version)

11.4.1 As stated in the PS or if not given, not later than 1 months prior to the issue of the Taking Over Certificate for the Works

Operation & Maintenance Documentation (Final Submission)

11.4.3 At a date set by the Engineer

Spare Parts List 13.1.3 As stated in the PS

Construction & Installation Plan

14.1.1 As stated in the PS, or if none is given, within 60 days of the Commencement Date of the Works, and in any case not less than 5 weeks before starting the construction of the Works on Site

Proposals for the construction of the Engineer’s Site Offices

15.6 Within 14 days of the Commencement Date of the Works

Particular Uses of Site 17.2.1 Within 14 days of the Commencement Date of the Works

Method Statements Programme

18.5.6.4 Within 30 days of the Commencement Date of the Works or at a date reviewed by the Engineer

Detailed written report of accidents, incidents and dangerous occurrence

18.6.4 Within 7 days of occurrence/accident

Name and qualification of safety representative

22.3.1 Not later than 4 weeks before appointment


Feb 2018 Page 158 of 170


for temporary site electricity


Feb 2018 Page 159 of 170

Appendix 5

5.0 TYPICAL TYPE TEST REQUIREMENTS

5.1 Electronic and Electrical Equipment The initial visual inspection shall be carried out to ensure that the equipment is of sound construction and, so far as can be ascertained, meets the requirements of the Specification.

5.1.1 Initial Performance Test (1) The initial performance tests shall consist of a comprehensive series of measurements of

the characteristics of the equipment to demonstrate that its performance is in accordance with its functional requirements, including detailed requirements of the Specification.

(2) This test shall normally be performed at an ambient temperature of 40°C +5°C while

supplied at its normal voltage and frequency, if relevant.

(3) This test shall extend to demonstrating compliance with any limitation on self-generated vibration or interference as stated in the Specification.

5.1.2 Modes of Testing

(1) Electrical tests will generally be applied to the 'external terminals' of the item of equipment

to be tested which are normally used to interface the subject equipment to other equipment or external circuits, e.g. power supply terminals, signal input/output terminals, frame (safety) earth terminals, etc. Tests may be applied in Common Mode and/or Series Mode, as described below.

(2) Common mode tests generally involve testing circuits with respect to the equipment's

frame earth. All accessible metal parts (intended to be connected to earth) are to be connected to the frame earth.

(3) All the terminals of the circuit to be tested shall be connected together, where practicable.

All terminals of circuits not involved in the test shall preferably be connected to earth. (4) For example, a common mode test on the AC power supply circuit of an item of

equipment would involve connecting all the supply circuit terminals together (e.g. phase (s) and neutral) and applying the test between those connected terminals and the equipment's frame earth terminal. The terminals of all other circuits, e.g. signal input/output terminals, shall preferably be connected to earth.

(5) Series mode tests generally involve testing circuit connections with respect to each other. (6) Where an item of equipment to be tested has a large number of identical interfaces

circuits series mode testing may be restricted to a representative sample of those interfaces, the proportion being to the agreement of the Engineer.

(7) The test is applied between terminals (other than the earth terminal) either associated

with the same circuit (e.g. between power supply terminals) or associated with different circuits (e.g. between input signal terminals and output signal terminals). All terminals of circuits not involved in the test shall preferably be connected to earth.

(8) For example, a series mode test on an RTU analogue input circuit would involve applying

the test between the positive and negative analogue signal input terminals, preferably with all other terminals connected to earth.

(9) For each item of equipment to be tested, there may be many combinations of terminals to

which series mode testing could be applied. Not al l combinations may be relevant or subject to the conditions against which a particular test is to be performed. However, the


Feb 2018 Page 160 of 170

Contractor shall test all combinations unless specifically agreed otherwise by the Engineer.

5.2 Mechanical Tests

5.2.1 Drop Test

(1) The drop test is intended to be carried out on units and sub-assemblies that are portable.

It is not intended that it be carried out on complete racks of equipment. (2) Casings or dust covers, which have to be removed for servicing, shall be removed after

subjecting equipment to this test to inspect for damage. The test is designed to reveal any weakness of assembly and to ensure that the component mountings are of adequate strength. It is not designed to check whether doors or windows made of glass will fracture and to this end meters, glass windows, etc., may be removed.

(3) The equipment shall not be deemed to have failed the drop test if externally accessible

components such as control knobs or connectors are damaged. The Engineer however reserves the right to ask for some form of guard, to prevent such damage, to be fitted at the Contractor's cost.

(4) Test conditions shall be in accordance with IEC 68-2-31. Information required for

paragraph 4.2 of that test:

a. Visual inspection and function test to specification. b. Assembled ready for installation. c. Connectorised cables removed, casings or covers in place. d. Not applicable. e. All. f. 25mm, 6 times. g. 25mm, 6 times.

i. Visual inspection and function test to specification. ii. Topple (or push over) test is not required.

5.2.2 Vibration Test

(1) The vibration test is designed to reveal any parts or components of the equipment that

may be prone to any resonance severe enough to cause possible damage or malfunctioning.

(2) The test shall be in accordance with IEC 68-2-6 1982. Information required for Chapter 12

of that standard:

a. Measuring Points: If four or less fixing points are used for the specimen, these shall also be used as checkpoints. If more than four fixing points are used then those nearest the corners shall be used as checkpoints. The checkpoints shall be located as close as possible to the fixing points.

b. Transverse Motion: Any transverse motion in excess of that specified in the above

standard clause 4.1.2 shall be noted and recorded in the test results.

c. Distortion: As defined in clause 3 in excess of the limits in clause 4.1.3 of the above standard shall be noted as defined in clause 4.1.3 paragraph 4 of the same standard.

d. Derivation of Control Signal Single point

e. Tolerances at check points shall be as clause 4.1.4.2 of the above standard. Where

these cannot be achieved, the actual values shall be recorded.


Feb 2018 Page 161 of 170

f. Monitoring of Specimen(s): The equipment shall be rigidly mounted in a jig so designed as to transmit the input vibration with minimum modification

5.2.3 Vibration Test 1

(1) Equipment intended for use with vibration isolators shall normally be tested with its

isolator. When this is not possible, the equipment shall be rigidly secured to the vibrator and the input vibration levels modified to include transmissibility of the isolators.

(2) Equipment under test is to be mounted in its normal operational attitude. (3) Frequency Range: See Chapter 6, Paragraph 5.5 (Equipment Requirements). (4) Vibration Amplitude: See Chapter 6, Paragraph 5.5 (Equipment Requirements). (5) Special crossover frequency: See Chapter 6, Paragraph 5.5 (Equipment Requirements). (6) Type and duration of endurance:

a. Endurance by sweeping 6 hours, i.e. 2 hours per axis b. Endurance at critical frequencies (as defined in the above standard clause 8.1): 1

minute at each frequency providing not more than four such frequencies exist per axis.

(7) Pre-conditioning: None. (8) Initial measurements Functional test to the appropriate test procedure. (9) Axes of vibration: Three mutually perpendicular axes in turn. (10) Force Limitation: Not required. (11) Test stages to be performed in the sequence below: (12) Vibration response investigation. (13) Endurance at fixed frequencies derived from vibration response investigation. (14) Endurance by sweeping (15) The equipment functionality shall be verified throughout the sweep test to the appropriate

test procedure. (16) Action to be taken after vibration response investigation. If less than four critical

frequencies are found in each axis, then endurance testing for the prescribed duration shall be performed at each frequency.

(17) Final response test not required. (18) Predetermined frequencies shall be derived from the vibration response investigation. (19) Conditioning at the resonance frequencies of the specimen on its isolators (where fitted)

shall be included. (20) Final measurements Functional test to the appropriate test procedure. (21) Any resonance liable to affect the performance or reliability of the equipment shall be

reduced to an acceptable level by suitable modifications and the complete test repeated.

5.3 Environmental Tests


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5.3.1 Dry Heat Test

(1) The dry heat test shall be carried out on each complete piece of equipment or assembly,

with all doors and covers being in place and closed as in normal operation. (2) Test conditions shall be in accordance with IEC 68-2-2. Information required for

paragraph 44 of that test:

a. Laboratory ambient. b. Visual inspection. c. Assembled and mounted in rack, enclosure or cabinet ready for operation or

installation. d. On. e. Maximum class temperature (see Chapter 6, Chapter 5.2, Equipment Requirements)

for 16 hours. f. At maximum class temperature after 16 hours, switch on and function test to

specification. g. Recovery at laboratory ambient. h. Visual inspection and function test to specification.

5.3.2 Low Temperature Test (in case applicable for Pune ambient temperature range)

(1) The low temperature test shall be carried out on each complete piece of equipment or

assembly, with all doors and covers being in place and closed as in normal operation. (2) Test conditions shall be in accordance with IEC 68-2-1. Information required for


a. Laboratory ambient. b. Visual inspection and function test to specification. c. Assembled and mounted in rack, enclosure or cabinet ready for operation or

installation. d. Off. e. Minimum class temperature (see Chapter 6, Paragraph 5.2, Equipment

Requirements) for 16 hours. f. At minimum class temperature after 16 hours, switch on and function test to

specification. g. Recovery at laboratory ambient. h. Visual inspection and function test to specification.

5.3.3 Change of Temperature Test

(1) If both Dry Heat and Low Temperature Tests are required (as decided by the Engineer)

they may be replaced by a single test in accordance with IEC 68-2-14. (2) Information required for paragraph 2.9 of that test:

a. Assembled and mounted in rack, enclosure or cabinet ready for operation or installation.

b. Minimum class temperature. c. Maximum class temperature. d. Per Minute. e. One. f. Visual inspection. g. On. h. Hours. i. None. j. Recovery at laboratory ambient. k. Visual inspection and function test to specification.


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5.3.4 Damp Heat Test

(1) The damp heat test shall be carried out on each complete piece of equipment or

assembly, with all doors and covers being in place and closed as in normal operation. (2) Test conditions shall be in accordance with IEC 68-2-30. Information required for


a. Maximum class temperature, two cycles. b. Visual inspection and function test to specification. c. Switched on, ready to use. d. None. e. Variant 2. f. At maximum class temperature after 12 hours, function test to Specification. At 6

hours after the temperature starts to fall a further function test to specification. Tests to be repeated during second cycle.

g. Laboratory ambient conditions. h. None. i. Visual inspection and function test to specification within 4 hours.

5.3.5 Driving Rain Test

(1) The test conditions shall be in accordance with IEC 68-2-18 Method Rb 2.2. (2) Information required for paragraph 5.3.8 of that document:

a. Minutes/m2 for a minimum of 15 minutes. b. No preconditioning of seals. c. Visual inspection and function test to specification. d. Table V1: a = 60°. B = 60°C. duration = 10 minutes. e. Table V2: diameter = 0.40mm. water f low = 0.10 + 0.005 dm3/min. supply pressure =

80 kpa. (3) Equipment functioning throughout the test to be verified by testing. (4) Any ingress of water shall be reported to the Engineer, the equipment shall be visually

inspected and function tested to Specification.

5.4 Electrical Tests

5.4.1 Supply Variations Measurements of equipment performance and maximum VA consumption shall be made, for supply voltage and frequency variations in all possible combinations of upper limit, normal and lower limit as detailed in the Specification. Throughout these tests, the equipment shall function in accordance with the Specification.

5.4.2 Supply Interruptions (1) The supply input to the equipment under test shall be interrupted for periods of 10 ms. (2) The tests shall be performed ten times at random for ac supplies and three times at

random for dc supplies. (3) The equipment shall be capable of withstanding these interruptions of supply input

without damage, interruption or resetting by the operator and shall continue to function and operate correctly in accordance with the Specification.

5.4.3 High Frequency Disturbance Test


Feb 2018 Page 164 of 170

(1) The High Frequency Disturbance test is required to determine whether an item of

equipment will continue to operate correctly when specified high frequency transients, representative of practical system conditions, are applied to the fully operating equipment.

(2) The test to be applied is based on IEC 255-4, Appendix E. (3) This test shall be performed for all equipment required to operate in environments subject

to Electrical Interference Class 2 or 3 (refer to Table 8-3) and shall be applied to the AC power supply terminals of that equipment.

(4) Waveform: a damped oscillatory wave with the envelope decaying to 50% of peak value

at the end of three to six cycles.

a. Frequency: 1 MHz tolerance + 10%. b. Source impedance: 200 ohm tolerance + 10%. c. Repetition rate: the test wave is applied to the equipment under test at a repetition

rate of 400 per second. d. Duration of test: 2 s tolerance + 10% 0% (see Sub-clause E5.2.7 of IEC 255-4,

Appendix E). e. Standard value of test voltage: Refer to Table 8-3. f. Test voltage tolerance: +0 -10%.

(5) The test voltage levels are the voltages at the output of the test circuit before the

equipment to be tested is connected to the test circuit terminals. (6) The test leads shall not be longer than 2 m. (7) The disturbance test shall be applied to the AC supply terminals of the equipment under

test in series mode (refer to Sub clause 2.1.3). (8) The tests shall be carried out with the equipment operating under nominal supply

conditions. (9) The equipment shall function in accordance with the Specification throughout the test.

5.4.4 Radio Frequency Interference (1) Portable radio communication transmitters are a common source of radio frequency

interference when they are operated in close proximity to equipment. A field strength of 10 V/m shall be assumed to be present in the VHF and UHF bands.

(2) These field strengths are approximately those expected at a distance of 35 cm from a 5

watt hand portable radiotelephone. These fields can induce currents of the order of 100 mA into cables, screens and metalwork.

(3) Other possible sources are low level radiation from adjacent equipment including

fluorescent lamps and signals from powerful but more distant radio, television and radar transmitters.

(4) The test to be applied is based on IEC 801-3 over a frequency range of 27 MHz to 500

MHz. The Severity Level (Chapter 5) to be applied shall be as follows: (5) The Contractor shall state to what field strength the equipment is immune, and include as

an option the cost of testing to 10 V/m. The equipment functionality and performance shall not be degraded during or after the RFI test.

(6) With regard to RTUs and tele-protection equipment, the command outputs shall be

immune to mal-operation with the cubicle doors open when the equipment is subjected to the radiated field strengths mentioned above.


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5.4.5 Electrical Stress Impulse Voltage Withstand

(1) The Impulse Voltage Withstand test is designed to demonstrate that the equipment has

been correctly designed to withstand, without damage, the electrical stresses to which it might be subjected in practice.

(2) The test to be applied is based upon IEC 255-4, Appendix E. (3) This test shall be performed for all equipment required to operate in environments subject

to Electrical Interference Class 2 or 3 (refer to Table 8-3) and shall be applied as follows:

a. To all AC power supply input and output terminals of all equipment. b. To all signal input/output, communication interface and DC power supply terminals of

RTU and tele-protection equipment. c. For the withstand test, the impulse voltage is a periodic transient voltage without

appreciable oscillations (see IEC Publication 60, High-voltage Test Techniques). (4) Impulse waveform: This shall be the standard 1.2/50 impulse specified in IEC Publication

60 and having the following tolerances:

a. Voltage rise time: + 30%. b. Voltage falls time: + 20%. c. Source impedance: 500 ohm tolerance + 10%. d. Source energy: 0.5 J tolerance + 10%. e. Standard value of test voltage: Refer to Table 3. f. Test voltage tolerance: +0 -10%.

(5) The test voltage levels are the voltages at the output of the test circuit before the

equipment to be tested is connected to the test circuit terminals. (6) The test leads shall not be longer than 2m. (7) Three positive and three negative impulses shall be applied at intervals of not less than

5s. Both common mode and series mode tests shall be performed (refer to Sub-clause 2.1.3).

(8) After the above tests, the equipment shall be visually inspected and function tested to

check compliance with the Specification.

5.4.6 Insulation Resistance (Across Isolating Barrier) Test (1) Where a barrier is used to provide isolation from external circuits, its insulation resistance

shall be measured. (2) If the barrier is required to withstand high voltage stresses, then it shall be stressed at the

specified voltage to demonstrate its withstand capability and a further insulation resistance test shall be made to ascertain that it has not been significantly degraded as a result of the stress being applied.

(3) The insulation of all circuits that include contacts of switches, relays or contractors for

isolation functions shall be tested for insulation resistance, R1. R1 shall not be less than 20 megohm when measured at 500 V dc.

(4) For switches, relays and contractors, 500 V is to be applied between:

a. The opposite ends of each circuit with contacts in open position. b. Both ends of each circuit to earth with contacts in closed position.


Feb 2018 Page 166 of 170

(5) For circuits intended for connection to 100 V ac or dc and above, 2 kV RMS shall be applied for one minute and this shall be followed by a further test for insulation resistance, R2.

(6) Stress to be applied between:

a. The individual circuits of this type b. Each circuit of this type and all other circuits including earth. These other circuits can

be strapped together electrically for the purpose of this test. (7) Final insulation resistance shall be such that either:

a. R2 > 20 megohm, or b. R2/R1 > 0.7

(8) For circuits intended to provide isolation against large differences in earth potential, the

barrier shall, after the initial resistance measurement, be stressed to the design voltage and this shall be followed by a further insulation resistance test.


Feb 2018 Page 167 of 170

Appendix 6

6.0 REQUEST FOR INSPECTION OF WORKS FORM Pune Metro Rail Project

CONTRACTOR:

REQUEST FOR INSPECTION OF WORKS

To the Engineer

Date

* Location ) Will be ready for your inspection ) on * Description of Works ) at prior to ) ) on at hrs

* Labour and plant to be used

Signed for Contractor. Received by

for Engineer

Date

Time

Filled in by Engineer Mr Please arrange inspection Mr Please check setting out Signed

Filled in by Inspector The above work was inspected and permission was given / not given to

proceed with next operation.

* The following remedial works were required

* Contractor informed verbally (to Mr by Mr on At hrs) * Remedial works inspected and permission given to proceed with next operation on At hrs) as supervised by Signed Date Time Verbal or written permission by the Engineer or his staff shall in no way relieve the Contractor of his responsibilities under the Contract. * To be completed if applicable.


Feb 2018 Page 168 of 170

Appendix 7

7.0 NOISE MONITORING (Used for this Contract for relevant activities viz. 25 & 33kV cable works from RSS to viaduct)

Noise Monitoring Instrument (a) Noise level meter, acoustic calibrator, portable wind speed meter and tripods shall be

provided for the use of the Engineer. (b) Noise level meter shall comply with the International Electro-technical Commission

Publications 651: 1979 (Type 1) and 804: 1985 (Type 1), and other noise measuring and analysis instrumentation shall be of a comparable professional quality.

(c) The noise level meter shall measure noise in terms of the A-weighted equivalent sound

pressure level (Leq). (d) The acoustic calibrator shall be able to generate a known sound pressure level at a

known frequency. (e) The portable wind speed meter shall be capable of measuring the wind speed in m/s.


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Appendix 8

8.0 FIRST AID REQUIREMENTS

8.1 Provisions by others

(a) First aid bases will be located at the main Project Civil Works Contractor's principal works areas. The bases will consist of a treatment room fitted with two treatment couches, a hand wash basin, sterilising equipment and lockable cupboards to contain sufficient medical supplies for the Contractor's workforce, the Engineer's site supervisory staff, the Designated Contractors working in the area and any visitors to the Site. The first aid post will be air-conditioned, with cooling capability sufficient to maintain the temperature of the inside of the building at 20ºC.

(b) A qualified doctor, nurse and assistant nurse will be in attendance at the first aid base

during all times when work is being undertaken on the Site, including work by the Designated Contractors and periods when only emergency activities are being undertaken, such as during periods of inclement weather.

(c) A fully equipped ambulance and driver will be provided at the first aid base during all

working hours. The ambulance will be equipped with emergency life support equipment suitable for application in construction site accidents.

8.2 Provisions by the Contractor

8.2.1 The Contractor shall supply portable first aid boxes maintained fully equipped at each local

site offices and any work locations where 20 or more persons work at a time.

8.2.2 In each site office and work location at least one of the Contractor’s employees shall be trained in first aid and should be available at all working hours for purpose of attending to emergencies.

8.2.3 The Contractor shall be responsible for making his employees aware of the location and access route to the nearest first aid base and if necessary shall provide facilities for evacuating a workman by stretcher from the worksite.

8.2.4 The Contractor shall keep the first aid base personnel informed of the number and identity of staff working within the area of responsibility of each first aid base.


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Appendix 9

9.0 WORKS AREAS

9.1 Works Areas (a) Temporary occupation of land is governed by Part VI of Land Acquisition Act 1894 (as

amended) which limits occupation to 3 years. (b) An area in Mihan / Higna Depot or some other suitable site shall be provided free of

charge for setting up of Contractor’s Site Office. (c) Prior to the Key Dates or the Works Area handover dates for returning any Works Area,

the Contractor shall carry out the following works:

a. construct all Permanent Works within the area, to the extent defined in this Appendix, in accordance with the requirements of the Contract,

b. reinstate the area to the condition as close as possible to its condition when it

was taken over,

c. form the area to the approved lines and levels and carry out such other works as may be required by the Engineer,

d. remove all rubbish, debris and other materials.

MAHA-METRO Contract No. P1/TR-02/2018 Part 3 Works Requirement - Particular Specification




BIDDING DOCUMENT

For

DESIGN, SUPPLY, INSTALLATION, TESTING & COMMISSIONING OF 25KV FLEXIBLE

& RIGID OVERHEAD CATENARY SYSTEM (OCS / OHE) AND SECTIONING POSTS FOR PUNE METRO RAIL PROJECT

MAHARASHTRA METRO RAIL CORPORATION LIMITED (MAHA-METRO) 101, The Orion, Opposite Don Bosco Youth Centre,

Koregaon Park, Pune 411001 Maharashtra INDIA



SECTION VII-B: WORKS REQUIREMENT – PARTICULAR SPECIFICATION



Table of Contents

1.0 GENERAL ..................................................................................................................................... 5

1.1 SCOPE AND PURPOSE ............................................................................................................... 5

1.2 DEFINITIONS ................................................................................................................................ 6

1.3 ABBREVIATIONS .......................................................................................................................... 9

1.4 STANDARDS ............................................................................................................................... 12

1.5 RELEVANT DOCUMENTS .......................................................................................................... 19

2.0 OVERVIEW OF THE PROJECT ................................................................................................. 20

2.1 GENERAL .................................................................................................................................... 20

2.2 CORRIDORS ............................................................................................................................... 20

2.3 KEY CHALLENGES .................................................................................................................... 21

3.0 SCOPE OF WORK ...................................................................................................................... 23

3.1 GENERAL .................................................................................................................................... 23

3.2 DETAILED DESCRIPTION .......................................................................................................... 23

3.3 DESIGN ....................................................................................................................................... 27

3.4 INTERFACE................................................................................................................................. 27

3.5 DOCUMENTS AND MANUALS .................................................................................................. 27

3.6 MAINTENANCE AND TRAINING ................................................................................................ 27

4.0 PERFORMANCE REQUIREMENTS .......................................................................................... 29

4.1 GENERAL .................................................................................................................................... 29

4.2 RAM SPECIFICATIONS .............................................................................................................. 30

4.3 SAFETY REQUIREMENTS ...................................................................................................... 35

4.4 SERVICE CAPABILITY ............................................................................................................... 35

4.5 CYBER SECURITY ASSURANCE .............................................................................................. 39

5.0 FUNCTIONAL REQUIREMENTS ............................................................................................... 41

5.1 GENERAL .................................................................................................................................... 41

5.2 RECEIVING SUBSTATION ......................................................................................................... 41

5.3 TRACTION NETWORK ............................................................................................................... 41

5.4 SCADA ......................................................................................................................................... 50

6.0 DESIGN REQUIREMENTS ......................................................................................................... 60

6.1 GENERAL .................................................................................................................................... 60

6.2 RECEIVING SUBSTATION ......................................................................................................... 60

6.3 TRACTION NETWORK ........................................................................................................... 60

6.4 OVERHEAD EQUIPMENT DESIGN ......................................................................................... 62

6.5 CIVIL WORKS AND ANCILLARY INSTALLATIONS .................................................................. 77

7.0 TECHNICAL REQUIREMENTS .................................................................................................. 81

7.1 TRACTION NETWORK ............................................................................................................... 81

7.2 TRACTION OVERHEAD EQUIPMENT ....................................................................................... 89



7.3 CABLING ..................................................................................................................................... 97

7.4 RETRACTABLE CATENARY SYSTEM .................................................................................... 101

7.5 TUBULAR STEEL STRUCTURES FOR SUPPORTING OCS ................................................. 101

7.6 CABLE SEALING SYSTEM ....................................................................................................... 112

7.7 CATENARY INSULATION ......................................................................................................... 113

7.8 EARTHING, BONDING AND LIGHTNING PROTECTION ....................................................... 113

8.0 INSTALLATION, INSPECTION, TESTING AND COMMISSIONING....................................... 115

8.1 GENERAL .................................................................................................................................. 115

8.2 TRACTION NETWORK AND OVERHEAD EQUIPMENT ........................................................ 120

9.0 MAINTENANCE AND TRAINING ............................................................................................. 136

9.1 INTRODUCTION ....................................................................................................................... 136

9.2 GENERAL PRINCIPLES OF AN EFFECTIVE MAINTENANCE SYSTEM ............................... 136

9.3 IMPLEMENTATION OF MAINTENANCE ................................................................................. 136

9.4 ASSISTANCE FOR MAINTENANCE ........................................................................................ 137

9.5 COMPREHENSIVE MAINTENANCE ........................................................................................ 138

9.6 TRAINING .................................................................................................................................. 138

10.0 SPARE PARTS, SPECIAL TOOLS AND TEST EQUIPMENT .............................................. 144

10.1 GENERAL ................................................................................................................................ 144

10.2 SPARES LIST .......................................................................................................................... 144

10.3 SECOND SOURCING ............................................................................................................. 145

10.4 LONG LEAD TIMES ................................................................................................................ 145

10.5 ROUTINE CHANGE ................................................................................................................ 145

10.6 SHELF LIFE ............................................................................................................................. 145

10.7 TESTING OF SPARES ............................................................................................................ 145

10.8 SPECIAL TOOLS AND TEST SETUP .................................................................................... 145

11.0 DLP / AMC OF OHE & SWITCHING STATIONS ................................................................... 146

11.1 SCOPE OF WORK FOR DLP/AMC OF OHE ......................................................................... 146

11.2 MAINTENANCE PROGRAMME OF OHE ............................................................................... 149

11.3 SCOPE OF WORK FOR DLP / AMC OF SWITCHING STATIONS ....................................... 161

11.4 MAINTENANCE PROGRAMME (SWITCHING STATIONS) .................................................. 165

12.0 MISCELLANEOUS .................................................................................................................. 173

12.1 FACILITIES FOR THE EMPLOYER'S REPRESENTATIVE ................................................... 173

13.0 CATENARY MAINTENANCE VEHICLE ................................................................................ 177

13.1 OHE CATENARY MAINTENANCE VEHICLE (8-WHEELER) ................................................ 177

13.2 CATENARY MAINTENANCE VEHICLE (4-WHEELER) ......................................................... 195



List of Appendices

Appendix A

Interface Specifications

Appendix B

Techncial Sheets

Appendix C

Test Sheets

Appendix D

Safety Requirements

Appendix E

Key Dates and Access Dates

Appendix F

Preliminary list of Deliverables

Appendix G

Control and Monitoring Signals (I/O list for SCADA)



CHAPTER 1

1.0 GENERAL 1.1 SCOPE AND PURPOSE

1.1.1 This Particular Specification specifies the objectives, guidelines and requirements for

Detailed Design, Supply, Installation, Implementation, Testing and Commissioning of Overhead (Flexible and Rigid) electrification for the following Corridor of Pune Metro Rail Project: Table 1.1: Pune Metro Rail Project corridors

SN Route Length / Type Stations

1 Corridor 1: Pimpri Chinchwad (PCMC) to Swargate

11.570km elevated + 5.019km underground

9 nos. elevated 5 nos. underground

2 Corridor 2: Vanaz to Ramvadi 14.925 km elevated 16 nos. elevated

Total 31.515 km 30 nos.

Table 1.2: Phasing of Commissioning

SN Section Expected Date of introduction of commercial services [Revenue Operation Date / ROD]

1 Reach 1 (NS Corridor): PCMC to Range Hill section (about 10.64km) including Range Hill Depot

Dec 2019

2 Reach 2 (EW Corridor): Vanaz to Civil Court Station (about 7.25km) including Vanaz Depot

June 2020

3 Reach 3 (EW Corridor): Civil Court (excl.) to Ramwadi Station section (about 7.67km)

Dec 2021

4 Reach 4 (NS Corridor): Range Hill (excl.) to Swargate Station (about 5.95km)

Dec 2021

1.1.2 Each corridor is planned with its separate depots viz. Range Hill depot for NS Corridor at

and Vanaz Depot for EW Corridor. Both the depots shall have inspection, light repairs and test tracks while the heavy repair facilities may be pooled at one place.

1.1.3 The Employer is in the process of developing Operation & Maintenance Plan for the Project concurrently with the progress of the Project implementation. The O&M Plan shall be progressively evolved and refined with inputs from various Project Contractors as well as other agencies and this shall facilitate the operational readiness for Service Trials & Revenue Operation.

1.1.4 The Works to be executed under the Contract include the design, manufacture, delivery, installation, testing, commissioning and technical / maintenance support including training of personnel for a complete, integrated overhead electrification system including all trackside equipments necessary to deliver the requirements of this Specification.

1.1.5 The Works to be executed under the Contract include the quality management and quality checking necessary to fulfil the quality requirements contained in Works Requirements: General Specifications and any quality requirements specified in the present volume.

1.1.6 The system consists of: (a) All civil works and equipment for the 25kV AC traction supply and overhead line for

mainlines and depots;



(b) All civil works and equipment for switching posts such as Sectioning and Paralleling Posts (SPs), Sub-sectioning and Paralleling Posts (SSPs) and Sub-Sectioning Posts (SSs) for mainlines and depots.

1.2 DEFINITIONS

In this Particular Specification and its appendices, the following list defines terms shall have the meanings ascribed to them below: Table 1.3: Definitions

SN Terms Definition

1. Acceptance Measurement Final definitive records of the measurement of the installed contact wire heights and staggers at OCS support and registrations and at mid- span.

2. Overhead Protection Conductor

A conductor on traction masts / structures / supports and bonded to their metallic parts / supports and connected to earth.

3. Air section Electrical sectioning of OCS for separating feeding network.

4. Auto-tensioning equipment

OCS Conductors terminated with balance weighs, Springs or hydraulic tensioning devices to maintain constant tension over a specified range of conductor temperatures by compensating for conductor thermal expansion and contraction.

5. Auxiliary substation Power received at 33 kV and transformed to 415 V by means of 33 kV/415 V transformers and then distribute to Auxiliary equipment in the passenger stations

6. Balance weight assembly The tensioning gear with weighs that are installed at each end of a tension section of an auto-tensioned OCS.

7. Blow-off Lateral displacement of the overhead contact system due to wind.

8. Bond Electrical connection between two or more conductors or non-current carrying metallic parts of traction masts or structures or supports and rails.

9. Bracket tube It comprises of standard bracket tube and insulated by bracket insulator. Messenger wire is supported from this member by catenary suspension bracket and catenary suspension clamp.

10. Briddle wire A Short loop of wire that supports a single contact wire from horizontal.

11. Bridging interruptor An interrupter which is provided at the neutral section to extend the feed from one substation to the overhead equipment normally fed by the other substation in emergencies or when the latter is out of use. This normally remains in the open position.

12. Cantilever assembly An OCS support frame typically for mounting a messenger and a contact wire with register and steady arm assembly that is mounted on a pole or portal beam drop arm.

13. Catenary or catenary system

The structure of conductor above the track which carries the electric supply for electric locomotives and is used for overhead electricity collection. It may be rigid or flexible overhead contact system.

14. Clearance to earth The clearance between any conducting parts and any parts which are earthed or intended to be earthed.

15. Contact wire The wire with which the pantograph or trolley pole makes for current collection.

16. Cross span A Single wire fastened between two supports that



SN Terms Definition

crosses the tracks just above contact wire level and supports one or more contact wires.

17. Current collection The act of picking up electrical power from Overhead contact wire by pantograph.

18. Dropper A fitting used in overhead equipment construction for supporting the contact wire from the messenger wire.

19. Electrical clearance The distance in air between live equipment and the nearest earthed part.

20. Encumbrance Encumbrance is defines as the axial distance on vertical plane between messenger and contact wire at OHE support in flexible overhead contact system.

21. End approach The Sloping end portion of Rigid Conductor rail so as to maintain smooth pantograph passage

22. Expansion joint Mechanical joint for absorbing expansion of rigid contact wire due to temperature changes

23. Feeding cables 25 kV Feeding cables from 25 kV switchgear to rigid conductor rail/ flexible OCS for supplying traction power.

24. Flexible post It is a power supply post where the incoming 25 kV feeder lines from substation are connected to the overhead equipments.

25. Flexible overhead contact system

It is a conventional type of overhead contact system. It is defined in this section at SN 35

26. Head span An OCS support structure with two or more wires over the multi-tracks and supports several cantilevers, or Several single contact wires in multi -track area.

27. Impedance bond A bond installed by the signal and telecommunication department which provides a low impedance path for traction return current and a relatively high impedance path for track circuit current.

28. Interrupter It is a single phase Vacuum load break switch to close/open the circuit on load. It is operated either by remote control or manually at site.

29. Jumper A conductor or an arrangement of conductors for electrical continuity not under tension, which forms electrical connection between two conductors or equipments.

30. Lightning arrester A device typically mounted on OCS poles and connected to the OCS, designed to protect the OCS and adjacent equipment due to lightning.

31. Main cable tray / trench / duct

Cable tray/ trench/duct, which will be used to run the cables along with the viaduct and underground tunnel other than the equipment room.

32. Mast A single vertical post embedded in the foundation or otherwise rigidly fixed in vertical position to support the overhead equipment with cantilever.

33. Messenger wire The conductor from which the contact wire is suspended by means of droppers.

34. Neutral section This is the dead zone of the OHE located approximately mid way between the adjacent substations, which are connected to different phases.

35. Overhead contact (or collection) system (OCS) or Overhead Equipment (OHE)

The part of the traction power system comprising the overhead conductors, OCS supports, Foundations, balance weights and other equipment and assemblies, that delivers the electrical power to non-self powered electric vehicles.

36. Pantograph A current collection device fitted on top of an electrically powered rail vehicle, hinged to allow it to vary in height



SN Terms Definition

as it rubs along the contact wire.

37. Paralleling interrupter An interrupter, which connects overhead equipments of two different tracks.

38. Portal A frame support structure, typically of galvanized steel, consisting of vertical columns supporting each end of a horizontal beam carrying multiple OHE for two or more tracks.

39. Pull-off / push-off cantilever

A cantilever that provides registration of the contact wire towards the pole or away from pole in relation to the centerline of track.

40. Push up (uplift) It is defined as a vertical displacement of a contact wire or the conductors of the overhead equipment due to pressure exerted by the pantograph either in static or in dynamic condition.

41. Receiving substation Power received at 132 kV from authority grid sub-station and transformed to 33 kV by 132/33 kV or transformers for auxiliary loads of stations, depots etc. and transformed to 25 kV for Traction loads.

42. Register arm It comprises of tube to register the contact wire in the desired position with the help of steady arm.

43. Regulating equipment A device for maintaining the tension of OHE conductors constant under all ambient temperature conditions. Note: Such OHE is called regulated OHE.

44. Return current circuit Running track rails and conductors forming part of traction return current circuit.

45. Rigid overhead contact system

The overhead conducting composite aluminium rail with copper contact wire including support fittings and insulators for distribution of electric power to the train.

46. Sag The difference between the average height of a conductor at its adjacent support and its height at the lowest point in the span.

47. Scissors crossovers A pair of parallel or nearly parallel tracks with crossovers provided in both directions between the two lines (i.e., trains can be routed from either line to either line, in both directions). Often, scissors crossovers are provided from a running line to a dead-end siding to allow for one train to be passed by another. Also referred loosely, as scissors crossing

48. Section insulator A device installed in the contact wire for insulating two elementary electrical sections from each other while providing a continuous path for the pantograph without break of current.

49. Sectioning interrupter An interrupter, which connects adjacent sub-sectors together to maintain continuity of supply. This normally remains in closed position.

50. Sectioning and paralleling post (SP)

It is a supply control post situated mid-way between two feeding posts at the neutral section and provided with bridging and paralleling interrupters.

51. Setting distance The horizontal distance from the nearest face of traction mast to the center line of the track.

52. Short neutral section Short neutral section of 5m length comprising of PTFE insulator.

53. Span The distance between the centre line of the adjacent supporting structures for the overhead equipment / lines is known as span.

54. Span width The distance across track or roadway between the columns of a portal, head span or cross- span.

55. Stagger Stagger is the horizontal distance of the contact wire



SN Terms Definition

from the vertical plane through the centre of pantograph pan at the contact surface.

56. Stay tube It comprises of Small tube and an adjuster at the end to keep the bracket tube in position

57. Steady arm It holds the contact wire and prevents it from lateral displacement.

58. Structure bond A bond connecting the non-current carrying metallic parts of a traction mast or structure or support to a traction rail.

59. Sub-sectioning and paralleling post (SSP)

It is a supply control post where sectioning and paralleling interrupters are provided.

60. Sub-sectioning post (SS) It is a supply control post where a sectioning interrupter / isolator is provided.

61. Support insulator Insulator for supporting rigid conductor rail.

62. Supporting fixture Adjustable supporting fitting for conductor rail so as to maintain the geometry of height and stagger of contact wire with respect to the track.

63. Tension length Length of conductor, which is stretched between the two anchor points.

64. Traction substation A traction substation is an electrical substation that derives power from RSS and feeds power to the catenary system

65. Turnout A section of track branching off from another. Sometimes spelled 'turn-out' or 'T/out'.

66. Two-track cantilever A single OCS Cantilever frame serving two adjacent tracks to one side of its supporting pole, and catering to the independent movement of the catenaries

1.3 ABBREVIATIONS

Table 1.4: List of Abbreviations

SN Abbreviation Definition

1. AC Alternating Current

2. ACOCB Alternating Current Outgoing Circuit Breaker

3. ACB Air Circuit Breaker

4. ACRC Alternating Current Rectifier Contactor

5. ACRCB Alternating Current Rectifier Circuit Breaker

6. AED As Erected Drawing

7. AFNOR Association francaise de normalisation

8. AMS Auxiliary Main Substation

9. ANSI American National Standards Institute

10. ASTM American Society for Testing and Materials

11. ASS Auxiliary Substation

12. AT Auxiliary Transformer

13. ATCB Auxiliary Transformer Circuit Breaker

14. ATIS Auxiliary Transformer Isolator

15. AVO Amperes-Voltage-Ohms (meter)

16. B Traction Busbar

17. BA Batteries

18. BAIT Batteries Interrupter

19. BFB Broad Flange Beam

20. BS British Standards

21. BW Balance Weight

22. BWA Balance Weight Assembly

23. CAMS Computer Aided Maintenance System

24. CB Circuit Breaker

25. C&C Control & Communication


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26. CCB Coupling Circuit Breaker

27. CIS Couping Isolator

28. CSD Cross Section Drawing

29. CT Current Transformer

30. CTATP Current Transformer for Protection of Auxiliary Transformer

31. CTC Current Transformer for Coupling

32. CTD Capacitor Tripping Device

33. CTIM Incoming Current Transformer for Measures

34. CTT Current Transformer for Traction Transformer

35. CTTTP Current Transformer for Protection of Traction Transformer

36. daN Deca-Newton

37. DC Direct Current

38. DCAC Direct Current Auxiliary Contactor

39. DCACB Direct Current charging Air Circuit Breaker

40. DCACC Direct Current Auxiliary Coupling Contactor

41. DCOCB Direct Current Outgoing Circuit Breaker

42. DCRC Direct Current Rectifier Contactor

43. DP Double Pole Insulator

44. DTN Data Transmission Network

45. EIS Earthing Isolator

46. EMIS Energy Management and Information System

47. FP Feeding Post

48. FRLS Flame Retardant Low Smoke

49. GRC General Remote Control

50. HMI Human Machine Interface

51. ICB Incoming Circuit Breaker

52. IEC International Electro-technical Commission

53. IEIS Incoming Earthing Isolator

54. ISO International Organization for Standardization

55. IRS Indian Railway Specification

56. IR Indian Railways

57. IS Indian Standard

58. IS Isolator

59. IT Interrupter

60. ITC Coupling Interrupter

61. ITL Integral Transverse Link

62. L Hand-operated Traction Isolator

63. LAAT Lightning Arrester for Auxiliary Transformer

64. LAN Local Area Network

65. LATT Lightning Arrester for Traction Transformer

66. LBCB Lighting Bridge Circuit Breaker

67. LBCCB Lighting Bridge Coupling Circuit Breaker

68. LBCCT Lighting Bridge Coupling Current Transformer

69. LBCT Lighting Bridge Current Transformer

70. LBCVT Lighting Bridge Coupling Voltage Transformer

71. LBEIS Lighting Bridge Earthing Isolator

72. LBVT Lighting Bridge Voltage Transformer

73. LCB Line Circuit Breaker

74. LEIS Line Earthing Isolator

75. LFCB Lighting Feeder Circuit Breaker (spare)

76. LFEIS Lighting Feeder Earthing Isolator

77. LIS Line Isolator

78. LV Low Voltage

79. LVACB Low Voltage Auxiliary Circuit Breaker

80. LVACCB Low Voltge Auxiliary Coupling Circuit Breaker

81. LVAT Low Voltage Auxiliary Transformer

82. LVATCB Low Voltage Auxiliary Transformer Circuit Breaker


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83. LVATEIS Low Voltage Auxiliary Transformer Earthing Isolator

84. LVCB Low Voltage Circuit Breaker

85. LVCCB Low Voltage Coupling Circuit Breaker

86. MVCB Medium Voltage Circuit Breaker

87. NCT Neutral Current Transformer

88. NMS Network Management System

89. NGR Neutral Grounding Resistor

90. OCC Operation Control Center

91. OCR Over Current Relay

92. OCS Overhead Collection System

93. ODC Over Dimensional Consignment

94. OHE Overhead Equipment

95. OLTC On Load Tap Changer

96. PCW Power Control Workstation

97. PICOP Person In Charge Of Possession

98. PLC Programmable Logic Controller

99. PNCT Primary Neutral Current Transformer

100. PNEIS Primary Neutral Earthing Isolator

101. PSA Power Supply Authority

102. PSU Power Supply Unit

103. PT Potential Transformer

104. PTFE Poly Tetra Fluoro Ethylene

105. RDSO Research Design and Standards Organization

106. ROCS Rigid Overhead Catenary System

107. RSJ Rolled Steel Joist

108. RSS Receiving Substation

109. RTF Reproducible Tracing Film

110. RTCC Remote Tap Changer Control

111. SCADA Supervisory Control and Data Acquisition System

112. SED Structure Erection Drawing

113. SF-6 Sulphur Hexa Fluoride

114. SNCT Secondary Neutral Earthing Transformer

115. SNEIS Secondary Neutral Earthing Isolator

116. SNLA Secondary Neutral Lightning Arrester

117. SP Single Pole Isolator

118. SP Sectioning Post

119. SSP Sub-sectioning and Paralleling Post

120. T/out Turnout

121. TEIS Transformer Earthing Isolator

122. TPC Traction Power Controller

123. TR Power Transformer

124. TSS Traction Substation

125. TT Traction Transformer

126. TTCB Traction Transformer Circuit Breaker

127. TTCCB Traction Transformer Coupling Circuit Breaker

128. TTIS Traction Transformer Isolator

129. UPF Unity Power Factor

130. UIC International Union of Railway

131. UPS Uninterrupted Power Supply

132. VCB Vacuum Circuit Breaker

133. VDU Video Display Unit

134. VT Voltage Transformer

135. VTB Voltage Transformer for traction busbar

136. VTBB Busbar Voltage Transformer

137. WPC Wrong Phase Coupling

138. WTI Winding Temperature Indicator

139. XLPE Crosslink Polyethylene


Feb 2018 Page 12 of 202

1.4 STANDARDS

1.4.1 This following list is provided solely for the convenience of the bidder. Standards

referenced within this document that are not identified in this list must still be compliant with.

1.4.2 Reference to any specifications shall be taken as reference to the latest version of that specification. Table 1.5: IEC Publications

SN Standard No. Description

1. IEC 61109 Insulator for overhead lines

2. IEC 62217 Polymeric HV insulators for indoor and outdoor use - General definitions, test methods and acceptance criteria

3. IEC 62271 High Voltage Switchgear and Controlgear

4. IEC 62271-1 High Voltage Switchgear and Controlgear – Part 1: Common Specifications

5. IEC 62271-3 High Voltage Switchgear and Controlgear – Part 3: Digital interfaces based on IEC 61850

6. IEC 62271-4 High Voltage Switchgear and Controlgear – Part 4: Handling procedures for sulphur hexafluoride (SF6) and its mixtures

7. IEC 62271-37-013

High Voltage Switchgear and Controlgear – Part 37-013: Alternating current generator circuit breakers

8. IEC 62271-37-082

High Voltage Switchgear and Controlgear – Part 37-082: Standard practice for the measurement of sound pressure levels on alternating current circuit breakers

9. IEC 62271-100 High Voltage Switchgear and Controlgear – Part 100: Alternating current circuit breakers

10. IEC 62271-101 High Voltage Switchgear and Controlgear – Part 101: Synthetic testing

11. IEC 62271-102 High Voltage Switchgear and Controlgear – Part 102: Alternating current disconnectors and earthing switches

12. IEC 62271-103 High Voltage Switchgear and Controlgear – Part 103: Switches for rated voltages above 1kV upto and including 52kV

13. IEC 62271-104 High Voltage Switchgear and Controlgear – Part 104: Alternating current switches for rated voltages higher than 52kV

14. IEC 62271-105 High Voltage Switchgear and Controlgear – Part 105: Alternating current switch-fuse combinations for rated voltages above 1kV upto and including 52kV

15. IEC 62271-106 High Voltage Switchgear and Controlgear – Part 106: Alternating current contactors, contactor-based controllers and motor starters

16. IEC 62271-107 High Voltage Switchgear and Controlgear – Part 107: Alternating current fused circuit – switchers for rated voltage above 1kV upto and including 52kV

17. IEC 62271-108 High Voltage Switchgear and Controlgear – Part 108: High voltage alternating current disconnecting circuit-breakers for rated voltages of 72.5kV and above

18. IEC 62271-109 High Voltage Switchgear and Controlgear – Part 109: Alternating current series capacitor bypass switches

19. IEC 62271-110 High Voltage Switchgear and Controlgear – Part 110: Inductive load switching

20. IEC 62271-111 High Voltage Switchgear and Controlgear – Part 111: Automatic circuit reclosers and fault interrupters for alternating current systems upto 38kV

21. IEC 62271-200 High Voltage Switchgear and Controlgear – Part 200: AC metal-enclosed switchgear and controlgear for rated voltages above 1kV and upto and including 52kV


Feb 2018 Page 13 of 202


22. IEC 62271-201 High Voltage Switchgear and Controlgear – Part 201: AC solid-insulation enclosed switchgear and controlgear for rated voltages above 1kV and upto and including 52kV

23. IEC 62271-202 High Voltage Switchgear and Controlgear – Part 202: High-voltage / low-voltage prefabricated substation

24. IEC 62271-203 High Voltage Switchgear and Controlgear – Part 203: Gas insulated metal-enclosed switchgear for rated voltages above 52kV

25. IEC 62271-204 High Voltage Switchgear and Controlgear – Part 204: Rigid gas-insulated transmission lines for rated voltage above 52kV

26. IEC 62271-205 High Voltage Switchgear and Controlgear – Part 205: Compact switchgear assemblies for rated voltages above 52kV

27. IEC 62271-206 High Voltage Switchgear and Controlgear – Part 206: Voltage presence indicating systems for rated voltages above 1kV and upto and including 52kV

28. IEC 62271-207 High Voltage Switchgear and Controlgear – Part 207: Seismic qualification for gas-insulated switchgear assemblies for rated voltages above 52kV

29. IEC 62271-208 High Voltage Switchgear and Controlgear – Part 208: Methods to quantify the steady state, power-frequency electromagnetic fields generated by HV switchgear assemblies and HV/LV prefabricated substations

30. IEC 62271-209 High Voltage Switchgear and Controlgear – Part 209: Cable connections for gas-insulated metal-enclosed switchgear for rated voltages above 52kV – Fluid-filled and extruded insulation cables – Fuild-filled and dry-type cable-terminations

31. IEC 62271-210 High Voltage Switchgear and Controlgear – Part 210: Seismic qualification for metal enclosed and solid-insulation enclosed switchgear and controlgear assemblies for rated voltages above 1kV and upto and including 52kV

32. IEC 62271-211 High Voltage Switchgear and Controlgear – Part 211: Direct connection between power transformers and gas-insulated metal-enclosed switchgear for rated voltages above 52kV

33. IEC 62271-300 High Voltage Switchgear and Controlgear – Part 300: Seismic qualification of alternating current circuit-breakers

34. IEC 62271-301 High Voltage Switchgear and Controlgear – Part 301: Dimensional standardization of high-voltage terminals

35. IEC 62271-302 High Voltage Switchgear and Controlgear – Part 302: Alternating current circuit-breakers with intentionally non-simultaneous pole operation

36. IEC 62271-304 High Voltage Switchgear and Controlgear – Part 304: Design classes for indoor enclosed switchgear and controlgear for rated voltages above 1kV upto and including 52kV to be used in severe climatic conditions

37. IEC 62271-305 High Voltage Switchgear and Controlgear – Part 305: Capacitive current switching capability of air-insulated disconnectors for rated voltages above 52kV

38. IEC 62271-306 High Voltage Switchgear and Controlgear – Part 306: Guide to IEC 62271-100, IEC 62271-1 and other IEC standards related to alternating current circuit-breakers

39. IEC 62271-307 High Voltage Switchgear and Controlgear – Part 307: Guidance for the extension of validity of types tests of AC metal and solid-insulation enclosed switchgear and controlgears for rated voltages above 1kV and upto and including 52kV

40. IEC 62271-310 High Voltage Switchgear and Controlgear – Part 310: Electrical endurance testing for circuit-breakers above a rated voltage of 52kV

41. IEC 60137 Insulated bushings for alternating voltage above 1000 volts


Feb 2018 Page 14 of 202


42. IEC 61869-1 Instrument transformers – Part 1: General Requirements

43. IEC 61869-2 Instrument transformers – Part 2: Current Transformers

44. IEC 61869-3 Instrument transformers – Part 3: Inductive Voltage Transformers

45. IEC 61869-4 Instrument transformers – Part 4: Combined Transformers

46. IEC 61869-5 Instrument transformers – Part 5: Capacitive Voltage Transformers

47. IEC 61869-6 Instrument transformers – Part 6: Current Transformers for Transient Performance

48. IEC 61869-7 Instrument transformers – Part 7: Electronic Voltage Transformers

49. IEC 61869-8 Instrument transformers – Part 8: Electronic Current Transformers

50. IEC 61869-9 Instrument transformers – Part 9: Additional Requirements and Digital Interface for Electronic Instrument Transformers

51. IEC 61869-10 Instrument transformers – Part 10: Low Power Standalone Current Sensors

52. IEC 60056 High voltage alternating current circuit breaker

53. IEC 60913 Electric traction overhead lines

54. IEC 60502 Power cables with extruded insulation and their accessories for rated voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV)

55. IEC 60228 Conductors of insulated cables

56. IEC 60076-1 Power transformers

57. IEC 60076-2 Power transformers – Temperature Rise

58. IEC 60076-3 Power transformers – Insulation levels, dielectric tests and external clearances in air

59. IEC 60076-4 Power transformers – Guide to the lightning impulse and switching impulse testing - Power transformers and reactors

60. IEC 60076-5 Power transformers - Ability to withstand short circuit

61. IEC 60383-1 Insulators for overhead lines with a nominal voltage above 1000 V - Part 1: Ceramic or glass insulator units for a.c. systems - Definitions, test methods and acceptance criteria

62. IEC 60383-2 Insulators for overhead lines with a nominal voltage above 1000 V - Part 2: Insulator strings and insulator sets for a.c. systems - Definitions, test methods and acceptance criteria

63. IEC 60038 IEC standard voltage

64. IEC 60059 IEC standard current ratings

65. IEC 60196 IEC standard frequencies

66. IEC 60099 Surge Arrestor

67. IEC 60099-4 Surge arresters - Part 4: Metal-oxide surge arresters without gaps for a.c. systems

68. IEC 60099-5 Surge arresters – Part 5: Selection and application recommendations

69. IEC 60099-6 Surge arresters – Part 6: Surge arresters containing both series and parallel gapped structures – rated 52kV and less

70. IEC 60099-7 Surge arresters – Part 7: Glossary of terms and definitions from IEC publications 60099-1, 60099-4, 60099-6, 61643-1, 61643-12, 61643-21, 62643-311, 61643-321, 61643-331 and 61643-341

71. IEC 60099-8 Surge arresters – Part 8: Metal-oxide surge arresters with external series gap (EGLA) for overhead transmission and distribution lines of ac systems above 1kV

72. IEC 60099-9 Surge arresters – Part 9: Metal-oxide surge arresters without gaps for HVDC converter stations

73.

74.

75. IEC 60529 Degrees of protection provided by enclosures (IP code)


Feb 2018 Page 15 of 202


76. IEC 60617-2 Graphical symbols for diagrams. Part 2: symbol elements, qualifying symbols and other symbols having general application

77. IEC 60721-3-4 Classification of environmental conditions - Part 3: Classification of groups of environmental parameters and their severities - Section 4: Stationary use at non-weather protected locations

78. IEC 60840 Power cables with extruded insulation and their accessories for rated voltage above 30kV (Um = 36 kV) up to 150 kV. Test methods and requirements.

79. IEC 60865 Short-circuit currents - Calculation of effects - Part 1: Definitions and calculation methods

80. IEC 60889 Hard-drawn Aluminium wire for overhead line conductor

81. IEC 60071 Insulation co-ordination - Part 1: Definitions, principles and rules

82. IEC 61000 Electromagnetic compatibility

83. IEC 61508-3 Functional safety of electrical/electronic/programmable safety-related systems. Part 3: software requirements

84. IEC 60398 Industrial electro heating installations - General test methods

85. IEC 61131 Programmable controllers

86. IEC 60137 Insulated Bushing for rated Voltage above 1 kV

87. IEC 60168 Tests on Indoor and Outdoor Post Insulators of Ceramic Material or Glass for Systems with Nominal Voltages greater than 1000 V

88. IEC 60228 Conductor of Insulated Cables

89. IEC 60273 Characteristic of indoor and outdoor post insulators for systems with nominal voltages greater than 1000 V

90. IEC 60296 Fluids for Electrotechnical applications - Unused mineral insulating oils for transformers and switchgear

91. IEC 60297 Mechanical structures for electronic equipment - Dimensions of mechanical structures of the 482,6 mm (19 in) series.

92. IEC 60372 Locking Devices for Ball and Socket Couplings of String Insulator Units – Dimensions and Tests

93. IEC 60376 Specification of technical grade sulfur hexafluoride (SF6) for use in electrical equipment

94. IEC 60622 Secondary cells and batteries containing alkaline or other non-acid electrolytes - Sealed nickel-cadmium prismatic rechargeable single cells

95. IEC 60028 International standard of resistance for copper

96. IEC 60146-1-1 Semiconductor converters, general requirements and line commutated converters. Specifications of basic requirements.

97. IEC 60146-1-2 Semiconductor converters, general requirements and line commutated converters. Application guide

98. IEC 60146-1-3 Semiconductor converters, general requirements and line commutated converters. Transformers and reactors

99. IEC 60721-3-4 Classification of environmental conditions- Classification of groups of environmental parameters and their severity- Stationary use at non-weather protected locations.

100. IEC 60721-3-3 Classification of environmental conditions- Classification of groups of environmental parameters and their severity- Stationary use at weather protected locations.

101. IEC 60571 Electronic equipment used on rail vehicles

102. IEC 60848 GRAFCET specification language for sequential function charts

103. IEC 60870-1-1 Tele-control equipment and systems. Part 1: General considerations. Section One: General principles

104. IEC 60870-2-1 Telecontrol equipment and systems - Part 2: Operating conditions - Section 1: Power supply and electromagnetic compatibility


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105. IEC 60870-3 Telecontrol equipment and systems. Part 3: Interfaces (electrical characteristics)

106. IEC 60870-4 Telecontrol equipment and systems. Part 4: Performance requirements

107. IEC 60870-5 Telecontrol equipment and systems - Part 5: Transmission protocols - ALL PARTS

108. IEC 61850 Communication networks and systems in substations

109. IEC 60947 Low Voltage Switchgear and controlgears

110. IEC 60721-2-5 Classification of environmental conditions - Part 2: Environmental conditions appearing in nature - Section 5: Dust, sand, salt mist

Table 1.6: BS/EN Publications


1. EN 15341 Maintenance/Maintenance Key performance indicators

2. EN 50122-1 Fixed installations - Part 1: Protective provisions relating to electrical safety and earthing

3. EN 50182 Conductors for overhead lines. Round wire concentric lay stranded conductors

4. EN 50317 Current collection systems - Requirements for and validation of measurements of the dynamic interaction between pantograph and overhead contact line

5. EN ISO 1461 Hot dip galvanized coatings on fabricated iron and steel articles. Specifications and test methods

6. EN ISO 14713 Protection against corrosion of iron and steel in structures. Zinc and aluminium coatings. Guidelines

7. EN ISO 2178 Non-magnetic coatings on magnetic substrates. Measurement of coating thickness. Magnetic method

8. EN 50318 Current collection systems. Validation of simulation of the dynamic interaction between pantograph and overhead contact line

9. EN 50125-2 Environmental conditions for equipment. Fixed electrical installations

10. EN 50119 Fixed installations. Electric traction overhead contact lines

11. EN 50121 Electromagnetic compatibility

12. EN 50124-1 Insulation coordination. Basic requirements. Clearances and creepage distances for all electrical and electronic equipment

13. EN 50124-2 Insulation coordination. Overvoltage and related protection

14. EN 50163 Supply voltages of traction systems

15. EN 50367 Current collection systems. Technical criteria for the interaction between pantograph and overhead line

16. EN 50052 Cast aluminium alloy enclosures for gas-filled high-voltage switchgear and control gear;

17. EN 50149 Copper and copper alloy grooved contact wires

18. EN 10025 Hot Rolled Products of Non-Alloy Structural Steels: Delivery Conditions

19. EN 10034 Structural Steel I and H Sections – Tolerances on Shape and Dimensions

20. EN 10055 Hot Rolled Steel Equal Flange Tees with Root and Toes – Dimensions and Tolerances on Shape and Dimensions

21. EN 10056 Structural Steel Equal and Unequal Leg Angles

22. EN 10083 Quenched and Tempered Steels

23. EN 10088 Stainless steel

24. EN 1301 Aluminium and Aluminium Alloys

25. EN 60811 Insulating and Sheathing Materials of Electric Cables

26. EN 50121-5 Railway application electromagnetic compatibility: Part 5 : Standard for emission and immunity of fixed power supply installations & apparatus


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27. EN 10034 Structural steel I & H sections – Tolerances on shape & dimensions

28. Euro Norm 19 IPE Beams; I-Beams with Parallel Flange Facings and Steel Products – IPN Beams – Dimensions

29. EN 50126 The specification and demonstration of reliability, availability, maintainability and safety (RAMS)

30. EN 50128 Communications, signalling and processing systems. Software for railway control and protection systems

31. EN 50129 Communication, signalling and processing systems. Safety related electronic systems for signalling

Table 1.7: RDSO Publications


1. TI/SPC/OHE/SNS/10000 Specification for Short Neutral Section Assembly (Phase Break)

2. TI/SPC/OHE/INSCOM/1070 Composite 9 tonne insulator (polluted zone (1050mm))

3. ETI/OHE/13 (latest version) Hot dip zinc galvanization of steel masts, tubes and fittings for 25kV ac OHE

4. ETI/OHE/76 (latest) Hard drawn grooved contact wire

5. ETI/OHE/50 (latest) 65mm2 Cadmium Copper Messenger wire

6. ETI/OHE/3 (latest) Stranded annealed copper jumper wire (50 sq mm)

7. ETI/OHE/13 (latest) Galvanised Steel tubes (Large Bracket)

8. ETI/OHE/27 Specification for section insulator assembly without section insulator

9. ETI/PSI/122 Specification for 245/145/123/72.5 kV double pole and triple pole isolators

10. ETI/PSI/116 220 kV/132 kV/66 kV AC double and triple pole outdoor SF-6 gas circuit breakers for Railway

11. ETI/PSI/117 220/132kV current Transformer

12. ETI/PSI/31 Standards for drawings for power supply installation

13. RE/OHE/25 Standard drawings for Traction overhead Equipment

Table 1.8: IS Publications


1. IS 209 Zinc Ingot - Specification

2. IS 398 (Part II) Aluminium conductors for overhead transmission purposes: Part 2 Aluminium conductors, galvanized steel reinforced

3. IS 398 (Part I) Aluminium conductors for overhead transmission purposes: Part 1 Aluminium stranded conductors

4. IS 2062 Steel for General Structural Purposes - Specification

5. IS 3043 Code of practice for earthing

6. IS 9968 (Part II) Specification for Elastomeric-insulated Cables - Part 2: For Working Voltages from 3.3 kV up to and Including 3 3kV

7. IS 1893 Criteria for Earthquake Resistant Design of Structures

Table 1.9: UIC Publications


1. UIC 564-2 Resistance to spread of flame

2. UIC 600 Electric Traction with aerial contact line

3. UIC 791-1 Maintenance guidelines for overhead contact line

4. UIC 870 Technical specification for grooved contact wires

5. UIC 505-1 Railway Transport Stock – Rolling Stock Construction Gauge

6. UIC 505-4 Effects on the Application of the Kinematic Gauges defined in the 505 Series of Leaflets on the Positioning of Structures in relation to the Tracks and of the Tracks in relation to each


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other

7. UIC 606-1 OR Consequences of the Application of the Kinematic Gauges defined by UIC Leaflets in the 505 Series on the Design of the Contact Lines

8. UIC 606-2 OR Installation of 25 kV and 50 or 60 Hz Overhead Contact Lines

9. UIC 608 OR Conditions to be complied with for the Pantographs of Tractive Units used on International Services

10. UIC 791 R Quality Assurance of Overhead Line Equipment

Table 1.10: AFNOR Publications


1. X60-000 Industrial maintenance – Maintenance function

2. X60-200 Maintenance - Technical documentations associated with an item throughout its life cycle

Table 1.11: ISO Publications


1. ISO 1190 Copper and Copper alloys

2. ISO 1035 Hot Rolled Steel Bars

3. ISO 1234 Split Pins

4. ISO 1337 Wrought Coppers (having Minimum Copper Contents of 99,85%) – Chemical Composition and Forms of Wrought Products

5. ISO 1460 Metallic Coatings – Hot Dip Galvanised Coatings on Ferrous Materials – Gravimetric Determination of the Mass per Unit Area

6. ISO 1461 Metallic Coatings – Hot Dip Galvanised Coatings on Fabricated Ferrous Products – Requirements

7. ISO 2092 Light Metals and their Alloys – Code of Designation based on Chemical Symbols

8. ISO 2340 Clevis Pins without Head

9. ISO 2341 Clevis Pins with Head

10. ISO 261 ISO General Purpose Metric Screw Threads – General Plan

11. ISO 262 ISO General Purpose Metric Screw Threads – Selected Sizes for Screws, Bolts and Nuts

12. ISO 2859/1 Sampling Procedures for Inspection by Attributes – Sampling Plans Indexed by Acceptable Quality Level (AQL) for Lot-by-lot Inspection

13. ISO 3768 Metallic Coatings – Neutral Salt Spray Test (NSS Test)

14. ISO 4014 Hexagon Head Bolts – Product Grades A and B

15. ISO 4017 Hexagon Head Screw Bolts – Product Grades A and B

16. ISO 4032 Hexagon Nuts, Style 1 – Product Grades A and B

17. ISO 404 Steel and Steel Products – General Technical Delivery Requirements

18. ISO 657 Hot Rolled Steel Sections

19. ISO 68 ISO General Purpose Screw Threads – Basic Profile

20. ISO 8402 Quality Management and Quality Assurance – Vocabulary

21. ISO 898 Mechanical Properties of Fasteners

22. ISO 9000 Quality Management and Quality Assurance Standards

23. ISO 9001 Quality Systems – Model for Quality Assurance in Design / Development, Production, Installation and Servicing

24. ISO 9002 Quality Systems – Model for Quality Assurance in Production and Installation

25. ISO 9003 Quality Systems – Model for Quality Assurance in Final Inspection and Test

26. ISO 9004 Quality Management and Quality System Elements


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27. ISO 965 ISO General Purpose Metric Screw Threads

1.5 RELEVANT DOCUMENTS

1.5.1 This Particular Specifications should be read in conjunction with the Part 3 General

Conditions (GC), the Particular Conditions (PC), the (Part 2) Works Requirement- General Specifications (GS), the Employer's Drawings and any other document including stand alone specifications of various sub-systems forming part of the Contract.

1.5.2 In the event of a conflict between the GS and this Specification, this Specification shall prevail.

1.5.3 In the event of a conflict between this Specification and any other standards or specifications quoted herein, the requirement of this Specification shall prevail.

1.5.4 In case of any discrepancy between Particular Specification main document and appendices, the appendices shall prevail.

1.5.5 Notwithstanding the precedence specified in Para 1.5.2, 1.5.3, and 1.5.4 the Contractor shall always immediately seek advice from the Employer’s Representative in the event of conflicts between Specifications.

1.5.6 The priority order of documents is as indicated (sorted from highest to lowest priority): (a) Particular Specification including appendices (b) General Specification (c) Indian Railway (IR) AC traction manual (d) Indian Railway (IR) book of treatise on electric traction distribution of Indian Railway

institute of electrical engineer (e) Other IR Standards (f) International Standards referenced herein (g) Other International Standards


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CHAPTER 2

2.0 OVERVIEW OF THE PROJECT

2.1 GENERAL

2.1.1 This Chapter gives an overview of the Project and the information provided in this Chapter is for reference only. The General features of the above Lines are mentioned here in below:

2.1.2 Trains are electric multiple unit (EMU). Modern rolling stock with stainless steel / aluminium body and VVVF 3-phase drive with regenerative braking has been utilised. The cars are air-conditioned.

2.1.3 MAHA-METRO has planned to adopt Communication Based Train Control (CBTC) System i.e., trains where Electric Train will run on 25 kV Traction System with moving blocks and automatic train operation (ATO) i.e. GoA2 with future upgradation to Driverless Train Operation (DTO) i.e. GoA3 and Unattended Train Operation (UTO) i.e. GoA4. The Contractor shall, therefore, engage a consultant of international repute having knowledge, background of 25 kV Traction System and CBTC to study the international procedures and practices for adopting Communication Based Train Control (CBTC) on various types of electric traction system and recommend measures to be adopted on 25 kV Electric Traction System for smooth running of trains. The consultant shall furnish a report in this regard to MAHA-METRO after detailed study within a period of two months from award of contract.

2.1.4 Rolling stock maintenance Depot for North South Corridor and East West Corridor will be at Range Hill and Vanaz respectively.

2.1.5 25kV single phase AC traction has been planned with flexible Overhead Equipment (OHE) on elevated and at-grade sections and Rigid Overhead Collection System (ROCS) for underground sections.

2.2 CORRIDORS

2.2.1 The Pune Metro Rail project consists of two corridors as detailed in Table 1.1. and the revenue operation dates are elaborated in Table 1.2 for various sections progressively.

2.2.2 The alignment GADs are provided in the ‘Tender Drawings’ with this RFP. However, the alignment of above corridors, number of stations and revenue opening date may change during design and construction stage.

2.2.3 Power supply for the above corridors is received at 132kV level at following locations: (a) Receiving Substation (RSS) at PCMC with incoming 132kV supply coming from

Chinchwad Substation of MSETCL.

(b) Receiving Substation (RSS) at Vanaz Depot with incoming 132kV supply coming from Parvati Substation of MSETCL.

(c) Receiving Substation (RSS) at Range Hill Depot with incoming 132kV supply coming from Ganesh Khind Substation of MSETCL.

2.2.4 Power will be will be stepped down to 25 kV level for feeding the Corridors overhead

electrification, Overhead Catenary System and 33kV level to feed the auxiliary power supply along the corridors at stations.

2.2.5 Duplicate 33kV feeders shall be laid along the Corridor route (tunnels, viaduct and at-grade) to feed power to the auxiliary substations at stations en route and at depots.


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2.2.6 The power feeding scenario envisaged is as under:

(a) PCMC RSS will feed (33kV as well as 25kV) to North South corridor in normal

scenario. (b) Vanaz RSS will feed (33kV as well as 25kV) to East West corridor in normal scenario. (c) Range Hill RSS will act as backup to both the Corridors and it shall be sized to cater

to either of the corridor at a time without any degradation of services

Contractor may study the scheme and suggest other options as well from optimization point of view.

2.2.7 OCC, BCC, Integrated Control Centre and Administrative Building (a) The Operation Control Centre (OCC) catering to both the corridors will be located at

one of the depots. (b) The Backup Control Centre (BCC) for will be located at another depot. Pune Metro administrative building (Head Office) will be located as per the relevant drawing. The locations of OCC, BCC and Head Office are indicative and may change.

2.2.8 Power Supply Diagram Refer to following drawings in the Employer’s Drawings section for power supply schematic:

Overall power feeding schematic

25kV OHE Sectioning Arrangement The power supply feeding schematics are indicative only and it wil be responsibility of the Contractor to design the entire power supply system which fulfils the functional requirements as elaborated in this document.

2.3 KEY CHALLENGES

2.3.1 The Traction Power Distribution and Overhead Electrification systems shall be adequate, safe and reliable. The Traction Power Supply system and shall be guaranteed at each stage of the works. The following are the Key Challenges presented to the Contractor: (a) The specified level of reliability, availability, maintainability and safety requirements of

the System shall be achieved and verified by the Contractor by analysis, simulation, testing and commissioning, and system demonstrations as required in this Specification.

(b) The design of the overhead electrification and the related systems shall be chosen so

that power loss are kept as low as possible; during defect liability period, power loss shall be measured by Contractor to prove the compliance to its design calculation;

(c) The space requirement given in the tentative layouts of rooms, etc. shall be critically

reviewed by the Contractor to economise on space and also to provide a layout amenable to good maintenance and operation practices, to achieve an overall economic design.

(d) Various interfacing issues with other Contractors are required to be resolved to ensure

timely completion of the Works. It is the Contractors responsibility to ensure that all interfacing issues are clearly defined and agreements sought from all concerned Contractors in accordance with the GS and the interface requirements.


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(e) The System Design shall meet the specified performance and operational requirements stipulated in this Particular Specification.

(f) The Contractor shall carry out Simulation study to ascertain the load requirement of

the system to verify the sizes of the equipments and submit report for approval by the Employer. A dynamic simulation study for interaction between contact line and pantograph shall also be carried out by the Contractor to ascertain the compatibility of the system and submitted to Employer for approval.

(g) The Contractor shall carry out a study to assess the work to be done to suppress the

effect due to 25kV ac traction (EMI/EMC) on Civil Engineering RCC construction, power, telecom, control, ETS and signalling circuits etc. for safety of public, personnel and equipment. These studies shall form part of detailed system design. Since passenger and personnel safety is involved in humid RCC tunnel environment for a high capacity metro system, the long time & short time induced voltage rise above earth potential shall be carefully computed based on reliable field data.

(h) 25kV AC & 415V/230V AC and control cables will require laying at different levels

within Switching Stations, Cable Galleries, Stations, train tunnels and undercroft. Liaison with the Civil Contractor & other Electrical System Contractors shall be undertaken to ensure that workable solutions for cable installation are established well in advance keeping in view the maintenance requirements.

(i) The cable feeders, overhead current collection system, other system components

shall be designed to withstand the atmospheric pollution and ambient conditions furnished in GS (clause 1.12) relevant to the location where installed. However, the equipment installed in open at the ground level or inside buildings at ground level shall be designed for working in the tropical conditions existing in the area and under the maximum ambient temperature and relative humidity levels prevalent in the area.

(j) The entire Scope of Works shall generally meet design requirements of fire safety in

accordance with NFPA-130 Standard for Fixed Guide-Way Transit System, 2013 (or later) edition, except where amended by this PS.

(k) The entire installation shall meet the protective provisions relating to electrical safety

and immunity, including those required against induced emf caused by 25kV ac traction.

2.3.2 Tubular portal structures for OCS

MAHA-METRO has planned to use tubular portal structures for supporting OCS throughout the mainlines. Since such structures have not been widely used in India, the Contractor shall duly consider the timely designs of the same including drafting / preparing all relevant documents for obtaining approvals from RDSO and other relevant statutory authorities. MAHA-METRO will proactively facilitate RDSO / Statutory approval process.

2.3.3 Civil and Other Constraints (a) Due to advanced programme of the civil works of various Sections, the locations of

OHE structure have been tentatively fixed according to site conditions and requirements. This will be provided to the Contractor.

(b) The Contractor will be required to interface with the other working contractors also.


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CHAPTER 3

3.0 SCOPE OF WORK

3.1 GENERAL

3.1.1 The Overhead Equipment works for the two Corridors and for both the Depots is to Design, Manufacture, Supply, Installation, Testing and Commissioning by the Contractor under this Contract and shall meet all performance, functions, design and technical requirements as defined in this Specification.

3.1.2 The scope of work also includes transportation, storage, loading / unloading, insurance and safe custody till handing over of the Works.

3.1.3 The scope of work includes the quality checking and quality management for all the works listed herein.

3.1.4 The scope of work includes the training to operation and maintenance personnel for the project.

3.1.5 The scope of work includes the supply of spares, maintenance tools and operation & maintenance manuals.

3.1.6 The equipment required for the project shall feature all equipments and systems required to form part of Overhead Equipment.

3.1.7 The scope of work includes the design of an Electrical Work Permits plan and the management of the Electrical Work Permits on site (relevant to ROCS/OHE and switching stations i.e. for the scope under purview of OHE Contractor, including: (a) organizing meeting on a weekly basis with other contractors to list the needs of

electrical work permits issuance (b) issuing and collecting back electrical works permits from contractors (c) de-energizing and locking out of the power supply and OHE contractor’s equipment

and fixing of earthing pole on the catenaries where required in accordance to the local safety rules and to the electrical work permits.

(d) keeping a record of all the work permits and providing a copy to the SHE manager of

the Employer representative.

3.1.8 This scope of work starts with the first energized system (NS1 Section i.e. PCMC to Range Hill) and ends at the end of the service trial period of last section i.e. NS2 (Range Hill to Swargate).

3.1.9 Two kinds of electrical permit shall be issued by the Contractor: (a) Electrical Work Permit (Permit-to-Work or PTW) ensuring that works are allowed and

that all equipment have been de-energized and no electrical hazard can be introduced (b) Testing, Troubleshooting, and Voltage Measuring (TTVM) Electrical Work Permit, for

works that needs to be done with the system energized.

3.2 DETAILED DESCRIPTION

3.2.1 132kV Bay Augmentation works This is in scope of other contractor.


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3.2.2 Receiving Substation

This is in scope of other contractor.

3.2.3 Traction Network

3.2.3.1 The scope of work comprises of design, manufacture, shop testing, supply, delivery at site, installation, inspection, testing and commissioning of 25kV AC 50 Hz Single Phase sub sectioning post, sub sectioning and paralleling post, sectioning and paralleling post and overhead contact system (flexible and rigid).

3.2.3.2 The scope of work broadly includes design, supply, installation, inspection, testing and commissioning of: (a) Feeding arrangements to the overhead contact system with suitable protection at

feeding post. (Protection relays required at TSS end are under scope of other contractor, while other protection relays at FP, SP, SSP etc. if foreseen, shall be under the scope of OHE Contractor. E.g. incoming feeder to Depot SSP may be required to be provided with Circuit Breaker and not interrupter; however the final scheme shall be as per design of the Contractor.)

(b) Sectioning and paralleling feeding arrangement with suitable protection (c) Sub-sectioning and paralleling feeding arrangement with suitable protection (including

all civil works of depot SSPs) (d) Sub-sectioning arrangement (@every 2-2.5km) with suitable protection (e) Supply of traction power through overhead contact system (flexible and rigid) with

suitable EMC mitigation (e.g. BT & RC depending on outcome of system studies), earthing and protection arrangements

(f) Catenary insulation for about cumulative 4km route length (g) Associated galvanized steel structures (tubular portal structures at mainlines and

normal masts at depot), buildings, foundations, ancillary equipments, feeders, jumpers and connections to flexible & rigid overhead contact system, etc.

(h) Interlocking and protection coordination of various equipment at SS, SP & SSPs (i) Providing earthing arrangement for all equipments and structures in the SS,SP &

SSPs. (j) All control and monitoring cables for necessary connection of equipments (k) Other associated equipments, such a battery, battery chargers, AC and DC

Distribution boards, control and relay panels, etc. to make the SP/SSP/SSs fully fit to perform its task.

(l) Structures and foundations to support the equipment. (m) Supply of spare parts and maintenance tools and operating and maintenance manuals (n) Other associated items of work (o) The Contractor shall submit six hard copies and two soft copies of drawings including

completion drawings


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Note: With regards item (h) above, the viaduct girders are going to have different span lengths ranging from 16.5 m to 54 m. While attempt shall be made to use the end segment of a span (having wider parapet) for installation of OHE support structure to the maximum extent, the Contractor may be required to make use of brackets / base plates at any other portion of viaduct similar to the arrangement shown in the related tender drawing.

3.2.3.3 The following items of work, in respect of 25kV feeder and retrun cables from TSS / Traction Posts to OHE are within the Scope of this Tender: (a) Final location survey of the route for 25kV cables between the TSSs / Traction posts

and corridor (b) Submission of details of possible alternative routes, together with their implications on

Work Methodology, Execution time, cost, utilities affected to be diverted and acceptable to civic bodies

(c) Preparation of cable paths as per the route accepted by the Employer and in

accordance with approved designs (d) Laying of cables in accordance with the Methodology (pulling, running out or

ploughing in) accepted by the Employer

(e) Straight through joints

(f) Cable terminations at either end (g) Cable termination structure and jumpering at both ends

(h) Testing and Commissioning of the Cables (i) Supply of Special Tools and plant and spare parts as specified in the Bid Documents

(j) Training of MAHA-METRO Staff and Training Instructors, as specified

(k) Supply of Operation and Maintenance Manuals for all equipment

(l) Deal and resolve in co-ordination with the Employer the interface with Local

Authorities like Pune Municipal Corporation (PMC), Pune & Chinchwad Municipal Corporation (PCMC), BSNL, Gas Supply companies, Power Supply Authorities, PWD, Municipal Corporation and other state government authorities etc. to ensure progressing of the field works as per schedule

(m) Interfacing with other Contractor as required

3.2.4 SCADA SCADA system is in scope of other contractor, however OCS Contractor shall provide provisions for interface of equipment to be supplied under this contract with the SCADA system and coordinate appropriately with SCADA contractor. The equipment to be monitored and / or controlled by SCADA together with the associated functionality shall, as a minimum, include that listed and described in Appendix G of this Particular Specifications.

3.2.5 Overhead Equipment

3.2.5.1 The scope of work comprises of design, manufacture, shop testing, supply, delivery at site, installation, inspection, testing and commissioning of the Overhead Equipment (flexible and rigid) for MAHA-METRO metro project.


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3.2.5.2 In the main lines on elevated sections and at-grade sections, the Overhead Equipment shall consist of simple catenaries system.

3.2.5.3 In the main lines in underground sections, the Overhead Equipment shall consist of Rigid Overhead Contact System.

3.2.5.4 For Depots: (a) the Overhead Equipment shall consist of tramway type for stabling, workshops,

Washing / Pit Lines etc. (b) the overhead line of the test tracks shall be same as main line type.

3.2.5.5 The following items of work are within the scope of work of this tender but not limited to: (a) All surveys on site necessary to do in order to design the OHE (b) The design of the OHE including simulation / system studies (c) Supply and erection of 25kV traction overhead equipment at-grade & elevated lines

and depots (d) OHE support structure with baseplate for viaduct (tubular portal structures) and

without base plate for depot sections (normal masts and portals) (e) Portals with drop arms with base plate welded for viaducts and without baseplates at

grade / depot (f) Drop arms attached to roof trusses in stations and in depot (g) Cantilever assemblies with silicon insulators for mainline and depot (h) Overhead equipment conductors like messenger wire, contact wire, bridle wire from

tramway OHE, jumpers, and dropper wires etc. (i) Rigid overhead conductor system in underground stations and tunnels. (j) Overhead Protection Conductor (OPC) and Buried earth conductor (BEC) (k) Booster Transformer and Return Conductor (BT & RC) if so required based on the

outcome of the system studies and agreement with the affected parties (telecom companies, DoT etc.). It shall be Contractor’s responsibility to convince and obtain approval from DoT and other affected parties. Irrespective of the outcome of the system studies, in case the Contractor is not able to obtain approvel from DoT / other affected parties, he shall install the BT & RC as per requirements of DoT / other affected parties.

(l) Integral transverse link (ITL), earth electrodes, earth connectors, earth strips etc. (m) Termination assemblies for conductors with silicon composite insulators (n) Anti-creep assemblies (o) Guy rod assemblies with base plate connection for viaduct and ‘U’ bolts embedded in

concrete blocks for depot (p) Regulated OHE with spring type ATD on viaduct and unregulated OHE in depot (q) Cut in insulators and section insulators (r) Requisite measures to minimize the EMI impacts on the neighbourhood of Airport and

other sensitive locations (s) Anti bird nesting and anti climbing (if required) provisions (t) 25kV Motorized operated isolators and interrupters and circuit breaker (u) All control and monitoring cables for necessary connection of equipments (v) Other associated equipments, such a battery, battery chargers, AC and DC

Distribution boards, control and relay panels, etc. to make the switching posts fully fit to perform its task.

(w) Bonding and earthing including earth mats or electrodes in depot area and Track sides

(x) All inspection, testing, integrated testing, and Commissioning of all erected equipment (y) Mast foundations and geotechnical investigations shall be done as per the

foundation’s design and calculation (z) Other miscellaneous works

3.2.6 Civil Works and Ancillary Installations


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3.2.6.1 The Contractor will be required to execute civil, finish & utility works at the depot SSPs location. The earthing work (earthmat, maintenance free earthing etc.) shall also be in the scope of Contractor for Depot SSPs.

3.2.6.2 The foundations of masts / portals in depots shall be under the scope of Contractor. 3.3 DESIGN

3.3.1 All the basic designs, drawings of the overhead contact system shall be arranged by the

Contractor himself.

3.3.2 All designs, legends, notes on drawings and schedules of materials shall be in English and shall be prepared in the metric system and all design and drawings shall conform to specification of Indian Railway RE/OHE/25, ETI/PSI/31.

3.4 INTERFACE

3.4.1 The purpose of the Interface Specifications is to provide Project Contractors involved in the interface with a clear overview of the purpose and functionality of each interface. It provides a framework such that Project Contractors can set to work in a co-operative way to produce the interfacing standard.

3.4.2 Details of the interfaces of OHE Contractor with the other contractors are in the Interface Specifications in Appendix A.

3.5 DOCUMENTS AND MANUALS

3.5.1 List of deliverables

3.5.1.1 The Contractor shall supply to the Employer’s representative’s a list of deliverables for the procurement, design, manufacture, Inspection, testing, installation, training, maintenance and operation of the Works.

3.5.1.2 The Contractor list of deliverables shall list all documents required in Part 2: Works Requirements - General Specification and list the document that the Contractor intend to produce.

3.5.1.3 All subjects listed in Appendix F List of deliverables shall be dealt in the Contractor list of deliverables.

3.5.1.4 The Contractor shall duly indicate in the list of deliverables the documents he intends to submit for information only and documents he intends to submit for notice of no-objection and the related time schedule.

3.5.1.5 The Contractor list of deliverable shall be submitted to Employer/Employer’s Representative within 2 months of the date of signing the contract.

3.6 MAINTENANCE AND TRAINING

3.6.1 This section describes the maintenance philosophy and training of maintenance staff for OHE installations taking into account international standards and Railway practices.

3.6.2 For the equipment of different stages, the Contractor shall be responsible for the maintenance of the equipment supplied under the contract till the Employer’s Taking Over of the whole works related to that stage.

3.6.3 The Contractor shall be responsible for the supervision of maintenance of the equipment supplied under the contract during the period specified in Section 9.4.


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3.6.4 The Contractor, upon noticing any defects, deficiency in quality and quantity of spares and materials shall without delay, arrange for alternative source of supply and submit his proposal to the Employer’s Representative for review.

3.6.5 During the Defects Liability Period (DLP) maintenance of all Works will be conducted by the Employer under the supervision of the Contractor. The Contractor shall ensure that in order to supervise maintenance during the DLP, personnel are always available with the relevant skills and level of competence.

3.6.6 During the Defects Liability Period (DLP), in the event of a failure, the Contractor shall undertake the management and investigation necessary to identify and rectify the cause.

3.6.7 The Contractor shall provide supervisory maintenance staffs who are expert in all the different levels of fault finding, maintenance and repair of the various systems supplied under the Contract covering at least the following: (a) 25kV OHE (Flexible & Rigid) (b) Switching stations including associated switchgear (c) Cabling system (25 kV ac)

3.6.8 Stipulations of Section 12.3 of the Part 2: Works Requirements - General Specifications shall apply here.

3.6.9 The Contractor shall provide training that enable all the installations, to be operated and maintained in the most efficient and safe manner, so as to achieve the maximum reliability and economy required by such Metro System.

3.6.10 The Contractor shall provide comprehensive training and documentation to the Employer’s staff in accordance with the requirement of section Part 2: Works Requirements - General Specifications.

3.6.11 The Contractor shall install mock-up equipment for system (including but not limited to OHE system, ROCS, cantilever, mast / portal etc.) and any such facility(s) considered necessary for the training of Employer’s staff in the Range Hill / Vanaz Depot training centre.


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CHAPTER 4

4.0 PERFORMANCE REQUIREMENTS

4.1 GENERAL

4.1.1 The Overhead Collection System shall achieve all performance requirements as specified in the Specification when operating in the NS and EW Corridor.

4.1.2 All subsystems, equipment to be used for the Overhead Collection System shall be of proven design and in use in other passenger carrying metro/railway systems.

4.1.3 Built-in diagnostics and remote monitoring functions for each microprocessor-based equipment module of the Overhead Collection System shall be provided by the Contractor such that the performance requirements can be demonstrated.

4.1.4 The reliability and maintainability processes and procedures shall be planned, integrated and developed in conjunction with the operating environment, and the design, development and production functions to permit the most effective and economical achievements of the systems and equipment design objective.

4.1.5 The system shall meet or exceed the requirements of CENELEC Standards EN 50126 / IEC 62278 or equivalent international standards for Reliability, Availability, Maintainability and Safety.

4.1.6 The latest versions of the specifications should be followed in respect of all standards. Further, the Contractor shall provide the relevant documents used for reference of the Employer.

4.1.7 There should not be impact on the Train normal operation provided in table 4.2 and 4.3 below for the following scenarios in Table 4.1: Table 4.1: Traction power supply scenarios

Scenario Supply arrangement

Outage of complete PCMC TSS

Supply to NS Corridor shall be available from Range Hill TSS including Range Hill depot Supply to EW Corridor and depot from Vanaz TSS

Outage of complete Vanaz TSS

Supply to EW Corridor shall be available from Range Hill TSS including Vanaz depot Supply to NS Corridor and depot from PCMC TSS

Outage of complete Range Hill TSS

Supply to NS Corridor and depot from PCMC TSS and Supply to EW Corridor and depot from Vanaz TSS

Outage of one traction transformer of PCMC or Vanaz TSS

Supply to NS Corridor and depot from healthy traction transformer of PCMC TSS and Supply to EW Corridor and depot from healthy traction transformer of Vanaz TSS Note: The Range Hill TSS may or may not be in outage or in partial outage

Each TSS shall be configured in fully redundant configuration i.e. 1+1 configuration.


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Table 4.2: Line 1: North-South Corridor (Train frequency)

Description Ultimate Horizon Year

Scenario 1 Scenario 2

Cars / train 3 6

Peak hours Headway (seconds) 120 240

Max. PHPDT demand (approx.) (with standees @8 persons per m2)

30000 30000

Table 4.3: Line 2: East-West Corridor (Train frequency)

Description Ultimate Horizon Year

Scenario 1 Scenario 2

Cars / train 3 6

Peak hours Headway (seconds) 120 240

Max. PHPDT demand (approx.) (with standees @8 persons per m2)

30000 30000

4.2 RAM SPECIFICATIONS

4.2.1 RAM Plan

4.2.1.1 A Preliminary RAM plan shall be submitted that will be the base for the writing of the

actual RAM Plan during the project stage. The Contractor shall update the RAM plan throughout the course of the Project, as required by actual design progress. This document shall cover the design, development, manufacture, test, installation and commissioning phases of the system. The Preliminary RAM plan shall define the process for the specification, verification and control of the Reliability, Availability, Maintainability and Operability requirements for the Pune Metro Rail System. It shall describe in particular: (a) The retained RAM and Operability approach, (b) The management of the Reliability, Availability, Maintainability and Operability

activities, (c) Task listing and time phasing for each task related to these activities, (d) List of RAM and Operability documents to be produced, (e) The description of RAM and Operability analysis methods and tools to be used during

the design and development of the system, (f) The description of the method of verification

4.2.1.2 The RAM plan shall update the Preliminary RAM Plan submitted during the call of tender, in order to: (a) Detail the RAM organization and activities that the Contractor will perform during the

Project, (b) Take into account any potential modifications of the project, its schedule or

organization.

4.2.1.3 The RAM Plan of the Contractor shall cover the design, development, manufacture, test, installation, commissioning and operation phases of the system.

4.2.2 RAM assessment

4.2.2.1 The Contractor shall perform a RAM assessment and report to be submitted that shall demonstrate the achievement of the RAM requirements of the System.

4.2.2.2 The Contractor shall develop procedures and performance analysis routines to confirm that the System achieves the RAM performances.

4.2.2.3 The Contractor shall estimate the RAM performances of the System taking into account: (a) The reliability and maintainability predictions


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(b) The RAM studies (c) The Operation Plan (d) The Maintenance Plan (e) The Operation and Maintenance Concept (f) Any other factor that could have any impact on RAM performances

4.2.2.4 The Contractor shall use an adapted methodology as reliability block diagrams to explain demonstrations.

4.2.2.5 The Contractor shall perform reliability predictions based upon the knowledge of the previous equivalent systems or based on part failure rates.

4.2.2.6 The Contractor shall define RAM objectives for each sub-systems of the system.

4.2.2.7 The Contractor shall ensure the monitoring of the RAM performance of the system until the end of DLP (defect liability period).

4.2.2.8 The Contractor shall perform a quantified RAM synthesis.

4.2.3 RAM reviews

4.2.3.1 The Contractor shall carry out RAM reviews at least after each major development phase and at Employer’s demand.

4.2.3.2 The aim of each Reliability, Availability and Maintainability review is to assess the conclusions of the RAM tasks in order to: (a) Estimate whether the RAM requirements have been correctly taken into account, (b) Identify the consequences of these conclusions on the remaining RAM tasks, (c) Identify the consequences of these conclusions on the design.

4.2.3.3 During these reviews, the Contractor shall pay particular attention to changes that may affect earlier decisions.

4.2.4 Maintenance Plan

4.2.4.1 The Contractor shall provide a maintenance plan of the system.

4.2.4.2 The maintenance plan shall provide a complete list of preventive maintenance procedures for each type of piece of equipment supplied under the contract.

4.2.4.3 The Contractor shall define and present in the maintenance plan: (a) The technical means and procedures necessary for the operator to perform his

maintenance operations (b) The maintenance time and workforce for every procedure (c) For corrective maintenance, the minimum information necessary for the operator to

define, when an alarm occurs, the exact nature of the failure, as well as the precautions to be taken (by the operator) to perform efficient maintenance tasks.

(d) For corrective maintenance, the tests and controls to perform in order to identify the exact nature of the failures, and after repair, to ensure the compliance of the equipments and their proper and safe operating condition.

4.2.4.4 For each preventive maintenance task, the Contractor shall issue a study in order to:

(a) Identifies the RAM or safety risk covered by the preventive maintenance task; (b) Justifies the periodicity of the maintenance task.

4.2.5 RAM Requirements Verification


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4.2.5.1 The achievement of the RAM requirements is measured during the whole performance checking period. If the System does not prove during performance checking period its ability to satisfy to the RAM requirements, performance checking period can be extended by the Employer. In that case, the Contractor shall improve the System until the System reaches the specified RAM requirements.

4.2.5.2 During all the warranty period, should one or several RAM requirements not being achieved for reasons under the responsibility of the Contractor, the Contractor shall improve the System by modifications of software, material, or procedures until the System met all the requirements. In this case, extension of warranties shall be implemented at no additional cost for the Employer.

4.2.6 Reliability Requirement

4.2.6.1 The Reliability requirements of this PS shall be subsidiary to the Availability and Maintainability requirements of this PS. If higher figures are required to achieve the Availability requirements and Maintainability requirements then these higher figures shall become the Reliability requirements for the Overhead Collection System.

4.2.6.2 The Reliability measure for the Power Supply system shall be the Mean Time Between Maintenance Action (MTBMA).

4.2.6.3 The OCS system shall achieve a MTBMA of no less than 7 days.

4.2.6.4 Maintenance actions shall include investigations where no fault or failure is identified.

4.2.6.5 The Reliability of the OCS System shall be demonstrated by the Contractor in accordance with the processes defined in the EN 50126 / IEC 62278 standard or international equivalent.

4.2.7 Availability Requirements

4.2.7.1 The Contractor shall be responsible for providing a System design, maintenance procedures, and defining the recommended spares holdings to ensure that the Availability requirements of the Overhead Equipment shall be achieved.

4.2.7.2 The measures for Availability shall be Mean Time Between Service-Affecting Failures (MTBSAF).

4.2.7.3 The availability of the Overhead Collection System system shall not be less than 99.99%.

4.2.7.4 The availability figures shown in the following schedule shall be met by the Overhead Collection System for both corridors. The MTBF for the following items of plant shall exceed the values listed: (a) Circuit breaker – 1 x 100000 hours; (b) Motorised switch – 5 x 10000 hours; (c) Motorised disconnect – 5 x 10000 hours; (d) Protection relay – 1 x 100000 hours; (e) Workstation or Programmable Logic Controller (PLC) – 1 x 100000 hours;

4.2.7.5 For the purposes of availability calculations, the Contractor shall assume that the service operating hours are 19 hours per day (05:00 am to 12:00 pm), for 365 days a year.

4.2.7.6 In all availability calculations the following access times shall be assumed: (a) 60 minutes for equipment located in equipment rooms at the platform level that are

accessible during traffic hours; and (b) 10 hours for equipment that is only accessible during non-traffic hours.


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4.2.7.7 The availability of the Overhead Collection System shall be demonstrated by the Contractor in accordance with the processes defined in the Specification.

4.2.7.8 Detrainment of passengers, during Defect Liability Period (DLP), caused due to failure of OCS may call for imposition of penalty on the Contractor. During DLP period, following completion of the project, the Supplier will be liable for defects in their work and shall be imposed by the Employer a penalty per day of unavailability.

4.2.7.9 Perturbation Analysis (a) A detailed System perturbation analysis shall be performed stating the types of

failures that could cause service interruptions and the failure management actions required to mitigate the effect of these failures.

(b) The service interruption analysis shall document all failure modes capable of causing revenue service disruptions.

(c) Operational actions, System design features or maintenance strategies that can reduce the impact of potential service interruptions shall be submitted to the Employer’s Representative for review.

(d) The Contractor shall perform RAM studies in order to demonstrate that the availability requirements are fulfilled. The Contractor’s RAM studies shall take into account the maintenance plan and the reliability specifications of his system.

4.2.8 MaintainabilityRequirements

4.2.8.1 System and Equipment design

(a) The System shall be designed to maximize Availability during traffic hours, to minimize

the amount of maintenance required to maintain the System and to ensure that any maintenance can be carried out with the minimum amount of time, the minimum amount of skill and at a minimum cost.

(b) The Contractor shall provide details of corrective and preventive maintenance

activities. (c) The Contractor shall specify, for each Line Replaceable Unit (LRU), the mean time

needed to recover to a normal operation configuration. 90% of these recovery times shall be lower than the estimated value.

(d) The possibility of disassembly of each LRU shall not interfere with other LRUs. (e) The Contractor shall design the system in order to allow easy cleaning operations. For

equipment interfaced with the Public, the Contractor shall design solutions and typologies of materials that minimize cleaning operations and repair of damages.

(f) Accessibility to test and diagnosis interfaces, to event recorders shall be effortless.

Their access shall be designed and located in that way. (g) The Contractor shall design the System in order to allow most of the maintenance

workload to take place during Business Hours. (h) The System shall inform the operator of any failure, dysfunction or disrupting event

that could occurs on the System. The understanding of diagnosis data by maintainers shall be easy and shall not require any specific expertise of the system.

(i) Diagnosis data shall indicate which LRU(s) are suspected as responsible of the

detected failure.


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(j) Maintenance documentation shall support maintainers for diagnosis data interpretation. A link between the maintenance documentation and diagnosis data shall be established.

(k) The Contractor shall identify each LRU with tags containing the following data: name,

serial number and part number. (l) The Contractor shall identify with tags: cables, connectors, relay, switches, fuses,

circuit breakers, test spots as well as any devices that the maintainer should have to manipulate.

4.2.8.2 Mean Time to Restore

(a) The maintainability measure for the Overhead Collection System shall be Mean

Time to Restore (MTTR). (b) The required MTTR shall be achieved for failures of the whole System or any part of

the System, whether service affecting or not. (c) The following MTTR shall be achieved:

a. 30 minutes for SSP/SP/SS equipment; b. 30 minutes for Low Voltage equipment; c. 30 minutes for equipment located in equipment rooms or control rooms or on

the platform. (d) The MTTR time measurement shall include on site diagnostics and rectification of the

failure (including software re-boot) up to the point that the System is restored to full functionality. In the event that the failure cannot be rectified, the measurement shall include the time necessary to remove the failed piece of equipment from the System and replace it with a functioning module.

(e) The MTTR does not include the time taken for designated personnel to arrive on site

(access time) to begin local diagnostic activities or the time taken for the replacement parts to be delivered to site.

(f) The maintainability requirements shall be demonstrated by the Contractor in

accordance with the processes defined in the Specification.

4.2.8.3 Line Replaceable Unit (LRU) Replacement (a) All line replaceable units shall follow maximum weight restrictions such that this can

be easily handled manually by a single person approx 30kg. If the weight of any LRU exceeds the expected value, the Contractor shall provide specific handling tools.

(b) The Contractor shall equip each piece of equipment to be handled by handling and

anchoring supports. (c) The Contractor shall design pieces of equipment robust enough to support successive

removals and assembly in workshop.

4.2.8.4 Service Life (a) All components, materials, software and other support required to repair and service

all OCS Equipment shall be available for at least 30 years from the Employer’s Taking over of the Works or Section.

(b) All updated components shall be fully backward compatible with the originally installed

component.


Feb 2018 Page 35 of 202

(c) The Contractor shall notify the Employer in writing prior to deleting any component of the System from general availability, and submit written assurances that it can provide functionally identical replacement units during the life cycle of the equipment. The notification period for the deletion of the component and written assurances shall not be less than the lead time for ordering or manufacturing the component plus twelve (12) months. Whenever applicable as required by CENELEC / IEC / BS/ IS, the Manufacturer shall have to produce a Safety Certification for the same.

4.2.8.5 General Maintenance Requirements

The Contractor shall define in the maintainability prediction studies, the unavailability and maintainability times of each failure of the transportation system. The Contractor shall perform all tests that the Employer shall require before and after the revenue service, in order to control the times defined by the Contractor. If the times measured during the tests are higher than the times defined by the Contractor, the Contractor shall update the RAM studies. In case of abnormal situation, if the time needed by the O&M Operator to recover is higher than the one defined in the prediction studies and the Contractor demonstrates that the required recovery time should have been lower, then the responsibility of the Contractor is limited to the part of unavailability corresponding to the demonstrated necessary time to recover.

4.3 SAFETY REQUIREMENTS

4.3.1 Refer to the Appendix D in present PS volume for requirements

4.3.2 The Contractor shall provide a OCS System for the safe routing, spacing, movement and control of trains and protection of the passengers.

4.3.3 The Contractor shall establish and assume complete responsibility of the system safety through the application of engineering and management principles, criteria and techniques to optimize all aspects of safety throughout all phases of the system life cycle. This shall apply to all systems supplied under this contract.

4.3.4 The OCS system shall provide hot swappable modules from which commutation shall not affect the normal and emergency operation of the system.

4.3.5 The OCS Equipment shall not lead to an unsafe condition when the plug-in module / card / equipment is taken out.

4.3.6 The safety performance requirement shall be achieved with a calibration / inspection interval of not less than 1 year.

4.3.7 The safety of the OCS system shall be demonstrated by the Contractor in accordance with the process defined in the GS.

4.3.8 The safety level of each function of the OCS in Chapter 5 shall be defined and demonstrated by the Contractor in accordance with the process defined in the GS.

4.3.9 All OCS equipment shall be protected from damage or reliability degradation due to vibration, shock and other atmospheric conditions.

4.4 SERVICE CAPABILITY

4.4.1 Service Capacity Requirements

4.4.1.1 The OCS system shall make provision for the sustained operation of equipped trains on both Corridors in each direction.


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4.4.2 Service Capacity Conditions

4.4.2.1 Per hour per direction service capacity requirement shall be achieved under the following conditions: (a) Equipped train station stops with average 30 second dwells time for all stations; (b) Minimum two-minute train layover at all terminals; (c) Considering all curves, gradients in the alignment and diverging train movements; (d) Train characteristics and performance shall be provided to the successful bidder. (e) Drawings and Systems being provided by other Project Contractors.

4.4.3 Train Types

4.4.3.1 The OCS System shall provide for the safe operation of the all train types including: (a) Equipped trains; (b) Non equipped trains (c) Engineer's trains and Light locomotives (d) Accident Relief Train

4.4.3.2 The key information of the rolling stock performance requirements is provided for reference hereunder: Table 4.5: Rolling Stock performance requirements (indicative)

Train composition DM-T-DM (3-car) DM-T-M-M-T-DM (6-car)

Average minimum design acceleration rate for dense crush loaded (AW3) train on level tangent track

1.0 m/sec2 for 0 to 30 kmph range

Average acceleration rate for crush loaded (AW2) train on level tangent track shall be as under:

0 kmph to 30kmph

0 kmph to 60 kmph

0 kmph to 80 kmph

1.05 m/sec2

0.65 m/sec2

0.35 m/sec2

Service braking rate from 80 kmph to 0 kmph for crush loaded train on level tangent track

1.1 m/s2

Emergency braking rate from 80 kmph to 0 kmph for fully loaded train on level tangent track

1.3 m/s2

The Emergency braking distance of 3-car train set with all bogie working under fully loaded condition

245m

Jerk Limiting Range 0.70 m/sec3

*Service Brake Response Time 2.0s

*Emergency Brake Response Time 1.5s max

*Service and Emergency Brake Release Time 2.5s

Resistance to motion (formula, curve, starting resistance) Note: The RS Contractor will provide formula for UG sections

𝑹 = 𝟏𝟒. 𝟎𝟏 + 𝟎. 𝟐𝟔𝟒𝑽+ 𝟎. 𝟎𝟎𝟏𝟗𝟏𝑽𝟐

N/t for elevated / at-grade section (V in kmph)

Maximum Vehicle Overhang /in each end) 3625mm ± 125mm

Maximum wheel diameter 860mm

Minimum wheel diameter 780mm

Maximum train design speed (safe train speed) 95 kmph

Maximum train service speed 85 kmph

Tare weight Cars (Maximum) 125T for 3-car unit with weight of any car not exceeding 43T

No of axles per Car 4

Axle Load 16 tonne (max)

Train length 70m approx (3-car)


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135m approx. (6-car)

4.4.4 Degraded mode

4.4.4.1 The traction system shall be able to allow the normal operation of the train in 2031, as per

the Operation Plan (Para 4.1.7 above) under the scenrios depicted in the figures below:

Figure 4.1: Normal power feeding scenario

Figure 4.2: Degraded power feeding scenario – PCMC TSS in Outage


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Figure 4.3: Degraded power feeding scenario – Vanaz TSS in Outage

Figure 4.4: Degraded power feeding scenario – Range Hill TSS in Outage

Figure 4.5: Degraded power feeding scenario – One TT of PCMS TSS in Outage


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Figure 4.6: Degraded power feeding scenario – One TT of Vanaz TSS in Outage

4.5 CYBER SECURITY ASSURANCE

4.5.1 Notwithstanding, the cyber security requirement defined elsewhere, the design of OHE/OCS system shall fully comply with cyber security requirements of the following standards.

ISO 27001

ISO 27002

ISO 27017

ISO 27018

NIST SP 800-53

NIST SP 800-82

ISA 99 / IEC 62443

4.5.2 Metro Rail faces new security challenges as system has become more interconnected, integrates more and more digital technologies and increasingly uses data to deliver higher capacity & performance and thus cybersecurity is essential to the safe and reliable operation of modern Metro Rail System. Therefore cybersecurity is required to ensure end-to-end information security, not only to prevent and to detect attacks, but also to react rapidly if they occur. Objective of Cybersecurity for Metro includes availability, integrity, confidentiality, reliability and safety of entire Metro Rail Eco-System.

4.5.3 Threats to control systems can come from numerous sources, including hostile governments, terrorist groups, disgruntled employees, malicious intruders, complexities, accidents, and natural disasters as well as malicious or accidental actions by insiders. Predominant type of cyber threats include:

Social Engineering and Phishing

Infiltration of Malware via Removable Media and External Hardware

Malware Infection via Internet and Intranet

Intrusion via Remote Access

Human Error and Sabotage

Control Components Connected to the Internet

Technical Malfunctions and Force Majeure

Compromising of Extranet and Cloud Components

Denial of Service (DoS) Attacks

Compromising of Smartphones in the Production Environment And a compromise could result in:


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Endangerment of public or employee safety

Loss of public confidence

Violation of regulatory requirements

Loss of proprietary or confidential information

Economic loss

Impact on entity, local, state, or

national security

4.5.4 The system shall be designed for protections against the cyber threats and ensure that the following incidents mentioned below but not limited to are avoided:

Blocked or delayed flow of information through networks, which could disrupt operation

Unauthorized changes to instructions, commands, or alarm thresholds, which could damage, disable, or shut down equipment, create environmental impacts, and/or endanger human life.

Inaccurate information sent to system operators, either to disguise unauthorized changes, or to cause the operators to initiate inappropriate actions, which could have various negative effects.

Software or configuration settings modified, or software infected with malware, which could have various negative effects.

Interference with the operation of equipment protection systems, which could endanger costly and difficult-to-replace equipment.

Interference with the operation of safety systems, which could endanger human life.

4.5.5 Major security objectives should include the following:

Restricting logical access to the network and network activity

Restricting physical access to the network and devices

Protecting individual components from exploitation

Restricting unauthorized modification of data

Detecting security events and incidents

Maintaining functionality during adverse conditions

Restoring the system after an incident

4.5.6 For this purpose, MAHA-METRO (through Telecom Contractor or otherwise) shall engage a Cyber Security Consultant, who will recommend Cyber Security Guidelines complying the requirements of above standards.

4.5.7 The Contractor shall be required to engage with designated Cyber Security Consultant of MAHA-METRO, at the early stage of design development. The Contractor shall consider the inputs of Cyber Security Consultant into their design and develop their System Safety & Cyber Security Assurance Plan and submit to MAHA-METRO for approval.

4.5.8 The Contractor shall be fully responsible for compliance with Cybersecurity standards and implementation of their System Safety & Cyber Security Assurance Plan. Any cost associated with implementation of Cybersecurity guidelines shall be deemed to be included in the bid proposal.


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CHAPTER 5

5.0 FUNCTIONAL REQUIREMENTS

5.1 GENERAL

5.1.1 Contractor shall issue during its preliminary design a functional preliminary specification for the whole OCS system and equipment, rehearsing all the function achieved by the system and their taking in account in the different ‘overhead equipment’ sub-systems.

5.1.2 For each ‘OCS’ sub-systems, the Contractor shall issue during its preliminary design a functional preliminary specification in respect with the requirements of this Chapter 5.

5.1.3 Content of those preliminary functional specifications shall be detailed by Contractor during detail design stage in detailed design functional specifications.

5.2 RECEIVING SUBSTATION This is in scope of other contractor.

5.3 TRACTION NETWORK Note: The Traction Substations are in scope of other contractor, however, Para 5.3.1 and 5.3.2 are provided herein for general information of the OCS Contractor, as well as enable him to understand the interface / coordination requirements with Power Supply Contractor.

5.3.1 Traction Substation

5.3.1.1 Traction Substation within Receiving Substation performs the task of converting the 132 kV incoming power to 27.5 kV single phase power and of supplying this power to the traction overhead equipment through appropriate switchgear and protection arrangements.

5.3.1.2 Traction feeder stations are fitted with 25 kV circuit breakers for ensuring the isolation of the faulty sections.

5.3.1.3 The purpose of the protection equipment is to ensure isolation or de-energizing of a system or equipment whose operating conditions have become faulty and/or abnormal to avoid: (a) any major repercussions on the traffic (b) any damages or dangerous effects to person and equipment

5.3.1.4 The protection relays required for protection of Traction Feeders (Overcurrent, Distance) and for protection against ‘Panto flash over’ and ‘Wrong phase coupling’ at Neutral Sections, shall be provided by the Contractor. In addition, the protection relays required for protection of feeders to Depot/s (Line differential, if required and Overcurrent) shall also be provided by the Contractor.

5.3.1.5 All the instantaneous relays should be capable of operating the circuit breaker within a duration of 120 ms from the occurrence of the fault. This time duration should include the dead time of the relays and this feature should be demonstrated during testing of the relays.

5.3.2 Traction Protections

5.3.2.1 The 25kV power supply and overhead contact system protection has been described in the following figure:


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Figure 5.1: Traction system protections

5.3.2.2 The general protection device is equipped with three protective functions:

5.3.2.2.1 The bus bar protection in switching posts and substations is triggered immediately on short circuit current and switches off both 25 kV and 132 kV circuit breakers.

5.3.2.2.2 The circuit breaker monitoring is triggered by the ‘Off’ command for the circuit breaker

and switches off the circuit breaker initially triggered but not tripped within a pre-set time.

5.3.2.2.3 The total current monitoring switches off all 25 kV circuit breakers if the current measured by the total current transformer exceeds an adjustable value during a specified period.

5.3.2.3 The overhead power line protection is equipped with several time and direction distance

steps, polygonal triggering zones, directional detection with high sensitivity, rapid activation for switching short circuited lines fault localization, earth contact relays and automatic re-closing.

Overhead Contact line

feeder point

25kv, 50Hz

Overhead

Contact line

protection

General

protection

Transformer

protection

Overhead power

line protection

132kv overhead power

network

132kv, 50Hz


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5.3.2.4 The transformer protection unit is equipped with high current time protection for 132 kV and 25 kV sides, tank protection which measures the fault current in the tank protection transformer and an activation signal multiplexor for the Buchholz protection and the stepping switch.

5.3.2.4.1 The digital transformer protection unit also incorporates differential protection, thermal overload protection and the facilities for storing the activation data.

5.3.2.5 The protective provisions for overhead contact line systems serve the basic purpose of

sensing and evaluating the occurrence of any electric faults and overloads, in order to: (a) Prevent or keep to a minimum any damage to the contact line installations and

equipment, (b) Minimise the hazards to persons being directly or indirectly exposed to impressible

voltages, (c) Maintain the best possible availability of the traction power supply and (d) Provide and process information which assists fault analysis.

5.3.2.6 Under Voltage Protection 25kV line shall be with Under Voltage Protection

5.3.2.7 The purpose of the protections installed in traction feeder stations is to isolate all or part of the dependent equipment from the network, in case of phase-to-phase or phase-to-earth / rail fault.

5.3.2.8 The Traction Protection system can be broadly divided into two main groups: (a) Traction set protection, which will essentially include all equipments starting from the

HV busbar to which the Traction Transformers are connected, upto the 25kV busbars from which the 25kV Traction Feeders take off.

(b) 25kV Traction Feeder Protection, including OHE protection

5.3.2.9 Traction set protection

5.3.2.9.1 Each HV circuit-breaker located upstream the power transformers ensures the

protection of: (a) the bus bars for connection to transformers on the HV side (b) the transformer, (c) the 25kV bus bars located downstream,

5.3.2.9.2 These protections include: (a) phase-phase and homopolar over-current protections on the HV side (fn 50- 51 and fn

50N-51N) (b) the differential current protection of power transformers (fn 87) (c) the over-current protection located on the secondary winding side of the transformer

(fn 50-51), (d) the over current tank relay protection installed on the main transformer (fn64), (e) The buchholz relay, installed on main tank and tap changer tank, as well (fn 80), (f) the temperature relay (fn 49) including:

a. oil temperature, b. winding temperature

5.3.2.10 Directional power protection


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5.3.2.10.1 The function of directional protection (fn32) is to check the power transit direction in the catenary system, mainly due to regenerative braking, which could flow back to the HV grid through the transformers. Two stages are involved:

(a) a slow one, (b) a quick one

5.3.2.10.2 When the first stage is activated, a signal is emitted and a time-out 1 is started. When time-out 1 ends, a second signal is emitted.

5.3.2.10.3 If, after 3 minutes, the fault still persists, a tripping command is sent to the concerned

traction set circuit-breaker.

5.3.2.10.4 When the second stage is activated, at the end of time-out 2, a tripping command and signal are emitted by the protection device; the 1st stage and 2nd stage current thresholds can be parameterized as well as time-outs, and angle alpha (α) of straight line D can be adjusted.

Figure 5.2: Directional Power Protection

5.3.2.11 25 kV feeder and OHE protection

5.3.2.11.1 Bus bar The protection shall consist of: (a) F50: Instantaneous over current protection (b) F51: Time delayed over current protection (c) F50N: Instantaneous earth fault protection (homopolar) (d) F51N: Time delayed earth fault protection (homopolar)

5.3.2.11.2 Track feeder Functional description (a) From a feeder station, and for the same direction, each track is fed and protected

through an assigned circuit breaker.

Stage 2

X

R

D

Stage 1


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(b) Each portion of OHE fed by a circuit breaker is called "sector". (c) Each sector is sub-sectioned into elementary sections (catenary section between two

breaking apparatus). (d) The sectors of same direction are put in parallel at the level of the paralleling station

through interrupters. (e) All the fault on:

the catenary network, together with the switchgear directly connected thereto,

the rolling stock (upstream the circuit breakers),

the paralleling stations (bus-bars, switchgear),

are detected and protected by the circuit breakers of the feeder station according to the following sequence:

a fault is detected by the two protection devices (minimum Z or Over current) of the same direction through the paralleling,

the related two circuit breakers are switched off,

the fault localisation system is put into service (operation is described later),

the paralleling interrupters open due to the lack of power on the twotracks after a temporisation of about 500 ms,

The re-closing order is given to circuit breaker within about 7 seconds, (f) If the fault remains (10% of the cases):

the circuit breaker of the faulty sector trips and this is blocked openfor 3 mn,

the fault locator determines the faulty elementary section

the circuit breaker for the healthy sector switches on (g) If the fault is transient (90% of the cases):

the 2 circuits breakers re-close, the paralleling interrupters close following the energising of the two sectors, after a temporisation of approximately 1 mn.

5.3.2.11.3 Track feeder protection

Each track feeder circuit-breaker is actuated by: (a) Minimum impedance protection, (fn 21) (b) Over current protection (fn 50-51). (c) F87: Differential Current Protection for TSS feeder CB’s which are directly

connected to switching posts. All other necessary provisions, space, CT cores, wiring etc. to be provided by the RSS contractor. Relay shall be provided by Traction contractor.

5.3.2.11.4 Differential protection

Differential protection is designed to detect faults in the area set to be protected. This protection shall be provided where the supply is extended to the main line having separate feeder breakers at the feeding post. This will work as replacement to impedance protection relay.

5.3.2.11.5 Minimum impedance protection This module is a single-phase impedance measuring (in R-X co-ordinates) relay, which operates when the impedance value falls below a selected adjustment threshold.


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The minimum impedance module defines the quadrilateral characteristic by fixing the straight lines D1, D2, D3 and D4. The possibilities of adjusting the various elements of the parallelogram enable it to be adapted to various network conditions. This protection is directional and selective; it makes a distinction between a high load and a distant fault of small intensity.

Figure 5.2: Minimum Impedance Protection The minimum impedance protection is self-supervised and an internal fault in the protection entails the tripping of the associated circuit-breaker.

5.3.2.11.6 Over current protection An over-current protection is designed to detect faults occurring very close to the feeder station. This protection causes the tripping of the circuit breaker when the current reaches a value exceeding the highest load on the network. Two stages of operation are foreseen:

an instant one,

a time-delayed one The tripping curves can be of two types:

2R R

X- Down Stream

X-UpStream

y

xcharacteristics

Short Circuit

characteristics

Load

characteristics

0

Q4

Q1

Q3

Z

r

30 max

Q

Q1

30 max

LEGEND

R

x

Q

r

z

Catenary/rail loop resistance (adjustable)

Catenary/rail loop reactance (adjustable)

Argument defined for short circuit characteristics

Module

Catenary/rail loop impedence


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constant over time,

if necessary, dependent over time, following an inverse, highly inverse or extremely inverse characteristic.

It should be noted that protections with thermal images, which are widely used in distribution networks, are not suitable for a 50 Hz catenary system.

5.3.2.12 Selectivity of protections Selectivity calculation is based on the second-stage time-outs of over-current protections. As a rule, for a 25kV fault, it is admitted that the time-out must be minimum but not nil to avoid tripping on a transient current or a load transfer. Therefore, HV protections are calculated with a longer timing, which remains below the power supplier line protection set values.

5.3.2.13 Other Protections

5.3.2.13.1 These protections are mainly concerned with the monitoring of the state and operation of:

SF6 gas pressures of HV and 25kV circuit breakers if any,

transformer temperature (oil),

non availability of auxiliary supply (d.c.) Two stages are involved:

the first one is an alarm,

the second one causes tripping (except for the SF6 gas pressure whichentails blocking) of the equipment concerned

5.3.2.13.2 Voltage protection

As a rule, there is no tripping following HV or 25kV under-voltage except for:

cancelling paralleling of two tracks

loss of voltage in auxiliaries which causes tripping of HV and 25kV circuit- breakers.

Only the monitoring and alarm of the upper voltage (25kV) entail a rapid regression of the transformer on-load tap changer.

5.3.2.13.3 Fault locator This function is activated following a circuit breaker tripping due to:

Minimum impedance detection,

Over current, allowing an auto reclosure sequence. The fault locator measures the catenary / rail loop fault impedance and compare with the minimum impedance relay and determine the kilometre point from the feeder station.

5.3.3 Switching Stations


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5.3.3.1 Traction power at 25kV is fed to the various Corridors from the Traction Substations (TSS) located in the premises of Receiving Substations (RSS), as explained below. For purposes of operation and maintenance, the Traction Overhead Equipment between Traction Substations is subdivided into several smaller sections by introducing switching stations as per Employer’s drawings.

5.3.3.2 Switching posts fall mainly under 3 Categories:

5.3.3.2.1 Sectioning Post (SP) It is a supply control post situated mid-way between two feeding posts at the neutral section and provided with bridging and paralleling interrupters. The function of Sectioning Post is to segregate the power supply feeds from adjacent substations, since the 2 feeds will have a phase difference between them and cannot be coupled together. The Sectioning Post will have a Neutral Section in front of it and the OHE on either side of the Neutral Section will not be bridged.

5.3.3.2.2 Sub Sectioning and Paralleling Posts (SSP) At strategic intervals the OHE is Sub Sectioned by means of an insulated overlap, which is normally bridged by an interrupter. In addition, the Up and Dn track OHE’s are paralleled at these SSP’s by means of Interrupter. The SSP provides a Sectioning facility and also helps to improve the voltage regulation because of paralleling.

5.3.3.2.3 Sub Sectioning Station (SS) With a view to limiting the length of any section of OHE, which can be affected by a fault or an electrical isolation for maintenance, the OHE is further Sub Sectioned, so that generally not more than 3 or 4 Metro Stations fall in one Sub-section. No paralleling facility is provided at these Sub-Sectioning Stations.

5.3.4 Locking and interlocking arrangements An interlocking device which makes the operation of the isolator or earthing switch dependent upon the position or operation of one or more other pieces of equipment.

5.3.4.1 Isolator

5.3.4.1.1 The operating mechanism box shall have provision for a padlock for locking its door.

5.3.4.1.2 The isolator shall have provision for locking its main rotating shaft with the help of padlock, both in ‘Open’ as well as in ‘Closed’ positions.

5.3.4.1.3 The pad locking in any intermediate position shall not be possible. Besides the above,

the isolators shall have two locking mechanisms, for the purpose of interlocking with the associated circuit breaker(s).

5.3.4.1.4 However, mounting arrangement for these locks shall be provided by the manufacturer

in such a way that it is possible to insert the key(s) from outside for operation of lock(s) and the successful bidder shall coordinate with manufacturer of circuit breaker and the Employer for this purpose.

5.3.4.2 Earthing switch

5.3.4.2.1 The operating mechanism box shall have provision for a padlock for locking its lid.

5.3.4.2.2 A mechanical interlock shall be provided in the operating mechanism of isolator and

earthing switch, so that operation of earthing switch is possible only when the isolator is locked in open position.


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5.3.4.2.3 This interlock shall also prevent closing of isolator unless earthing switch is locked in open position.

5.3.4.2.4 An integral lock shall be fitted in the operating mechanism box of the earthing switch for

locking the operating mechanism both in ‘Open’ as well as ‘Closed’ positions.

5.3.4.2.5 The design of the earthing switch shall be such as to permit use of a padlock for locking the operating handle of the earthing switch both in ‘Open as well as ‘Closed’ positions.

5.3.4.3 Interlocking arrangements for 25kV Circuit Breaker

5.3.4.3.1 The CB shall be provided with a suitable interlocking device for electrical and

mechanical interlocking with its associated isolator(s), such that: (a) the isolator(s) can be operated only when the CB is locked in ‘open’ condition, and

(b) the CB cannot be operated both manually and electrically either on LOCAL or on

REMOTE unless the isolator(s) is locked in the CLOSE or OPEN condition.

5.3.4.3.2 Three types of isolator interlocking schemes shall be utilized. The details of these schemes are indicated below:

5.3.4.3.2.1 Single isolator interlocking (SI)

(a) Under this scheme, the circuit breaker shall be interlocked with its single associated

isolator. This interlocking scheme shall be provided on the circuit breaker to be installed as transformer breakers and circuit breaker for controlling feed to the shunt capacitor.

(b) In this scheme the key shall be trapped in the lock mounted on the circuit breaker mechanism when the circuit breaker is in closed position.

(c) The key can be released from the operating mechanism when the circuit breaker is in the ‘open’ position only.

(d) Any attempt to forcibly withdraw the key when the circuit breaker is in the closed position shall result in tripping of the circuit breaker.

(e) The key thus released from circuit breaker shall be utilized to operate the lock mounted on the isolator.

(f) It shall be possible to release this key from the isolator lock only when the isolator is locked in ‘open’ or ‘closed’ position.

(g) Once the key has been removed from the circuit breaker operating mechanism, it shall not be possible to operate the circuit breaker either manually or electrically by local / remote control.

5.3.4.3.2.2 Double isolator interlocking (DI)

(a) The scheme is identical to the SI scheme but in this the circuit breaker shall be

interlocked with its two numbers associated isolators. (b) The interlocking shall be provided on circuit breaker to be installed as feeder breakers.

5.3.4.3.2.3 Bus coupler isolator interlocking (BCI) (a) Under this scheme the circuit breakers of adjacent bay shall be interlocked with the

bus coupler isolator / interrupter.


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(b) The operation of the bus coupler isolator / interrupter shall not be possible unless both the circuit breakers of adjacent circuit are locked in open position.

(c) In this scheme the two keys so released from the circuit breakers shall be inserted in a

key exchange box (which shall be supplied loose) for releasing a third key which shall be used for operating the bus coupler isolator /interrupter.

5.3.4.3.3 The interlocks provided on the circuit breakers installed at a traction substation:

(a) Shall have non-interchangeable key codes to safeguard against any mis-operation.

(b) The lock meant for mounting on the associated isolator(s) and bus-coupler isolator

shall be bolt type lock of approved design.

(c) The internal mechanism of the lock shall be made of non-ferrous metal and the outer housing shall be of steel hot dip galvanized.

5.3.4.3.4 One spare duplicate key shall be supplied with each of the three types of interlocking

schemes.

5.4 SCADA Note: The SCADA is in scope of other contractor, however, the OCS contractor is required to closely interface with SCADA contractor particularly in respect of 25kV OCS / Switching Stations. The description hereunder is provided for general information of OCS Contractor, which will enable him to comprehend the SCADA related interface requirements.

5.4.1 General The proposed SCADA system shall be equipped with following functions:

5.4.2 Remote Monitoring

5.4.2.1 The system shall collect and transmit remote monitoring information from the field supervised equipment to the work stations.

5.4.2.2 In normal operation, the PLCs and RTUs shall be able to monitor the status of the HV, traction and auxiliary supply equipment. The operator shall receive alarms relating to different events and alarms on equipment, e.g. low level or loss of voltage on 25kV AC System, 33kV cables and 415V low voltage boards etc.

5.4.2.3 The SCADA software shall be designed with necessary process display screen to provide a graphical depiction of the power supply network for the NS & EW Corridors. This shall include the Receiving Substations, Auxiliary Substation, Traction Substation, sectioning and sub-sectioning posts and Local Auxiliary power distribution for Main Line and Depot. Two separate views for complete Traction Line & Auxiliary Line should also be designed.

5.4.2.4 The SCADA System shall collect the operator’s request and field information changes. Any change on the field or any operator request shall be processed as an event. The SCADA System may generate additional events resulting from the processing of the filed information and/or operator request. All events processed by the SCADA System shall generate an update of the related dynamic display objects and also be recorded in logging list. The logging list shall contain all the events in chronological order that occurred within a certain period of time. All the events shall have a time stamping of 1 msec. Furthermore, alarm types events shall be recorded in the alarm list and generate an alarm procedure initialisation.

5.4.2.5 The event Logging System of SCADA System shall support the following features and options:


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(a) Historical Storage of events with facility to retrieve the same later (b) Configurable layout: columns, fonts, toolbars, Colouring, and so on. (c) Configurable scrolling behaviour (d) Configurable presentation modes: log mode /event mode, latest at top/bottom (e) Updating/Frozen presentation modes. (f) Easy navigation through scrolling, go to date, time filters. (g) Filtering (By Station, Device, and Period etc.) (h) Extensive filtering that can be stored and easily called up later (i) Find, Sorting by column (j) Exporting data to other Windows applications like MS Excel etc. (k) Printing (l) Commenting of events by operator

5.4.2.6 The SCADA System shall be able to handle various types of alarms, typically: (a) Alarm generated due to change in field information (b) Alarm generated due to fault in SCADA system equipment and communication link.

5.4.2.7 The details of the individual parameters to be monitored in provided in the section “Input/output Requirement” in this specification.

5.4.2.8 The important functions in the remote monitoring are:

5.4.2.8.1 Event management

5.4.2.8.1.1 The system shall collect the operator’s requests and field information changes. Any change on the field or any operator request shall be processed as an event. The SCADA system may generate additional events resulting from the processing of field information and / or operator requests.

5.4.2.8.1.2 The SCADA system shall record any events caused by faults, malfunctions, warnings or alarm information generated automatically by the selected equipment. A central recording system shall be provided to record the following events, including but not limited to: (a) Change of state of remote terminal unit input parameters; (b) Events designated as alarms; (c) Faults; (d) Control actions; (e) Text entered by operations personnel; (f) System generated messages, e.g. equipment malfunction;

5.4.2.8.1.3 Events shall be given an order of priority to allow events to be classified, sorted and filtered. Subject to the requirements of the approved operations plan, events shall be classified as: (a) Emergency

This type of fault shall require instant attention in order to minimise interruption of the normal operation or the risk of injury to personnel or passengers and shall be classified as an Alarm;

(b) Urgent

This type of fault shall require reasonably prompt, but not instant attention in order to minimise interruption of the normal operation and shall be classified as an Alarm; and

(c) Non Urgent


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This type of fault shall be dealt with in a more convenient manner while more urgent events are dealt with first. This type of event shall not directly result in any degradation of the normal operation. These need not be configured as alarms. These are to be stamped in event list only.

5.4.2.8.1.4 The event records shall be available as a text table, with each event classified by its

priority level and shall be tagged with details of the date and time at which the event occurred. Additionally, the operations personnel identification code shall be recorded for each event that is initiated by the operations personnel. Each event shall be displayed and highlighted until acknowledged by the operations personnel. All events shall continue to be displayed until the event has been acknowledged and cancelled in the automatic event log, and provided the fault has been satisfactorily rectified in the equipment which generated the event.

5.4.2.8.1.5 All data messages transmitted through the SCADA network shall be tagged with the time at origin to an accuracy of at least 1 millisecond and shall be sorted and logged in time tagged order on the central database.

5.4.2.8.1.6 Each SCADA workstation shall be capable, at any moment in time, of sorting and filtering events in accordance with their priority to the level required by the operations personnel. A facility shall also be provided to enable a summary printed event record report to be prepared, listing not only the current active events, but also any events, including faults and alarms, reported and/or cleared during the period since the previous summary report. The event records shall also be able to be interrogated in a structured manner to determine the trends and associations between different events based on association by location, time or equipment type. All data records associated with the day’s railway service once stored within the central database shall be collated, sorted and accessible within one minute of a request being issued by any workstation in the SCADA system.

5.4.2.8.1.7 The logging list shall have various filter facilities to enable the operator to display different format of events. The filter keys shall typically include: (a) location (b) equipment group (c) time period (d) event category (e) other options Any combination of the filter keys shall be possible. When a filter is applied to the logging list, a specific display should be presented to the operator to avoid confusion.

5.4.2.8.1.8 In the event that a particular incident gives rise to numerous SCADA events, then the SCADA workstations shall be capable of displaying either all such events or only the most all-encompassing event. In the event that the most all-encompassing event is chosen to be displayed, all the associated events shall still be recorded with the most all-encompassing event.

5.4.2.8.1.9 The SCADA system shall produce regular automatic reports of the overall power system reliability indices with faults categorised by system (e.g. feeders, HV Power etc.) and by location (e.g. RSS, ASS etc.).

5.4.2.8.1.10 All databases established within the SCADA system shall be accessible for maintenance and exporting of data as required by the Employer. This requirement shall also include any database used to configure the graphics used on the workstation VDUs. The Contractor shall supply the necessary database tools, manuals, documentation and training required to enable the maintenance and exporting of such data to be performed.

5.4.2.8.1.11 At any time the OCC operations personnel shall be able to request an immediate update of any particular equipment status at any location. This request shall be responded to no more than 2 seconds from issue of the request.


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5.4.2.8.2 Alarm Management

5.4.2.8.2.1 Alarm shall be generated in case of any change from “normal” to “alarm” value of a

monitored state. The processed alarm shall be considered as an alarm appearance event and shall generate an alarm.

5.4.2.8.2.2 Similarly, alarm shall be generated in case of changes from “alarm” to “normal” value of a monitored or processed alarm. This shall happen whenever a reconfiguration action is required from the operator in order to continue operation. The alarm procedure shall ensure that the operator is informed of the alarm disappearance so that he may restore normal configuration and continue operation.

5.4.2.8.2.3 The SCADA system shall be able to handle various types of alarms, typically: (a) Monitored alarm

Shall be directly linked with the value of a field-monitored alarm. (b) Complex alarm

Shall be the result of processing the values of one or more field events. This shall be in the nature of derived (computed) alarms to be defined during engineering.

(c) Conflicting alarm

Shall apply to a processed status resulting from several distinct field monitored states, when the sources give inconsistent information e.g. inconsistent inputs resulting from chattering of breakers or non-zero voltage/current appearing on SLD when corresponding breaker is in open state.

(d) Control failure alarm

When performing such remote control, the SCADA system shall check the correct monitored or processed status change. If this event does not occur after a predefined time, the SCADA system shall generate a Control failure alarm.

(e) Uncontrolled state change alarm

If a monitored or processed status associated to such remote control changes without previous control action from the operator or the system, an uncontrolled state change alarm shall be generated.

5.4.2.8.2.4 Alarm Classification for Display

This classification shall be programmed in the OCC and the local equipment, but can be easily modified and reloaded in the OCC as well as in local equipment. All alarms shall be classified into four levels of priority. Each level of priority shall be segregated and characterized by a distinguishable colour and a display attribute (flashing, ...) that are the same on all the Workstations and the screens of the system: (a) Level 0: used for non severe alarms and events cases that do not need any

acknowledgement from an Operator; it appears on the relevant view, then disappears when it disappears on site, without any Operator action;

(b) Level 1: used for non severe alarms and events cases that however need

acknowledgement from an Operator. It appears flashing on the Workstation. The Operator acknowledges it, and then it is displayed as fixed. When it disappears on site, it disappears also on the Workstation without any other action from the Operator.


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(c) Level 2: used for alarm cases that are self-maintained by the equipment, and then

need an erasing control to stop the alarm signalling. The alarm is maintained active until the Operator sends an erasing control order that resets the alarm bit if the RTU input is back to the normal state. The alarm appears flashing on the Workstation. When the Operator acknowledges the displayed alarm, the alarm becomes fixed. When the RTU input goes back into its normal state, the erasing control becomes possible from the OCC;

(d) Level 3: used for severe alarms that are not self maintained by the equipment and

need acknowledgements after both appearing and disappearing of the alarm. The alarm is maintained active until the Operator sends an acknowledgement control. After disappearing of the alarm, i.e. when the input comes back to the normal state, it is also necessary to send an acknowledgement control. The alarm appears as flashing. When the Operator acknowledges the alarm it becomes fixed if the RTU input is always in alarm state. When the alarm disappears, following acknowledgement or return of the RTU input to its normal state, it is displayed in flashing with a different colour. The operator then has to acknowledge the alarm again.

The alarms and events as classified above shall appear in a display window. These shall be displayed on a priority basis. When there are several alarms or events of the same priority, the system will establish another priority between them: the older they are, the lower is their priority.

5.4.2.8.2.5 Audio Visual Alarm

5.4.2.8.2.5.1 Generation of alarm shall lead to an audio visual signal for the operator. The signals shall be generated in such a manner that it immediately draws the attention of the operator.

5.4.2.8.2.5.2 There shall be two categories of audible alarms easily distinguishable by separate tones or sounds for events classified as emergency, urgent and non-urgent. A mute facility shall be provided to silence the alarm. Once the event causing the alarm has been acknowledged, the alarm shall be muted. It shall be possible to acknowledge alarms individually or in groups from the alarm display page. When the status of an alarm returns to normal condition, a return-to-normal message to this effect shall be generated.

5.4.2.8.2.5.3 The nature of all audible alarms shall be accompanied with a corresponding message, providing details of the alarm, which is presented on the workstation display. When an alarm is initially received a corresponding visual flashing indicator shall appear on the display. Once the alarm has been acknowledged the flashing indicator shall transfer to a permanent illumination.

5.4.2.8.2.5.4 In the event of multiple events initiating audible alarms, only one alarm shall be broadcast at any time. The highest category of alarm shall always take priority, even in the event that a lower priority alarm is already being broadcast. Once the higher category has been acknowledged and muted, the next lowest category of alarm shall initiate the alarm broadcast.

5.4.2.8.2.5.5 To avoid unnecessary and nuisance alarms or alarms generated by testing, a facility shall be provided to enable alarm blocking/filtering to inhibit particular or global alarms, from any workstation. Inhibited alarms shall activate an appropriate message, detailing the non-alarmed parameters and the remote terminal units affected.

5.4.3 Web Enabled Operator Consoles All operator consoles shall be web-enabled. It shall work through the web browser and be able to host a full graphic user interface. The web clients can connect to the SCADA services at the OCC/BCC through LAN, WAN or through the internet.


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5.4.4 Data Exchange The SCADA systems shall be able to exchange various types of data with the other application software.

5.4.5 Calculated Data

5.4.5.1 It shall be possible to define the calculations on real-time data and historical data, periodically and on request. The results shall be incorporated into the database as calculated data available for display & report generation.

5.4.5.2 The user shall be able to define calculated analog values using database points as the arguments and mathematical functions as the operations. Functions such as addition, subtraction, multiplication, division, maximum value, minimum value, average, count, square root, etc. shall be provided.

5.4.6 Trending

5.4.6.1 Trend displays shall enable the user to select real-time and historical data for trending on graphical displays and for tabular displays. In graphical trending it shall be possible to assign any number of tags to a single window for trending.

5.4.7 Deleted

5.4.8 Remote Control

5.4.8.1 The SCADA System shall transmit and execute predefined commands from the work stations to the field supervised equipment. Controls may be generated by operator or the system and executed by the system. Operator should be able to take actions wherever and whenever required. In case of an emergency or abnormal situation, the Operator shall be able to control the various items of equipment, typically: isolation of the faulty sections or circuit, restoration of the normal configuration after the fault has been remedied.

5.4.8.2 Three levels of control management are possible, namely:

5.4.8.2.1 Centralized from OCC control room: In that mode, all the actions are carried out from the OCC provided that from the equipment and from the local control room, the appropriate configuration are in place to enable it.

5.4.8.2.2 Local mode from RSS control room: The equipment can be operated from the local

control room through the workstation connected to the local area network. An authorization is proposed to the operator to take over the management from the OCC. Operation of the equipments from this workstation is possible when the access rights are granted by the OCC operator. The local workstation can carry out operation of equipment either by logging into the server at OCC or BCC or be capable of independent operation when the communication with OCC or BCC is temporarily unavailable.

5.4.8.2.3 Local mode from the equipment: The equipment is associated with a change over switch

with two positions: “local” or “remote”. Its actuation sets the working mode in remote (from OCC) or in local (from equipment) which means it can be operated fully manually. The actuation of the switch in manual mode has the highest priority over the other actions from the local control or the OCC.

5.4.8.3 The various outputs have been indicated in the section “Input/ Output Requirement” in this

specification. Following control functions shall be necessarily available in the SCADA:

5.4.8.3.1 The SCADA system shall provide facility to open / close the breakers. It shall be guided by Remote / Manual control selection at the equipment. In case of remote selection,


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operation can be done from SCADA. In case of manual selection, the operation from SCADA shall be inhibited.

5.4.8.3.2 It shall be possible to control the breakers and interrupter via Operator request or via

automatic control procedures. The control functions shall be Close/Open of the equipments as per IO Lists. The operator initiated Open/Close control functions shall be possible using Select-Check-Execute sequence.

5.4.8.3.3 Control command Logging: The SCADA system shall log the control operations by the

operators in the event list so that any closing opening other than issued by the operator from SCADA can be differentiated from the Event list.

5.4.8.3.4 Permissive for Local Operation: In order to facilitate local maintenance of the

equipments and to prevent unauthorised local operations, Permissive for Local operation shall be provided by way of Access Control Rights so that the field operator can carry out operation of the power equipment only after the above permission is granted from the Control Centre. SCADA system should ensure that no operation is performed without permission from Operator. Further, even after granting the permission of local operation, the events and parameters shall continue to be monitored.

5.4.8.3.5 Remote control inhibition management: Alienation of a Power Supply Equipment: The

operator shall be able to inhibit / block the equipment control from SCADA system. This blocking action shall be available in the blocking list. The control inhibition / control blocking shall be possible individually for each equipment being processed. The operator shall be possible to cancel the blocking also. The user performing the blocking / daglocking shall be logged in the event list along with the details such as identity of the Power Operator who alienated the equipment, identification of the alienated equipment, its status when it has been alienated, time at which alienated, identity of the Power Operator that de-alienated the equipment, its status when it has been de-alienated, and corresponding time.

5.4.8.3.6 This means that once the equipment is alienated, the “remote control inhibition” shall

prevent any operator or the system from sending a remote control to that particular equipment. The SCADA System shall handle, for each controllable item of equipment, a control status, which is a combination of:

local / remote operation,

remote control inhibition.

5.4.8.3.7 The SCADA System controller shall have access to a list showing all remote control inhibitions currently active.

5.4.8.3.8 To alienate equipment, the OCC operator needs to have proper level of access rights to

de-alienate the equipment. An equipment alienated by a Operator can be de-alienated by a new Power Operator on condition that he has the same level of access rights.

5.4.8.3.9 An alienated equipment is displayed in the colour corresponding to its status (red, green

or blue), and is accompanied with a special alienation symbol.

5.4.8.3.10 The blocking and daglocking actions shall be available in the SCADA system in the form of blocking list for Identification of the blocked equipment, status of equipment when it has been alienated, time of blocking.

5.4.9 Sectioning in Traction System

5.4.9.1 This feature applies mainly to Traction installations. For the protection of engineering

works, the Operator may set (or cancel) the isolation of any subsection of the line. Such action shall involve setting (or cancelling) a grouped inhibition on the remote control of all the traction supply equipment of the relevant sub- sector. An identification number shall be requested to the operator. All Subsectors of the OCS shall be identified by a unique


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number and relevant switches shall automatically open or close for setting or cancelling the isolation of that particular sub-sector. In scheduled or unscheduled maintenance periods, the Operator, in co-ordination with the relevant staff, shall be able to protect the areas of work by isolation of the relevant section or circuit. Setting a section or circuit isolation shall involve the following steps on the equipment: (a) Open the relevant apparatus, (b) Setting remote control inhibition on each one, (c) Prove and confirm correct operation to Operator.

5.4.9.2 If all the steps have been performed successfully, the system shall give authorisation to proceed with the engineering work. An unique identification, given by the SCADA system or controller, (OCC operator be defined during detailed design) will identify the particular isolation. The Operator will then give this identification and authorisation to proceed to the PICOP (the transmission method and process is to be defined later). After the engineering work has been completed, the PICOP shall request the Operator to cancel the corresponding isolation using the relevant identification.

5.4.10 Traction power off request

5.4.10.1 The Emergency Trip Switches will be used for switching off the Traction Power Supply of corridor 1, corridor 2 or depot in case of emergency. The ETS switches are installed in OCC/BCC and at each RSS.

5.4.10.2 After activating an ETS an individual signal is sent to SCADA. Accordingly to a trip matrix proposed by the Contractor, SCADA macro switches off relevant circuit breakers and send signal to indicate the electrical section de-energized.

5.4.11 Logics & Interlocking

5.4.11.1 To improve the overall power availability, a common practice consists to supply the system with two separate incoming connected to different sources. In case of deficiency of a source, appropriate switching should execute so that the other one supply could feed the power.

5.4.11.2 In case of power failures, the system redundancies shall be operated to restore the normalcy in the system. There shall be a provision to operate these redundancies and interlocks through automatic mode or through manual mode.

5.4.11.3 In automatic mode, the complete sequence shall be designed and operated in an appropriate manner to ensure safety of equipments and personnel.

5.4.11.4 In manual transfer mode, it can be transfer with breaking or transfer without breaking. In transfer with breaking the faulty switchgear is opened first and the other one is then closed. The three Circuit Breakers are never closed at the same time. In transfer without breaking mode the operator selects the switchgear to be opened and closes the one in parallel. The electronic device implements the sequence with the appropriate time out.

5.4.11.5 The Remote Monitoring of CBs are doubled and complemented: two bits: bit 1 and bit 0. Once received a test of complementarily shall be carried out; if not correct, an alarm will be declared. The value « 1 » represents the active position (effective position).

5.4.11.6 The Remote Monitoring of other equipment is simple and not complemented: one bit. The value « 1 » represents the active position, except for: busbars, and OHE, for which the value « 1 » represents absence of voltage.

5.4.11.7 For safer operation interlocking has to be implemented in SCADA system. The following interlocks mainly to be provided:


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(a) Breaker-Isolator interlocking in 33 kV ASS Ring – It should not be possible to operate Isolator when consecutive breaker is in Close condition and breaker operation should not be possible when isolator is in open condition.

(b) 33 kV ASS Ring Network Inter Loop-interlocking: When Potential Transformer of

consecutive loop is showing voltage, extending power from one loop to other should not possible.

(c) In a 33 kV ASS ring Network Loop only n-1 switchgears should be active. This

restriction is applicable when both feeding CB for the ring are closed. ‘n’ is the maximum number of switchgear of the loop including the end ones. If only one feeding CB is close and the other alienated, then all the switchgears of the loop can be closed simultaneously. Closing of all switchgear simultaneously with both CB closed is forbidden.

5.4.12 Tele Measuring

5.4.12.1 In the power system, some of the data needs to be measured and monitored like Voltage,

Current, Frequency, Power factor consumption of energy for traction and auxiliary services. Dedicated equipment picks up the relevant information and in turn delivers to the local RTU which translates them into a digital value to be sent to OCC.

5.4.12.2 The voltage and currents measurement requirements are indicated in I/O Requirement Section in this specification. The list shall be covered in scope of the RTU. The RTU shall be provided with necessary analogue input modules to receive the 4 to 20 mA signals from the transducers of equipment like the PT mounted. The transducers shall be in the scope of the Contractor.

5.4.12.3 This information is recorded and used for several purposes among which statistics, consumption supervisory, etc. are few examples: (a) The measuring functions shall permit to know the integrated power consumption of the

various equipment (RSS, TSS, and ASSs), and current values or voltage values on several parts of the network.

(b) The energy (i.e. kWh, kVArh, p.f) shall be measured for each equipment supplying the

network i.e.

Each 132 kV incoming,

Each 132kV outgoing feeder

Each 33 kV CB feeding power to auxiliary transformer in ASS

Each 25 kV CB feeding power to OHE in RSS (c) The measuring of Maximum demand will be made at an interval of 15 minutes. The

measurement will be done through latest digital signal processing based multifunction meters.

(d) Voltage & Current shall be measured at following points:

Each 132 kV incoming,

33 kV at RSS and ASS level

25 kV at TSS level (e) These indications will be updated every 5 seconds. They will be displayed on the

Operator Workstation.

5.4.13 Instant Status & Report (IS&R) Generation

5.4.13.1 A data and software storage system (archives) with removable storage media facilities shall be provided at the OCC for the historical storage of database records and software.


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5.4.13.2 IS&R function shall provide for periodic historisation of analog and status data.

Historisation shall take place in standard RDBMS package like MS SQL Server, Oracle etc. IS&R shall support archival of history data in external mass storage media like DAT drive, SDLT, MO Disk, CD &/or DVD. The archived data shall be retrievable on demand for analysis.

5.4.13.3 Web based reporting function shall support following types of reports based on data availability: (a) Standard substation parameters like MW, MVAR, Amp, Voltage etc (b) Frequency / voltage band violation report (c) Energy exchange report (d) Substation energy balance report (e) Reliability Indices (f) Equipment operation report (g) Hardware Status report (h) Additional user configurable report

5.4.13.4 These reports shall be available on shift / daily / monthly and yearly basis on query. It shall be possible to export the generated reports into excel.

5.4.13.5 The storage system shall utilise optical disc technology, which shall allow the data to be indexed and shall allow random and sequential searches. Each data storage facility shall have a capacity adequate to hold all operational and user programmable software as well as data records generated over the previous minimum period of 60 days without the replacement of storage media. All data records generated within the minimum 60 days period shall be available for recovery from any Control Centre workstations, within 25 seconds of completion of any request procedure. Retrieval of such data shall not degrade the performance of the SCADA system.

5.4.13.6 An automatic alarm shall be triggered in the OCC Workstation in the event that the accumulated data and software is stored for more than a pre-defined period (maximum seven days) without being backed up. The bulk data storage system shall have sufficient capacity to provide a master historical data storage of all software and recorded data for the entire SCADA system. All software files contained within the SCADA workstations shall be able to be up-loaded to the OCC for historical data storage.

5.4.13.7 The historical data storage system shall index the storage media to enable rapid retrieval of data by date and time and be capable of event searches based on selectable criteria.

5.4.14 Operational Aids

5.4.14.1 Various functions shall be provided in the system to assist the operator in the operation. Some of the features are as follows, but not limited to: (a) Log on (b) Log off (c) Filing (d) Accountings (e) Reports as described above (f) Trends (g) Find, Sorting by column, Copy/Paste of events to other windows application (h) Printing (i) Commenting of events by operator (j) Search with a provision of easy sorting through several criterion (k) Inhabits and tags


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CHAPTER 6

6.0 DESIGN REQUIREMENTS

6.1 GENERAL

6.1.1 This section is dealing with OCS system and equipment design requirement.

6.1.2 The Contractor shall ensure that the designs proposed are of most modern and latest available technology internationally. The Contractor shall propose the designs, supported with references of designs adopted in other similar metros in India and worldwide most recently with improvements in the designs based on the aesthetics, working experience or financial savings.

6.1.3 For Validation of design of complete system, the Contractor shall arrange auditing of design of works within the scope of work which primarily covers 25kV OHE / ROCS system as per EN/IEC/RDSO and other relevant Standards from reputed Independent Agency (Auditor), who have already undertaken similar job in past for other Metro system.

6.1.4 The Contractor shall ensure the proposed designs are compliant to the RAMS requirements elaborated under Clauses 4.2 and 4.3 above.

6.2 RECEIVING SUBSTATION This is in scope of other contractor.

6.3 TRACTION NETWORK

6.3.1 Traction Substation Note: TSS is in scope of other contractor, however this description is provided for general comprehension of OCS Contractor. The Traction Substation mainly comprises of: (a) 132 kV/27.5kV Traction Transformer (02 nos.) (b) 25 kV Incoming Circuit Breakers (02 nos.) (c) One 25kV Bus Coupler Interrupter, along with its 1 isolator with earth switch on cable

side of it (d) 25kV outgoing feeders each consisting of one circuit breaker and its 1 isolators with

earth switch on cable side of it (refer Employer’s Drawings for number of feeders for three TSSs))

(e) Instrument transformers, as necessary for protection and measurement (f) Protection relays, measurement meters and associated devices, as necessary (g) All interconnecting power cables, including 25kV cables from TSS exit point upto the

Interrupter/isolator located on the viaduct, for feeding the OHE (h) All return cables from the track-side Impedance bonds to the buried rail at TSS and

onwards tothe traction transformer (i) All control and monitoring cables for necessary connection of equipments


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(j) Other associated equipments, such a battery, battery chargers, AC and DC Distribution boards, control and relay panels, etc. to make the traction substation fully fit to perform its task.

6.3.2 27.5 kV Switchgear

6.3.2.1 The 27.5 kV switchgear shall be outdoor switchgear and shall consist of structure mounted

Circuit breakers, interrupter and isolators electrically linked.

6.3.2.2 This switchgear shall comprise: (a) incoming circuit breakers and interrupter with associated Isolators (b) Bridging and paralleling interrupter (c) motorised isolators (d) associated measuring, controlling, monitoring, and protecting devices (e) These apparatuses shall be structure mounted with the switching apparatus at pole

top level and control equipment at hand level along with transmitting mechanism.

6.3.2.3 Circuit breaker / interrupter All circuit-breakers shall follow the same electrical and mechanical characteristics and must be in accordance with IEC standards 62271-100 or RDSO’s standard ETS/PSI/116 (4/88) with latest modifications.

6.3.2.4 Isolators All isolators shall follow the same electrical and mechanical characteristics and must be in accordance with IEC 62271-102 or RDSO’s specification ETI/PSI/122 (with latest modifications).

6.3.2.5 Monitoring Box Mounted on the pole at hand level (1.2m), it shall be made of steel-sheets, totally enclosed, dust- proof and water tight type (IP55), equipped with: (a) Access doors with padlocks (b) 415/240 V heating device (c) 110V DC control and monitoring relays and motors (d) Remote control and monitoring multi-pin connector (e) Internal lighting controlled by door position (f) 240 V AC plug (g) 3 positions switch (Remote / local / manual ) (h) Handle (Facade or beside) (i) Label (Facade) Note: 1. Any handle operation shall disable motor supply 2. All equipment shall withstand power frequency test at 2000V 50Hz / 1mn. 3. The earthing connector shall be located externally

6.3.3 Connections

6.3.3.1 Cable path shall be needed between: (a) The incoming circuit-breaker and its corresponding transformer, (b) The outgoing circuit-breaker and the OHE via an opening on the viaduct, (c) The transformer and the return current connecting strip, (d) The burried rail in TSS and the rail via an opening on the viaduct


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The position and alignments of cable paths shall firstly be such as to facilitate pulling, laying and securing of the cables and, secondly, shall not hinder access to the bus-bar box-section. Metallic cable paths shall be linked to a ground collector.

6.3.3.2 Transformer to the 27.5 kV switchgear Each connection between transformer secondary windings and the 27.5kV switchgear incoming circuit breakers shall be realised with 4 x 240 mm2 copper cables.

6.3.3.3 Overhead Contact System Each connection between 27.5kV switchgear outgoing circuit breaker and the corresponding OHE pole mounted isolator shall be realised with 2 x 240mm2 copper cables.

6.3.3.4 Return current From the tracks (through impedance bonds, if provided), the return current flows back to each transformer with 4x240mm2 copper insulated cables connected to intermediate connecting strip (CS) which allows to isolate, under particular safety procedure, the track side from the feeder station side in case of intervention on equipment (i.e. earth measurement, works).

6.3.3.5 Electrical connections The connecting strip shall permit to connect all the elements (so as to realise an integral transversal link), such as: (a) Return current cables to transformers (b) Track impedance bonds (c) Overhead Protection Conductor (OPC) (d) Buried Earth Cable (BEC) (e) Earth mesh (f) OHE masts (g) Metallic fences

6.3.3.6 Electrical connection between messenger and contact wire and with various equipments The following types of jumpers are used to electrically connect between various conductors and equipment of OCS: (a) Copper jumper (hard drawn bare conductor) is used for connection from cross feeder

to OHE. (b) Stranded annealed copper conductor (known as G jumper) is used to connect

electrically between one OHE with another, as in the case un-insulated overlap, turn outs, diamond crossings, crossovers to carry the full OHE current.

(c) Potential equalising stranded annealed copper conductor jumpers (known as F jumpers).

(d) In-span jumpers (known as H jumpers) used to connect messenger wire and contact wire every 350 m.

(e) Aluminium large jumpers is used to connect all aluminium cross feeders wherever needed to connect aluminium bus terminal of FP, SSP, SP etc.

(f) Stranded annealed copper conductor (large size) used to connect cross feeders to OHE, isolators to OHE etc.

6.4 OVERHEAD EQUIPMENT DESIGN

6.4.1 Design Planning


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6.4.1.1 The project design of overhead contact line system process primarily consists of the following phases: (a) Preliminary design study, (b) Design planning, (c) Project implementation planning, (d) Preparation of review document

6.4.1.2 TheContractor shall carry out preliminary design study which examines the various options for the overhead line system and also identifies any additional infrastructure works required on track layout, bridges, etc. This study produces technical solutions, including the design of the OHE, adaptation of track layout, structural alterations to bridges, and an estimate of the implementation period etc. Thereafter the Contractor shall submit the summary report of the design study for appreciation of the Employer’s Representative.

6.4.1.3 The design planning commences with the preparation of an OHE circuit diagram based on data provided in the preliminary design study. The process of design planning is described in the figure given below:


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Figure 6.1: Design Planning Process

6.4.1.4 The design study carried out by the Contractor, including all planning documents, pole locations and OHE layout diagrams, shall be distributed with an explanatory report to all concerned.

6.4.1.5 A site inspection of the line by all project participants is the first phase of the project implementation planning which has to be organised by the Contractor. The project implementation planning process is given in the following figure:

Prepare overhead contact line

system circuit diagram

DESIGN PLANNING

Identification of constraints such as

points, sub-sectioning structures,

railway crossings, etc .

Preparation of the wiring design

with the pole location at

constraints

Preparation of the wiring design

with the pole location in between

constraints

Project implementation planning

Explanatory report

Overhead contact line

system layout plan.

DESIGN PLANNING PROCESS


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Figure 6.2: Project Implementation Planning Process

6.4.1.6 A review process of intermediate and final results during project implementation planning avoids errors, and thus additional costs and time delays.

6.4.1.7 In order to resolve obstacles, the Contractor shall implement deviations after obtaining notice of no objection from the Employer’s Representative.

6.4.1.8 After completion of the work, the revised documents will give an accurate picture of the installed OHE which is needed for operation and maintenance.

6.4.2 Design Philosophy The following basic demands must be made on the design of a contact line installation:

Internal

Review

PROJECT IMPEMENTATION PLANNING PROCESS

Approvel of the design study by the

respective infrastructure entities

Agreement of the overhead contact

line layout with all specialist

participating with all specialist in

the planning by meens of a joint

inspection on foot or by discussion.

Selection of foundation

type

Project documents

Start of Construction

Material Procurement

Checking and approval for

construction by the

infrastructure entities

Material and quality

determination

Static Analysis

Fit foundation to

transverse profile,

determination of pole

length and verification of

clearances.

Survey of transverse

profiles

Subsoil investigation


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6.4.2.1 Persons and equipment must not be placed in any danger from the operation of contact lines.

6.4.2.2 At all speeds, the dynamic interaction of the current collector and the contact line has to ensure that interruptions to power transmission do not occur under normal condition and for design speed 90km/h+10%.

6.4.2.3 All components of the system should have a longer life. For this, the following specific requirements are important: (a) Adequate mechanical and electrical strength, (b) Resistance to loads imposed by wind and aggressive substances in the air, (c) Corrosion resistance of all component, (d) Uniform, low contact wear of the contact wire.

6.4.2.4 During the design of overhead contact line installations in built-up areas, aesthetic and city planning aspects have to be observed.

6.4.2.5 Nature and environment protection have to be taken into account.

6.4.2.6 The investments for the installation and the costs for operation and maintenance should be as low as possible during the life cycle of the equipment.

6.4.2.7 It is essential that each installation is designed to allow faults to be quickly and precisely localized.

6.4.2.8 The system shall be designed in accordance with the design requirements of EN 50119 / IEC 60913, and book on treatise on Electric Traction Distribution issued by Indian Railways institute of electrical engineering including the following items contained in it: (a) Volume-II Part III: The layout and layout plans, wiring of points and crossing, structural

design of overhead equipment supports, arrangement of masts, cantilever arrangement, tramway type overhead equipment, bonding and earthing, OHE sectioning etc.

(b) Volume-II Part-IV: Selection of span, dropper schedule, determination of dimensions of cantilever assemblies, design of overlaps, automatic tensioning of overhead equipment, clearance study, jumpers, switching stations etc.

6.4.2.9 The Contractor shall carry out computer simulations (dynamic simulation between contact

line and pantograph using a validated software tool) to demonstrate the anticipated current collection performance. The adopted computer simulation programs should be validated against physical testing results, in accordance with EN 50318.

6.4.2.10 The Contractor shall submit cross-section drawing OHE installation indicating all the details in the drawing, so as to ensure installation of OHE properly during inspection by the Employer’s Representative.

6.4.2.11 Contact line systems have to be designed to function in a defined range of ambient temperature of Pune area to be obtained from meteorological department at Pune. The standard EN 50125-2 specifies environmental conditions of ambient temperature and wind pressure / wind velocity to be considered for design of overhead contact line by the Contractor.

6.4.2.12 Climatic conditions found in Pune are given in GS.The design of contact lines with respect to wind loads involves two main aspects: (a) Verification of serviceability, avoidance of pantograph de-wiring caused by wind

deflected contact wire,


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(b) Reliable design of structural elements to withstand the wind loads which probably will occur during the life time of the installation.

6.4.2.13 The maximum deflection of OCS support structure under maximum load at the height of

messenger wire shall not exceed 1.5%.

6.4.2.14 When OCS support structures are are used between tracks in station, the structure width / diameter shall not exceed 30 cm.

6.4.2.15 The Contractor should design the contact line system in such a way so that the period of line closure, for planned maintenance work or to repair contact lines and tracks, are kept as low as possible.

6.4.2.16 The Contractor should ensure that hazards due to electricity must be limited to acceptable values by adequate design of installations. Those hazards could arise from: (a) The overhead contact line to rail voltage, (b) The operating current and short circuit current, (c) The electric field, (d) The Heating effect, (e) The magnetic field, (f) Rail to earth potential, (g) Induced longitudinal voltages, (h) Capacitive charges etc.

6.4.2.17 The governing important standards but not limited for reliability and safety to be followed by the contractor are EN 50119, EN 50121, EN 50122-1, EN 50124-1, EN 50124-2, EN 50163, and EN 50367.

6.4.2.18 The Contractor shall adopt the correct choice of design insulation level which should ensure that the equipment will withstand the necessary voltages.

6.4.2.19 Depot design requirement: (a) The overhead contact system of test track shall be of main line type (b) The OHE inside the stabling lines and the inspection bay shall be provided on drop

arms (c) The shunting necks provided near approach to depot shall be at grade and therefore independent mast at grade shall be provided.

(d) The wiring of full tension length at stabling lines, inspection bay, workshop siding etc. shall start from their dead ends.

6.4.3 Rigid Overhead Collection System (ROCS) – Design Parameters

6.4.3.1 Type of overhead contact system

The Rigid Overhead Contact system shall include 25kV ac overhead rigid conductor rail with contact wire, associated jumpers, support structures and ancillary equipment.

6.4.3.2 Clearances: Minimum Electrical and Mechanical Clearance The minimum electrical and mechanical clearances shown in Table below shall not be infringed under the worst operating conditions of the overhead line equipment, the rolling stock and pantograph. Table 6.1: Minimum Electrical and Mechanical Clearance (mm)

SN Item Normal inside tunnel

1 25kV Live metal to earth Static

270mm


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SN Item Normal inside tunnel

Dynamic (passing) 170mm

2 25kV Live metal to vehicles Static Dynamic (passing)

290mm 190mm

3 Phase difference (47.6kV) Static Dynamic (passing)

540mm 350mm

4 Gap at insulated overlap or air gap on rigid OCS between conductors of different electrical sections

400mm

5 Gap at uninsulated overlap or expansion joint on rigid OCS 200mm

The minimum clearances inside the tunnel for 25 kV traction are those specified in IEC 60913 (latest). The values shown in the Table above shall be used as a minimum. In the event of additional space being available, the space shall be used to enhance the electrical clearances above the stated values, before consideration is given to increase the system height.

6.4.3.3 Mechanical Clearance Mechanical clearance to any point from the OCS with power off shall be adequate to provide for manoeuvring of working tools while carrying out maintenance work on the OCS. During detailed designing, the Contractor shall ensure that the minimum clearance between pantograph and insulator is 100mm.

6.4.3.4 Rolling stock The locked down height of the pantograph is 4048 mm, the minimum OCS height is 4318 mm.

6.4.3.5 Supporting structure The Contractor shall interface with designated civil Contractors to verify bored tunnel, box tunnel and station box cross-sections and also in respect of moving dimensions.

6.4.3.5.1 Safety of supporting structure Supporting steel structure for overhead contact system shall have a safety factor not less than 3 times yield point strength of steel against dynamic operational loads. Grouting shall be designed with a factor of safety as 4 and shall be load tested individually.

6.4.3.5.2 Anchor plug and anchor bolt/ Chemical fasteners of supporting fixture Anchor bolt shall be installed for the supporting fixtures of rigid conductor rail at intervals finalised on basis of detailed design. The type of bolts shall be similar to the designs used in Indian Metros or chemical fasteners of adequate design. The supporting fixtures shall have facility of adjustment so as to install the rigid OCS at the designed height with the requisite stagger of the conductor rail. Yielding point strength of the fixtures and fitments shall have adequate factor of safety, considering worst loading/torsion conditions and dynamic loading on account of pantograph thrust and movement. The Contractor shall furnish the supporting design details.

6.4.3.5.3 Supporting steel fixture The supporting steel fixtures shall be provided at suitable intervals based on design consideration. The interval between successive fixtures shall not permit undue sag and vibrations. The Contractor shall furnish the supporting data of similar systems, which may


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have been provided on other metro systems with 25kV ac rigid conductor OCS. The steel work shall be hot dip galvanized and the nuts, bolts and washers shall be stainless steel of suitable grade for moist and polluted tunnel atmosphere.

6.4.3.5.4 Support Insulator Type of OCS support insulator to be provided shall be a proven one. The electrical and mechanical properties of support insulator for the 25kV ac rigid conductor shall be in accordance with the recommendations of IEC 383 / 1109. The minimum creepage distance of the insulator shall be 1100mm, wet power frequency withstand voltage shall be 145kV and dry lightning impulse withstand voltage shall be 250 kV in accordance with the recommendations of IEC 60913. The mechanical design should be proven to take the fluxul stress to support the design train headway of 90 seconds. Supporting insulator fixture shall permit free sliding of Rigid conductor to allow for expansion on account of temperature changes.

6.4.3.5.5 Preventing loosening of nuts and bolts Adequate measures shall be taken for preventing all bolts and nuts from becoming loose, through use of lock nuts/ spring washers.

6.4.3.6 Expansion Joint

6.4.3.6.1 Typical arrangement and Interval between expansion joints. Expansion joints shall be provided at suitable intervals but the maximum interval may be allowed up to 250m depending upon the site condition.

6.4.3.6.2 Parallel contact wires at expansion joint Parallel contact wires shall be of adequate length to provide for suitable expansion joint assembly with provision for adequate number of flexible continuity jumpers. Separation distance between two OCS sections at expansion joint shall not be less than 200mm to ensure smooth passage of pantograph. No expansion joint shall be provided in the station area. Suitable gradient will be provided to ensure smooth change over. The expansion joint may be erected at site or prefabricated from the manufacturing works.

6.4.3.7 Sectioning equipment

6.4.3.7.1 Air-gapsection The structure of air-gap section shall be same as that of an expansion joint. At insulated air-gaps, separation distance between two OCS sections at the overlap shall not be less than 400 mm, with two OCS sections aligned such that pantograph passes satisfactorily. No air-gap section shall be provided in the station platform area. Air-gap sections shall be provided at the crossovers to segregate two sections. In case air-gaps are not found practicable, only in exceptional circumstances the section insulators may be permitted.

6.4.3.8 Jumper wire for rigid conductor Jumper wires for rigid conductor shall be of stranded annealed copper with adequate current carrying capacity. Connection of jumper wire to rigid conductor rail shall be through suitable bimetallic terminals each having at least two fixing bolts. Bolts shall not conduct any current. Jumper wire shall be flexible to allow creeping of rigid conductor. The design shall ensure that the jumper loops remain at least 75 mm above the contact plane.


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6.4.3.9 Anchors Anchors shall be provided for prevention of unidirectional creeping of rigid conductor rail.

6.4.3.9.1 Location of anchoring Anchoring shall be provided in the middle of one conductor run length between two expansion joints.

6.4.3.9.2 Anchoring Insulators and Hardware The design shall be such that the Insulator and hardware used at anchoring location shall be least affected by passing pantographs. Materials for anchors shall be corrosion resistant such as hot dip galvanized or of stainless steel. Suitable bimetallic fitment shall be integral with the hardware to prevent electrolytic corrosion to aluminium.

6.4.3.10 Rigid conductor rail and contact wire Conductor rail shall be of Aluminium alloy section with wearing copper contact wire. The conductor rail shall have anti-corrosion treatment on its surface. Sections of transportable lengths will be joined together to form lengths up to 250m between expansion joints. The contractor shall furnish the merits of the conductor rail system offered indicating the life, speed potential of installation, strength and conductivity of joints, maintainability and the supporting details including performance of similar rigid conductor systems if provided by him on any other metros system. Contact Wire shall be Round or Flat Bottom, 150 sqmm area and shall comply with EN 50149. Contact wire shall be made from Continuous Cast Copper (CCC) rod of minimum 21 mm diameter as per RDSO Specification. Also, Contact wire shall be hard Drawn Grooved Copper contact Wire complying to RDSO standard ETI/OHE/76 (6/97).

6.4.3.11 Standard length of conductor rail system Standard length of conductor rail offered shall not be generally less than 10 metres. However, the length offered shall be supported by the data of various metro systems using similar/same size rigid conductor OCS and the site condition.

6.4.3.12 Protection cover for rigid conductor rail Protection cover with Warning Boards of material and design to be approved by the Employer for rigid conductor rail shall be provided at station area, below the ventilation ducts and where there is a possibility of maintenance personnel inadvertently coming close to the rail. In case of continuous provision of protection covers, Warning Boards shall be provided on the protection cover at 5m intervals. The waterproof cover shall be provided on the conductor rail where water leakage will occur in the tunnel. The material should be Fire Retardant Low Smoke, Zero-Halogen (FRLSOH).

6.4.3.13 Height of rigid conductor rail and contact wire Minimum Height of the contact wire plane shall not be less than 4318mm from the safety distance criterion as per EN-50122-1 and keeping safety clearance and electrical clearance as per IEC 60913.

6.4.3.14 Stagger of rigid conductor and contact wire Stagger of rigid conductor contact wire shall be limited to 200mm, nominal, from rail centre on tangent track and on the curves, however, the value of stagger shall be finalised based on pantograph profile obtained from the rolling stock Contractor. Stagger of rigid conductor and contact wire (200mm) shall be achieved over a suitable length to avoid grooving on the pantograph current collection strips.


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6.4.3.15 The design of OCS shall permit a displacement of track by 50mm horizontally without need for changing any component.

6.4.3.16 Permissible gradient of contact wire Gradient of contact wire shall be not more than 1/1000 on main tracks and not more than 2/1000 on stabling line tracks at terminal stations. Deviation from these limiting values shall only be with specific permission of the Engineer. The junction with level contact surface shall be joined by a transition gradient half that adopted for the main gradient.

6.4.3.17 Cross Over The separation of contact wire at centre of the turn out shall be not less than 250 mm and not more than 300mm from the track, which it serves at any point after the take off.

6.4.3.18 Transition from Rigid to Flexible Catenary System The transition from Rigid overhead conductor system in the tunnels to flexible overhead catenary system in the ramp portion shall be so designed that passage of the trains (electrical multiple units) is as smooth as possible without resulting in any pantograph jerk, sparking and wear of components. The cross-sectional area of copper (current carrying capacity) to remain the same throughout the installation. The design should be a proven one.

6.4.3.19 Indicators Boards (a) OCS section indicator Boards shall be provided at approach to each electrical section

of OCS, which shall be visible to Train Operators (Drivers) from an adequate distance.

(b) Number plates shall be provided at support locations, the numbering scheme (for flexible OCS and rigid OCS) to be adopted shall be submitted for review of Engineer.

(c) Warning indicator Board shall be provided at approach to termination of contact wire. (d) “Warning: 25kV ac“ Boards shall be provided at locations and intervals decided upon

by the Employer. These boards shall be prominently displayed at the platform at frequent intervals.

6.4.4 Contractor’s Design Responsibility

6.4.4.1 Design Environment

This is furnished in Clause 1.12 of GS and Chapter 4.0 of this Specification.

6.4.4.2 Detailed Design of the OCS Based on the survey of entire route, the Contractor shall offer the most suitable OCS profile including OCS sectioning and work out in detail the OCS construction plan including return current longitudinal (continuity) and transverse (equalizer) bonding plan.

6.4.4.3 The above application designs shall be based on standard arrangement Design principles and specially for: (a) OCS supports and spans, adequate common parallel run at expansion joint; (b) Arrangement of jumper connections at expansion joints and at feeder connections; (c) As far as possible section insulators shall not be used on the main line. The

crossovers, turnout etc. shall be designed through over laps;


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(d) Transition arrangement between ROCS and flexible OHE shall be such that area of cross-section remains the same throughout this section;

(e) The insulator and OCS fittings must be able to take the fluxul stresses to

accommodate train headway of 90 seconds; (f) The components and fittings shall be of type and metallurgy, which are rust and

corrosion proof. Steel components shall be hot dip galvanised. Nuts, bolts and spring washers shall be suitable grade stainless steel.

(g) The fittings, jumpers etc. shall need minimum maintenance and to the extent possible

shall be of “fit and forget” type.

6.4.4.4 Insulators suitable for humid and urban polluted atmosphere of Pune shall be used. The insulator shall be oil resistant and the surface finish should be such that least amount of dust is able to accumulate on the insulator surface.

6.4.4.5 The design shall be coordinated fully with the requirements of the signalling and train control system, final track work, tunnel work and any specified design requirements that those systems or facilities may dictate for the operation and management of the services.

6.4.5 Submittals

6.4.5.1 Basic Design Based on the basic designs worked out and route survey, the Contractor shall prepare and submit a detailed OCS final design, together with hardware applications design appropriate for the whole Project. The design of the support and anchor assemblies shall ensure adequate clearance from the pantographs under dynamic conditions. The submittal shall include a tabulated allocation of all parts for the OCS. The Contractor shall select a full range of proven OCS components, and shall demonstrate by means of engineering calculations that all elements of the selected system are capable of meeting the Design Criteria, Safety, and Operational requirements as stated in these Specifications. When computer programs are proposed for use, the Contractor shall submit typical hand calculations, together with comparable computer data input and output, for verification of the program, together with a description of the software.

6.4.5.2 Drawings for review Construction drawings shall be prepared and verified at site. The site verified plans shall be submitted to the Employer for review. These shall include but not be limited to: (a) General Traction Power supply diagram (b) Schematic sectioning Diagrams (c) OCS construction Plans These shall include chainage of all support anchors and air gaps, height over rail level and other general particulars. On-site verification of the plans shall be carried out and based on final construction plan. OCS layout shall be finalized for construction.

6.4.5.3 OCS layout plan Based on the finalised construction plan, OCS layout plan shall be developed and submitted for review by Engineer. The OCS layout plan incorporating following information shall be submitted:


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(a) The alignment of the conductor; (b) Chainage of each support structure location; (c) Exact chainage of all expansion joints, anchors and air gaps; (d) Direction and value of stagger at each location; (e) Clearance of live conductors to fixed structures with respect to reference chainage; (f) Alignment and layout of feeders; (g) Jumper connections to switches and feeder tails; (h) List of infringements, if any; (i) Numbering of each support structure with respect to reference chainage; (j) Location and serial number of isolator switches; (k) Final Sectioning diagram drawn to a convenient scale showing identification number

of section insulators and elementary sections (4-span overlaps shall be used); (l) Transition Element drawing (from ROCS to FOCS; (m) General arrangement of OCS at SSP, SP and SS; (n) OCS profile drawings: In case the height of contact wire is changed, an OCS profile

drawing showing the actual height of the contact wire at each location and the gradient adopted until normal height of contact wire is achieved.

(o) Return current and Earthing and Bonding plan: Return current circuit Earthing and bonding plan in interface with Track construction Contractor, Signalling and Train Control Contractor.

Proceed to construction: Based on finalized plans field construction work may proceed.

6.4.6 Construction Requirements

6.4.6.1 Track route and layout inspection and preparation of installation work As preparatory work prior to installation, the location and position of supporting fittings, rigid conductor rail and anchoring shall be verified and marked at site. Height of the tunnel from top of rail at various locations shall be confirmed.

6.4.7 Installation of supporting structure

6.4.7.1 Supporting structure Supporting anchor bolts shall be supplied and installed by the Contractor.

6.4.7.2 Supporting Insulator and accessories Supporting insulator and accessories for rigid conductor rail shall be mounted on supporting structure to enable adjustment of the conductor to required stagger as per the final design drawings.

6.4.8 Installation of rigid conductor and contact wire

6.4.8.1 Transporting material

6.4.8.1.1 Care shall be taken that no breakage, dent, crack or bending of any component takes place during transportation. Adequate care shall be taken to prevent any damage due to rust by applying rust prevention paint. Painting schedule to be submitted for review by Engineer.

6.4.8.1.2 Materials delivered at work site shall be laid up neatly at nominated locations so that

interference does not occur from other works going on nearby.

6.4.8.2 Installation of rigid conductor rail and contact wire

6.4.8.2.1 Due care shall be taken while handling the rigid conductor rail that no twisting or bending or development of any crack takes place. Temporarily supporting the rail with one end cantilevering should be prohibited.


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6.4.8.2.2 While installing the rigid conductor rail, safe practices shall be adopted.

6.4.8.2.3 The erection of conductor rail shall be commenced from the anchor structure and

continued on to the expansion joint.

6.4.8.2.4 Before installation of the end approach of expansion joint, adjustment of final length shall be in accordance with the measured temperature in the tunnel.

6.4.8.2.5 On curved track, the conductor rail lengths appropriately bent to requisite curvature

taking into account track conditions and deviations of contact wire shall be provided.

6.4.8.2.6 On turnouts the level of the crossover contact wire shall be raised so that it does not come in contact with train pantographs running on the main track, and for the trains negotiating the turnout, the passage and current collection by pantograph is smooth.

6.4.8.2.7 Adequate tensile force shall be maintained in the contact wire.

6.4.8.2.8 The contractor shall interface with Tunnel and Station Civil Contractor and shall be

responsible for centre line marking of track (even without its laying) on the roof of the tunnel.

6.4.8.2.9 The Contractor shall submit the OCS installation plan to Employer for approval.

6.4.8.3 Jointing the rail

If the rail lengths are bolted together, the bolting process shall be of proven design with use of proven components.

6.4.9 Installation of Feeding System

6.4.9.1 Design requirement of traction power cables

6.4.9.1.1 25 kV feeder cables shall conform to the specifications of these cables given in Clause 7.3. The number of cables constituting a feeder shall take in account the whole current requirement of a single source of feed.

6.4.9.1.2 The feeder cables and the jumper cables shall be sized to provide for environmental

derating corresponding to the laying method and maximum overload and short-circuit currents.

6.4.9.1.3 The cable terminations shall be suitably designed for adequate insulation, mechanical

strength, low resistance and against fraying of strands, developing cracks or getting loosened with vibrations, wear and tear.

6.4.9.1.4 The interrupters and isolators meant for sectioning shall be located near the station area

generally structure mounted on viaduct close to the sections required to reduce length of cables.

6.4.9.1.5 Connection of feeder cables to OCS conductor rail shall be through flexible jumper and

terminal connectors and shall be of bolt fixing type. Details shall be submitted for review of Engineer.

6.4.9.1.6 The feeder cable jumpers shall be flexible to accommodate rigid conductor rail

movement due to temperature variations.

6.4.9.1.7 Due care should be taken to lay and connect the cables to switchgear and to OCS to ensure that the current carrying capacity of the system is not de-rated. All connectors shall be robust and of proven types.


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6.4.9.2 Return conductor and earth conductors

6.4.9.2.1 Return Conductor Return conductor shall be aluminium conductor conforming to Bureau of Indian Standards, specification IS: 398 (Part I)-Latest Revision. OR Copper conductor of adequate size to be finalised by EMC simulation study. The Conductor shall conform to Indian Railway’s RDSO specification for “Annealed stranded copper conductors (ETI / OHE/ 3, Latest version) and IS:9968 (Part 2).”

6.4.9.2.2 Earth Conductor Earth Conductors shall be made of flexible copper conductors of adequate size to be finalised by EMC simulation study. The Earth Conductor shall conform to Indian Railway’s RDSO specification for “Annealed stranded copper conductors” (ETI/OHE/3, Latest version) and IS: 9968 (Part 2).

6.4.9.3 Submittals of Designs and drawings for review The designs and drawings for the cable runs, connection and jumpering arrangement of the 25kV feeder cables to the OCS and Earthing and return current conductors shall be submitted to Engineer for review. The drawings shall include but not be limited to the following: (a) General arrangement drawings for each type of joint and connection (b) Individual Site location drawings over the entire route (c) Bonding and Earthing plans over the entire route

6.4.9.4 Cable Installation Requirements

6.4.9.4.1 General As preparation work prior to cable installation, the location and position of cable supporting fittings shall be ascertained and actually at site in coordination with other civil works so as to avoid any error in installation. Provision of adequate clearance for running cables across tracks and at location of jumpers to OCS should be ensured through interface with Civil Contractors who may have to provide niches to obtain such extra clearance.

6.4.9.4.2 Cable laying and protection At any location where any damage or rubbing to cables or touching with walls is expected, fibre glass or equivalent cable protection cover shall be provided.

6.4.9.4.3 Bending of cables Bending of cable shall be executed gradually and bending radius of the cable shall be not less than allowable bending radius of cable. Bending of cables shall not be executed repeatedly. Special precaution shall be taken for bending at cable ends where shrinkable sleeves and petticoats are fitted.

6.4.9.5 Final Adjustment and Measurement of OCS After the equipment has been finally adjusted, the equipment shall be subject to final measurements jointly with the Employer. The checks shall include but not be limited to:


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(a) Support location member, its height above rails level and stagger, gradients in OCS; (b) Contact wire height at mid span between successive support members; (c) Anchors, expansion joints and air gap separations; (d) Clearance checks to ensure pantograph passing clearances, both electrical and

mechanical clearance Pantograph test to ensure smooth shock free passage especially at section insulators at air gaps, at turnouts, crossovers and change of height of the contact system

(e) Fittings or jumpers and cable connection to

Overhead conductor rail

Return current circuit connected to running rails

6.4.10 Site Testing and Inspection

6.4.10.1 In accordance with this Specification and the GS a detailed protocol for inspection and testing of complete OCS shall be prepared and the tests and complete methodology for testing shall be submitted for review by the Engineer.

6.4.10.2 Installation checks and tests (a) Visual inspection of overhead contact system installation, random check of

components; electrical and mechanical clearances, air gaps and general alignment. (b) Continuity test of each joint in traction and return current circuit. (c) Insulation resistance of 25kV ac overhead contact system shall be as per international

standards. (d) Physical examination of rail bonds. (e) Checking of construction gauge (f) Return current continuity test, testing of joints. (g) Earth resistance test.

6.4.10.3 Partial Acceptance Tests After physical verification and measurements, tests as indicated below but not limited to these, shall be carried out:

6.4.10.3.1 Circuit continuity, loop resistance test The purpose of this test is to prove the OCS section contunuity. These test checks both the OCS and the rail return system for electrical continuity. The test entails short-circuiting a discrete section of the OCS by connecting the OCS to the rails at one end and applying a variable ac voltage at the other end. The length of section under test should be approximately 1.0 - 2.0 km (i.e. in the station to station zones). An ac source with variac to provide requisite testing current.

6.4.10.3.2 High voltage ac test Meggering of OCS sections at 2.5 kV and record results.

6.4.10.3.3 Pantograph tests will be performed using a self-powered transit vehicle in order to identify any locations where arcing may occur.

6.4.10.3.4 The Contractor shall be responsible for all adjustments required as a result of these

tests.

6.4.10.4 System Acceptance Tests

6.4.10.4.1 Successive Energisation Each electrical section shall be energised successively at 25kV ac from for one minute with adjacent sections isolated and connected to traction earth. Finally entire section shall be energized for at least 24 hrs.


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6.4.10.4.2 Short circuit tests shall be carried out as per a detailed test protocol, which shall be

submitted for review by Engineer.

6.4.10.5 Integrated Testing and Commissioning

6.4.10.5.1 All the items of supply and required for completion of the work in all respects, testing and commissioning of the overhead equipment system as well as associated work for facilitating trial run of the rolling stock and Integrated Testing and Commissioning shall form part of the work covered by the contract whether specifically stated or not. During train trial Contractor shall be responsible for providing and fixing discharge rods during power block permission/Cancellation before ROD.

6.4.10.5.2 High speed tests shall be carried out by means of running the trains initially at slow

speed, then increasing the speed in stages up to full speed permitted for the section. On successful completion of the high speed tests, the OCS shall be declared fit for pre-revenue system tests.

6.4.10.5.3 The Contractor shall be required to operate and maintain the OCS until Taking Over by

the Employer.

6.5 CIVIL WORKS AND ANCILLARY INSTALLATIONS

6.5.1 General Unless stated otherwise in the Contract Documents the whole of the civil, structural, services and finishing works shall be constructed to comply with relevant laws and regulations of the Indian Government and of Maharashtra State Government as well as complying with the requirements of the Pune public utility authorities, fire regulations and such additional requirements as may be stated in the documents. The design requirements relating to fire safety and escape shall be generally in accordance with IS, NFPA, BS 476 and other applicable standards.

6.5.2 Civil and Structural Design The Contractor shall perform the civil and structural design, including the preparation of calculations, drawings, specifications, cost estimates and other documents, for but not limited to: (a) General arrangement (layout and elevation); (b) Structures and sub-structures; (c) Foundations;

6.5.3 Architectural services

6.5.3.1 The Contractor shall perform the Architectural services design, including the preparation of calculations, drawings, specifications, cost estimates and other documents, for but not limited to: General arrangement (layout and elevation), Section and details (a) Walls, floors, ceiling finishing (b) Doors, frames and windows (c) Toilet rooms, and partitions including equipments (d) Concrete (types and treatments) (e) Thermal and moisture protection (f) Electrical and mechanical fittings (g) Building surrounding environmental arrangement

6.5.4 Auxiliary services


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The Contractor shall perform the Auxiliary service design, including the preparation of calculations, drawings, specifications, cost estimates and other documents, for but not limited to: (a) Cables routing (cable trenches, trough, trays etc...) (b) Earthing

6.5.5 Battery Rooms In battery rooms, the following additional precautions have to be taken: (a) the walls & floor must be resistant to electrolyte action and provided with acid resistant

tiles. (b) ceilings should be painted with acid-resistant paint which does not give off harmful

vapour. (c) Ventilation by means of induced draught is preferred. An air change rate of 5 times the

room volume per hour is recommended.

6.5.6 Exterior finish External finish of the Building shall be attractive and pleasing to the eye preferably of stable and durable cladding of granite or equivalent of approved shade and design.

6.5.7 Signages Depending upon the layout and construction finally adopted, the various installations shall be provided with signboards, both in Hindi and English. These Sign boards are in addition to equipment labelling, which shall be provided as per approved drawing. The Contractor shall submit drawings for the proposed Signage’s, for Employer’s notice of no-objection and the Signage’s shall be provided in accordance with approved drawings.

6.5.8 Traction network equipments

6.5.8.1 Equipment pedestals Pedestals for Control and Monitoring panels at grade, where required, shall be of mass concrete M15 in accordance with IS: 456.

6.5.8.2 OHE Foundations

6.5.8.2.1 General

6.5.8.2.1.1 'At-grade', concrete foundations shall be used for supporting the OHE masts, portals and head span which shall be in stabling yards and depots. The Contractor shall carry out the geotechnical investigations for foundation design.

6.5.8.2.1.2 Switching stations (SSP, SP, SS) gantries including VCB for automatically switched neutral section shall be provided mostly on the gantries of the viaduct with bolted base plate with anchor ‘U’ bolts grouted in the parapet.

6.5.8.2.1.3 The equipment for the switching stations and VCB shall be in panel and the panel foundation or steel frame works should be designed by the Contractor in such a way so as to have minimum noise and vibration.


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6.5.8.2.1.4 The Contractor shall ensure effective proper interface with the concerned civil contractor for proper design and execution of all the foundations and steel frame works mentioned above.

6.5.8.2.2 Design Principles

6.5.8.2.2.1 The concrete foundations shall be designed to withstand safely, the vertical loads and the bending moments arising parallel and perpendicular to the track and the principal loads which are required to the reckoned while arriving at the vertical loads and bending moments are: (a) Weight of the OHE, weight of cantilevers including insulators etc., weight of any

equipment such as OCS and any conductor, isolator, interrupter etc. on the structure, weight of structure itself.

(b) Radial forces arising out of the pull on contact wire, messenger wire, anticreep wire, feeder, return conductor, aerial earth wire etc. and the bending moments occurring on the top of foundation due to such radial forces.

(c) Wind forces, due to wind blowing parallel or perpendicular to the track, on conductors, cantilevers, pole-mounted equipments and on the structure itself.

(d) In addition, weight of a man with equipment standing on the cantilever shall also be considered for calculating the bending moments and direct load.

6.5.8.2.2.2 However, when the effect of full wind is taken in the calculations, for any particular case of

load combination, the effect of the weight of a man standing on the cantilever need not be considered, as an addition. In other words, the more severe case between the two alternatives viz:

without man and with wind,

with man and with reduced (20%) wind load, shall be considered.

6.5.8.2.2.3 The foundations designed shall be checked for safety against Seismic forces (ZoneIV) in accordance with IS: 1893.

6.5.8.2.3 Types of foundations The following types of foundations are used: (a) Side Bearing: This type is generally used in level grounds, cutting and good

consolidated embankments with sufficient shoulder width. (b) Side gravity: This type is used in good consolidated embankments, where the

shoulder with is insufficient. (c) Pure gravity: This type is used in unconsolidated banks and in ash filled areas. (d) In those areas, where black cotton soil is encountered, special Black Cotton soil

foundations may be used.

6.5.8.2.4 Soil pressure

6.5.8.2.4.1 Soils are classified in accordance with their capability to withstand the mechanical forces to which they are subjected.

6.5.8.2.4.2 They are generally defined in terms of maximum permissible pressure which could be withstood by them.

6.5.8.2.4.3 Three types of soil are taken into account:


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(a) Normal Soil: Maximum permissible pressure is 0.11 Mpa to 0.22 Mpa (b) Rocky Soil: Maximum permissible pressure is 0.5 MPa to 1.0 Mpa, for soft rock and

2.4Mpa for hard rocks (c) Loose Soil: Maximum permissible pressure is 0.06 MPa.

6.5.8.2.4.4 The Contractor shall ensure the design criteria mentioned in Clauses 6.5.8.2.2,6.5.8.2.3 and 6.5.8.2.5 for foundation and associated requirements to the satisfaction of the Employer’s Representative.

6.5.8.2.5 Concrete Mix

6.5.8.2.5.1 Concrete for foundations shall be of nominal mix of grade M15 obtained by mixing cement, coarse aggregate, fine aggregate and water in accordance with proportions given in Table 9 of IS: 456.

6.5.8.2.5.2 For grouting, muffing and embedding of structures, in foundations and for cable trenches at switching stations, nominal mix concrete M-20 shall be used, in accordance with IS:456.

6.5.8.2.5.3 Deleted

6.5.8.2.6 Bolted base masts / portals / gantries

6.5.8.2.6.1 Base plates (a) As already stated, the OHE structures, portal and gantries uprights to be located on

the viaduct parapet, are required to be provided with steel base plates, welded to the structure / upright.

(b) The typical arrangement of base plates for structures/uprights and for anchor on

viaduct, shall be provided to the successful bidder. (c) The Contractor should ensure that the steel used for base plates shall be of weldable

quality as per national/ international standards.

6.5.8.2.6.2 Anchor bolts shall be suitably designed by the Contractor, to transmit the mechanicalforces from the structure to parapet; shall be provided by the viaduct contractor (see interfacing document) at the time of casting and installation of parapets.

6.5.8.2.6.3 The Contractor should ensure by interfacing with the viaduct contractor that these anchor bolts are provided, strictly in accordance with design (bolt diameter, spacing etc.), failing which it could lead to problems in installation of structure / uprights on viaducts.

6.5.8.2.6.4 Fencing post: Foundation for fencing posts shall rest on consolidated soil. In case of the depot, if the depth of unconsolidated soil is less than 1.5 m below the datum level, the fencing shall be with rectangular parallel piped in shape. If the depth of unconsolidated soil is more than 1.5 m, the foundation block shall rest on reinforced concrete piles cast-in-site or reinforced concrete foundation may be adopted as desired by the Employer’s Representative.

6.5.8.2.6.5 Rigid OCS base support: The Contractor shall interface with civil contractor of tunnel section for drilling the hole and providing rigid OCS base support including chemical mortar for better strength as per designed load furnished by him.


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CHAPTER 7

7.0 TECHNICAL REQUIREMENTS

7.1 TRACTION NETWORK

7.1.1 General

7.1.1.1 The Traction Power Supply Network transforms the High voltage 132kV into 25kV by means of transformers and distributes the 25kV through adequate protecting and sectioning equipment to the Over Head Catenary system (OHE) which feeds the Electric Multiple Units.

7.1.1.2 It is mainly composed of Feeding Posts (FP), Sectioning Post (SP), Sub-Sectioning Post (SS) and Sub-Sectioning & Paralleling Post (SSP), collectively referred to as ‘Switching Stations’.

7.1.1.3 The traction network uses single phase load fed from a balanced three phase system which introduces a current and voltage unbalance in the system. The Contractor should examine the effect of unbalancing and ensure permissible level of current, voltage and harmonics generated in the traction network system to minimize the ill effect on unbalancing.

7.1.1.4 The Contractor shall examine the voltage drop and ensure permissible level of voltage drop of the catenary system of traction network for varying load current drawn by the metro car.

7.1.1.5 The technical features of various equipments and components associated with the traction network are given below:

7.1.2 27.5 kV Switchgear

7.1.2.1 General

7.1.2.1.1 The 27.5kV switchgear consists of structure mounted Circuit breakers, interrupter and isolators electrically linked.

7.1.2.1.2 The steel structure for mounting shall be in accordance with IEC standards

7.1.2.1.3 All circuit-breakers shall follow the electrical and mechanical characteristics in

accordance with IEC standards 62271-100 or RDSO’s standard ETS/PSI/116 (4/88) with latest modifications.

7.1.2.1.4 These equipments shall be pole mounted with the switching part at pole top level,

separated from the control equipment located at hand level and base pole mounted, both connected together with a transmitting mechanism.

7.1.2.1.5 These equipments shall follow the electrical and mechanical characteristics and must

be in accordance with IEC standards IEC 265-1 and IEC 62271.

7.1.2.1.6 All parts shall withstand at least 10000 operations without any signs of detriment.

7.1.2.1.7 27.5kV switchgears of TSS and of underground SSP, SP & SS shall be indoor GIS type with SF6/Vacuum circuit breaker/interrupter. 27.5kV switchgears of outdoor switching posts shall be outdoor type with SF6/Vacuum circuit breaker/interrupter.

7.1.2.2 Circuit Breakers / Interrupters

7.1.2.2.1 SF6 type Circuit breaker


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The current rupturing part consists of a couple of moving and fix contacts embedded in a body fastened on cast resin material or hard porcelain brown glazed insulated at 52kV (according to the IEC 273), and the moving contact is connected by mean of slipping contact.

7.1.2.2.2 Vacuum type Circuit breaker and interrupter The current rupturing part consists of a vacuum bottle embedded in silicon rubber to prevent water condensation. Bottle is fastened on hard porcelain brown glazed insulated at 52 kV (according to the IEC 273), and the moving contact is connected by mean of flexible copper braid.

7.1.2.2.3 All apparatuses up and down stream connectors shall be made of pre-drilled copper plates in order to receive 2 x 240mm2 copper cable each.

7.1.2.3 Characteristics of breaker

Power frequency withstand one minute in kV (rms):

95 kV for 25 kV Impulse withstand (1.2/50 microsecond) in kV (peak):

250 kV for 25 kV,

7.1.2.4 Isolators

7.1.2.4.1 The Isolator shall be air insulated type and shall include: (a) Up & down stream connectors (b) Vertical break (c) Motor operated where required and manually operated capability (d) Locking and interlocking devices (e) Open / Closed auxiliary contacts (f) Low voltage multi-pin connector and flexible cable

7.1.2.4.2 All Isolators shall follow the same electrical and mechanical characteristics and must be in accordance with IEC 62271-102.

7.1.2.4.3 All interrupters and isolators shall have provision for pre-drilled copper plates in order to

receive 2 x 240 mm2 cable.

7.1.2.5 Measuring Transformers

7.1.2.5.1 All measuring transformers shall follow the same electrical and mechanical characteristics and must be in accordance with IEC 44-1 (CT) and IEC 44-2 (VT) or RDSO’s specifications ETI/PSI/117 (7/88), PSI 3156 of 1992.

7.1.2.5.2 Voltage transformers

(a) Primary connectors: 25kV connectors shall be made of bronze pipe 20, length 60mm.

(b) Secondary connecting box: Secondary winding connection will be realized through a

dust-proof and water tight type (IP55) connecting box fitted with a 6.3A fuse and able to receive 2x10mm2 screen-cable.

(c) Voltage transformer 25000/110 V shall be dry resin, and shall ensure that self-heating shall be less than 1°C per hour.


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(d) The self-heating has to comply with the climatic conditions defined in General Specifications

(e) The maximum temperature rises should be in accordance with the insulation medium, as defined in the IEC standard 44-2.

7.1.2.5.3 Current transformers

(a) Primary connectors: Consist of up & down stream connectors, made of pre-drilled

copper plates in order to receive connector fittings rated at 1250 Amps for 2 x 240mm2 cables or bus bar connection. The connectors shall be able to handle at least 2500A for 5 min without overheating.

(b) Secondary connecting box: Secondary winding connection will be realized through a dust-proof and water tight type (IP55) connecting box and able to receive 2x10mm2 copper screen-cables.

(c) Current transformers shall be dry resin, and shall ensure that self-heating shall be less than 1°C per hour.

(d) The self heating has to comply with the climatic conditions.

(e) The maximum temperature rises should be in accordance with the insulation medium, as defined in the IEC standard 44-1.

7.1.2.6 Indoor 25kV Gas Insulated Switchgear (GIS)

7.1.2.6.1 General

7.1.2.6.1.1 Indoor 25kV GIS switchgears (circuit breakers or interrupters as per final approved design)

will be used for SS/SSPs in underground tunnel sections.

7.1.2.6.1.2 The scope of work comprises of design, manufacture, shop testing, supply, delivery at site, installation, testing and commissioning supervision of 1-phase, 27.5kV, 16kA Gas Insulated Indoor type Switchgear. The supply will include all supporting structures, auxiliary equipments, mechanical linkage, spring drive, SF6 gas piping, auxiliary circuit wiring, interlocking devices, current and voltage transformers, cable End boxes, meters and other accessories.

7.1.2.6.1.3 The switchgear is used for controlling 25kV OHE feeder and 25kV cable. Vender to confirm suitability of equipment for this application and also confirm maximum over voltage during switching operation.

7.1.2.6.1.4 In case protection is included in the scope, vendor is responsible for selection of proper relays, CT/PT application check, co-ordination of relay setting and all assistance during integrated testing. The CTs shall be located above the HV cable termination socket.

7.1.2.6.2 Main features required

7.1.2.6.2.1 The 27.5kV equipment shall be built according to the relevant IEC/EN standards.

7.1.2.6.2.2 Unless indicated otherwise herein, all equipment supplied and installed shall comply with the IEC/EN standards.

7.1.2.6.2.3 Bus zone wise busbar segregation should be provided with gas monitoring system for each bus zone.

7.1.2.6.2.4 Individual Pressure gauge to be provided for each circuit breaker compartment installed at the front of the panel in order to supervise the SF6 Gas Pressure.


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7.1.2.6.2.5 Internal insulation level between live part and earth when the pressure of gas goes to the atmospheric pressure should not be less than 1.2*27.5kV

7.1.2.6.2.6 The metal enclosures for SF6 gas insulated equipment / module shall be made from material which does not require protective painting either internal or external switchgear.

7.1.2.6.2.7 GIS supplier should have supplied similar GIS for any metro / rail system. This shall be explained in bidder’s technical proposal. The tender will be required to explain availability of spares and services from technically trained manpower in India to support the ultimate customer MAHA-METRO in future.

7.1.2.6.2.8 The incoming (single core) cable feeder shall be of suitable size. The termination arrangement shall be designed for such cables. The outgoing connections from GIS shall also be cable.

7.1.2.6.2.9 The disconnectors and earthing switches shall be mechanically interlocked against maloperation. Feeder earthing switch shall be isolated from earthed enclosures and shall permit testing of switchgear. It shall also be possible to carry out high pot DC testing of Cable core without disconnecting the cables.

7.1.2.6.2.10 The conductors / bus bars shall be of copper and enclosure shall be made of corrosion resistant metal.

7.1.2.6.2.11 The gas barrier insulation between compartment shall withstand 1.5 times maximum rated pressure on one side and vacuum on the other side.

7.1.2.6.2.12 All gas sampling shall be possible during normal operation and without loss of gas.

7.1.2.6.2.13 Loss of gas per annum shall not exceed 1% by weight in each compartment.

7.1.2.6.2.14 Adequate burden/capacity shall be available in instrument transformers to permit provision of protection/measuring equipment. The instrument transformers shall have separate metering cores to permit measurement of values of energy, power, current and voltage as per required accuracy.

7.1.2.6.2.15 VTs should be pluggable type and provision should be available to manually disconnect the VTs from the circuit without the need to take associated circuit breaker or busbar out of service.

7.1.2.6.2.16 Clear visual indication of Isolator and earthing switch, whether open or closed shall be provided.

7.1.2.6.2.17 The Switchgear panel should be of modular design with a flanged connection between circuit breaker and busbar compartment.

7.1.2.6.2.18 Interrupting Medium for Circuit breaker shall be Vacuum/ SF6. The actuating drive should be Spring drive. To give the highest reliability of the system, following loss of supply voltage the operating mechanism shall have local stored energy sufficient for duty cycle of O-CO without the need of recharging. The circuit breaker shall be provided with an anti pumping coil for all the command going to the switchgear. All interlock and auxiliary system within the actuation system shall be designed so that the circuit breaker execute operation only when it is in a position enabling to do so completely and reliably.

7.1.2.6.2.19 The isolator shall be fitted with a suitable power actuation system backed up by an emergency manual actuation in case of mal function of the former. The isolator shall not change position under the effect of electro dynamic loads.

7.1.2.6.2.20 In case of any replacement or extension of switchgear panels at site it should be possible to replace or add a fully assembled circuit breaker without interfering the


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operation of the adjacent feeder as well as without any bus zone degassing. All circuit breaker of same rating should be interchangeable.

7.1.2.6.2.21 Monitoring of Gas in the enclosure Each gas compartment and each bus zone should have its own temperature compensated density indicator featuring 3 auxiliary contacts for alarm. The protection devices for the equipment shall ensure permanent monitoring of gas pressure inside each compartment by means of temperature compensated monitoring devices triggering a dual alarm threshold annunciation system in the event of gas pressure drops. The design of the cable termination shall allow plugging and unplugging the HV cable without need of opening the GIS and without any gas filling.

7.1.2.6.2.22 The modules individually as well as assembly subject to various routine test and type test

7.1.2.6.2.23 Site test shall include leakage test, moisture contents in dielectric medium and power frequency test (if required as per relevant standards).

7.1.2.6.2.24 Earthing Entire metallic enclosure shall be bonded and effectively earthed using copper bonded steel conductors.

7.1.2.6.3 Technical Specification

SN Parameter Values

1 Enclosure Type Single Phase Enclosure

2 System Voltage 27.5kV

3 Rated Insulation Voltage 40 kV

4 Rated frequency 50Hz

5 Rated Current 2000A @ 40 Deg C

6 Power Frequency withstand voltage 95kV rms

7 Lightning Impulse withstand voltage 200kV rms as per EN 50124-1

8 Rated short time current 16kA for 3sec

9 Peak withstand current 40kA peak

10 Guaranteed SF6 gas loss per year < 1%

7.1.2.6.4 Cable Termination kit

Confirmation of incomer cable size would be made available to the vendor at the time of manufacturing clearance. The cable entry shall be vertically from underneath the panel.

7.1.2.6.5 Outgoing feeders are two runs of 240sqmm copper cable. Along with bid vendor to submit SLD and the GA drawing indicating the space requirement (length x depth) and the minimum clearance required in front of the cubicle and back side from the operation / maintenance consideration.

7.1.3 LV Power and Control Equipments

7.1.3.1 General The LV power and control equipment at switching posts mainly comprises of: (a) 415/230V AC Distribution Board


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(b) DC-UPS including Battery, Battery chargers (c) 110V DC Distribution Board (d) Interface cubicle to act as a link between switching posts’ equipments and

‘GATEWAY’ To SCADA (e) Interconnecting power and control cables.

7.1.3.2 SSP Room As part of the Depot SSP Building, the Contractor is required to build the Depot SSP Room complete with cable gallery, cable paths and covers and other general electrical facilities such as lighting, ventilation, fire detection and alarm system, earthing system etc.

7.1.3.3 AC distribution board The AC Distribution Board has 2 incoming feeders from the LV Main Distribution Board (outside the scope of this Contractor). There are 240 V outgoing feeders for feeding the power required for control and monitoring of switchgear etc.

7.1.3.4 Auxiliary Power Supply This shall be provided by a 110V DC battery and charger system.

7.1.3.5 Grounding Frames shall be made electrically continuous by connection with copper bar, at least 30 x 3 mm size or 50x6 mm GI strip may be, provided for the grounding of the equipment.

7.1.3.6 110V DC Equipment specification The following 110V DC source equipment shall be provided.

7.1.3.7 Battery

7.1.3.7.1 Each battery shall be of stationary compact, nickel-cadmium type. They shall be maintenance free.

7.1.3.7.2 The capacity of the battery shall be decided by the Contractor taking into account the

permitted voltage tolerance of the individual loads, the power consumption of various loads, the length of time they are in operation and the manner in which they draw power.

7.1.3.7.3 The precise capacity of battery shall be determined to ensure total autonomy of the

station for 8 hours as required to retain the power supply of the standby lighting and of the control / monitoring auxiliaries in case of total failure of the AC sources.

7.1.3.7.4 The battery protection shall be as close as possible to the battery and shall be contained

in separate enclosure for negative and positive pole respectively. The enclosure shall be made of insulating material. The connection between the battery and its protection shall consist of single conductor and shall be run in such a manner so that they are protected from physical damage.

7.1.3.7.5 Each battery half shall be connected through its own battery distribution board to the

main board, and each battery half section shall have its own supervisory equipment to indicate and alarm for the maximum and minimum voltage levels on float-charge and earth fault.

7.1.3.8 Battery charger

7.1.3.8.1 The battery charger shall be Float cum Boost type suitable for charging Ni-Cd cells and

duly certified, accepted by the battery manufacturer.


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7.1.3.8.2 AC Power Supply (a) Voltage: 230V / 415V +/- 10% (b) Frequency: 50Hz +/- 3% (c) Maximum short-circuit current: 4000A rms (d) Recharge to 80% of the battery capacity: 8 hours

7.1.3.8.3 DC Output (a) Power supply voltage: suitable for a battery of 110 V (b) Operating period after AC supply failure: 8 hours (c) Constant power drain: shall be decided by the Contractor, to deliver the full duty. The

minimum capacity of the Battery shall not be less than 300AH.

7.1.3.8.4 The AC and DC terminal strips shall be separated from each other.

7.1.3.8.5 Each battery charger shall be: (a) designed to ensure operation according to the battery ratings as described below, (b) installed in a sheet cabinet with feet, closed by panels. (c) Ventilation shall be natural.

7.1.3.8.6 Characteristics The chargers shall be diode and thyristors regulated type, wired as Graetz Bridge.

7.1.3.8.7 Operating and floating rates The voltage at the charger current output terminals shall be automatically kept within +1% for variations of +10% / -15% of the AC voltage and of +5% of the frequency, whatever may be the output required. The residual ripple ratio shall be as low as possible (less than 3.5%) so as not to disturb the various operating circuits.

7.1.3.8.8 Equalization charge operation This charge shall be able to take place up to the floating voltage within +1% under the same conditions as above.

7.1.3.8.9 Automatic change-over from floating to equalization charge and conversely Following any failure of more than five minutes of the AC supply network, the charger shall automatically revert to the charge position right upon return of the voltage and shall remain on this position throughout the time set by an adjustable timer (from 1 hour to 20 hours). After this time, the charger shall return to floating operation. The charger shall remain in floating operation if the network failure is shorter than five minutes.

7.1.3.8.10 Direct operation The charger shall be capable of operating directly, without the battery, under the same conditions of accuracy as for the floating and charge modes.

7.1.3.8.11 Manually controlled operation Operation in manual control shall be possible, i.e. it shall be possible to execute manual adjustment of the voltage in case of malfunction of the regulator.

7.1.3.8.12 Alarms The status of all battery chargers shall be indicated locally, as well as at the OCC (through SCADA), as per the following convention:


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Green – Healthy and in-service,

Yellow – Healthy and standby,

Red – Defective. The change of status from “Healthy” to “Defective” shall be accompanied by an audible alarm/hooter, both locally and in the OCC.

7.1.3.8.13 Protections and monitoring The battery charger equipment shall also include: (a) a signalling light denoting the opening of the make-break switch on the AC side,

controlled by the tripping of one of the Miniature Circuit Breaker protecting the various circuits of the apparatuses,

(b) a signalling light denoting the opening of the make-break switch on the DC side through actuation of the magneto-thermal relay,

(c) a voltmeter indicating the voltage on the AC side (d) a voltmeter indicating the voltage on the DC side (e) A centre-zero ammeters which shall indicate whether the battery is under charge or

the battery is only delivering the load. (f) the position of the various circuit-breakers and of the protection and fault relays shall

be monitored through two flip-flop stages. (g) An inspection light shall be fixed inside the charger compartment, which will

automatically come “on” when the charger compartment is opened for inspection. This shall be independent of the “on/off” position of battery changer and shall be operative when the 415 V supply is available to the charger.

7.1.3.9 110V DC Distribution Board

Distribution of the 110V DC sources shall be gathered inside a specific cabinet.

7.1.4 Traction Protections

7.1.4.1 The purpose of the protections installed in traction feeder stations is to isolate all or part of the dependent equipment from the network, in case of phase-to-phase or phase-to-earth / rail fault. The Traction Protection system can be broadly divided into two main groups:

7.1.4.2 Traction set protection, which will essentially include all equipments starting from the HV bus bar to which the Traction Transformers are connected, up to the 25kV bus bars from which the 25kV Traction Feeders take off.

7.1.4.3 Traction set protection: Each HV circuit-breaker located upstream the power transformers ensures the protection of: (a) the bus bars for connection to transformers on the HV side (b) the transformer (c) the 25 kV bus bars located upstream,

7.1.4.4 Directional power protection (a) The function of directional protection is to check the power transit direction in the

catenary system, mainly due to regenerative braking, which could flow back to the HV grid through the transformers. Two stages are involved:

a slow one

a quick one


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(b) When the first stage is activated, a signal is emitted and a time-out 1 is started. When time-out 1 ends, a second signal is emitted.

(c) If, after 3 minutes, the fault still persists, a tripping command is sent to the concerned

traction set circuit-breaker. (d) When the second stage is activated, at the end of time-out 2, a tripping command and

signal are emitted by the protection device; the 1st stage and 2nd stage current thresholds can be parameterized as well as time-outs, and angle * of straight line D can be adjusted.

7.1.4.5 Minimum impedance protection

(a) This module is a single-phase impedance measuring (in R-X co-ordinates) relay,

which operates when the impedance value falls below a selected adjustment threshold.

(b) This protection is directional and selective; it makes a distinction between a high load

and a distant fault of small intensity. (c) The minimum impedance protection is self-supervised and an internal fault in the

protection entails the tripping of the associated circuit-breaker.

7.1.4.6 Over current protection An over-current protection is designed to detect faults occurring very close to the feeder station. This protection causes the tripping of the circuit breaker when the current reaches a value exceeding the highest load on the network.

7.1.4.7 Fault Locater Fault locator is activated following a circuit breaker tripping due to:

Minimum impedance detection

Over current This allows an auto re-closure sequence . The fault locator measures the catenary/ rail loop fault impedance and compare with the minimum impedance relay and determine the kilometre point from the feeder station.

7.1.4.8 Cable Connections

7.1.4.8.1 Between TSS and OHE each connection between the 25 kV Outgoing Circuit Breaker / Isolator at TSS and the OHE pole mounted Isolator shall be realised by means of 2x240 sq.mm copper cables.

7.1.4.8.2 Between running track and the Buried Rail in RSS a connecting strip, as per

specifications shall be provided on the Viaduct / near the track.

7.1.4.9 The mid-point of the Impedance Bond (or the Earthing rail, if no impedance bond is provided) of each track shall be connected to the above Connecting Strip, by means of 4x240 sq mm copper cables. The connection between the Connecting strip on the Viaduct and the buried earthing rail in the TSS shall be realized by means of 8x240 sq mm copper cables.

7.2 TRACTION OVERHEAD EQUIPMENT


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7.2.1 General

7.2.1.1 The expenditure for construction, operation and maintenance of overhead contact line installation should be as low as possible through the entire service life. Therefore, the Contractor has to select the components and elements in such a way so as to get maximum reliability and which require very little or no maintenance. This does not absolve the responsibility of the Contractor for using the national/ international standards.

7.2.1.2 The Contractor should sincerely use the corrosion protection measure including the menace of bimetallic effect so as to derive longer service life of various equipment, fittings and components.

7.2.1.3 Various equipments, fittings, insulators and components shall be chosen in such a way by the Contractor so as to have easy installability and interchangeability.

7.2.1.4 The Contractor shall ensure selection of suitable material of collector strip of the pantograph duly interfacing with rolling stock contractor so as to minimize the wear on contact wire.

7.2.1.5 The Contractor shall ensure the electrical separation of the overhead contact lines of the adjacent tracks and, wherever possible, the use of separate poles for each track should be considered.

7.2.1.6 The overhead contact line should be such that the period of line closure for planned maintenance work or repair of OHE and track are kept as low as possible: it should not exceed 3 hours for normal maintenance.

7.2.1.7 The Contractor shall collect all the relevant regional and national directives and laws with regard to nature and bird protection and ensure installation of bird protection devices so as to reduce the potential hazards significantly.

7.2.2 Support Structures Note: MAHA-METRO intends to use tubular portal structures for mainline and conventional structures for depot OCS. Refer to Clause 7.5 for tubular structures.

7.2.2.1 Hot dip galvanized steel structures of overhead equipment support: the Contractor shall ensure zinc coatings of various type of mast, tubes and fittings including fabricated mast as per IS 209, ETI/OHE/13 latest version and shall not be less than 85 microns locally and 100 microns for area.

7.2.2.2 The Contractor shall adopt the following types of mast of various sizes of H type mast e: (a) Normal mast-Single , (b) Overlap anchor mast, (c) Overlap intermediate mast-holding two OHE, (d) Overlap central mast-holding two OHE, (e) Anticreep central mast, (f) Anticreep anchor mast, (g) Gantry, head span and portal mast.

7.2.2.3 The Contractor shall select proper type of portal and head span arrangement which shall be used in depot depending on number of tracks and the clear span of the portal.

7.2.2.4 The Contractor shall adopt H type drop arm only to get rid off the menace of bird nesting.

7.2.3 Contact wire

7.2.3.1 The contact wire shall be of 150 sqmm hard drawn grooved, flattened copper conductor, as per EN 50149 configuration similar to BF-150.


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7.2.3.2 The contact wire should be drawn out of continuous cast rods of minimum diameter of 21

mm. Contact wire shall conform to latest RDSO specification ETI/OHE/76.

7.2.3.3 The Contractor should ensure the following minimum values of the contact wire: (a) Linear weigh 1.340 kg/meter (b) Breaking load 5265 daN (c) Coefficient of linear expansion (α) 17 x 10-6 degree C (d) Elongation factor (λ) 91 x 10-6 (e) Conductivity 98% (f) Resistivity 1.777 x 10-8 ohmmeter

7.2.4 Messenger wire

7.2.4.1 The Messenger wire shall be of Cadmium copper, diameter 10.5 mm, consisting of 19 strands, each of 2.1 mm diameter. The nominal cross section of the Messenger wire is 65 sq. mm. The messenger wire shall conform to Indian Railways' RDSO specification No. ETI/OHE/50 (Latest Revision). The Contractor should ensure the following minimum values of the messenger wire: (a) Linear weight 0.5973 kg/meter (b) Breaking load 3844 daN (c) Coefficient of linear expansion (α) 17 x 10-6 degree C (d) Elongation factor (λ) 118 x 10-6 (e) Conductivity 81% (f) Resistivity 2.93 microhm.cm

7.2.5 Feeder wire (a) Raw material Aluminium / Steel (b) Cross Section (sqmm) 268.35 (c) Diameter(mm) 22.05 (d) Composition Aluminium (30 wires Ø 3.15)

Steel (7 wires Ø 3.15) (e) Weight per meter (kg) 1.107 (f) Breaking load (daN) 9600 (g) Dilatation (calf. α) 18 x 10-6 (h) Elongation (calf. λ) 132 x 10-6 (i) Conductivity (in % of copper) 61% (j) Resistivity (μΩ/sq,cm/cm) 2.6264

7.2.6 Overhead Protection Conductor

7.2.6.1 An ACSR conductor, consisting of 7 steel wires each of 2.5 mm diameter and 12 aluminium wires also of 2.5 mm diameter each, with a nominal cross section of 93.3 sq.mm. The overall diameter of the conductor is 12.5 mm. The ACSR conductor shall conform to Bureau of Indian Standard specification IS: 398 (Part II) Latest Revision. The Contractor should ensure the following minimum values of the aerial earth wire: (a) Linear weight: 0.437 kg/meter, (b) Breaking load: 4610 kgf (4520 daN), (c) Coefficient of linear expansion (α) 17 x 10-6 degree C, (d) Elongation factor (λ): 132 x 10-6 (e) Conductivity: 61%, (f) Resistivity: 2.8264 microhm.cm

7.2.7 Buried Earth Conductor (BEC)


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7.2.7.1 An ACSR Conductor, consisting of 7 steel wires each of 2.5 mm diameter and 12 aluminium wires also of 2.5 mm diameter each, with a nominal cross section of 93.3 sq.mm is used as BEC. The overall diameter of the conductor is 12.5 mm. The ACSR conductor shall generally confirm to Bureau of Indian Standard specification IS:398 (part-II) latest version or as per design.

7.2.8 Bridle Wire

7.2.8.1 Bridle wire shall be of cadmium copper, consisting of 37 strands each of 1.1 mm diameter with a nominal cross section of 35 sq. mm and overall diameter of 7.7 mm. The Bridle Wire shall conform to Indian Railway's RDSO specification ETI/OHE/50, Latest version, for cadmium copper conductor.

7.2.9 Droppers

7.2.9.1 Flexible droppers, made of bronze, consisting of 1 wire of 7 strands each of 0.65 mm diameter and 6 wires of 7 strands each of 0.54 mm diameter, with crimped endings with eye on either end and reinforced automatic clamps (copper alloy made) on messenger wire and contact wire, are used as in-span droppers. The nominal cross sectional area of the droppers is 12 sq.mm and the diameter is 5 mm. Alternate specifications of droppers with different cross-section (less or more) may be considered subject to compliance of the same with EN 50119 (or equivalent other standards), their provenness in other metro / railway systems and subject to the overall designs meeting all functional and specified requirements.

7.2.9.2 Flexible stainless steel wire, 5 mm diameter and 19.6 sq.mm cross section with crimped ending eyes and fixing parts on either end will be used as Register arm dropper.

7.2.10 Jumpers

7.2.10.1 The Contractor should adopt proper sizes of jumpers to be used in the OHE at various locations: (a) 26 sqmm 2 jumper of annealed copper, consisting of 19 strands, each strand

containing 7 wires each of 0.5 mm diameter, with a nominal Cross Section of 26 sq mm and diameter of 7.5mm. This is used as In-span jumper.

(b) 75 sqmm jumper of annealed copper, consisting of 37 strands each containing 7 wires

each of 0.6 mm diameter, with a nominal cross section of 75 sq mm and diameter of 12.70mm. This is used as Continuity Jumper.

(c) 164 sqmm jumper of annealed copper, consisting of 37 strands each strand

containing 7 wires each of 0.9 mm diameter, with a nominal cross section of 164 sq mm and diameter of 18.1 mm. This is used as Continuity Jumper and Feeding Jumper.

7.2.11 Cantilever Assemblies

Modular Cantilever System (MCS) as per RDSO Specification no. TI/SPC/OHE/MCS/0150 (08/2015) shall be provided for mainlines and test tracks in depot. Tubes of “Hot dip galvanized steel” will also be acceptable subject to the modular cantilever system otherwise meeting all specified requirements. For other tracks in depot, conventional proven cantilever arrangement may be provided.

7.2.12 Insulators

7.2.12.1 All OHE insulators shall be silicon composit insulators, conforming to IEC 61109, and the latest RDSO specification.


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7.2.12.2 Section Insulators are deployed when it is necessary to electrically separate one section of the OHE from another. The arrangement provides the necessary insulation between adjacent sections of the OHE.

7.2.12.3 The Contractor shall ensure to select the Section Insulators which should meet the following requirements: (a) Light weight (b) Better current collection at maximum commercial speed (c) Long Life permitting a large number of panto-passages per day (d) Less maintenance: the skids should not require frequent checks and adjustments

thereby permitting the Section Insulators to be left unattended for long periods.

7.2.12.4 Section insulators should be equipped of proper supporting arms allowing the smooth passage of pantograph by accurate tuning of the skids.

7.2.12.5 Such Section Insulators shall be used on Main lines.

7.2.12.6 In stabling and depot lines, Section Insulators of conventional design to Indian Railway's RDSO specifications ETI/OHE/27 Latest version shall be used.

7.2.13 Neutral Sections

7.2.13.1 All neutral section shall be automatically switched short neutral sections (if required as per design).

7.2.14 Automatic Tensioning Device

7.2.14.1 Deleted

7.2.14.2 For all the requirements on mainlines and depots, Spring Auto Tensioning Device as per RDSO Specification no. TI/SPC/OHE/SPRING ATD/0110 (03/2012) or better shall be provided.

7.2.14.3 The automatic tensioning devices shall be proven type and shall be provided with all accessories required for complete installation and technical documentation etc.

7.2.15 Earthing and Bonding

7.2.15.1 The Contractor shall design earthing and bonding as per the standards and submit for approval of Employer. The Contractor shall take adequate steps to the following aspects: (a) a safe low resistance path for the return current from the rail to earth and back to

traction substation. (b) avoidance of dangerously high 'touch potentials'.

7.2.15.2 The European Norms EN 50122-1 and 50122-3 and Bureau of Indian Standards specification IS:3043, shall be followed.

7.2.16 Conductors mechanical tensions

7.2.16.1 For main lines, the mechanical tension of the messenger wire and of the contact wire 150 sqmm (tensioned at 1200 daN each) are kept constant within the temperature range of +20°C to +60°C (by sun and electric heating effects) by means of tensioning device.

7.2.17 Depot

7.2.17.1 Depot: in entire depot except test track, unregulated tramway type OHE shall be used with 150 sqmm contact wire.


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7.2.17.2 There will be isolation of OHE in inspection lines, stabling lines and washing lines.

7.2.17.3 The isolation will be done with double pole isolators with earthing heel and the earthing heel on each isolator shall be earthed individually by providing earth pits.

7.2.17.4 The Contractor will provide, whenever it is necessary, interlocking system with depot equipment. It will be a mechanical key based system.

7.2.18 Rigid Overhead Collection System (ROCS)

7.2.18.1 The ROCS shall include 25kV ac overhead rigid conductor rail with contact wire, associated jumpers, support structures and ancillary equipment.

7.2.18.2 The ROCS includes an aluminium profile and the copper contact wire inserted inside the aluminium profile.

7.2.18.3 Technical data (a) The rigid catenary has a specific aluminium section shape (b) The aluminium cross-section shall be not less than 2200 mm2 (c) The current rating are 3500A steady and 5000A peak (d) The resistance of the aluminium profile should be less than 15 ∗ 10−6 Ohm/m. (e) The resistance of rigid catenary system with contact wire mounted should be less

than 14 ∗ 10−6 Ohm/m. (f) The horizontal inertia moment is 338.04 cm4.

7.2.18.4 Contact wire profile The contact wire shall be 150 sq mm of copper which shall be inserted into profile leaps without setting up mechanical tension.

7.2.18.5 The height of feeding aluminium profile with regard to running tread will not be constant, and in order to connect two profiles from different height, the contractor shall adopt maximum gradient 0.4%.

7.2.18.6 Gradient breaking shall not be allowed on overlap, tension section and junction areas between OCS and feeding aluminium profile.

7.2.18.7 Stagger

Stagger is measured at contact wire axis

The maximum value of stagger with regard to pantograph axis shall be 250mm

Stagger shall not be nil even on a short distance

7.2.18.8 Span Either in curve or in alignment the nominal length of a span shall be 8 to 15m depending on permitted sag. Higher spans (>11m) are preferred. Span length shall be adopted to site configuration and shall take into account other installations

7.2.18.9 The steel supporting structure and fittings to be hot dip galvanized as per IS 209 and Indian Railway RDSO specification ETI/OHE/13 latest version. Zinc coating shall not be less than 85 micron locally and 100 micron for area.

7.2.18.10 The distance between supports depends on the speed of rolling stock, the inertia of the system and the maximum sag allowed. The interval between supports may be set from 8 to 15m.


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7.2.18.11 Earth rod support: An earth rod support shall be installed approximately at every 20 metres which is fixed on the aluminium profile by means of a clip flange.

7.2.18.12 Two Teflon bearings are set between the aluminium profile and the clamp.

7.2.18.13 The clamp is fastened to the insulator with a (M16) screw having adequate strength.

7.2.18.14 In order to have self Alignment of clamp and profile for staggering or in curves, the clamp can easily turn around with the (M16) screw.

7.2.18.15 Rigid conductor rail The conductor rail is of aluminium alloy section with wearing copper contact wire. The copper contact wire is maintained on aluminium profile due to the elastic pinch of the profile. Because of the elastic pinch of the profile, no bolt is required to maintain contact wire on the aluminium profile.

7.2.18.16 Joints It is particularly important to have the two consecutive bars perfectly carried and aligned. The splice connecting the two consecutive bars shall be of self-centring type and ensures the bars are in the right position.Aluminium alloy of splice is strictly the same as the one used on the aluminium profile bar and the cross section of splice also the same as the cross section of the profile.The Contractor shall ensure minimum electrical resistance of the joint.

7.2.18.17 Expansion Joint Expansion joints shall be provided at suitable intervals but the maximum interval may be allowed up to 250m depending upon the site condition. Parallel contact wires shall be of adequate length to provide for suitable expansion joint assembly with provision for adequate number of flexible continuity jumpers. Separation distance between two OCS sections at expansion joint shall not be less than 200mm to ensure smooth passage of pantograph. For an expansion joint, the two consecutives over head catenary system sections have to be electrically connected. Electrical connection is made through aluminium power feed blocks. Power feed blocks are clamped at the top of the aluminium profile.

7.2.18.18 Air-gap section The structure of air-gap section shall be same as that of an expansion joint and at insulated air-gaps, separation distance between two OCS sections at the overlap shall not be less than 400mm, with two OCS sections aligned such that pantograph passes satisfactorily. No air-gap section shall be provided in the station platform area and these shall be provided beyond the station platform. Air-gap sections shall be provided at the crossovers also to segregate two sections and in case air-gaps are not found practicable, section insulators shall be used.

7.2.18.19 Insulators


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Insulators shall be of silicon composite type. Type of over head system support insulator to be provided shall be a proven one. The electrical and mechanical properties of support insulator for the 25 kV ac rigid conductors shall be in accordance with the recommendations of IEC 383 / 1109. The minimum creepage distance of the insulator shall be 1100mm, wet power frequency withstand voltage shall be 132kV and dry lightning impulse withstand voltage shall be 250 kV in accordance with the recommendations of IEC 60913. Supporting insulator fixture shall permit free sliding of rigid conductor to allow for expansion on account of temperature changes.

7.2.18.20 Midpoint anchoring arrangement The middle point between two expansion joints is fixed to prevent from unidirectional creeping of rigid conductor rail. This is carried with two anchor suspensions. The Contractor should ensure the arrangement of midpoint anchoring in such a way that there is flexibility of contact wire height adjustment as well as shifting of profile position according to track cant without displacement of rigid conductor rail. Anchor suspensions are made of copper-aluminium alloy.

7.2.18.21 Electrolytic action between copper and aluminium To prevent from galvanic corrosion on the aluminium surface due to the presence of copper, special grease shall be used. The grease contains also particles which then prevent aluminium oxide formation. Holes are drilled at the down of the profile, near the contact wire to evacuate water resulting from condensation. These two precautions (grease and holes) avoid the presence of electrolyte.

7.2.18.22 Transition arrangement The transition from rigid to flexible catenary and vice versa is made through a special part called transition element and Its purpose is to slowly increase the inertia of over head catenary system from flexible to rigid. The flexibility at the end of the transition element allows a smooth passage of the pantograph and avoids hard points. At the end of the element, the elastic pinch is not sufficient, that is why it is necessary to close the sleeves of the profiles with bolts. Because the top of the profile is cut, a protective sleeve is set over the transition element to avoid water inside the profile and the total length of the transition element is 5m. The transition element can be followed by a 4m ramp to make a sectioning between rigid and flexible.

7.2.18.23 Special arrangement for tunnel equipments


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According to standards, rules, and UIC 564-2 extended application to ROCS, all catenary components composed of composite materials should have an improved behaviour to fire, in order to decrease fumes opacity and gas emission in case of burning.

7.3 CABLING

7.3.1 General

7.3.1.1 All cables including (25 kV and LV cables) required for works, except where otherwise stated specifically in this Bid Documents, shall be supplied and installed by the Contractor.

7.3.1.2 All cables for elevated and at-grade sections shall be FRLS (Fire Retardant Low Smoke) and FRLSZH (Fire Retardant Low Smoke Zero Halogen), anti-rodent and anti-termite Type. All power and control cables shall be armored.

7.3.2 25 kV traction cables

7.3.2.1 25 kV Traction cables are mainly required for the following connections: (e) 25 kV cable feeder from outgoing switchgear at TSSs to OHE pole-mounted isolator

on viaduct, (f) 25 kV cable from outgoing switchgear at SSPs / SSs / SPs to the feeding gantries

located at mainlines and Depots.

7.3.2.2 General Requirements The Contractor shall calculate and shall justify the section of these cables as regard to:

the route installation,

the thermal conditions in service,

the climatic conditions,

the energy and currents flowing through this cables, taking into account the worst electrical conditions

7.3.2.3 Dimensional and Electrical Cable Characteristics

25 kV cable shall be dry-insulated, radial-field cable, based on proven technology. They will be insulated with chemically cross-linked polyethylene, with semi-conducting screen over a copper conducting core, and insulating envelope and polyvinyl chloride protective sheath.

operating voltage: 27.5 kV,

specified voltage: 26/45 kV(52 kV) (according to IEC 840),

Conductors : copper with 240 sq mm (number of runs as per design)

7.3.2.4 Characteristics

7.3.2.4.1 Conducting Core The conducting core is made of bare annealed copper, according to class 2 per publication IEC 228.

7.3.2.4.2 Core Screen The screen placed over the core consists of extruded covering of semi-conducting material.

7.3.2.4.3 Insulating Envelope


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The insulating envelope consists of extruded solid dielectric, made of chemically cross-linked polyethylene. Its nominal thickness and tolerances comply with the requirements set forth in standard IEC 502-1.

7.3.2.4.4 Insulating Envelope Screen The screen placed over the insulating envelope consists of a non-metallic semi-conducting part, associated to a metallic part. The non-metallic part, consisting of a semi-conducting material, will be easily separable from the insulant in order to facilitate cleaning of the latter. This semi-conducting material will have to constitute a mat which protect the insulant from expansion strains. The metallic part applied over the semi-conducting part will consist of stranded wire with copper tape

7.3.2.4.5 Outer Protective Sheath The anti-corrosion outer protective sheath, applied directly over the metallic screen, consist of a heat-setting mix of polyvinyl chloride, whose grade is compatible with the operating temperature of the cables; it must ensure protection against corrosion. The nominal thickness of this sheath will be determined according to the requirements set forth in standard IEC 502-1 The protective sheath will carry the indications listed below, in letters and digits at least 6 mm high:

designation of ownership,

nature and cross-sectional area of conductors,

specified cable voltage,

phase numbering,

manufacturer’s name.

7.3.2.5 Connecting Junctions Connecting junctions shall reconstitute perfectly all elements of the 25kV cables, so as to obtain electrical and mechanical characteristics at least equal to those of the cable. The Contractor will submit to the client, for approval, a detailed description of the technique foreseen for execution of connections in MV lines. However, maintenance and repair being able to be carried out only during a short period of time, at night, due consideration shall be given to connection processes having the following characteristics, quality being otherwise equal:

quickness of execution,

possibility of replacement without having to disturb the cable,

small bulk. All 25 kV Straight through joints and terminations shall be heat shrinkable ‘Raychem Type’ or equivalent. Alternately proven accessories of other technology with equivalent performance may also be proposed.

7.3.2.6 Execution Rules The entire supply will be executed according to all Rules of the Art pertaining to professional-grade equipment, and in compliance with the technical specifications and


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specifications of the International Electrotechnical Commission relative to power supply cables (IEC 840). The Employer will deliver the supply, upon request, only after execution of in-plant inspection operations and satisfactory testing according to the technical requirements imposed. The cables shall pass all the tests stipulated in the IEC rules in force on the date of the order. The sleeves and the insulating materials used shall meet the guarantee requirements imposed. The equipment shall be capable of withstanding intensive use without alteration, and of performing its duty even after extended idle period.

7.3.2.7 Atmospheric and Climatic Conditions The entire equipment will be designed for operation in hot weather, according to the climatic conditions defined in General Specifications. The equipment will be sturdy and properly treated against corrosion. This protection shall be suited to the various environmental conditions encountered in the various parts of the network. It must be noted that environmental conditions will be very severe during construction; these conditions shall not be the cause of any alteration of equipment or material whether already installed or simply stored.

7.3.3 25kV Cables for Underground Section – Additional Requirements

7.3.3.1 Cables

7.3.3.1.1 Cables to be used for U/G section shall be XLPE, FRLS, zero halogen type.

7.3.3.1.2 The permitted voltage drop at any point shall not exceed 5% under any condition.

Current rating shall be determined taking into consideration the following installation methods as applicable:

In the tunnels

In cast –in pipes

Trenches

Ducts

7.3.3.2 Cable Construction

7.3.3.2.1 The conductor shall be annealed; circular stranded, of compact design, plain copper complying with IEC 228. The DC resistance per km of each conductor at 20 degree C shall not exceed the appropriate maximum values given in IEC 228. Conductor screen shall be of non-metallic material and consist of a layer of extruded thermoses semi-conductive compound of suitable thickness and volume resistively. It shall be easily removable from conductor during jointing.

7.3.3.2.2 Insulation: The insulation shall be XLPE complying with IEC 502 and IEC 811. The

insulation shall have a high degree of cross-linking, free from contaminants and air voids, heat resistant and shall be applied by the extrusion process.

7.3.3.2.3 The XLPE insulation shall be suitable for use on power cable in wet and dry locations at

conductor temperature not exceeding 90 degree C for normal operation and 130 degree C for emergency overload condition.


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7.3.3.2.4 The nominal thickness of the XLPE insulation shall be an extruded thermoset semi- conductive material. The screen shall be tightly fitted to the insulation to exclude all air voids and yet be easily stripped on site.

7.3.3.3 Shield

7.3.3.3.1 The metallic insulation screen of each core shall be annealed, uncoated copper tapes

applied over the non-metallic semi-conductive insulation screen on each core. The metallic insulation screens of the cores shall be in contact with each other, such that the screen is electrically continuous throughout each cable length. The metallic insulation screen shall be applied in such manner that electrical continuity will not be distorted or disrupted when subject to bending during normal installation.

7.3.3.3.2 The fillers shall be non-hygroscopic material and compatible with the other materials of

the cable and capable of operating continuously the maximum operating temperature of the cable without adverse effect. The fillers shall be applied in such a manner that it can be easily removed without damaging the cable.

7.3.3.3.3 A suitable binder tape of fire retardant, LSOH material shall be applied over the laid up

cores to form a compact circular cable.

7.3.3.3.4 The laid up cores shall be sheathed with an extruded layer of inner sheath which shall be compatible with the operating temperature of the cable. The thickness the sheath shall comply with the requirements of IEC 502/ IS 7098.

7.3.3.4 Metallic Sheath

7.3.3.4.1 A metallic sheath shall be provided over the core of the cable. The material of the

sheath shall be aluminium in combination with copper armour wire, with materials of the highest quality.

7.3.3.4.2 The sheath shall be impervious to moisture, reasonably close fittings and free from

defects and impurities such as oxides which could give rise to failure under working conditions.

7.3.3.4.3 The metallic sheath or the combination of metallic sheath and copper wire armour shall

be capable of carrying the rated fault current. The Contractor shall submit his proposed method complete with calculations for metallic sheath earthing for the acceptance of the Employer’s Representative.

7.3.3.5 Outer Sheath

7.3.3.5.1 The outer sheath shall consist of a layer of extruded thermosetting compound that also

meets the under mentioned requirement .Sheath shall be suitable for exposure to tunnel environment, and for the operating temperature of the cable. The sheath shall also incorporate a mixture of approved anti-termite compound. The mixture in the sheath shall not be soluble in water.

7.3.3.5.2 London Transport Executive Three Meter Cube Smoke Emission Test, using optical

measuring instruments. The maximum value of absorbance AO (ON), AO (OFF) shall be 0.8 & 1.2 respectively.

7.3.3.5.3 The US National Bureau of Standard Smoke Chamber Test, used to evaluate plaque

samples of materials of constant thickness. (NFPA-258 Smoke Generation of Solid Materials 1982). The maximum specific optical density shall be 170 under the non- piloted condition.

7.3.3.5.4 The flame propagating criteria of US IEEE Standard 383, with a minimum test short

circuit time of five minutes, in the IEEE Standard 383 test.


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7.3.3.5.5 IEC 332 Parts 1 and 3, Category B, tests on single and bunched cables under fire conditions.

7.3.3.5.6 Limiting Oxygen Index of at least 30, to ASTM D-2863.

7.3.3.5.7 A temperature index (TI) of 260 degree C to ASTM D-2863.

7.3.3.5.8 All insulation is to be moisture and heat resistant, with temperature ratings appropriate

to the application conditions, and in no case lower than 90 degree C.

7.3.3.5.9 When a sample of the cable is subjected to a combustion test for the determination of the amount of halogen acid gases (other than hydrofluoric acid) as set out in IEC 754 – Part 1 the halogen acid evolved shall not exceed a maximum of 0.5%.

7.4 RETRACTABLE CATENARY SYSTEM

Not Used

7.5 TUBULAR STEEL STRUCTURES FOR SUPPORTING OCS

7.5.1 Introduction This specification covers the technical and associated requirements for multi sided / circular steel structures for carrying the OCS. The structures shall be supplied complete with structural steel works, bolts, nuts, washers and miscellaneous fittings. It is not the Employer’s intent to outline all the technical requirements or to set forth those requirements adequately covered by applicable codes and standards. Contractor shall furnish high quality work and materials meeting the requirements of this specification and industry standards. The Contractor shall bear full responsibility that the steel structures are designed and fabricated in accordance with all codes, standards and applicable government regulations and perform under the condition and to the standards specified herein. No deviation shall be made from this specification and standards unless waived or modified in writing by Employer. Contractor shall obtain from its sub-vendors a statement as to compliance with this specification without exception and/or if there are any exceptions, these shall be described in detail and included in Contractor's proposal. Contractor shall add a statement that no other exceptions are taken to this specification. Contractor shall furnish design calculation of each type of structure and a complete set of reproducible detail drawings to Employer.

7.5.1.1 Works to be provided by the Contractor Contractor shall provide the materials, work and services explained in this specification.

7.5.1.2 Contractor’s Agreement with Structure Manufacturers Contractor shall have the technical and manufacturing support of a reputed international manufacturer of utility poles. The manufacturer shall make a written agreement with the Contractor for providing design and manufacturing support for the project. The manufacturer shall also be able to undertake the assembly and erection of structures at site or provide installation supervision at site. Copy of the agreement shall be submitted. In case the structure manufacturer with whom the contractor makes agreement for design and supply is a multinational company, they should have a registered subsidiary company in India for their Indian operations. They should also have production facilities (including


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galvanization facility) in India for manufacturing for this requirement. Proof of this shall be submitted. The Indian subsidiary should also have facility for providing after sale supports to the contractor / Employer in India.

7.5.1.3 Tubular Structure Manufacturer’s Experience The manufacturer with whom the Contractor makes an agreement shall have a minimum international experience of 5 years in design, manufacturing and supply of utility structures. The manufacturer shall have to submit proof of his experience in design, manufacture and supply of utility poles in terms of purchase orders or completion certificates. Such certificates shall be submitted along with the agreement with the Contractor also. The manufacturer should also have conducted 4 full-scale testing of poles in NABL accredited independent lab in past 4 years. Copies of previous test reports for such poles shall be submitted.

7.5.2 Codes and Standards The specified material and services shall be furnished in accordance with, but not limited to, the relevant Indian/international standards, including all addenda, in effect, unless otherwise stated in this specification: In case Indian standards are not available for any of the items, relevant ASTM codes or equivalent other international codes as mentioned shall be adhered to manufacturing and installation.

ASTM – American Society for Testing and Materials

A 36 / 36 M Standard Specification for Structural Steel, Book 01.04

A 123 Specification for Zinc (Hot-Dip Galvanized) Coatings on iron and Steel Products, Book 01.06, 15.08

A 153 Specification for Zinc Coating (Hot Dip) on Iron and Steel Hardware, Book 01.06.15.08

A 572/572M Specification for High-Strength Low Alloy Columbium Vanadium Steels of Structural Quality

A 780 Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

AWS – American Welding Society

D1.1-92 Structural Welding Code – Steel. Specification for Carbon Steel Covered Arc-Welding Electrodes

A5.17-89 Specification for Carbon Steel Electrodes and Fluxes for Submerged Arc-Welding

ASCE – American Society of Civil Engineers

ASCE SEI 48-05 Design of Steel Transmission Pole Structures

ISO – International Standards Organization

ISO9001 Quality System Model for Quality Assurance in Design / Development, Manufacture and Testing

ISO 9002 Quality System Model for Quality Assurance in Production, I installation and Servicing

Indian Standards

IS 5613 for determining the clearance diagrams for the pole

IS 802 for sag tension and loading calculation


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IS 4759: 1984 Hot dip zinc coatings on structural steel and other allied products (second revision)

ETI/OHE/13 RDSO standard for hot dip galvanization of structures

Full scale testing

IEC 60652 – 2002 Loading tests on overhead line structures

These codes and standards set forth the minimum requirements which may be exceeded by Contractor if, in Contractor's judgment and with Employer’s acceptance, superior or more economical designs and materials are available for successful and continuous operation of Contractor's equipment as required by this specification.

7.5.3 Technical Requirements

7.5.3.1 Design

7.5.3.1.1 General AII designs are to be made in accordance with the information provided herein and elsewhere in the bidding documents. AII outline dimensions are fixed but where no dimensions are given, the framing, may be modified to suit the Contractor's design, subject to compliance with all the requirements of the specification. The steel structures design shall be the responsibility of the manufacturer. It shall be designed for the configuration, loadings and limitations provided elsewhere in the bidding documents. The Contractor, at Employer’s request, shall explain and provide all the necessary information pertaining to the design of any or all elements of the structure. Structures shall be designed so that member unit stress does not exceed the yield point stress of the material. The ratio of major axis of tubular diameter to wall thickness shall be such that local buckling does not govern member design. Structure deflection under maximum load condition including over load factors shall be no more than 1.5 % of the structure height or 80mm (at the tip of the structure for permanent loads and at the contact wire level for wind loads) whichever is less. Cross section of the pole shall be 12-sided polygons or round. Cross arm member, if required shall be of appropriate cross section and shall conform to Employer’s general arrangement drawings. The strength of the attachment of cross arms to the columns shall be sufficient to develop the full capability of the cross arm. Members requiring more than one length of tubular section shall be constructed by telescoping the sections together with sufficient overlap to develop the full strength of the member. Minimum overlap shall be 1.5 times the maximum inside diameter of outer section at the telescopic joint. Fittings, accessories, attachment plates etc. and lighting brackets, and hand line attachment shall be welded to the structure.

7.5.3.1.2 Structural Analysis Elastic methods of analysis shall be used. Stability shall be provided for the structure as a whole and for each structural element. The load effects resulting from the deflected shape of the structure and individual elements shall be considered during design. The analysis shall include all structural members (including inter pole ties, bracings and guys, if required) in their actual, manufactured geometry and sizes.


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When values for the following are specified, the analysis shall include: differences in support elevation, support movement and erection tolerances. The structural design shall be done using proper internationally accepted design software.

7.5.3.1.3 Clearance Minimum clearances between live parts of OCS system and steel structures shall be maintained as per the standards/codes/rules.

7.5.3.1.4 Design Loads The steel structures shall be designed to withstand the loading conditions to be encountered e.g. multiple cantilevers on one structure, radial loads due to curve / stagger, dead load of system etc. Methodology as provided in relevant literature of ACTM/RDSO to be followed.

7.5.3.1.5 Allowable Stresses The allowable stresses for tubular members, guys (if applicable) and connection bolts shall comply with the requirements of ASCE SEI 48-05, Design of Steel Transmission Pole Structures and other relevant standards.

7.5.3.2 Materials

7.5.3.2.1 General AII materials shall comply with the requirements of an ASTM specification unless otherwise specified. Material to be welded shall comply with the requirements of ANSI/AWS D1.1.

7.5.3.2.2 Structural Plates Plate and "product of a coil" that is used to produce load carrying components shall be considered structural plate. Material used for grounding plates, identification plates, pole caps, disposable cage plates and similar components does not need to be classified as structural plates. Structural plate less than or equal to 31.75 mm (1.25 in.) in thickness shall conform to ASTM A36, ASTM A572, ASTM A 633 or ASTM A871. Yield strength of Plates used for manufacturing the shafts shall be conforming to Gr 65 of ASTM A572. The silicon content of plates used for the pole shaft shall be limited to less than 0.06 % to have a better quality of Galvanizing.

7.5.3.2.3 Bolts and Nuts Material for anchor bolts shall conform to grade 6.8 or 8.8 as per the requirement. Exposed portion of the Anchor bolts shall be galvanized in accordance with ASTM A 153. Material for headed bolts shall be of grade 6.8 or 8.8 and shall be galvanized in accordance with ASTM A 153. When inch size bolts are used, they shall conform to: ASTM A307, ASTM A325, ASTM A490 or ASTM A449 when bolt diameter exceeds 38.1 mm (1.5 in.) Threaded rod shall be of grade 6.8 or 8.8. When inch size threaded rods are used, they shall conform to ASTM A36, ASTM A354, ASTM A449, ASTM A588 or ASTM A687.

7.5.3.2.4 Weld Material


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The material used for making welds shall be compatible with the parent material, as defined by ANSI/AWS D1.1-92 and shall meet the impact requirements as specified for the lowest toughness requirements of the plates being joined.

7.5.3.3 Detailing

7.5.3.3.1 Typical Details Telescoping splices joining sections (slip joints) shall be designed to assure a minimum overlap of 1.5 times the largest inside diameter of the outer section. Anchor bolts for the pole shall be provided with top and bottom templates to form a cage at job site. This is to get a proper alignment of bolts during casting of foundation.

7.5.3.3.2 Circumferential welds Shaft-to-shaft, pole shaft-to-base plate, and pole shaft-to-flange shall be full penetration welds. Arm shaft-to-arm bracket shall be partial penetration groove weld with fillet overlay, sized to develop the full strength of the shaft. Other accessories (Lugs and plates for grounding, jacking, climbing and identification) shall be fillet and/or groove welds sized to develop the loading requirements of the attachment.

7.5.3.3.3 Longitudinal Welds Longitudinal welds in outer section of slip joints and within 76.2 mm (3") of a full penetration weld shall be full penetration. Longitudinal welds shall be a minimum of 60% penetration in other locations.

7.5.3.3.4 Plate Bends The minimum inside radius of plate bends shall be such that cracking does not occur. Care must be taken to prevent the steel from cracking especially at the free ends of the bend either during the bending operation or subsequently due to residual stresses.

7.5.3.4 Fabrication

7.5.3.4.1 General The manufacturer shall prepare a detailed drawing of the pole and submit it to Employer for approval. Fabrication shall be performed in strict compliance with Employer’s approved detail drawings. Material substitution or deviations from the final approved drawings shall not be made without written approval from Employer. The manufacturer shall accurately identify all material to assure proper usage.

7.5.3.4.2 Structure Shaft The structure shaft shall present the most pleasing appearance possible consistent with the strength requirements in the specification and drawings. No multi-ply steel plates will be allowed. For the structure fabrication shaft shall be made with number of sections specified.

7.5.3.4.3 Structure Slip Joint Structure section shall be made with telescopic slip joints for easy assembly either in air or on the ground at the construction site. Overlapping shall not be less than 1.5 times the largest inside diameter of the female section.


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At site, slip joints shall be done using proper hydraulic jacking devises only. Manual chain pulley arrangements shall not be allowed to make slip joints. The taper (if allowed) of each section at a slip joint should match the taper of the adjacent section to provide proper splice tolerances. No circumferential weld within a shaft section shall be permitted. Other type of connection will not be permitted.

7.5.3.4.4 Grounding Provision Grounding clamps or nuts shall be provided near the top and base of each pole. The wire lug shall be welded to the exterior of tubular column sections near the top and the base for grounding, in addition to any other ground wire requirements shown on Employer’s general arrangement drawing

7.5.3.5 Material Preparation Edges shall be in accordance with ANSI/AWS D1.1. Burrs or sharp notches that may be detrimental to the structure or that pose a safety hazard shall be removed. Re-entry cuts shall be rounded. Care shall be taken to prevent separation of the outer surface and reduction of the cross sectional properties below those required by design. If separation occurs during bending, it shall be repaired in accordance with ANSI/ AWS D1.1. MiII scale shall not be considered as the surface. When hot bending is required, heating shall be done evenly over the entire bend area and shall be of sufficient temperature to minimize separation and necking down of the cross section. The temperature used in hot bending shall be such that the physical properties of the steel are not diminished.

7.5.3.6 Welding Unless otherwise specified herein, or note on drawings, welding shall conform to the AISC Specification and weld procedure qualifications shall be in accordance with AWS D1.1, Section 5 "Qualifications". A written welding procedure specification as shown in Appendix E of AWS D1.1 (Forms E-1, E-2 or E-3 as applicable) shall be prepared for each procedure and submitted for review and acceptance by Employer when requested. Weld details on Contractor's shop detail drawings shall include identification of weld and method to be used for making the weld in accordance with AWS D1.1, Section 2, "Design of Welded Connections", and Section 4, Technique. Preheat and inter-pass temperature of AWS D1.1 shall be followed. Welding shall be done by the shield metal-arc, gas shielded flux core, gas shield metal arc or submerged-arc processes. Welding electrodes shall be AWS A5.1, low hydrogen classification E70XX- EXXX, for submerged arc welding, unless noted otherwise. Where steel other than ASTM is specified electrode selection will be subject to acceptance by Employer. The storage of welding consumables (welding wire, electrodes, fluxes and gases) shall be in accordance with AWS D1.1 and the welding consumables manufacturer's recommendations. Care shall be taken in assembling and fitting and welding shall be controlled to minimize shrinkage stresses and distortion. AII finished work shall be of good quality and have a neat appearance without warpage. Caution shall be exercised to obtain full penetration welds as specified. When inspection of a weld zone is called for on Employer’s design drawings, procedures shall be in accordance with non-destructive testing procedures of AWS D1.1 and the following additional requirements:


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Circumferential and longitudinal welds within the slip joint area of tubular sections shall be shear wave ultrasonically inspected in accordance with AWS D1.1. Longitudinal welds in tubular sections, where visual inspection is not adequate, shall be magnetic particle or dye penetrate tested. Attachment welds shall be examined by visual inspection. Magnetic particle or dye penetrate testing in accordance with AWS D1.1 shall be used at questionable area by visual inspection. Contractor shall furnish a shop test report indicating complete test results of all non- destructive testing and inspection conducted. Welding of pole sections shall be done using a SAW type welding and pole closing machine. The pole-closing machine shall have the required dimensions so that pole sections shall move through it during the welding process. The machine shall have the required jigs from all directions to hold pole section intact while welding to get proper shape and welding quality. Open arm type welding machines without automatic jigs for holding the pole during welding shall not be used for welding of pole-sections, as they will not provide the required strength and shape.

7.5.3.7 Surface Preparation and Coating

7.5.3.7.1 Galvanizing All structural steel shall be hot-dip galvanized after fabrication in accordance with ASTM A 123. Surface preparation by means of seven-tank process shall be during galvanizing. Exposed welds shall be mechanically cleaned. Fabrication and preparation of material for galvanizing shall conform to the requirements of ASTM A143. When specified in the drawings or specification, embrittlement test of designated galvanized material shall be performed in accordance with ASTM A 143. All fabrication work on pole sections (including welding of base section with base plate) shall be complete in all respects before hot dip galvanizing. No cutting grinding or welding shall be allowed on any of the pole sections after hot dipped galvanizing. The manufacturer should operate their own galvanizing factory with a minimum capacity of 16 Mtr in terms of zinc bath length and 2.5 Mtr in terms of width & 3.3 Mtr in depth, so that pole sections with such outside dimension can be galvanized in a single dip operation. Hot dipping shall be done with single dipping method. Cold galvanizing methods shall not be applied on any of the pole sections while manufacturing / galvanizing. Pole manufacturer shall declare the size of their galvanizing bath (LxWxD) to show their capability to do proper galvanizing. Lead content in the zinc solution should not be more than 0.001%. The manufacturer is required to indicate the size of galvanizing baths as well as proof of ownership and test certificate from Government Accredit agency as proof of low lead zinc bath. Bolts, nuts and washers shall be galvanized in accordance with ASTM A 153. Bolts and nuts shall be assembled after galvanizing and shall fit with finger pressure only and nuts shall be interchangeable on any bolts without shake. Wrench tightness or spinning fit shall be caused for rejection. Only the exposed threaded portion shall be galvanized in case of foundation Anchor bolts. Repair of damaged hot dip galvanized surfaces during shipping or handling shall be in accordance with ASTM A780.


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Heavy runs or lumps of excess zinc will not be acceptable in any area where they will interfere with bolt hole alignment (such as the "drip end" of punched angle braces, etc.), with matching flat surfaces which are to be bolted together, or are of such size and location that normal handling or erection may cause them to be dislodged. Sharp, pointed, "stickers" of zinc, which could cause injuries in handling, shall be removed. Straightening of steel after galvanizing shall be accomplished without the use of heat. Steel so straightened shall be inspected to assure no deformation or cracking of galvanizing layer. AII materials shall be cleaned or washed after galvanizing to remove traces of flux, flux inclusions, preflux slats, acid ash, dross or other extraneous materials. The presence of wet storage stain (White Rust) shall be caused for rejection. Preparation for Shipping and Storage Each shipment shall include a detailed packing list identifying all items by part number, including hardware. Special care shall be exercised in the handling, packaging and shipping of the materials to prevent denting, bending, or any other damage of the sections, cross arms and anchor bolt cages. Suitable cushioning, protective padding, dun age or non-metallic spacers shall be used to prevent vangs and flanges welded to the tubular sections from damaging other tubular parts and to prevent damage and shifting during transit. Small parts and fasteners shall be carefully boxed, crated, bagged or otherwise containerized and protected for shipment. Small pieces shall be bundled, with all the pieces in any bundle having the same mark. AII small pieces such as bolts, ground wire and insulator connections shall be packed in boxes. Bolts of different size or length shall be wrapped in separate sacks before boxing. Description, quantity and marks or description of contents shall be shown on the outside. Shipping shall be as specified and shall be in complete structure lots. AII identifications shown on bundles, boxes or other containers shall be included on Contractor's shipping and packaging lists. All Materials shall be arranged to allow safe unloading at site. Galvanized steel will be stored in the field pending erection. Contractor shall provide storage and handling instructions to minimize damage to galvanized surfaces.

7.5.3.8 Marking AII parts of structures shall be appropriately marked or numbered. AII markings shall be indelible and clearly visible after galvanizing. Each pole shaft shall have a welded identification tag at 1.5m above ground level, which includes customer name, structure type, manufacturer name, year and month of fabrication. Each shaft section, cross arm and other separate pieces of structure shall have a welded identification tag marked with part number and serial number. All letters and numbers on identification tags shall have a minimum height of 15mmand be legible after galvanizing.

7.5.4 Installation Assembly and installation of structure at site shall be conducted by the manufacturer directly. Experienced engineers of the manufacturer shall be available at site while conducting these activities. Manufacturer shall submit the installation procedure to the Employer before starting the installation work. Assembly of pole sections at site shall be conducted using hydraulic jacking devices and/or suitable chain pulley blocks to achieve proper jacking force.


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7.5.5 Tests

7.5.5.1 General

AII materials shall comply with test criteria, and Employer’s acceptance of the steel structure and its components shall not relieve the Contractor of his responsibility for meeting all the requirements of this specification. The steel structures and its components shall be given the manufacturer's routine shop tests and quality conformance tests. When specified, these tests shall be witnessed by Employer or its representative. Tests results shall be submitted to Employer. No steel structure shall be shipped until released for shipment by Employer.

7.5.5.2 Material Contractor shall furnish four (4) copies of certified mill test reports covering chemical and mechanical properties of the structural steel. Stock material may be used with Employer’s concurrence where stock can be satisfactorily identified with the specified ASTM specification. Contractor shall furnish all shop test reports for Employer’s review and records.

7.5.5.3 Quality Conformance Inspection This is intended to eliminate defective materials and components of the steel structures. Each component shall be inspected for conformance to the approved drawings. This inspection shall include, but not limited to:

a) Ultrasonic inspection of base plate more than 50mm thick prior to welding for

laminations. b) Visual inspection of dimensions to assure that tolerances are met. c) Visual inspection of cut edges to ANSI/AWS D.1.1 criteria. d) Visual inspection of bent surfaces for surface separations (supplemented by magnetic

particle in questionable areas); e) Visual inspection of bolt holes to assure that they are cylindrical, perpendicular, free of burrs and without torn or ragged edges;

f) Visual inspection of all welds to ANSIIAWS D1.1 Section 8 criteria; g) Ultrasonic inspection of all full penetration welds h) Ultrasonic inspection of shaft to base plate weld after galvanizing for base plate

thicker than 50mm (maybe waived if routine audits show no history of defects); i) Visual inspection of all structural partial penetration or fillet welds, in questionable

area use magnetic particle inspection according to ANSI/AWS D1.1 Section 8 criteria; j) Visual inspection of finish; k) Magnetic thickness measurements of finish coatings.

7.5.5.4 Full Scale Tests If required by Employer, the Contractor / pole manufacturer shall be in a position to conduct type testing of the poles to ensure the satisfactory design and manufacture of steel poles and its components in accordance with the applicable standards mentioned herein in the specification. If the poles are being manufactured by using established internationally accepted software, all pole types need not be tested in full-scale conditions. In any case, at least one pole type shall be full scale tested. While selecting the sample for testing, pole type having maximum quantity shall be selected for testing. Full scale testing shall be conducted for 6 load cases up to ultimate (100 %) loading conditions as per IEC 60652-2002. Poles successfully tested up to 100 % load can be


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used in the line. Testing of poles shall be conducted in black conditions. Tested poles shall be fully hot dip galvanized in single dipping method before being supplied to the site. Full scale testing shall be conducted at a third party testing center only. Contractor's / manufacturer's own test center shall not be used for testing of poles. Selected test center must have previous experience of testing utility poles. The pole shall be erected on a rigid foundation and the vertical axis though the center of gravity shall not be out of plumb by more than two tenths percent (0.2%) of the height at any level. The pole structure shall sustain the load including overloads. These loads shall be applied in increments and shall be held constant for a period of five (5) minutes before increasing or removing the loads. The Contractor shall submit for Employer’s approval his proposed method and facilities of applying and measuring the loads on the structure. The load measuring devices with appropriate numbering shall be suitably calibrated prior to and following the test in accordance with the manufacturer's recommendation at the presence of Employer’s Structural Design Engineer / Representative(s). Structure deflections under load shall be measured by suitable procedure at points designated. Deflection readings shall be recorded for the "before- load" and "Load-off" conditions. The Contractor shall submit, fifteen (15) days prior to the performance of the tests, his testing programs to Employer for review and approval. These shall include test procedures, diagrams or test arrangements showing the points of location and magnitude of the loads to be applied, the designated points for deflection measurements, etc. The pole to be tested shall be inspected in the presence of Employer’s Structural Design Engineer who shall conduct a visual check and evaluate all parts of the structure for sign of failure following the completion of each test. After completion of test, the test structure can be considered failure if the structure experienced any of the following:

a) After the loads have been removed, the pole structure does not return to its original

position within reasonable tolerance; b) Failure (i.e. bending, yielding, breaking, etc.) of the material or weld is detected; and c) Test structure does not pass all physical and dimensional checks as required in the test specified in this specification.

Such a failure shall be corrected and tested at the Contractor's expense. In case of no failure, tested poles can be used for installation in the line.

7.5.5.4.1 Test Reports The Contractor shall furnish two (2) copies of a test report in English Language and that shall include:

a) The designation and description of the pole tested; b) The name of "Employer"; c) The name of the person or organization (responsible engineer) that specified the

loading, electrical clearances, technical requirements and general arrangement of the prototype;

d) The name of the Engineer from Employer who attended the test. e) The name of the Manufacturer. f) A brief description and the location of the test facilities; g) The names and affiliations of the test witnesses;


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h) The dates of each test load case; i) Design and detail drawings of the pole, including any changes made during the

testing program; j) A rigging diagram with details of the points of attachment to the pole; k) Calibration records of the load-measuring devices; l) A loading diagram for each load case tested; m) A tabulation of deflections for each load case tested; n) In case of failure; Photographs of failure: Loads at the time of failure; a brief

description of the failure; The remedial action taken; The dimension of the failed members; and Test coupon reports of failed members;

o) Photographs of the overall testing arrangement and rigging; p) Air temperature, wind speed and direction, any precipitation and any other pertinent meteorological data;

q) MiII test reports of poles used in the test report; r) Test result of the test coupons taken following the completion of test.

7.5.6 Data And Documentation Requirements

7.5.6.1 General Contractor shall furnish data and information on predicted performance, interface requirements and construction features of all steel structures supplied by the Contractor. The accuracy of such information and its compatibility with overall performance requirements specified by Employer are the sole responsibility of the Contractor. AII information submitted as part of the Proposal Data will become part of contract data for successful bidder. Any deviation from such data requires Employer’s approval for such a deviation to be acceptable to Employer.

7.5.6.2 Data to be submitted along with the Proposal for vendor approval

a) Description and outline drawings of proposed poles including configuration, material detail, shapes, sizes and representative connection details.

b) Description of design calculations to be performed and buckling criteria to be used; c) Reference list of previous experience of the pole manufacturer d) Proof of previous experience of the pole manufacturer for manufacturing of poles e) Certified sample mill test reports f) Proposed time bar schedule to meet delivery, installation / erection date(s) of the steel

poles and its components; g) Copy of ISO9001 Certification of the pole manufacturer. h) Tentative Quality Control procedures and qualifications, and non-destructive testing to

be performed. i) Detailed list of all assumptions / exceptions and/or deviations taken by the Bidder to the requirements of this specification or, if none are taken, a statement indicating that no exceptions or deviations are taken by the Bidder.

j) Details of equipments available with the manufacturer for making these poles. k) Dimensions of the hot dip galvanizing facility of the manufacturer shall also be

provided to ensure their capacity

7.5.6.3 Data to be submitted after vendor approval

a) Calculations, clearance diagrams and loading trees b) List of Drawings and schedules of submittals; c) List of Codes used; d) The final design calculations of all types of poles showing design assumptions,

analysis, joint fixity, foundation fixity, eccentricities induced to structure deflections and assumptions and computations used to determine radius of gyration and other critical sections;

e) Maximum moments, shears, axial loads and member section modules required and furnished including at ground level, joints, splices and other critical sections;


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f) Detailed assembly and fabrication drawings; g) Bill of materials and parts list for each type of poles; h) Dimensions of each section and components of each type of poles including Bill of

materials. i) Test reports. j) Calculations of stresses in the ground line, attachment connections, and moment

connections; k) Maximum horizontal and vertical deflection at top of pole, at shield wire and conductor

attachments, and at cross arm joints. l) Detailed QA Program based on ISO 9001; m) Detailed Contract Schedule Activity for the steel poles; n) As-built shop/erection drawings as finally approved. Erection drawings shall show only one (1) structure each with its component parts, and shall have an identification mark. The number and length of bolts, with spring type of washer, nuts and locknut required for the assembly shall be shown at each connection. A complete list of material listing quantities of all material required for the structure or part structure shown, including bolts, nuts, locknuts, washers shall be shown on Contractor's detail drawings. The bill of material shall include the quantity of pieces required, mark number, description, size, length, weight and total weight of material shown on the drawing, and the reference drawing on which the member is detailed. Detail drawings shall show each individual member's dimensions and tolerances, welding requirements, connections, identification mark, quantities, material designation, surface treatment, and a bill of material. The Contractor shall furnish in the manner, number of copies and within the time set forth in the Contract.

7.6 CABLE SEALING SYSTEM

7.6.1 Scope

7.6.1.1 After erection of materials and equipment through wall and opening has been completed, it is the responsibility of the Contractor to fill up voids and openings with fire resistant materials to protect fire or smoke from spreading out from one room to other room or one floor to another floor through these voids and openings.

7.6.1.2 Foolproof sealing system is a pre-requisite for proving protection against fire, water, energy/power loss, humid temperature variations, pull tension and rodents, wherever cables are entering in to the electrical substation (ASS, TSS), traction switching stations (SP, SSP, SS), control room, SCADA room, electrical equipment cabinets, power and UPS room, transformers, building and power equipment.

7.6.2 Applicable codes and standards The fire barrier shall comply with the following codes and standards: NEC 300-21: Spread of fire or products of combustion

7.6.3 Material description

7.6.3.1 Specifications: Composition: Low smoke index, halogen free rubber compound based on Ethylene Propylene Diene Monomer (EPDM). The material (EPDM rubber) of module with center plug / wrap / core shall be fire resistant as per UL 1479 of BS 476/20 and ensure protection against dust, water and penetrating solid objects as per IP54/55 for all indoor applications and IP67 for all outdoor applications (IEC 60529). The fire resistant rating of the sealing material shall be more than 2 hours.


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7.6.3.2 The sealing system shall be EPDM Modular based cable-sealing system based on multi-diameter technology.

7.6.4 Installation

7.6.4.1 The modular sealing system and fire barrier shall be installed where:

(a) Voids, sleeves, and openings appear on wall, floor, beam and shaft, provided for cable tray / raceway installation, which must be sealed after the erection work, shall be completed.

(b) Voids, sleeves and openings provided for future installation

(c) Voids exist between electrical conduits and sleeves

(d) Voids exist between electrical cabling and cable tray / raceway on fire wall and floor

(e) Voids exist between cable tray / raceway and sleeves on fire wall and floor

(f) The method of fire barrier installation shall be in accordance with the manufacturer’s

instruction and listings.

7.7 CATENARY INSULATION

7.7.1 General Insulation shall be applied on catenary in area where there is likelihood of foreign object falling on the catenary leading to fault situation. Such areas include covered areas like stations and other congested areas through which the alignment is passing. For Pune Metro project, it is estimated that cumulative about 4km route length will constitute such situation.

7.7.2 Technical Specification Catenary wire by 3M insulation scheme with 1 Layer of Scotch 13, 6 layers of Scotch 23 and 2 layers of Scotch 33. Entire scheme is to be used with 50% overlap only and moderate stretch.

7.8 EARTHING, BONDING AND LIGHTNING PROTECTION

7.8.1 General

7.8.1.1 The earthing system consists of earthmats (for substations, switching stations etc.), earth electrodes, buried earth conductors, earth bars in equipment room, connections from earthmats / electrodes to earthbars / equipments / structures etc. The rebars in civil structures also form part of overall earthing system and as such requires bonding with earth system. Lightning protection system consists of air termination, protection conductors, their connections earth electrodes.

7.8.1.2 Copper bonded steel conductors (UL tested, complying to IEC 62561-2 standard) shall be used for all earthing system i.e. for earthmats, earth bars, earthing connections etc.

7.8.2 Earthmats (in other Contractor’s scope) The Earth Mesh design and installation shall be done in accordance with relevant provisions in IEEE 80-2013 (or latest) and IEEE 837-2014. Earth network should be designed taking into account conductors' temperature rise as regard to the faulty current levels. The Contractor will have to provide a buried earth mesh in the Substation site. The design of the Main Earth Mesh shall be done by the Contractor, taking into account the site conditions (soil resistivity etc). The Main Earth mesh shall be exothermically welded


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as per IEEE 837-2014 for the purpose of maintaining equipotential bonding, by means of two Copper Bonded Steel conductor of appropriate size (buried earth conductor).

7.8.3 Earthing & Bonding Connections

7.8.3.1 To provide protection against the hazardous voltages is made which may arise as a result of a broken contact wire or as a result of a potential difference (voltage difference) between two conductive parts due to induced voltages, all possible metal or concrete parts in the zone should be bonded together and earthed. For the concrete structures falling in this zone, a connection socket or Earth Bridge tested with Copper current collector part having threaded hole and the stud Cadwelded with steel bar the other end of which should be arc welded with the reinforcement bar, before being cast into the concrete similar to the below drawings. The Earth collection plates can then be interconnected externally with a jumper either externally or they can be both interconnected even before the casting is done depending on the situation and ease of installation.

7.8.3.2 For the same reasons of maintaining equipotential bonding and stronger electrical connectivity between different precast components, Earth bridges (or equivalent) should be used for the applications of connections between Plinth segments, Pier Caps and Girder, Pier Earth test points and any multiple precast segments placed close to each other.

7.8.3.3 The Structure or masts too need sound earthing. In locations close to the masts, an interconnecting conductor shall be bonded between the mast and the nearby earth bridge that is embedded in the foundation of the mast.

7.8.3.4 In applications needing interconnection for grounding purpose or reducing EMI/EMC effects, Tinned Copper braids with masticated ends shall be used.

7.8.3.5 Different Earth Electrodes Earth Electrodes protecting equipment or assets of different systems or applications like Telecom, Power etc. at locations other than substation should ideally be interconnected. This shall be achieved by using Potential equilization clamps. This helps in maintaining equipotential among different earthing types, by getting interconnected during the potential rising beyond a point and returning back to the disconnect phase during normal conditions.

7.8.4 Lightning Protection

7.8.4.1 The vertical earth electrodes should be consisting of Copper bonded Steel electrodes, tested to IEC 62561-2 and UL 467 and laid in a crow’s feet manner, so as to dissipate the lightning energy in a radial manner. Length of the electrodes should be 6 or 8 feet. These electrodes should be enveloped with Ground Enhancement material as per IEEE 80-2013 and tested to IEC 62561-7 standard.


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CHAPTER 8

8.0 INSTALLATION, INSPECTION, TESTING AND COMMISSIONING

8.1 GENERAL

The Contractor shall operate a robust system for the control of effective working on the site. The Contractor shall follow the underlying principles of construction, management and maintenance which are depicted in the following figure:

Figure 8.1: Construction, Management and Maintenance Additionally, the Contractor shall ensure deployment of appropriate experts / engineers for fulfilling the System Assurance and RAMS activities.

8.1.1 Requirement of team managers

8.1.1.1 The Contractor shall keep the following minimum set of team to manage installation, inspection, testing and commissioning:

8.1.1.2 One site manager per team (a) He shall be available at site during prescribed duty hours. (b) He shall be responsible for all technical and organizational matters, general planning

and supervision, and man power planning connected with the efficient installation, inspection, testing and commissioning of OHE and related works in accordance with prevailing prescribed schedules and regulation.

Management

Working

Commisioning Maintenanec Alterinng

Operate

Monitoring Setting

Switching Adjusting Controlling

Servicing InspectionScheduled

RepairUnscheduled

Repair

Preventive

Maintenance

Corrective

Maintenance


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(c) Study of the day-to-day technical, stores and organizational problems so as to effectively assess and monitor the progress and completion of assigned work within prescribed key/access dates and he shall initiate appropriate measures to deal with these.

(d) Watch on the availability of equipment and material required for the work and initiate

necessary action well in advance for procurement of items involving prolonged delivery and effective follow-up action to ensure progress and completion on prescribed key/access dates.

(e) Coordinate with the concerned Contractor for interface requirements and maintain

close liaison with power supply authorities. (f) Provide adequate skilled man power and keep watch on adequacy and alertness of

the team so as to avoid failures, break downs and accidents.

8.1.1.3 One site execution assistant manager per team (a) He shall be available at site during prescribed duty hours and execution of work. (b) He shall be responsible for efficient execution of work so as to maintain the key /

access date. (c) He should possess adequate knowledge of rules and regulations. (d) He shall be responsible for any type of accidents/emergency. (e) He should account and verify periodically the stores and tools so as to offer for

checking by Employer or his representative. He shall be responsible for security of the equipment and materials.

(f) He shall keep updated compiled detailed progress report and submit it to the

Employer or his representative periodically or when ever required by checking authority.

8.1.1.4 Quality manager

(a) He shall be responsible for quality assurance plan including detailed inspection,

testing, and commissioning including prescribed acceptance test of OHE and related works for its equipments and materials.

(b) He shall be accountable for any accident/mishap for lack of inspection, testing etc. (c) He shall keep updated compiled detailed inspection, testing etc. report and submit it to

the Employer or his representative, at least once a month, or when ever required by checking authority.

(d) He should coordinate with the concerned contractors along with his site team for

quality interface. (e) Detailed visual inspection of the OHE in his OHE Inspection Car periodically. (f) Detailed inspection of switching stations and other related installations, in particular,

protective gear. (g) Frequent surprise checks of working gangs at work. (h) Check of the procedure followed for installation/erection to verify that all prescribed

safety rules are being rigidly followed.


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(i) Periodic inspection of subordinate offices, including stores, for following quality assurance plan.

(j) Current Collection Test over his entire jurisdiction during commissioning / warranty

period.

8.1.2 Installation

8.1.2.1 General Requirements

8.1.2.1.1 The Contractor shall comply with all Enactment's in executing the Works, including but not limited to all statutory provisions on occupational health and safety. The Contractor shall coordinate with Other Contractors in the execution of the Works. The Contractor shall also cooperate with all Relevant Authorities in the execution of the Works. The installation of all equipment shall be undertaken at all times by suitably trained and competent employees of the Contractor, to the satisfaction of the Employer’s Representative. Only appropriate tools, plant, equipment and vehicles shall be used. Installation of all equipment shall be in accordance with the Construction and Installation Plan described in the GS. Installation of all equipment shall conform to the best industry practices. Precautions shall be undertaken to ensure the safety of personnel and equipment for all installation works. The Contractor shall, prior to starting any installation and construction work, identify any possible hazards, and implement measures of eliminating and/or controlling such potential hazards, in line with safe working practices.

8.1.2.1.2 The Contractor shall ensure that all areas of work are sufficiently illuminated for the

works to be undertaken and that a safe system of work is employed for all activities.

8.1.2.1.3 The Contractor shall operate a robust system for the control of persons entering or working upon the site.

8.1.2.1.4 The system shall include as a minimum:

(a) register of all employees; (b) personal identification with photograph; (c) levels of competency; (d) date of expiry; (e) date of issue; (f) signature; and (g) register of all visitors.

8.1.2.1.5 The Contractor shall co-operate, at all times, with the Employer’s Representative and Other Contractors to ensure that the Site is protected from unauthorised admission, either wilfully or otherwise. The Contractor shall make due provision for the safe access and egress to the Site of Works for its staff and subcontractors. This access shall be maintained such that it is free of all hazards and is in a safe condition throughout the duration of the Works.

8.1.2.2 Specific requirements

8.1.2.2.1 The installation and construction work pertaining to this Contract shall include, but not

be limited to the following: (a) Finalisation of the Construction and Installation Programme; (b) Survey on Site and review the technical requirements shown in this Specification and

the Employer’s Drawings; (c) Production of the calculation sheets and installation drawings for Site installation; (d) Production of specific site designs and drawings based on typical designs and

drawings supplied; (e) Installation in accordance with the finalised installation drawings; (f) Co-ordination with Other Contractors;


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(g) Submission of the installation reports and records; (h) Testing and commissioning, as per finalised protocol and programme. (i) Production of as built drawings, documents, calculation sheets, and records.

8.1.2.3 Installation plan The Contractor shall undertake installation work in stages as shown in the detailed installation programme. Installation, testing and commissioning of later stages shall not impact revenue operation of earlier stages. As a minimum, the detailed Construction and Installation Plan shall include but not be limited to all the activities described. The Contractor shall submit installation details and methods of all activities, equipment and tools to be used for installation, safety issues, supervision, temporary land occupation needed and the vehicles to be used for installation.

8.1.2.4 Works area The Contractor will be given appropriate temporary work sites at depots or other locations. The Contractor shall comply with the requirements specified in General Specifications in relation to the use of works sites allocated to the Contractor.

8.1.2.5 Temporary works The design of the Temporary Works shall be submitted to the Employer’s Representative for review. All Temporary Works shall be removed on completion of the Section, or as directed by the Employer’s Representative. All Temporary Works shall be clearly distinguishable from the Permanent Works.

8.1.2.6 Construction plant and equipment The Contractor shall provide for himself the required number of sets of Construction Plant & Equipment, for Construction. Areas will be available to Contractor for his office and godown and part of other needs. In addition the Contractor will be permitted to use the Substation sites for storage of materials, equipments etc. and also for a small site office, till the Substations are ready for commissioning.

8.1.2.7 Site supervision and safety issues

8.1.2.7.1 The Contractor shall set up a Site supervision system, which shall be part of the overall safety, system assurance and quality management system. Details of Health and Safety requirements at Site are described in General Specifications.

8.1.2.7.2 The Contractor shall adopt an appropriate quality management system throughout the

entire Site installation period to ensure that the System performance requirements as specified in this PS are achieved. The Contractor shall provide sufficient number of suitably experienced supervisors and skilled workers to ensure that the progress and quality of the work, both on Site and in the Contractor’s workshops, are maintained to the satisfaction of the Employer’s Representative.

8.1.2.7.3 Supervisors shall have a minimum of five years’ previous experience in a supervisory

capacity on similar projects and all the skilled workers including linesmen electricians fitters and craftsmen, shall have a minimum of two years’ previous experience in installation of similar systems.

8.1.2.7.4 The Contractor’s supervision system shall be responsible not only for the supervision of

the concerned system installation but also for the supervision of the installation of the primary fixing system (mast foundation), the earth mats and systems, etc. The supervisors shall work on a full-time basis during the entire installation process.


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8.1.2.7.5 The Contractor shall maintain a set of drawings at each project site which accurately reflect the current status of field changes. The Contractor shall obtain letter of no-objection from the Employer’s Representative for any such changes. The Contractor shall prepare final drawings showing the as built configuration. These drawings shall be developed in a logical format to facilitate routine system maintenance and trouble-shooting. All drawings and details shall be endorsed by the Contractor.

8.1.2.7.6 The Employer’s Representative reserves the right to undertake, at any time, checks on

the proficiency of the Contractors staff, licensing and all associated documentation. Should any of the Contractors staff be found incompetent or unlicensed he shall be removed from the site until their Competency has been established.

8.1.2.8 Workmanship

8.1.2.8.1 All the installation shall be carried out according to the instructions shown in this

Specification and Employer’s Drawings.

8.1.2.8.2 All assemblies of equipment and their components and parts shall be completely interchangeable if they are of similar type

8.1.2.8.3 The style and procedure of the workmanship shall be consistent throughout the Works.

8.1.2.8.4 Unless otherwise specified, the Employer’s Representative shall decide the final colours

for all paint work and other finishes to be applied to any part of the Works.

8.1.2.8.5 All parts, which are subject to, wear or damage by dust shall be completely enclosed in dust proof housings.

8.1.2.9 Change in key dates (KD) and access dates (AD)

The bidders attention is invited to the various Key Dates and Access Dates, described in the subsequent paragraphs. It is essential that the Contractor shall achieve the identified work by the specified Key Date mentioned against it, failing which Liquidated Damages shall become leviable as set out in the Contract. The Employer will, on his part, make all efforts to provide to the Contractor access to information as well as to various locations at stations/track/viaduct, in stages, in order to plan/execute his activities for time-bound completion of his obligations under the Contract, as per the Access Dates mentioned in the subsequent paragraphs. If, however, due to any reasons, the Employer is not in a position to provide access or shared access, as per the stated Access Dates, the Employer, in these circumstances, will inform the Contractor, in writing, about the proposed revised Access Date, at least 8 weeks before the scheduled Access Date. The Contractor shall suitably make necessary changes in his Work Program and shall ensure that, irrespective of the revised Access Dates, the concerned Key Dates are adhered to.

8.1.3 Inspection

8.1.3.1 All installation work will be subjected to the inspection by the Contractor to the entire satisfaction of the Employer’s Representative to ensure that the work is done in accordance with the specifications and approved drawings, designs and Employer’s prescribed Quality Assurance Standards.

8.1.3.2 The inspection programme of the Contractor shall generally cover the following but not limited to:

8.1.3.3 The Contractor shall implement the provisions of the Quality Assurance Manuals and Quality Assurance Programmes as specified by the Employer’s Representatives.

8.1.3.4 The Contractor shall adopt Procedure for: (a) Source Inspection


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(b) Incoming raw material inspection (c) Verification of materials purchased (d) Fabrication controls (e) Site erection controls (f) Safety inspection and audit

8.1.3.5 The Contractor shall adopt Inspection procedure for: (a) Manufacturer and quality control procedure (b) Field / site activities

8.2 TRACTION NETWORK AND OVERHEAD EQUIPMENT

8.2.1 General

This section describes the installation, inspection, testing & commissioning relating to the Switching Stations and Traction Overhead Equipment in conformity with the requirements of international standards and Railway practices.

8.2.2 Installation

8.2.2.1 This section deals with the installation of overhead equipment and switching stations.

8.2.2.2 The Contractor shall furnish the design and drawing of complete formwork (i.e.) the form as well as their supports for the notice of no-objection from Employer’s Representative before starting of any installation work is taken up.

8.2.2.3 The Contractor shall provide sufficient number of suitably experienced supervisors and skilled workers to ensure that the progress and quality of the work, both on Site and in the Contractor’s workshops, are maintained to the satisfaction of the Employer’s Representative.

8.2.2.4 The Contractor shall provide for himself the required number of Work Trains / trucks for Construction and considering the necessity. The Contractor is advised to carefully consider the works trains/trucks design so that the working platforms have the flexibility to enable this train/truck to pass the height restriction and yet be of sufficient height for safe and efficient installation of OHE when on site.

8.2.2.5 Contractor shall provide following handling equipment for installation of the material as mentioned below: (a) Travelling hoists and unloading jib cranes for switching substations. (b) Any other handling arrangement in order to ensure smooth handling of Overhead

equipment, from point of receipt at site to the final point of installation.

8.2.2.6 Contractor will be required to interface with the civil contractor for various civil works related with traction network installation at the following locations: (a) Installation of OHE Masts / Portals on the Viaduct/Depot (b) Traction Switching Stations on the Viaduct / Depot (c) Cable path and earthing and bonding arrangements along Viaduct, depot section (d) Any other items not included in this section

8.2.2.7 Anchor bolts on the parapet, shall be provided by the civil contractor at the time of casting and installation of parapets.

8.2.2.8 Erection of gantries / portals, mast and supporting structures shall cover following items, but not limited to: (a) Structures and gantries may consist of the following types but not limited to:


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Broad flanged beams

Rolled steel joists

Fabricated structures

Two track cantilever / Multi cantilever structure

Tubular masts / portals (b) The method of erection of structures, gantries and other supporting frames shall be

subject to the notice of no objection from Employer’s Representative. (c) Supply of all necessary galvanized steel bolts, nuts, lock-nuts, washers etc. wherever

required as per approved designs and drawings and fastening the same for making a complete assembly of the steel work at site.

(d) Erection of anti-climbing, if required and anti-bird nesting device on the structures.

8.2.2.9 Erection of overhead equipment (flexible and rigid) Erection of overhead equipment (flexible and rigid) shall cover following items, but not limited to: (a) All work shall be done in accordance with methods of erection and installation of

overhead equipment and the Contractor shall obtain notice of no-objections from the Employer’s Representatives.

(b) The entire equipment shall be erected in accordance with the finally adopted sectioning diagrams.

(c) The bracket assemblies shall be erected in such a way that the free length of the bracket tube beyond the catenary suspension bracket is at least 200 mm to facilitate adjustment during maintenance.

(d) The choice of stay arms shall be such that their adjusters are capable of adjusting minimum of 90 mm in either direction except as otherwise relaxed.

(e) No chipped or cracked insulators shall be installed. 1600 mm creepage path type silicon composit insulators shall be used.

(f) The messenger wire shall be suspended from pulley blocks hung from the suspension clamp eye of bracket assemblies.

(g) The contact wire shall be suspended from pulleys hung from droppers fitted to the messenger wire in their final position. In curves, the contact wire shall be run in pulley located at traction masts or supports, corresponding to the approximate final position of the wire.

(h) Droppers shall be correctly positioned in each span to ensure correct level of contact wire as per dropper chart applicable to the span.

(i) The auto-tensioning device shall be erected initially with 70% of the required counter- weight / tension for 72 hours and the temperature and contraction /expansion of the conductors recorded. Thereafter the maximum and minimum positions of movement of counter weight / tension arrived and marked on the structure.

(j) All insulators shall be so positioned that they are away from the swept zone of the pantographs. The live parts of these insulators shall also be so located that they are at least 2m away from structures other than those supporting traction overhead equipment.


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(k) All jumper connections including anti-theft jumpers shall be made properly with parallel clamps and finished neatly without any loose wire or cables. The length of flexible jumpers shall be adequate to avoid any disturbance to overhead equipment or restraint in the relative movement of conductors, but the jumpers should not be excessively long. The ends of jumpers shall be tinned, including the portion inside the first parallel clamp.

(l) The physical separation required between overhead equipments and bracket assemblies on the same structure at insulated overlaps shall be ensured.

(m) Installation of Rigid Overhead Contact System (ROCS) in the depot’s inspection /

repair lines shall include design of the first tension length of flexible OHE, immediately before the Rigid Overhead Contact System and junction of Contact wire between the two systems.

(n) Transition from Rigid Overhead Contact System to Flexible Overhead Contact System

and Vice-versa should be installed properly so as to pass the pantograph smoothly.

8.2.2.10 Erection of all Switching Stations in the ‘elevated’ and ‘at-grade’ locations shall cover following items, but not limited to: (a) 25 kV Switchgear (b) Jumpers and connecting cables (c) LT and Control Cables from the Switching Station to the Station control room in the

nearest station (d) Structures and foundations (if necessary) to support the equipments and all other

relatedworks to make the Switching Station complete and for its successful and satisfactory working.

8.2.2.11 Erection of 25 kV Switch Gear and associated equipment at Switching Stations shall cover

following items, but not limited to: (a) Erection of 25 kV Single Pole Vacuum Circuit Breaker: (b) 25 kV Circuit Breaker shall be erected complete with operating mechanism, all fittings

and accessories including terminal connections and necessary jumpers. (c) Grouting shall be done for the supporting frame and mechanism box on foundation

block and mounting of other accessories in their respective places. (d) The Contractor shall supply and erect enamelled number plate.

8.2.2.11.1 Erection of 25 kV Pole Isolators (a) 25 kV pole isolator shall be erected and alignment of complete with mounting base,

operating rod, operating mechanism, and all accessories required for its smooth and trouble free operation including terminal connections and necessary jumpers.

(b) Mounting shall be done for support insulators. (c) Padlock shall be provided for each isolator. (d) Isolator switches shall normally be so mounted that when the switches are operated,

the operator faces the directions of the motion of trains. The operating handles and contact blades shall be correctly aligned for easy operation.

8.2.2.11.2 Erection of 25 kV Potential Transformers

(a) Mounting arrangement for the transformer shall be fixed. (b) 25 kV Potential Transformer shall be erected complete with all fittings and accessories

including its terminal connections and jumper wires.

8.2.2.11.3 Erection of 25 kV Current Transformers (a) Mounting arrangement for the transformer shall be fixed.


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(b) 25 kV Current Transformer shall be erected complete with all fittings and accessories including its terminal connections and jumper wires.

8.2.2.11.4 Erection of Lightning Arrestors of 42 kV for 25 kV system

(a) Mounting arrangement for the Lightning Arrestor shall be fixed in position. (b) 42 kV class Lightning Arrestor for 25 kV system shall be erected complete with all

fittings and accessories including its terminal connections and jumper wires.

8.2.2.12 The Contractor shall provide suitable bonding and earthing arrangements at the grade as adopted on the Indian Railway and on viaduct, suitable arrangements will have to be made to ensure. (a) A safe low resistance path for the return current from the rail to earth and back to

traction substation. (b) Avoidance of dangerously high 'touch potentials' along the viaduct portion.

8.2.2.13 The following earth conductors shall be provided by the Contractor as part of the OHE: (a) Aerial Earth Cable (AEC) shall be installed as per approved drawing and connection

between AEC and all metallic structures like the platform canopy, foot bridges etc. shall be established.

(b) Buried Earth Cable (BEC) shall be installed as per approved drawing and connected to various parts by means of flexible copper cables.

(c) Interconnection of the earthing systems

8.2.2.14 Contractor will have to provide the necessary pipe conduits to carry such cables along the viaduct from the main duct provided by the civil contractor to the equipment to connect. The size and arrangement of such pipe conduits will be decided depending upon the actual site conditions obtaining.

8.2.3 Installation requirements of flexible overhead contact system

8.2.3.1 The Contractor shall adopt the best industry practices for installation and assembly work for an overhead contact line system.

8.2.3.2 During commencement of the installation the Contractor shall keep ready in advance and submit to the Employer’s Representative a site management plan for review.

8.2.3.3 The Contractor shall assure the Employer’s Representative for review of its site management and submit the site management for notice of no objection while starting the work.

8.2.3.4 For any violation of site management rules/procedures, the Contractor shall be held responsible and the work shall be suspended without any consequence on delays till all the corrections are made.

8.2.3.5 The Contractor shall respect the implementation documents such as pole and foundation tables, material lists, contact lines lay outs etc. with reference to approved design drawing submitted by him form the basis of work.

8.2.3.6 The Contractor shall have to produce the compiled detailed implementation document to the quality team of the Employer’s Representative, including the relative quality checking reports, as a matter of checking proof as and when required.

8.2.3.7 The Contractor shall subdivide the installation documentation into two parts and these are documents for individual stations and inter-station sections.

8.2.3.8 The Contractor shall follow in general primary characteristics of selected methods that have proven themselves in practice are described below:


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Tasks Working Steps

Foundation Survey of Locations, Search for cables and pipelines, Secure ballast, excavating, scaffolding, drilling, ramming, anchor bolts, installing foundations earthing, pouring and compacting concrete. Check viaduct anchor bolts and their locations.

Set Poles Attach brackets, Clean excavation or hole, mount or insert pole and align, pour concrete or underfill poles. Prepare the mounting arrangement of portal beam and/or head span wire, mount portal beam and/or head span wire.

Preparation of cantilevers

Calibrate poles, calculate cantilever dimensions, saw tubes and drill, cut threads, mount fittings and insulators

Cantilever Assembly

Bolt cantilever to pole and secure against turning, remove transport protection for insulator

Mount tensioning Device

Insert midpoint anchor, attach ropes for messenger wire mid point anchor and tension to the specified force.

Midpoint anchor installation

Install midpoint anchor, attach ropes for messenger midpoint anchor and tension to the specified force.

Preparation of Droppers and stitch wires

Measure the contact wire support clamp, calculate and manufacture droppers, cut stitch wire to length.

Install contact line String messenger and contact wire singly or together, connect with the tensioning device at the start of the tensioning section, string under tension, clamp into the cantilever and terminate at the midpoint anchor and the tensioning device at the end with specified tensile force, release the tensioning device. Install the stitch wires and droppers during the stringing work, install the contact wire midpoint anchor, tension the stitch wire. Unwiring of cable should not be done by hand.

Adjustment Work Check the contact wire height and stagger and adjust if necessary by altering the cantilever and dropper.

Electrical Connectors

Install electrical connectors at connected overlaps, isolated overlaps, fix points, bridges, switches between contact line and positive feeder line.

Install overhead line Disconnectors

Install and adjust drive mechanism; linkage and disconnector parts, connect remote control cable and power feeder or switching lines. Verify all elementary electrical OHE section.

Install traction power supply

Fix insulators, string traction supply power line, tension and clamp in

Plates and labels Attach pole, disconnector and traction power line number, attention and warning plate at the prescribed positions. Provide anticlimbing device if required.

Railway Earthing Connect metal parts in the contact line range and poles with the selected rails; lay and connect earthing connections. Verify earth resistance values.

Revision of Plans Revision of the documents to comply with the installation

8.2.3.9 Installation and adjustment of the overhead line supports and contact lines

(a) The Contractor shall plan and install the cantilevers and contact lines as soon as track

laying, the foundation in the depot and U-bolt on the viaduct, pole erection and it’s setting are completed. The cantilever dimensions can be calculated on the basis of thepole positions.

(b) The cantilever supports and the contact lines within a tensioning length shall have to beinstalled using during one technological sequence (integrated overhead line installation) so as to complete the work quickly to comply the commissioning as per key / access dates.


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(c) The Contractor should plan and preassemble the cantilever assembly in advance so

that it can be installed along with stringing of contact line which will reduce the time of installation of OHE.

(d) The Contractor shall interface with track contractor to get marking of rail head height on the pole so that fabrication of droppers shall be taken in advance before stringing of contact lines. Such practice will further reduce the time of installation.

8.2.3.10 Installation of section insulators, cross-over contact lines, railway earthing

(a) The Contractor should ensure proper installation practice for erection of section

insulator and highly skilled staff of the team. He should install it on tensioned contact wire only. Since section insulators provide abnormality in the overhead contact line as a result of their mass and importance of location, the contractor shall exercise utmost care in height adjustment of the entry and exit sections and of the gliding skid as it has significant influence on the pantograph dynamics and avoidance of premature wear.

(b) The Contractor shall also take extra precaution during the installation of the contact

lines over crossovers to ensure that both contact wires in the pantograph entry area are located on one half of the collector head, since collector head traps could otherwise arise. The Contractor shall carefully install and adjust the droppers in contact linesabove the switches to achieve better results.

(c) Earthing lines in 25 kV AC systems are attached to the poles and the metallic

equipment located in the area of the overhead lines and to the provided connection points on the rail through signaling impedance bond (if required) and OHE integrated transverse link, with the inclusion of return current and earthing conductors. Since these works rarely require track closures, this work contractor shall have to plan and execute before track closure and therefore the installation time can be reduced further.

(d) The Contractor is required to draw out the various activities in the form of steps to

ultimately erect the section insulators and the crossovers. This is necessary for complicated work for better understanding of work team.

8.2.3.11 Equipment for installation and maintenance

(a) The Contractor has to arrange specialized equipment and specialized vehicles in

addition to usual tools and vehicles to comply with the requirement for qualified installation and maintenance of overhead contact line systems. It will be necessary for correct, rapid, and safe working of installation, inspection, maintenance, and repair activities.

(b) The Contractor has to ensure that these equipment are user friendly, simple in

handling and ensure continuous operational availability even during rough railway operation under any abnormal situation/condition, which is essential for high availability.

(c) The Contractor shall ensure to keep voltage tester at working site to ensure that the

line is de-energized which is necessary if the line is charged during installation for antitheft measures or otherwise charged with 25 kV.

(d) The Contractor shall arrange adequate number of safety belts and protective helmets

for accident free working on the overhead contact line system. (e) The Contractor shall produce the list of minimum tools and equipments, specialist

vehicles and normal vehicles require for installation, inspection, testing, and commissioning for notice of no-objection of the Employer before planning for starting the work.


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8.2.4 Installation requirements of the ROCS 8.2.4.1 Track route and layout inspection and preparation of installation work:

8.2.4.1.1 As preparatory work prior to installation, the location and position of supporting fittings,

rigid conductor rail and anchoring shall be verified and marked at site.

8.2.4.1.2 Height of the roof / soffit from top of rail at various locations shall be confirmed.

8.2.4.2 Installation of supporting structure

8.2.4.2.1 Supporting anchor bolts of supporting structures shall be supplied and installed by the other Contractor.

8.2.4.2.2 Supporting insulator and accessories for rigid conductor rail shall be mounted on

supporting structure to enable adjustment of the conductor to required stagger as per the approved final design drawings.

8.2.4.3 Installation of supporting structure, conductor rail and contact wire

8.2.4.3.1 Care shall be taken that no breakage, dent, crack or bending of any component takes

place during transportation.

8.2.4.3.2 Adequate care shall be taken to prevent any damage due to rust by applying rust prevention paint.

8.2.4.3.3 Materials delivered at work site shall be laid up neatly at nominated locations so that

interference does not occur from other works going on nearby.

8.2.4.3.4 Due care shall be taken while handling the rigid conductor rail that no twisting or bending or development of any crack takes place. Temporarily supporting the rail with one end cantilevering should be prohibited.

8.2.4.3.5 While installing the rigid conductor rail, safe practices shall be adopted.

8.2.4.3.6 The erection of conductor rail shall be commenced from the anchor structure and

continued on to the expansion joint.

8.2.4.3.7 Before installation of the end approach of expansion joint, adjustment of final length shall be in accordance with the measured temperature.

8.2.4.3.8 On curved track, the conductor rail lengths appropriately bent to requisite curvature

taking into account track conditions and deviations of contact wire shall be provided.

8.2.4.3.9 On turnouts the level of the crossover contact wire shall be raised so that it does not come in contact with train pantographs running on the main track, and for the trains negotiating the turnout, the passage and current collection by pantograph is smooth.

8.2.4.3.10 Adequate tensile force shall be maintained in the contact wire when installed.

8.2.4.3.11 The Contractor shall interface with Civil Contractor and shall be responsible for Centre

line Marking of Track (even without its laying).

8.2.4.3.12 The Contractor shall submit the ROCS installation plan to Employer’s representative for notice of no objection.

8.2.4.4 Jointing the rail


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The conductor rail lengths bolting process shall be of proven design with use of proven components.

8.2.4.5 The Contractor may have to employ a work train to install the contact wire with appreciable speed. The example of the work train is given in following figure which the Contractor has to employ for speedy installation:

Figure 8.2: ROCS installation work train Legend of work train: 1 – wire mounting trolley 2 – greasing device 3 – pulling cables 4 – rigid pi bar 5 – contact wire 6 – way of run for contact wire mounting

8.2.4.6 The interrupters and isolators meant for sectioning shall be located in the station area in a

room close to the sections required to reduce length of cables. Connection of feeder cables to ROCS conductor rail shall be through flexible jumper and terminal connectors and shall be of bolt fixing type and the details shall be submitted for review by the contractor to the employer’s representative. The feeder cable jumpers shall be flexible to accommodate rigid conductor rail movement due to temperature variations. Due care should be taken to lay and connect the cables to switchgear and to ROCS to ensure that the current carrying capacity of the system is not de-rated and all connectors shall be robust and of proven types. The Contractor shall provide and maintain documentation at all stages of the works in the formats prepared by him (contractor) duly obtaining notice of no objection from the Employer’s Representatives.

8.2.4.7 The Contractor shall maintain the documentation so as to identify the status of inspections. Such documentation shall contain: (a) list of certificates received for each batch of goods and materials incorporated in the

works and compare this against the certification required by the Contract. (b) list the inspection activities undertaken by the Contractor on each element of the

works and compare these activities against the amount of inspection and testing required by the contract.

(c) Summaries of any actions proposed by the Contractor to overcome any deficiencies

so identified during various inspections including the inspection by his (Contractor) quality manager.


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8.2.4.8 The Contractor shall also inform the Employer’s Representatives in writing, when any portion is ready for inspection giving him at least 24 hours advance intimation to enable him to inspect the same, without retarding progress of the work.

8.2.4.9 Employer’s representatives shall have free access at any time to every part of the works and to all places where materials for the works are stored or being prepared.

8.2.4.10 The Contractor shall furnish with reasonable facilities and assistance to the Employer’s Representatives during inspection.

8.2.4.11 The Contractor shall conduct formal, documented Safety Inspections, at least in a month and report of each safety inspection shall include the actions taken to resolve any problems or shortcoming discovered during the inspection. The report shall be made available for audit purposes and be discussed at the relevant meetings.

8.2.4.12 The Contractor shall submit the basis of inspection to be carried out in advance to the Employer which should be based on international standards and the various specification adopted by Indian Railway Research Design and Standard Organization etc.

8.2.4.13 The quality manager of the Contractor shall conduct 100 percent inspection and keep a record.

8.2.4.14 The Employer’s Representative may inspect 10 percent of ordered quantity on supply items in manufacturer’s premises in presence of Contractor and the manufacturer

8.2.4.15 100 percent inspection on supply items shall be inspected by the quality manager of the Contractor in the manufacturer’s premises on supply items and shall keep records.

8.2.4.16 The Employer’s Representative may inspect 10 percent of ordered quantity on supply items at site in presence of contractor.

8.2.4.17 100 percent inspection on supply items shall be inspected by the quality manager of the contractor at site on supply items and shall keep records.

8.2.4.18 Such inspections shall include quality procedure checks and during inspection qualified staff shall be provided by the contractor.

8.2.4.19 Demonstration of conformity of overhead contact system: (a) The Contractor has to compile a complete detail inspection (on installed OHE and on

supply of equipment and materials) carried out by his quality manager and Contractor shall submit a report to the Employer once in a month.

(b) Monthly, the Employer’s Representative may conduct inspections of progress

activities of the Contractor at least one km for every 10 km. (c) The Contractor shall arrange inspection by Employer’s at least one kilometer of

installed OHE stage wise, on every 10 kilometers and random check on supply of equipment and materials.

(d) The Contractor shall conduct current collection test as per EN50317 to demonstrate

that a newly installed overhead contact line satisfies the quality requirement for a given running speed.

(e) The Contractor shall check the electrical and mechanical line parameters to fulfill the

electrical requirements, both the static (validation of static dimensions) and the dynamic (validation of dynamic behavior) design requirements within the design tolerances as per schedule of dimensions.

(f) As erected drawing shall be submitted by the contractor so as to ensure that defects,

modifications, corrections pointed out during inspection have been carried out.


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8.2.5 Testing

8.2.5.1 The Contractor shall co-ordinate & arranges testing equipment etc. required for testing

facilities.

8.2.5.2 Factory Inspection and testing of supply items of equipment and components of Overhead contact line: (a) One month before factory acceptance test, Contractor shall submit to the Employer’s

Representative the test content. This test content shall refer to appropriate standards.

(b) The Contractor quality manager will assist to all factory acceptance test on equipment and components of Overhead contact line in the manufacturer’s workshops. After each test, a test report shall be made, giving a pass or fail status, and shall be submitted to the Employer’s Representative.

(c) The Contractor design and quality team shall conduct the factory acceptance test on equipment and components of Overhead contact line in the manufacturer’s workshops. This will be performed on 10% of the quantity ordered based on random selection of the product offered for inspection. The Employer’s Representative may take part to inspection.

(d) Such material immediately after completion of inspection and testing shall be sealed before shipping in presence of witnessing by Employer’s Representative, manufacturer’s representative and the Contractor.

(e) Type test shall have to be performed as per specification if it has not been done earlier by an national / international accredited reputed agency.

(f) More over the Employer reserves the right to order type test irrespective of whether the type test conducted earlier or not.

(g) Concerning type tests, test certificates issued by national / international recognized agencies may be asked to issue, if the Contractor cannot carry out these tests himself and if the test certificates are related to a similar equipment of same capacity and design.

8.2.5.3 The following major equipment and components shall be inspected and tested in the

manufacturer’s workshops: (a) Hard drawn grooved copper contact wire for electric traction (150 sqmm): the material

shall be inspected and tested as per EN50149 specification, UIC 870 specifications and as per Indian Railway RDSO specification ETI/OHE/76 (latest revision). The quantity to be inspected shall be in number of drums and be >= to 10% subject to minimum one drum per shipment.

(b) Hot dip zinc galvanization of steel mast with plates, tubes and fittings: the material shall be inspected and tested as per EN ISO 2178 specification and as per Indian Railway RDSO specification ETI/OHE/13 (latest revision).

(c) The Contractor shall carry out testing on weldings done on the OCS support structures.

(d) The Contractor shall carry out load carrying capacity test on each type of OCS support structure on first batch of production.

(e) The Contractor shall carry out load carrying capacity test on 10 % of each type of cantilever tubes and fittings.


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(f) The Contractor shall ensure that the galvanization shall only be done after required plates are welded properly and holes of proper size are made.

(g) Messenger wire—Cadmium copper stranded conductors: the material shall be inspected and tested as per EN 50182 specification and as per Indian Railway RDSO specification ETI/OHE/50 (latest revision). The quantity to be inspected shall be in number of drums and be >= to 10% subject to minimum one drum per shipment.

(h) Short Neutral Section (not foreseen currently): the set of 25kV PTFE type short neutral section shall be inspected and tested as per Indian Railway RDSO specification TI/SPC/OHE/SNS/0000 (latest revision). The complete set of automatic switched short neutral section as per latest design including VCB and its circuitry shall be type tested (if already not done) and performance witnessed.

(i) Aerial Earth Wire: the material shall be inspected and tested as per IS-398 (part II) - latest revision.

(j) Buried earth cable: the material shall be inspected and tested as per Indian Railway RDSO specification ETI/OHE/3-latest revision and IS:9968 (part II)- latest revision.

(k) Silicone Composite Insulators 1600mm creepage distance: the silicon composite insulators for stay, bracket and 9-ton insulators shall be inspected and tested as per Indian Railway RDSO specification TI/SPC/OHE/INSCOM/1070 (latest revision) and as per IEC 61109 specification.

(l) The Contractor shall ensure that the tests of checking the operation of isolators and earth isolators will have to be performed as routine test.

8.2.5.4 Final factory tests

(a) The final factory tests will be carried out on the fully assembled equipment as

specified. Thereafter, if required and permitted by the technical features of the equipment, the equipment may be dis-assembled for transportation purposes. The dis-assembly should not, however, cause any deterioration of the technical performance of the equipment. In respect of certain routine tests, it may be necessary to repeat the tests at more than one stage, and the Contractor should ensure that this is done, as required by the Employer’s Representative. The fact that certain tests had to be carried out on the equipment and/or any part, at more than one stage, cannot be claimed by the Contractor, as reason for any failure/sub-standard technical performances of the equipment.

(b) The Employer reserves the right to halt the proceeding of any assembly work, which

would not be in accordance with the stipulations of this section. (c) All delays which could arise from additional tests, from modifications required due to a

defects will not be able to be used by the Contractor to justify price increase or time extensions.

(d) Each piece of equipment will be subjected to two successive tests: in the factory and

on the site after assembly. (e) Tests of (d) above will be carried out by the Contractor’s responsibility and in the

presence of the Employer’s Representative. (f) Tests of (d) will be subjected to a certificate. Provisional acceptance will be granted

only after execution of (d) of tests.

8.2.5.5 After shipment and Preliminary tests

8.2.5.5.1 After shipment


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(a) The Contractor should perform at this stage the tests verifying that any damage has

taken place during transportation. (b) The Contractor should ensure to carry out, at least, the tests listed in the column “after

shipment” of each concerned equipment test sheet (test sheet in Appendix C)

8.2.5.5.2 Preliminary tests: the Contractor should ensure at this stage the tests verifying that equipment have been installed and assembled correctly.

8.2.5.6 On site test of flexible OCS

8.2.5.6.1 The Contractor has to compile detail complete test of installed OHE carried out by

Contractor’s quality manager and report submitted to the Employer’s Representative once in a month.

8.2.5.6.2 The Contractor shall arrange test by Employer’s Representative also at least one km of

installed OHE on every 10km: (a) The strength of the insulation of the entire equipment as installed shall be tested with

a 2500V Megger and desirable value is 25 mega-ohm as per para 20967 of Indian Railway AC traction manual.

(b) The electrical continuity of the line and the existence of bad contacts, if any, will be tested with a Megger.

(c) electrical independence of individual elementary sections in relation to one another shall also be tested with a Megger.

(d) All isolators shall be tested for smooth and trouble free operation.

(e) All automatic tensioning devices installed shall be tested for sensitive functioning adjustment including x-y settings and marking on poles.

(f) The stager and height of contact wire (at mid point and at support) over the entire section of completed overhead equipment and the clearances available shall be measured and the measurement shall be checked against approved drawings. These measurements shall be carried out at low speed with a vehicle or device to be arranged by the Contractor, the movement of which will follow the track levels as closely as possible. Tolerance that will be permitted on the dimensions indicated in the approved drawings.

(g) The actual position of the two contact wires, relative to each other, at overlaps and turnouts shall also be checked. Special attention shall be paid to a smooth movement of Pantographs over section insulators, particularly those which are likely to be frequently traversed.

(h) The mechanical behavior of the entire equipment shall be tested at various speeds under normal pantographs pressure without energizing the overhead equipment. Tightening of bolts must be checked before and after such check.

(i) If the overhead equipment, after being subjected to the above tests in an un- energized condition, is found to be satisfactory, it will be energized with the normal 25kV AC supply.

(j) Testing of OHE Tests shall then be conducted to check if the current collection performance (as per EN50317) of the over head equipment is satisfactory after ensuring that the contact wire is adequately smooth. For this purpose, an observation vehicle shall be attached next to the electric locomotive / train. The behavior of the over head equipment will be watched at the various speeds. Current collection shall


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be considered unsatisfactory, if long blue flash is observed, indicating that the contact between the contact wire and the pantograph is not smooth.

8.2.5.7 Inspection and testing of switching stations

(a) As soon as a switching station is ready for inspection and testing, the Contractor shall

advise the Employer’s Representative in writing and should submit jointly the internal checking testing report with the passed status without any observation.

(b) Testing will be carried out on Contractor’s cost. (c) Those shall include the test which the Employer’s Representative may like toconduct

with a view to assure himself of the soundness of these equipments and their erection in compliance with these specifications.

(d) Testing equipment such as 2500 and 5000V Muggers, Earth megger and accessories,

Continuity test apparatus, Avometer and staff required for the tests shall be provided by the Contractor free of charge.

(e) The Contractor shall take full responsibility and submit the report to the Employer’s

Representative. (f) The Contractor shall carry out visual inspection which shall include check for satisfactory workmanship, shall cover all connections, painting, plastering, cleanliness of all insulators etc. and compliance with Indian Electricity Rules.

(g) The Contractor shall carry out by operating every individual items of equipment such

as vacuum interrupters, vacuum circuit breaker, isolators etc. to ensure thatthe equipment as a whole is functioning properly and is mechanically sound.

(h) Continuity test of high tension connections after setting such interrupter, circuit

breaker and isolator in their respective positions shall also be conducted by the Contractor as part of the operation test.

(i) The Employer’s Representative shall carry out random test equipment wise /

component wise. (j) The strength of insulation of the various items of equipment shall be tested by the contractor with a 2500 V/ 5000V megger as required.

(k) All isolators will be tested for smooth and trouble free operation. (l) Vacuum interrupter and circuit breaker: Operation of trip and close coils for interrupters and circuit breaker shall be tested for satisfactory performance.

8.2.5.8 Earthing

(a) Each wires will be checked for continuity and electrical isolation for every 1000m

approx including at integral transverse bond by the Contractor. (b) Clearance between earth wires and out-of-run wires of overhead equipments and

signals shall be checked by the Contractor. (c) Earth resistance shall be measured separately for each pit and inter-connected earth

pit at every switching station by the Contractor and meet the requirement of the Earthing and bonding scheme to be developed by Contractor for approval by Engineer.

8.2.5.9 Detailed procedure for test


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(a) The detailed procedure for inspection and testing will be organized by the Contractor. (b) The Contractor shall submit the proforma to the Employer’s representative for notice

of no objection in advance for indicating the results of tests for switching stations. (c) The Contractor shall submit the results of tests for switching stations in the approved

proforma to the Employer’s Representative.

8.2.5.10 Acceptance test (a) The Contractor should ensure the requirement for acceptance as set out in EN 50119

so as to conduct the test on technical / functional aspect and safety aspect. (b) Thereafter the Contractor along with Employer’s Representative shall list out all the

defects. (c) After all the defects are rectified the Contractor along with the Inspector confirms that

the inspected section is free from safety aspect and recommends energizing of the line.

(d) After energization of the OHE, test runs are conducted to know the interaction

between contact line and the pantograph. Thereafter defects are listed and rectified.

8.2.6 Testing and inspection of ROCS 8.2.6.1 Inspection and testing of complete ROCS shall be prepared and the tests and complete

methodology for testing shall be submitted for review by the Contractor to the Employer’s Representative.

8.2.6.2 Major equipment of ROCS that is supporting structure, Insulator, copper aluminium hanger clamp and aluminium profile, expansion joint, power feed block, anchor, conductor rail, joints and protective cover shall be inspected and tested in manufacturing workshop in presence of the Contractor, Employer’s Representative and the manufacturer. The quantity inspected and tested shall be 10% of the ordered quantity on random basis. The necessary tests for hot dip galvanization of steel supporting structures as mentioned in Clause 7.2.2 shall be applicable here also in case ROCS. The final factory test as mentioned in Clause 8.2.5 shall be applicable to ROCS equipments also as relevant.

8.2.6.3 Installation checks and tests (a) Visual inspection of overhead contact system installation, random check of

components; electrical and mechanical clearances, air gaps and general alignment. (b) Continuity test of each joint in traction and return current circuit. (c) Insulation resistance of 25kV ac overhead contact system shall be as per

international standards. (d) Physical examination of rail bonds. (e) Checking of construction gauge. (f) Return current continuity test and testing of joints. (g) Earth resistance test.

8.2.6.4 Partial acceptance test After physical verification and measurements, tests as indicated below but not limited to these, shall be carried out.

8.2.6.4.1 Circuit continuity, loop resistance test:


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(a) The purpose of this test is to obtain the ROCS section. (b) These test checks both the ROCS and the rail return system for electrical continuity. (c) The test entails short-circuiting a discrete section of the ROCS by connecting the

ROCS to the rails at one end and applying a variable ac voltage at the other end. (d) The length of section under test should be approximately 1.0-2.0 km (i.e. in the station

to station zones).

8.2.6.4.2 High voltage ac test: Contractor shall Megger the ROCS sections at 2.5 kV and record results.

8.2.6.4.3 Pantograph tests will be performed using a self-powered vehicle in order to identify any

locations where arcing may occur.

8.2.6.5 The Contractor shall be responsible for all adjustments required as a result of these tests.

8.2.7 Commissioning of traction network and overhead equipment

8.2.7.1 General

8.2.7.1.1 “Commissioning” shall be the process of completion of works through a series of integrated test that demonstrate the installation and performance of Works in accordance with the specified criteria.

8.2.7.1.2 Suitable instructions shall be provided by the Contractor for commissioning and future

maintenance of the transformer and its accessories.

8.2.7.1.3 The Contractor and manufacturer shall be associated with the Employer’s Representative during the proving / pre-commissioning / commissioning of the equipment at site.

8.2.7.1.4 Commissioning of the protection scheme shall be done in stages from one end of the

section. Satisfactory performance of section with TSSs operation shall be observed.

8.2.7.2 Commissioning of flexible overhead contact system

8.2.7.2.1 The electrical integrity of the overhead contact line system should be established once all previous requirements have been satisfied which shall be ensured by the Contractor. The commissioning tests should ensure that all configurations with regard to electrical sectioning are in accordance with the design requirements and should include:

(a) Checks that the system complies with to EN 50122-1 which is regarding protective

provisions relating to electrical safety and earthing, (b) Application of the nominal voltage to the overhead contact line, (c) Electrical section proving tests (d) Dynamic tests of the integration between contact line and pantographs depending on the type and scale of the project and dynamic validation should be carried out in accordance with EN 50317 (regarding current collection) to ensure compliance with the performance criteria as defined in the specification.

8.2.7.2.2 The Contractor will have to supply the testing and measuring apparatuses and testing

cars required for the commissioning.

8.2.7.2.3 The Contractor has to accompany Employer’s Representative during such inspections if required before submission of the reports to the Electrical Inspector to government of India.

8.2.7.3 Commissioning of ROCS


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8.2.7.3.1 All the items of supply and required for completion of the work in all respects, testing and commissioning of the rigid overhead contact equipment system as well as associated work for facilitating trial run of the rolling stock and Integrated Testing and Commissioning shall form part of the work covered by the contract.

8.2.7.3.2 During train trial Contractor shall be responsible for providing and fixing discharge rods

during power block permission/cancellation.

8.2.7.3.3 The Contractor will have to supply the testing and measuring apparatuses and testing cars required for the commissioning.

8.2.7.3.4 Till the end of the Contract, Contractor shall provide and fix discharge rod when required

and requested by any other Contractor or by Employer’s Representative.

8.2.7.3.5 Maximum design speed tests shall be carried out by means of running the trains initially at slow speed, then increasing the speed in stages up to full speed permitted for the section and on successful completion of the high speed tests, the ROCS shall be declared fit for system acceptance tests.

8.2.7.3.6 The Contractor shall have to provide all the documents including drawings and reports

required for inspection of electrical inspector to government of India before commissioning.

The Contractor has to accompany Employer’s Representative during such inspections if required before submission of the reports to the Electrical Inspector to government of India.


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CHAPTER 9

9.0 MAINTENANCE AND TRAINING

9.1 INTRODUCTION

9.1.1 This section describes the maintenance philosophy and training of operation and maintenance staff for OHE and related system taking into account international standards and Railway practices.

9.1.2 This training shall enable all the installations, to be operated and maintained in the most efficient and safe manner, so as to achieve the maximum reliability and economy required by such Metro Rail System.

9.2 GENERAL PRINCIPLES OF AN EFFECTIVE MAINTENANCE SYSTEM

9.2.1 The Contractor shall develop a maintenance philosophy and management plan which shall comply with the state of the art and with the general prevailing standards with regard to the maintenance of durable goods, in particular, standards FD X60-000 and EN 15341.

9.2.2 The management of the maintenance process entails defining various levels of responsibility and enabling them to implement the strategic orientations defined by the directing authority: (a) by defining their respective missions, (b) by setting objectives for each person, (c) by translating these objectives into action plans, (d) by implementing the means required to carry out action plans, (e) by diagnosing the causes of any deviation from the set objectives, (f) by taking corrective measures concerning the action plans or the objectives.

9.2.3 This management process requires a global approach and helps to improve the performance of the maintenance work of different components with quality, on time and at low cost.

9.2.4 The Contractor will implement the management and management procedures of the maintenance process described in Clause 9.2.2 above at three levels: (a) at the level of human resources and management in the context of the scheduling of

work, the allocation of human resources and the training of personnel, (b) at the skills level to ensure quality, safety and suitable working conditions, (c) at an economic and financial level to ensure responsible management of production,

spare parts, purchasing and miscellaneous costs.

9.2.5 Within the context of this approach, the management control function ensures timely advice to be given to those with operational and maintenance responsibility: (a) by placing at their disposal the tools and information required for piloting and

diagnosis, (b) by participating in carrying out this diagnosis, (c) by participating in the task of defining the objectives to be achieved.

9.2.6 The process of maintenance management must incorporate two major components: the management of human resources and the study of the most suitable means of achieving the set objectives. This is one of the first guidelines of maintenance organisation.

9.3 IMPLEMENTATION OF MAINTENANCE


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9.3.1 The maintenance plan shall be based on four levels of preventive maintenance which differ according to the nature and scope of the interventions carried out there: (a) level 1: systematic in-service examinations, which provide a means of detecting

(without any specific tools and by personnel who are not necessarily skilled) any anomalies which may have occurred in service according to a random or fortuitous process, and which may affect traffic and safety,

(b) level 2: systematic periodic inspections, which allow skilled personnel to ensure that,

taking account of the service to be provided until the next scheduled intervention of similar importance, the equipment or the element inspected offers predetermined guarantees of reliability.

(c) level 3: the replacement of elements which are triggered within the framework of

systematic preventive maintenance (when the element reaches the end of the programmed potential) or conditional maintenance (when it is noted in the course of an inspection that the normal operation threshold criteria have been reached), but also within the framework of corrective maintenance,

(d) level 4: interventions on dismantled elements and structural equipment (such as body)

carried out to restore the elements concerned to the same level of operation as an identical new one. These interventions (or overhaul operations) usually involve resources related to a reconstruction of the element in question.

9.3.2 The frequency of the maintenance operations defined in the cycle can be expressed either

in time (e.g.: every 6 months) or in units of actual utilisation (e.g., months of operation, electrical power or current flowing through an equipment, mechanical wearing). The choice depends essentially on the foreseeable or observed disparity in service of elements belonging to the same family within the relevant cycle.

9.3.3 The achievement of the objectives assigned to the maintenance division with regard to quality, safety and regularity for the lowest possible overall cost requires the implementation of a number of resources which must be perfectly tailored to the requirements.

9.3.4 In accordance with Section 9.3.3, Contractor will provide the facilities and tools so that the set objectives can be achieved.

9.3.5 Owing to the cost of these facilities, the number of maintenance centres to be equipped and the necessity of keeping the maintenance actions consistent and uniform, the main choices of facilities and tools are integral part of the System maintenance policy and program.

9.3.6 When determining these requirements, in-depth knowledge in the dedicated maintenance plan is needed while taking due account of the experience acquired in similar fixed installation which has been in service for several years.

9.4 ASSISTANCE FOR MAINTENANCE

9.4.1 The assistance for maintenance, as per (refer Section MS of Pricing Document), shall cover the taking in charge the assistance for maintenance starting from issuance of the completion certificate of works of Reach 1 (NS1) Section to the end of the DLP of last Reach (NS2).

9.4.2 During this period, the scope of work shall meet the requirements of GS Section 12.

9.4.3 The Deployment of the Maintenance/Planning Experts and Technical Maintenance Experts may not be continuous and they may be required to supervise the maintenance in short periods at a time as required by the Employer/Employer’s Representative.


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9.4.4 The number of Man Months of Maintenance/Planning Experts to be provided by the Contractor is given under Cost Center E of Section MS (Pricing Document). The number of Man Months of Technical Maintenance Experts to be provided by the Contractor is indicated therein. The Technical Maintenance Experts may be Technical Maintenance Expert for assistance for maintenance of Overhead Equipment and switching stations as required by the Employer.

9.4.5 Above experts shall be qualified engineers in the relevant field with a minimum of 8 years on site experience. Their Curriculum Vitae shall be submitted to the Employer/Employer’s representative for notice of no-objection.

9.5 COMPREHENSIVE MAINTENANCE

9.5.1 The works covered by this are described later in this specification (refer Chapter 11).

9.5.2 The Contractor is authorized to use Contract Spares in order to ensure the works related to this option. If the Contract Spares falls below the level required to achieve the RAM requirements, then the Contractor shall warn the Employer so that the Employer can replenish the stock of Contract Spares to the level required to achieve the RAM requirements. The Employer will replenish the stock of Contract Spares in accordance with Cost Center D of Section MS (Pricing Document).

9.6 TRAINING

9.6.1 Introduction

9.6.1.1 The Contractor shall provide comprehensive training to the Employer’s staff, in accordance with the requirements detailed herein, which shall include: (a) Operations Staff; (b) Maintenance Staff; (c) Staff who are to become Trainers within the Employer’s organisation.

9.6.1.2 The Contractor shall adapt the content of its standard training courses and training methodologies to be specific to the Employer’s infrastructure and also to the trainees’ skills and background.

9.6.1.3 The Contractor shall: (a) Set up training class rooms at the Employer’s premises and at the Contractor’s

premises, as appropriate; (b) Provide competent training instructors, training manuals, training simulators, all

necessary aids and materials as required for training.

9.6.1.4 All the training courses shall be conducted before the commencement of site acceptance testing and commissioning of the relevant section or stage.

9.6.1.5 Except as otherwise agreed with the Employer’s Representative, no training course shall be started before the completion of the design phase.

9.6.1.6 Training courses shall be conducted at a combination of the following locations, as applicable to the nature of the topic to be trained and the project timescales: (a) Training class room at the Employer’s premises; (b) Training class room at the Contractor’s premises; (c) Contractor’s or manufacturers’ factory premises; (d) Employer’s construction site locations.


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9.6.1.7 The training instructors shall be qualified and competent personnel, with good communicationskills and a minimum of 5 years of practical experience in the technical fields relevant to theContractor’s scope of work.

9.6.1.8 The training instructors shall include system designers and engineering staff, as appropriate, sourced from the Contractor, its Sub-Contractors or its equipment manufacturers.

9.6.1.9 The cost of all travel, accommodation and appropriate daily allowances to assist to the training at the Contractor’s manufacturing facility shall be borne by the Employer.

9.6.1.10 The training requirements (number of courses, course duration and contents, number of trainees in each category) indicated below for the operations and maintenance staff connected with switching stations & OHE, is indicative at this stage of the preliminary requirements for training which shall be used by the Contractor for the purpose of cost estimation.

9.6.1.11 During bidding stage, the Contractor shall indicate the cost per instructor week for the following types of courses and provide accordingly the breakdown of the Cost Center C of Section MS (Pricing Document) accordingly: (a) Training for the operating personnel of the Employer in OHE (at Pune)

(b) Training for the maintenance personnel of the Employer in OHE (at Pune)

(c) Training in OHE for the maintenance personnel of the Employer in the manufacturing

premises of the main supplier/sub-contractor (outside Pune in India as well as abroad) - rates to be indicated separately for training to be imparted within the country as well as outside the country.

9.6.1.12 The final requirements for training will be decided by the Employer’s Representative in

consultation with the Contractor, during the course of Detailed Design, taking into account the trainees’ skill and background, the maintenance strategy to be employed, the staging of the project for revenue service and any other Employer constraints.

9.6.1.13 Different types of training courses covering various sub-systems, depending upon the actual duty list of the trainee, shall be provided for inspectors and technicians.

9.6.1.14 Operations training courses shall be provided for the control centre, depot and station staff.

9.6.1.15 System engineering and maintenance courses shall be provided for engineering and maintenance staff with detailed trouble shooting and repair training provided for the workshop inspectors and technicians.

9.6.1.16 The Employer’s Training Instructors shall attend all types of training courses to enable themsubsequently to train the Employer’s staff in all aspects of the operation and maintenance ofthe OHE system.

9.6.1.17 The maximum number of trainees of each training class shall normally not exceed fifteen, except as otherwise agreed in advance with the Employer’s Representative.

9.6.1.18 The Contractor shall determine the number of classes for each type of training course to meet the course objectives.

9.6.1.19 Where the supplied training courses are insufficient the Contractor shall develop additional training courses, manuals and materials to make good the deficiency as part of the Contractor’s Defects Liability responsibilities.

9.6.2 Training Plan


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9.6.2.1 Within sixty days after the Commencement Date of the Works, the Contractor shall submit

a Training Plan to the Employer’s Representative for review.

9.6.2.2 The Training Plan shall include, as a minimum, the following: (a) Program of training courses and the submission schedule for training materials; (b) Materials to be supplied for training; (c) Overview and description of objectives of each training course; (d) Locations where the training courses are to be conducted; (e) Equipment configuration and set-ups for practical exercises; (f) Contractor’s training organisation chart, including the role and responsibilities of

individual key persons; (g) Qualifications and experience of the training instructors; (h) Details of the training simulators to be provided or developed, if applicable.

9.6.3 Training Courses

9.6.3.1 The Contractor shall provide training courses for all appropriate elements applicable to the scope of the OHE systems including interfaces to other parties, as applicable.

9.6.3.2 The courses shall provide all necessary knowledge and skills for the Employer’s staff to operate and maintain the sub-systems under normal, degraded and emergency modes of operation.

9.6.4 Training Materials

9.6.4.1 The Contractor shall submit all of the training materials including the trainer’s guides, training manual for trainees, training aids and presentation materials to the Employer’s Representative for review, at least three months before the commencement of a training course.

9.6.4.2 The training materials shall be prepared in a form to facilitate long-term storage and also allowing for easy reproduction in the future.

9.6.4.3 Training materials shall be suitably modified, before the commencement of courses, duly incorporating the Employer’s comments.

9.6.4.4 The Contractor shall ensure, where possible, that Interactive Computer Based Training (CBT) is provided to cover all appropriate sub-system elements.

9.6.4.5 CBT training shall be based on current industry techniques and methods for the training of staff.

9.6.4.6 Prior to the commencement of a training course the Contractor shall issue the following documents, in a timely manner, to the Employer: (a) For allocation to each of the Employer’s Training Instructors:

a. Two sets of the trainer’s guides; b. One set of each training manual for each trainee.

(b) For the Employer’s Records:

a. Two sets of the trainer’s guides; b. Three additional sets of each training manual.

9.6.4.7 The contents of the trainer’s guide shall be prepared in accordance with a format which

shall be agreed in advance with the Employer’s Representative.


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9.6.4.8 All of the training materials shall be accurate and match with the actual design and configuration of the system as installed at the Employer’s site.

9.6.5 Interactive Computer Based Training (CBT)

9.6.5.1 The Contractor shall ensure, where possible, that interactive CBT is provided for the System and all sub-systems. The training shall make use of the current industry techniques and media for the training of staff.

9.6.5.2 As a minimum the following interactive functions shall be considered: (a) Step by step three dimensional system and subsystem assembly/disassembly; (b) Simulated operation, maintenance and testing of system and sub-system; (c) Activate and deactivate step by step guides to items a and b; (d) Failure and fault investigation step by step guide; (e) Self and Employer’s Training Instructor assessment modes; and (f) Re-assessment mode.

9.6.5.3 The Contractor shall submit an operations CBT information document and a Maintenance CBT information document to the Employer’s Representative for review. The operation CBT information document shall contain, but not be limited to, the following details: (a) General introduction of the system functionalities and objectives; (b) Description on the system operation principles; (c) An overview on the system configuration; (d) General description of the functions of each key component of the System (with

photographs showing the outlook of each typical equipment); (e) Types of provisions in each location throughout the network; (f) List of potential hazards that may arise in operating the System; and (g) Specific points to note in operating the System.

9.6.5.4 The maintenance CBT information document shall contain, but not be limited to, the following details: (a) A general description of the proposed maintenance strategy / plan of the System; (b) The maintenance plan and procedures proposed for the System; (c) A general description of the 1st, 2nd and 3rd line maintenance works required for the

System; (d) An introduction to the tools required for maintaining the System; (e) A description of the symptoms of the common faults found on the System; (f) A description of the self-diagnostic capability of the System; and (g) Points to be noted in maintaining the System.

9.6.6 Video Recording

9.6.6.1 Video Recording for major phases of installation, commissioning and testing of various equipments related to OHE system have to be made for instruction purposes to the trainees in future.

9.6.6.2 The recordings shall be edited with sound track of well compered technical talk and data. The total site visits for video recording shall be approx 24 times but not limited to. The total edited run time shall be approx 1.5 hrs for OHE and related topics in two stages. The edited copies shall be supplied on high quality video cassettes / CD’s in four prints.

9.6.7 Training Records

9.6.7.1 The Contractor shall devise a system for assessing the level of knowledge, understanding of the course content and the proficiency of the trainees.


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9.6.7.2 The methodology of the assessment system and the format of records shall be submitted to the Employer’s Representative for review three months before the commencement of each training course.

9.6.7.3 The Contractor shall develop questionnaires for completion by the course trainees to determine the level of satisfaction with the course content.

9.6.7.4 Appropriate scoring and weightages shall be assigned to each question such that the scores provide a balanced view of the trainee’s satisfaction and the actual usefulness / relevance of the training course to the job requirements.

9.6.7.5 The questionnaires shall be submitted to the Employer’s Representative for review three months before the commencement of the training course.

9.6.7.6 Upon completion of each training course, the Contractor shall distribute the questionnaires to the trainees to fill in.

9.6.7.7 The Contractor shall submit a training report to the Employer’s representative for review within two weeks after completion of each course.

9.6.7.8 The training report shall include a summary of the training course conducted, the results of trainees’ assessment and the course evaluation questionnaires.

9.6.7.9 The Contractor shall issue an appropriate training certificate to the trainees who pass each assessment.

9.6.8 Training of theEmployer’s Operation Staff

9.6.8.1 The Contractor shall conduct courses for the operational aspects of the OHE system. Each course will be attended by about 20 operations staff.

9.6.8.2 The Contractor shall train the Employer’s staff in the normal day-to-day operation of the OHE System. The Employer’s staff shall also be trained to address efficiently and effectively failures of equipment, software and operation of the OHE System in these abnormal conditions. The Contractor shall, as a minimum, provide the following training: (a) Recovery to normal operations after a System failure and other incidents; (b) Selection and de-selection of backup control functions; (c) Data logging, retrieval and preservation; (d) Contingency arrangements; (e) Training scenarios for all operational aspects; and (f) Any other aspect as per Employer’s requirements.

9.6.8.3 The training courses shall include the following, as a minimum: (a) Overview of the OHE System; (b) Brief description of the operating principles of each sub-system; (c) Operational features and functions; (d) Familiarisation and use of all Human Machine Interfaces (HMI); (e) Interpretation of system status, alarm messages and indications; (f) Report generation relating to operational and engineering data; (g) Normal operating procedures; (h) Operatingproceduresunderdegradedoperatingmodes; (i) Operating procedures under emergency situations; (j) Procedures for recovery from minor or simple faults; (k) Use of the Operation and Maintenance Manuals and associated documentation.

9.6.9 Training of the Employer’s Maintenance Staff


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9.6.9.1 The Contractor shall conduct courses on the maintenance aspects of the OHE system. Each course will be attended by about 20 maintenance staff.

9.6.9.2 Maintenance Training shall include: (a) Principles of operation; (b) Preventative and corrective maintenance tasks and procedures; (c) Fault repair to the lowest level replaceable unit; (d) Use of test equipment, diagnostic and maintenance aids; (e) Software maintenance including database structure, generation, modification and

system software organization; and (f) Any other aspect as per Employer’s Requirements.

9.6.9.3 Offshore Training: Contractor shall submit an offshore training programme for OHE system.

9.6.9.4 Contractor shall submit a training programme for following instructor-weeks for OHE System in following areas:

SN Description Total Period

(Man Months)

Remarks

1 Design of rigid overhead Catenary System 4 During the Design Stage

2 Design of flexible Overhead Catenary System 4

3 Design of 25 kV switching stations 4

4

Manufacturing facilities, Testing methods and procedures, Working Metro installations. Short Module course on System description, architecture and installation practices of OHE system

12

Note: The above requirement is tentative and Employer may alter the same suitably. However, the total provision of Contractor’s trainers shall be in line with Pricing Document.


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CHAPTER 10

10.0 SPARE PARTS, SPECIAL TOOLS AND TEST EQUIPMENT

10.1 GENERAL

10.1.1 Contractor shall provide spare parts in accordance with the requirements of Section 13 of the GS and as per this section. All spare parts for which the Contractor has been authorised to provide through a written instruction by the Employer’s Representative shall be provided 6 weeks before commencement of revenue service.

10.1.2 The quantity of contract spares associated with NS1 and EW1 Sections equipment, shall be sufficient for the period between the issuance of the completion certificate for NS1 and EW1 Sections until the end of the DLP for the NS1 and EW1 Sections works.

10.1.3 The quantity of contract spares associated with NS2 and EW2 Sections equipment, shall be sufficient for the period between the issuance of the completion certificate for NS2 and EW2 Sections until the end of the DLP for the NS2 and EW2 Sections works.

10.1.4 Refer to Table 1.2 for the definition of above Reaches.

10.2 SPARES LIST

10.2.1 The Contractor shall submit to the Employer’s Representative a list and provide spares required as per the General Specifications.

10.2.2 The spares shall be distinctly grouped as follows: (a) Contract spares – shall be as the agreed final list of spare parts to be procured by the

Employer the maximum of using the formula as indicated in the General Specifications.

(b) Commissioning spares – the Contractor shall keep on the Site throughout the installation, erection and commissioning periods, sufficient stocks of Spare Parts to enable immediate replacement of any item to be used during the contract period at no charge to the Employer; and

(c) DLP spares – In addition to the Contract Spares, the Contractor shall keep sufficient stocks of Spare Parts in an off-site location in Pune throughout the Defects Liability Periods to enable rapid replacement of any item during the Defect Liability Period at no charge to the Employer.

10.2.3 The Contractor shall submit to the Employer’s Representative for review the calculations

and spares list. The arithmetic link between the spare parts quantities, the formulas given in General Specifications, the RAM values and the lead time to replacement from manufacturing to the project site must be clearly stated in the calculation details.

10.2.4 The spares list shall be grouped by subsystem, test equipment and special tools as applicable for stocking identification.

10.2.5 The spares list shall have detailed description with drawing references and correlation with the maintenance manuals.

10.2.6 The spares list shall distinctly group spares covering NS1 and EW1 Sections and spares covering NS2 and EW2 Sections.

10.2.7 The initial contract spares list shall cover the items as per Appendix K of Pricing Document.


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10.2.8 This initial list shall be updated according to pre RAM plan and the RAM plan figures. The list covers the Contract Spares for all Reaches.

10.3 SECOND SOURCING

10.3.1 The Contractor shall identify principal and second-source suppliers that can supply the systems and sub-system spares listed.

10.3.2 The Contractor shall ensure that second-source supplier information is maintained up to date throughout the service life of the System.

10.3.3 The Contractor shall make the second-source supplier information available to the Employer’s Representative at the time of submission of the final design.

10.4 LONG LEAD TIMES The Contractor shall identify the lead times for all spare parts. Parts with long lead times shall be identified as such to the Employer’s Representative in the spares list.

10.5 ROUTINE CHANGE In the event that any item of the supply requires be routinely changing or calibrating regardless of whether it appears in the spares list or not, it shall be identified to the Employer’s Representative together with the routine change interval.

10.6 SHELF LIFE In the event that any of the spares identified have a particular shelf life or storage requirement, this shall be made known to the Employer’s Representative with the submission of the spares list, including the necessary action for disposal or storage.

10.7 TESTING OF SPARES The Contractor shall ensure that all spares are correctly calibrated, tested and labeled prior to their delivery. Test certificates for each piece or set of equipment shall be submitted to the Employer’s Representative.

10.8 SPECIAL TOOLS AND TEST SETUP

10.8.1 The Contractor shall provide the necessary tools and test & measuring equipment to meet the testing, commissioning and maintenance requirements of the Contract.

10.8.2 The Contractor shall submit a schedule of all tools and equipment with details of calibration and supplier.

10.8.3 The Contractor shall set up an offline-testing platform at a suitable place provided by the Employer. The testing platform shall have the capability to test whether any printed circuit board is defective or is okay.

10.8.4 The testing platform shall be commissioned before revenue operations.


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CHAPTER 11 11.0 DLP / AMC OF OHE & SWITCHING STATIONS

11.1 SCOPE OF WORK FOR DLP/AMC OF OHE

11.1.1 General

11.1.1.1 During Defect Liability Period /Annual Maintenance contract, Contractor shall depute

dedicated manpower round the clock in shifts prescribed in Table 11.1 at designated placeas agreed by Employer for attending breakdowns and preventive maintenance activities. This shall be read in conjunction with Clauses of PC applicable for DLP and AMC as well. The following requirement is in addition to the responsibility of the Contractor during DLP defined in Bidding Documents. Table 11.1: Maintenance staff for OHE

SN Staff

Designation No. of persons to be deployed

Min. Qualification

1 Sr. Engineer 1 Degree with 5 years experience of similar nature

2 Field Engineer 1 per shift Degree with 3 years similar experience / Diploma with 5 years similar experience

3 Skilled 3 per shift ITI with 3 years similar experience

4 Un-skilled 2 per shift --

11.1.1.2 Contractor shall set-up OHE Depot, corresponding stores, repair shops, which includes

furniture, material racks staff cup-boards, tools instruments, material handling instruments, communication instruments, material consumable etc. in addition to proper upkeep of all the installations and vehicles in OHE. Manpower mentioned above shall be able to perform duties as follows:

11.1.2 Duties of Senior Engineer / OHE

11.1.2.1 He/She shall be in-charge of Contractor’s OHE maintenance team responsible for Safe, efficient maintenance of OHE installation at depot and mainline. He/She should be fully conversant with the layout and sectioning of OHE and also the rules and procedures laid down for efficient maintenance of OHE and safe working on OHE. In particular he shall:

11.1.2.2 Supervise the preventive and corrective maintenance of installations under his charge in accordance with the standard and prescribed schedules, to keep them fully serviceable all times and in a state of good repair. To ensure proper record of preventive and corrective maintenance of all installation in his control and submit monthly report to Employer with completion and next due dates (equipment wise).

11.1.2.3 Ensure advance planning of Preventive maintenance with a view to avoid OHE failures and requirement of power blocks for OHE maintenance based on the work done in consultation with the Operation Control Manager (OCM) through Traction Power Controller (TPC) and ensure completion of work within the time allotted.

11.1.2.4 Carry out detailed inspections of OHE under his control by Catenray Maintenance Vehicle (CMV) to cover the entire section once in two months and submit the inspection report to Employer without fail. To carry out all necessary inspections of his assets as per the


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statuary requirement or otherwise and shall notify and rectify any defects / deficiencies found during such inspections.

11.1.2.5 Scrutinize daily reports and other defects on OHE, as well as reports from TPC inspections reports of Employer and arrange prompt rectification of defects pointed out and report compliance to Employer and ensure their implementation.

11.1.2.6 Instruct train and supervise staff under his control and ensure that they shall operate and maintain the equipment properly and in particular do actually observe all prescribed rules and regulations, Joint Procedure orders issue time to time safety precautions, SHE policy laid down for this to ensure proper training of all the staffs working under him, ensure Personnel Protective Equipment (PPE) while working on the system for self and working staff as well.

11.1.2.7 Ensure that special testing instruments tool and equipment including the OHE inspection cars (provided and maintained by others) and breakdown vehicles, for maintenance of OHE are properly cared for and maintained in proper condition.

11.1.2.8 Ensure that special tools and instruments provided for maintenance and testing of all installations are carried for corrective and preventive maintenance, their timely calibration, storing at proper place etc. He shall ensure that other safety equipment including bonding and earthing are functioning effectively.

11.1.2.9 Keep Employer fully informed of all-important development and seek their guidance when required.

11.1.2.10 Ensure proper upkeep of drawing, manuals and other all relevant literature as per laid-down conditions of contract agreement.

11.1.2.11 Check the work done by maintenance gangs under him to ensure the quality work and that compliance with prescribed schedules is adhered to.

11.1.2.12 To ensure submission of prescribed periodical returns after careful scrutiny and remedial measures suggested to avoid recurring failures and submit:

i) Failure analysis reports ii) Unusual occurrence reports iii) Power block and PTW reports iv) Accidental reports v) Staff position reports

to Employer and compliance of the instructions issued if any on the basis of such returns.

11.1.2.13 To ensure proper competency with their validity of the staff working under him and arranging training for issue of competency and depute staff for refresher course.

11.1.2.14 Ensure making of each equipments history, technical details updated and submit as and when required by the Employer promptly.

11.1.2.15 Ensure display of details of inspection schedules and the limit / tolerance and kept ready at site.

11.1.2.16 Keep the maintenance team, for attending to breakdowns, in constant readiness to act promptly and expedite restoration whenever there is a breakdown. To attend any emergency / breakdown wherever and wherever required in a minimum possible time.

11.1.2.17 To follow all statutory regulations in force from time to time.

11.1.2.18 Carry out any other duty assigned to him by Employer related to work.


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11.1.3 Duties of Field Engineer

11.1.3.1 The field Engineer of OHE will be under the Sr. Engineer/OHE and each Field Engineer will be responsible for the following:

11.1.3.2 Maintenance of the OHE and allied installations in his jurisdiction in accordance with the prescribed schedules with a view to avoid failures.

11.1.3.3 Submission of the requirements of power blocks / Track access for OHE maintenance, in Co-ordination with P-way maintenance and other departments concern as far as possible, so as to take maximum advantage of Non traffic hours.

11.1.3.4 Detailed inspection of OHE under his charge by CMV or on foot as indicated ininspection schedule.

11.1.3.5 Scrutiny of daily foot patrol reports, daily reports of defects and take prompt action to rectify the defects brought out.

11.1.3.6 Close supervision of the maintenance gang under his control to ensure a highstandard of work and compliance with prescribed schedules. Also convey each and every preventive and corrective maintenance progress himself to TPC as well as it should be written in the progress register.

11.1.3.7 Keeping the team under his control in readiness to deal with breakdowns and take prompt action to attend any failure and breakdowns following all safety rules and regulations.

11.1.3.8 Guidance to the maintenance staff for the proper execution of work in accordance with standing instructions.

11.1.3.9 Ensuring that tools and equipments under his charge are properly cared for and maintained in proper condition.

11.1.3.10 Keeping watch and taking necessary and timely action to recoup spares required for the system.

11.1.3.11 Preparation and submission of periodical reports and returns to Sr. Engineer.

11.1.3.12 Keeping Employer informed of all important developments and seeking their guidance when required.

11.1.3.13 Ensuring proper cleaning of each equipment.

11.1.3.14 Keeping proper records of all reference drawing, manuals, maintenance schedule etc. for proper operation and maintenance of equipments.

11.1.3.15 Ensuring safe working by maintenance personnel at site while doing of maintenanceof equipments.

11.1.3.16 Ensuring proper competency of the maintenance personnel before commencementof maintenance activity.

11.1.3.17 Ensuring periodical checking / inspections of all testing tools, safety equipmentsand measuring equipments etc. timely and their rectification of deficiencies / defectsnotices if any and maintaining their proper records.

11.1.3.18 Carry out any other duty assigned to him by Employer related to work.

11.1.4 Duties of Working staff (Skilled /Unskilled)

11.1.4.1 All Staff should have requisite competency to enable them working independently.


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11.1.4.2 Every staff should be conversant with the safety rules pertaining to his work and be

capable of independently attending to minor repair and adjustment work on OHE. For this purpose he is required to always carry his tool box, communication equipment, other equipments as required for cleaning, measuring, lighting, safety equipments (such as discharge Rods), ladder etc. with him.

11.1.4.3 Skilled staff should look for the common types of defects on OHE when they aredeputed for patrolling duty and report defects noticed during such patrolling to thesupervisors.

11.1.4.4 Every skilled staff should be able to carry out temporary repair in the event of breakdowns so as to restore traffic as quickly as possible and to deal with repairs necessary for all types of breakdowns of OHE.

11.1.4.5 Make general check of all earth connections.

11.1.4.6 Staff shall carry out the cleaning, oiling, bolting, servicing, minor adjustments andrepairs, daily checks and other works as part of corrective and preventivemaintenance.

11.1.4.7 Carry out any other duty assigned to him.

11.2 MAINTENANCE PROGRAMME OF OHE

11.2.1 General

11.2.1.1 Contractor shall develop and submit maintenance program in order to achieve high reliability and ZERO DEFECT OHE, and to ensure effective execution of the maintenance work for the approval of Employer. Document shall be based on the manufacturer recommendation and previous experience of the equipment installed in other railways / metros, O&M manuals, 25kV ACTM in force, General Rules for Metros, Safety Rules, Applicable Standards etc. Documents shall include the but not limited to:

(a) Organization Chart for AMC (b) Maintenance activity (c) Periodicity (d) Detailed Procedures (e) Checklists/ Registers/ Reports Formats (f) List of Equipments (T&P) to be used for maintenance including measurement

instruments (g) Precautions (h) Any other formats

11.2.1.2 Contractor shall provide & maintain an emergency road vehicle (with driver) in good

working condition all the time and keep all spares and T&P in accordance to the List as per Table 11.2. In case Emergency road Vehicle is under maintenance, standby arrangements are to be made by Contractor. Emergency Road vehicle shall be equivalent to TATA 1109 or higher capacity so that it can carry all T&P and spares including 7 mtrs. Long Aluminum Ladders and with sufficient seating capacity for maintenance gang.

11.2.1.3 Contractor shall also ensure that CMV is maintained in good working condition all the time and to ensure that keep all spares and T&P in accordance to the List as per Table 11.2. Maintenance of CMV is to be done by designated contractor.Contractor shall also maintain records for maintenance of Emergency vehicle and CMV. Provision of this clause in respect of CMV maintenance will be applicable only in case CMV is in scope of OHE Contractor. Wiring should be done by RRV/ wiring train/CMV, manual wiring will damage the OHE wires


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11.2.1.4 However minimum guidelines for the same are as follows. Maintenance activities are broadly categorized as Follows: A) Preventive Maintenance B) Corrective Maintenance Table 11.2: OHE Emergency Material (T&P) and Spares to be kept in CMVs & Emergency Road Vehicle

SN Item (T&P and Spares) Quantity

T&P

1 Pull Lift, 0.75 Ton 2



4 Tirfor 3-Ton cap with rope and handle 2

5 Tirfor 1.5-Ton cap with rope and handle 1

6 Tirfor 0.75-Ton cap with rope and handle 1

7 Single Sleeve Pulley 6”, 4” 1 each

8 Double Sleeve Pulley 6” 2

9 Double Sleeve Pulley 4” 2

10 D-Shackle Diameter 25mm 2




14 Φ16 x 1.5m flexible wire rope (Sling) 3




18 Comealong clamp, RC 2

19 Comealong clamp, OPC 2

20 Comealong clamp, Contact Wire 4

21 Comealong clamp, Catenary 4

22 Kink Remover 1

23 Contact wire positioning device (Al / wooden) 1

24 Mallet 1

25 Hammer 1kg (copper) 1

26 Twister 1

27 First Aid Box 1 no.

28 33kV hand gloves 1 pair

29 Hydraulic operated crimping tool with die 1 no.

30 Hand operated crimping tool with die 1 no.

31 Contact & Messenger wire cutter 1 no.

32 Dropper wire cutter 1 no.

33 Crow bar 1 no.

34 Tommy bar 1 no.

35 Manila rope 1/2", 3/4", 1” diameter 15m each

36 Safety belt 2 nos.

37 Operating rod 1 no.

38 Discharge rod 8 nos.

39 Aluminium extendable ladder 11m 1 no.

40 Aluminium ladder 6m 1 no.

41 Halogen lamp assembly 4 nos.

42 Search light rechargeable and portable 4 nos.

43 Spirit level 1

44 Bull dog clamp (1/2”) 4

Spares As per ACTM

1 RC suspension clamp 2

2 OPC suspension clamp 2

3 OPC Splice 2


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4 RC Splice 1

5 I-section steady arm (high speed) 1

6 Steady arm, bend type for mainline 4

7 Steady arm, special type for IOL 4

8 9-ton adjuster 2

9 Bracket tube fitting 1

10 Stay tube fitting 1

11 Complete cantilever assembly 1

12 Continuity “G” 165 sqmm jumper for mainline 1 no.

13 Continuity “G” 105 sqmm jumper for yard (4m) 1 no.

14 RC strain clamp 1 no.

15 OPC strain clamp 1 no.

16 BT, RT cap 2 each

17 Anchor Double Strap Set 2 sets

18 Dropper lug 10 nos.

19 Section insulator 1 no.

20 Hybrid / composite insulator, stay tube 2

21 Hybrid / composite insulator, BT 2

22 Insulator, hybrid 9-ton 2

23 Porcelain insulator, 9-ton 2 nos.

24 Porcelain insulator, ST 2 nos.

25 Porcelain insulator, BT 2 nos.

26 Insulator, Disk 1

27 Insulator, Pedestal 1

28 Complete ATD assembly 1 each type

29 SS Wire Rope 1

30 PG clamp, RC-1551 1

31 PG clamp OPC 1

32 Catenary contact wire PG clamp 1031 4



35 Splice catenary 4

36 Splice contact 2

37 Ending Cone, catenary 3

38 Ending Come, contact 2

39 J-bolt 6

40 Swivel clip 4

41 Dropper clip, contact 6

42 Dropper clip, catenary 6

43 Dropper wire piece, 10m 1

44 Span dropper 12

45 Inclined dropper 4

46 Messenger wire 20m

47 OPC wire (50m) 1

48 Contact wire 20m

49 Complete maintainer tool box with all tools of required sizes (spanners, ring spanners, screw drivers, pliers, hacksaw, hammers, adjustable wrench, allen key set etc.)

2 boxes

50 All types of buts, bolts, ‘U’ bolts, washers, rivets, pins, split pins etc.

20 nos. each

Notes: 1. The above list is indicative and not exhaustive. If any additional spares, Tools & Test

Equipment are required the same may be indicated by the Contractor. However, nothing extra will be paid for any additional spares, Tools & Test Equipment indicated by the Contractor.


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2. The costs of spares, Tools & Test Equipment listed above for maintenance during DLP/AMC have to be included in the quoted prices. Nothing extra will be payable for such spares, Tools & Test Equipment.

3. If any additional spares, Tools & Test Equipment apart from the ones mentioned

above are required during the DLP/AMC period the same will be arranged by the Contractor, without any extra payments.

4. This will not absolve the Contractor of his responsibility to fulfill the DLP/AMC

obligations as per relevant clauses of tender conditions.

5. Contractor has to ensure availability of above spares, Tools & Test Equipment along with Test certificates, calibration certificates etc.

6. The requirement given above is indicative and minimum in nature (for guidance

purpose only). Prior approval of engineer-in-charge will have to be taken before supply of spares, Tools & Test Equipment along with details regarding the make & model no. of items specified above.

7. Spares mentioned in list are indicative. Contractor shall propose the spares list

(including any other spare part) to be maintained in CMV as per installed OHE in the corridors.

8. If any OHE spare is consumed at site, then it has to be recouped on the same day.

For this Contractor has to maintain sufficient reserve as per time required for procurement under his custody which shall be approved by Employer. All the above OHE T&P and Spares has to be check with in the periodicity of 15 days.

9. These T&P and Spares shall become the property of Employer at the end of

Contract.

11.2.2 Preventive Maintenance

11.2.2.1 OHE is subject to dynamic oscillations due to the constant contact and movement of the

fast moving pantograph coupled with wind pressure. It is necessary to maintain the OHE in perfect condition through proper checks on its geometry and all parameters adopted in the design. Following activities are to be carried out during preventive maintenance:

11.2.2.2 Foot Patrolling

SN Done by Paved section At grade

1. Skilled staff associated by unskilled staff Monthly Weekly

2. Field Engineer 6 monthly Monthly

Indicative checklist for foot-patrolling is enclosed as under: Table 11.3: Checklist for Foot-Patrolling (Monthly for Paved Section and Weekly for Graded Section)

Items To be checked

Foundation (At Grade)

Damaged / Cracked

Tilted

Water collection around foundation

Side earth filling required

Top of foundation not visible

Wild growth, if any

OHE support Hit mark or damage to mast


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structures

Number plate missing

Number plate damaged / hanging loose

Contact wire height; RL/IMP (rail level / implantation) not painted

Anchor

Nut checknut or lock plate pin missing from anchor bolt & guy rod.

Anchor bolt rusting

Bracket Assenbly

Bracket insulator damaged

Stay insulator damaged

9 tonne insulator damaged/slipped

Any other defects noticed, C/L assembly displumbed

Section Insulator

Abnormal wear of runners

Core insulator very dirty

Core insulator having flash marks / damaged

Regulating Equipments

Y distance is abnormal

Free movement of balance weight

SS rope strands found cut/caging

Whether equalizing plate is negatively tilted towards mast

OHE Span

Span droppers abnormally out of plumb

Span dropper damaged

Any abnormality in respect of jumpers

Damaged to catenary strands

Excessive sagging/hogging of cont.wire

Insulator

Insulator name plate missing

Insulator lock missing/damaged

Condition of pedestal insulator

Any sign of sparking/overheating

RC & BT

Suspension insulator damaged

Soundness of connection of RC with ITL

Any other defects noticed at booster transformer station

Earthing

Connection of plinth jumper

Connection between main BEC to plinth

Connection between segment to segment

Connection between mast to OPC

Connection between mast to hand rail

Connection between BEC to steel structure at platform

Connection between fire water pipe to BEC in platform

Connection between IB or ITL and OPC, BEC, RC

General Checking

Cautions board missing

Tree branches near OHE (4 mtr. range)

Position mast base plate bolts (at viaduct)

Bird nests and pieces of stray wire

Minor defects rectified if any during patrolling (such as removing of kites and threads (with discharge rods))

Major defects noticed, if any

11.2.2.3 Current Collection Tests

It is necessary to carry out periodic tests to detect points at which contact between the contact wire and pantograph is unsatisfactory resulting in sparking. Such current collection tests are performed at night. A video camera shall be fixed on the roof of the train selected for current collection test, so that it can capture the complete view of pantograph interaction with OHE. A display screen connected to camera, able to show real time view, may be installed in saloon of the train to observe the sparking. Above arrangement for current collection shall be done by RS wing. During current collection test (in nonrevenue hours) one OHE staff shall be deputed in driving cab to announce the approaching location by using PA system of the train. The location where the sparking is observed and the severity of the sparking should be


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immediately noted down by the OHE engineer jointly with RS staff. A report of such locations shall be prepared of complete section in prescribed format and the OHE at the sparking location got checked up as soon as possible to find out and eliminate the cause of sparking. Compliance report for attending the sparking location recorded during current collection test shall be submitted to the Employer in due course of time. The current collection tests as above should be carried out by the maintenance in-charge once in 6 months over his entire section. Employer representative may also accompany during such tests so information should be given in advance.

11.2.2.4 Special checks While the majority of items require attention only during Periodical Maintenance and Periodical Overhaul, items listed below will require more frequent attention as indicated against each:

11.2.2.4.1 Insulators Generally insulators need cleaning along with the maintenance schedule. At locations subject to smoke pollution or pollution due to industrial dust, the frequency of cleaning will have to be fixed based on the extent of such pollution. Where pollution is heavy, cleaning may have to be done more frequently. Polluted zones of complete section are to be identified by incharge in consultation with Employer and cleaning of insulators is to be done before monsoon and winter season.

11.2.2.4.2 Bi-metallic clamps The condition of junctions shall be checked by thermal imaging camera to be provided by OHE Contractor. The hot spot hence noticed shall be immediately attended in next available power block. Bi metallic strip wherever provided shall be replaced with new one. Yearly checking of condition of bimetallic strip provided in Switchgears of Switching post shall be carried out. All the worn out strips shall be replaced.

11.2.2.4.3 Earth Connections Apart from general inspection of bond and earthing connections during foot-patrolling, all such connections should be specially checked for continuity and soundness of connections once in a year. Particulars of all earthing connections should be entered in a register station-wise for each section and the dates of yearly inspection entered therein.

11.2.2.4.4 Feeders Foot-patrolling of 25kV feeders should be carried out every month. During this check, the Maintainers shall also check that safety guards provided under the feeders properly earthed, if the clearances are adequate and caution notice boards are in position.

11.2.2.4.5 OHE supported on steel girder bridges should be examined as frequently as possible depending upon traffic conditions.

11.2.2.4.6 Bird nests

Vigil should be exercised especially during the nesting season and the nests removed as soon as possible.

11.2.2.4.7 Pre-monsoon checks Some of the items to be attended to are: (a) All pulley type ATD’s shall be checked for their free movement & X-Y values adjusted

if required;


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(b) All tree branches in the section shall be trimmed to avoid any untoward incident; (c) Earth continuity and earth resistance shall be checked for all equipment installed in

section and recorded as per IE rules, rectification action shall be taken as required; (d) Special check shall be carried out to ensure working of isolators; (e) Where there is dripping of water on OHE/OCS from overline structure on earlier

occasion shall be regularly monitored. If found, same should immediately informed to civil/works department;

(f) Mast is to be checked for any leaning at grade section; (g) PVC sleeve on BEC wire under track circuited rail to be checked for itshealthiness to

avoid signal failures due to short circuiting Any special instruction if issued time to time shall be complied.

11.2.2.5 Routine Maintenance This schedule shall be carried out by CMV preferably during power block. During the schedule, fittings are not generally dismantled, but all fittings, which are found defective, must be replaced. In addition clearances, heights, staggers etc. should be checked and corrected. The details of work to be carried out during this schedule are as under:

11.2.2.5.1 Masts, portals and cantilever supports and conductors (Periodicity: 24 months on viaduct locations and 12 months on Grade Locations) (a) Check rail level and setting distance against markings on the masts and entries in the

register. Variation above 30mm in setting distance and 20mm in rail level should be notified to the P-Way for correction. Variations, even within the above limits, should not be permitted if the Schedule of Dimensions is infringed.

(b) Check all steel parts and remove rust, if any, from painted steel work. Rusted portions,

after cleaning, must be given two coats of zinc chromate primer followed by aluminium paint.

(c) Check all anchors for tightness of bolts, nuts, and check nuts and pins; lubricate all

turn buckles / adjusters and pulleys. (d) Nut Bolt of mast base plate at viaduct to be checked and tightened, if required. At

grade examine the base of each structure to ensure that muffs permit drainage of water. Clean the muffs removing any muck or dirt. Cracked or damaged muffs must be recast.

(e) Check all bonds thoroughly; defective bonds must be rectified and missing bonds

provided. (f) Check and tighten all bolts and nuts. Marking with paint/marker pen is to be done to

avoid un-necessary tightening. (g) Check all galvanized pipes and fittings. Where galvanization is found to be chipped

off, the fitting of pipe should be replaced. Minor chippings may be repaired using 'cold galvanizing paint'.

(h) Examine register arm and all hooks and fittings for cracks. Condition of steady arm for

any damage to crimped portion has to be checked especially at rigid dropper location. (i) ST, BT, RC & 9-Tonne anchor Composite Insulators has to be cleaned with soft and

clean cloth and check Insulators for flash mark. Apply Insulating spray paint at any flash mark on Insulators. Clean all porcelain insulators and carefully check for cracks


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and broken sheds. If more than 2 sheds are broken or there is any crack on the core the insulator should be replaced.

(j) Note down the CW height & stagger in grade section and adjust If required as per

SED’s. (k) Check presence and condition of caution notice boards, number plates, coasting

boards, etc. Paint or replace the boards as required. Ensure that they are all well secured.

(l) Ensure that the drain holes in the tubes are free and not clogged. (m) As the bracket is articulated, check the position with reference to the axis of the mast.

The position will vary with temperature and distance from anti-creep. The register arm and steady arm should asfar as possible be in the same plane as the bracket.

(n) Check for either spring washer or locknut on bolt. Mouth of split pinshould be

opened fully. (o) Check for any broken strands of jumpers (p) Check for proper tightening of nut bolts of caution board & number plate. (q) Contact and Messenger Wires: Check carefully condition of contact and Messenger

wires, particularly for kinks and twists in contact wire and broken strands of Messenger wire. Any stranded conductor (Messenger wire etc.) should be spliced if more than 20 per cent of the strands are broken. In case of less than 20% strands are broken, it may be secured by dropper clip.

(r) Droppers

Droppers should be vertical and tight. replace if found loose with appropriate dropper

Check droppers for any damage or rubbing at multi cantilever location, correct if required.

11.2.2.5.2 Turnouts

(Periodicity: 12 months) The point at which one track separates/meets with another track is called turnout. From OHE point of view turnouts are provided for smooth transition of pantograph during movement of train from main line to branch line or vice-versa. (a) With OHE Inspection Car running on main line check up if pantograph glides smoothly

under the loop line OHE without any contact.

(b) While moving on main line to branch line (Turnout) or vice versa smooth transition of pantograph from main line to turnout wire at appropriate take-off must occur. Take-off/Take-on of main line wire should be at a stagger of 55-65 cm.

(c) Check stagger of both the OHEs at turn outs. (It shall not normally exceed 300 mm). (d) Check that the main line OHE of overlap type turn out is about 50mm below that of the

turnout OHE. (e) Check the sag of Section insulator at turnouts/crossovers should be zero. Also check

the stagger.


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(f) Check up cross contact bar, if any, for displacement and distortion. Check up for hit marks, if any.

(g) Check up rail level and setting of the obligatory mast. (h) Check up for hard spots near rigid droppers, and contact above rail burn area, if any.

11.2.2.5.3 Section Insulators (Periodicity: Monthly for polluted zone locations and Quarterly for others on Main Line) (a) Section insulators on the main lines such as at neutral sections and yards/depot

should be attended to as under once in three months. (b) Clean Core insulators with soapy water, rinse thoroughly with potable water. Use dry

and fluffless cloth. Replace Section Insulator if badly chipped or even slightly cracked. (c) Check runners for flash-marks. Carbon deposition on is to be cleaned by carbon

cleaner. (d) Check level of the assembly and adjust as required. Longitudinal and transversal

parallelism with regards to running plane should be checked and corrected if necessary.

(e) Diameter of contact wire at both ends of SI is to be measured and recorded. Check for

excessive contact wire wear near anchor clamps. (f) All nuts, bolts, check nuts and split pins of runners and dropper is to be checked and

tightened properly if required. (g) Smooth gliding of pantograph underneath SI is to be checked and any hitting or

problem in smooth transition is to be adjusted by adjustable droppers. Note: Section Insulator installed at depot to mainline interface and in polluted zone must be cleaned with Soapy water on monthly basis. Section Insulators: Section insulators (Tramway) in the yards/depot should be attended to as under once in Six months: ii) Clean insulators and replace badly chipped or even slightly cracked insulators. iii) Check runners for flash-marks. iv) Check level of the assembly and adjust as required. v) Check for excessive contact wire wear near anchor clamps. vi) Measure and record min. electrical clearance between runners and core

insulator. Correct if less than specified. vii) Check that pantograph passes underneath the SI smoothly.

11.2.2.5.4 Manual Isolators (Periodicity: 12 months) (a) Check number plates for cleanliness and security. (b) Check correctness of operation, alignment of contacts and arcing horns. Check earth

continuity where applicable. (c) Lubricate moving parts and locks. (d) Check interlocks where provided.


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(e) Check that the distance between male and female contacts and electrical clearance in open position and adjust them as specified.

11.2.2.5.5 Overlap (IOL/UIOL)

(Periodicity: 24 months on Via duct locations and 12 months on Grade Locations) Where two OHE’s wire lengths are overlapped to each other with adequate horizontal separation (500mm for IOL & 200mm for UIOL) and suitable stagger is known as overlap. The overlap is so arranged that both OHE’s are available to the pantograph for minimum 2 mtr at the same level on either direction of central mast. Thereafter the OHE’s are raised gradually by 500 mm and held at intermediate mast by Registration Arm Assembly (RRA) Clamp. (a) Check height and stagger of OHE In the overlap section. (b) Check whether the normal minimum clearance of 500 mm is available between the

two OHEs in an insulated overlap and 200 mm in an un-insulated overlap. (c) Check whether the lifting of out-of run OHE is correct. (d) Check that parallel running of contact wires in the overlap for a minimum 2m in the

panto sweep region. (e) Check jumpers for any damage or signs of heating at jumper fittings / PG clamps.

Check the tightness of RRA clamp and jumper fittings.

11.2.2.5.6 Contact Wire thickness (Periodicity: 12 months) Measure and record thickness of contact wire at 2 locations of platform where the train starts and mid location of every kilometer near swivel clip. Marking is also to be done at the same locations for future reference.

11.2.2.5.7 Neutral Sections Neutral Section shall be checked by in-charge on monthly basis as per list below: (a) Neutral Section (SI Type)

Since this type Neutral section is formed by using three Section Insulators, hence all three SI shall be checked independently according to check points of Section Insulator.

(b) Short Neutral Section

i) Check runner for any Flash mark or Hitting. If hitting marks observed on runner, readjustment of neutral section is to be done with the help of Jig. If runners are badly worn out then replace it.

ii) Check condition of arcing horn. iii) Check PTFE rod for any flash mark. Clean with normal water. Detergent is

to be used if found dirty. iv) Measure the PTFE rod wear, turn it if more than 13 mm. Replace it if already

turned four times. v) Check the droppers for tightness. vi) Check the condition of adjuster, earthing jumper, splices, lock nut pins etc. vii) Check the hogging, if found improper then adjust it.

11.2.2.5.8 Regulating Equipment


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(Periodicity : 12 months) Pulley Type: Inspect the good condition of the tensioning device assembly with a special interest on the following points: (a) Check the position of the stainless steel cable in the anchor clamp, compensating

plate and measure X, Y parameters. (b) Check the good condition of the stainless steel cable: for any damage, wear or broken

strand. Change the cable if necessary. (c) Check the alignment of the pulleys and free movement of counter weight. Any rubbing

of SS cable should be attended immediately. (d) Check the tightening of the Nuts & bolts and the open V pins, and the condition of the

pulleys. (e) Grease the ball bearings with the grease pump on the axles end. Use only the SKF

(LGE P2) or equivalent grease. Put the grease until the new grease coming out the side of the ball bearing.

(f) Preferably use a manual grease pump. (g) Condition of equalizing plate and corrective action for contact creep Spring Type ATD Maintenance of Spring ATD shall be done as per recommendation of manufacturer (OEM) and previous experience of the equipment installed in other railways/metros, O&M manuals, 25kV ACTM in force.

11.2.2.5.9 Bonds & Earthing Connection In depots/yards (a) Check all bonds and replace defective or missing bonds. Paint all bonds. (During Foot

patrolling) (b) Inspect earths (Earth Pits) and record earth resistance. Earths (Earth Pits) having

resistance of over 10 ohm should be attended to. (Annually) In main line (a) Check all connections and condition of BEC, plinth jumpers.(During Foot patrolling) (b) All ITL/ Impedance bonds connections with RC, OPC, BEC and rails are to be

checked for their healthiness. Check for any sign of heating, attend if required. (Annually).

11.2.2.5.10 Sites affected by accidents

Such sites should be specially checked and attended to.

11.2.2.5.11 Feeder Lines (a) Check earthing of towers (b) Measure and record earthing resistance of towers (c) Clean insulators and replace those, which are cracked or chipped.

11.2.2.6 Periodical Overhauls (Periodicity: 4.5 years)


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The bottom line of carrying out any scheduled maintenance is that once it is carried out that equipment should not fail till the next schedule falls due. The aim of POH is to recondition and restore the installation in the condition it was when it was first commissioned, whereas preventive maintenance has for its objective to take care of the wear and tear during normal service and forestalling possible failures by regular inspection and prompt attention. The work involved during POH is somewhat greater in scope than the pre-commissioning tests, since after years of service many parts would have suffered wear and tear, of which necessary adjustments will have to be made or repairs done to make good the wear, or the irreparable items replaced. The POH of OHE should be planned on a programmed basis as per the schedules laid down. For programming POH, the entire section should be divided into smaller sections in accordance to identified polluted zones. a) Cantilever

One complete cantilever in identified polluted zone is to be replaced and its thorough cleaning and detailed examination of its moving parts for free movement is to be done. Check complete cantilever component for cracks, rust and thread damage with a magnifying glass. The crack fittings and damage threads fittings should be discarded. Deteriorated GI fittings and pipes should be repaired by using cold galvanized paint. If any major defect is found another cantilever from the same section shall be examined for the same. Remedial action to be initiated if the problem persists in consultation with Employer.

b) Regulating Equipment (Pulley Type ATD)

All regulating equipment(ATD) should be replaced with the overhauled ATD. SS rope should be closely examined for any damage to its strands. Ends of SS rope is also to be reversed. X &. Y values to be adjusted as per temperature chart either by wire cutting or by adjuster. Removed ATD is to be taken to workshop for cleaning and check for any rubbing mark on pulley block, if any replace the same. All lubricating holes should be free for passage of grease. Check for free movement of bearing of pulley block. Grease should be applied in the bearing by grease gun. Damaged part is to be replaced with new one.

c) Jumpers, Messenger and Contact Wire

POH of all jumpers i.e. Continuity, Anti Theft, Equi-potential, feeder jumpers etc. to be done. Dismantle all jumper connections. Clean the conductors by emery paper, if there is a sign of overheating. Remove kink if noticed. Check for broken/damage strands. Check for overheating or corrosion especially at PG clamps & BM flange connection.

11.2.3 Corrective Maintenance

11.2.3.1 Bottom line of carrying out preventive maintenance is that once it is carried out that

equipment should not fail till the next schedule falls due. Generally it shall be carried out during non traffic hours on main line. Despite of above intense maintenance schedules and different proven power supply arrangements installed following failures are observed in OHE. These failures are to be attended during revenue hours after taking power and traffic block of affected section.

11.2.3.2 Catenary strand break/parting is predominating failure in OHE Remedial action: Above breakdown has to be immediately attended after taking Power and traffic block on main line by temporary restoration i.e. taking load by tirfor. Same is attended by catenary splicing in night power block (during non-revenue hours).Approx.


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Time for temporary restoration: 6-10 minutes in case of strand broken and 25-30 minutes in case of parting

11.2.3.3 Failure of ST/BT insulator Remedial action: Above breakdown should immediately be attended after taking Power and traffic block on main line by replacing the faulty insulator with new one. Approx time for restoration: 15-20 minutes in each case i.e. replacement of ST or BT insulator.

11.2.3.4 Contact wire parting Remedial action: Above breakdown has to be immediately be attended after taking Power and traffic block on main line by splicing contact wire. Approx. Time for temporary restoration: Approx. two hours in case of parting since It requires highly skilled and trained artisans as smooth panto run is to be maintained on spliced contact wire.

11.2.3.5 Section Insulator burnt and parted Remedial action: Above breakdown is a major breakdown and shall be attended as per site conditions immediately. Approx. time for temporary restoration: 2-3 hours in case of replacement of SI since It requires highly skilled and trained artisans and precision work to replace SI and smooth panto run is to be maintained by leveling of SI by droppers. As in case, multi activity may be required/involved such as splicing of Contact wire in place of SI and replacement of nine tonne insulator etc.

11.2.3.6 Breakage of span dropper Remedial action: Above breakdown should be attended after assessment of situation as if only one dropper is broken. Same is to be attended by replacing in night block (nonrevenue hours). If the damage is more or in overlap spans same should be attended immediately to avoid pantograph entanglement. Approx time for restoration: 6-10 minutes for each dropper.

11.2.3.7 For attending above breakdowns Contractor’s OHE team should be ready at designated place all the time and immediately move to the place of breakdown/incident by Emergency Road vehicle generally. For the movement of Emergency Road vehicle all necessary permissions e.g. Road permit, movement in no entry area, RC, PUC etc. from local authorities are to be taken by the by the Contractor and be valid all the time. Only in case of major breakdowns, if required, CMV can be moved after taking due permissions from traffic controller to the breakdown site in consultation with Employer official. In addition to above, any other breakdown during revenue hours may occur due to any reason which is also to be attended by Contractor’s OHE team and train services are to be restored at the earliest.Unusual Occurrence report should also be submitted within 3 days to the Employer in prescribed format.

11.3 SCOPE OF WORK FOR DLP / AMC OF SWITCHING STATIONS

11.3.1 General


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11.3.1.1 During Defect Liability Period / Annual Maintenance Contract, Contractor shall depute

dedicated manpower round the clock in shifts prescribed in Table 12.4 at designated place as agreed by Employer for attending breakdowns and preventive maintenance activities.This shall be read in conjunction with Clauses of PC applicable for DLP and AMC as well. The following requirement is in addition to the responsibility of the Contractor during DLP defined in Bidding Documents. Table 11.4: Maintenance staff for Switching Stations

SN Staff Designation No. of persons to

be deployed Min. Qualification

1 Sr. Engineer 1 Degree with 5 years experience of similar nature

2 Field Engineer 1 per shift Degree with 3 years similar experience / Diploma with 5 years similar experience

3 Skilled 3 per shift ITI with 3 years similar experience

4 Un-skilled 1 per shift -

11.3.1.2 Contractor shall set-up Depot, corresponding stores, repair shops, which includes

furniture, material racks staff cup-boards, tools, instruments, material handling instruments, communication instruments, material consumable etc. in addition to proper upkeep of all the switching stations’ installations. Manpower mentioned above shall be able to perform duties as follows:

11.3.2 Duties and Responsibilities of Sr. Engineer (Switching Stations)

11.3.2.1 Sr. Engineer (Switching Stations) is the field in-charge of all the Switching Station installations including stores working under him and directly responsible for the safe and efficient maintenance of traction switching stations. in his jurisdiction. He must be thoroughly conversant with all technical details of the equipments under his charge including their rating, trend of power demand and also correct method of their operation andmaintenance. In particular he/she shall responsible for the following:

11.3.2.2 To supervise the preventive and corrective maintenance of installations under his charge accordance with the standard and prescribed schedules to keep them fully serviceable all times and in a state of good repair. To ensure proper record of preventive and corrective maintenance of installations in his control and submit monthly report to Employer with completion and next due dates (Equipment wise);

11.3.2.3 To maintain proper co-ordination with TPC, OHE team, E&M team, Civil wing, Power supply authority and other concerned departments and render assistance when required to ensure reliability of power supply;

11.3.2.4 To ensure advance planning of preventive maintenance of switching stations and submit in advance to Employer and ensure their implementation. To plan in advance the requirement of power blocks for switching stations maintenance based on the work to be done and submit the same well before to Operation Control Manager (OCM) through TPC and ensure for availing the complete section power blocks and also completion of the work within the time allotted.

11.3.2.5 To keep his organization in constant readiness to deal promptly with any breakdowns and failures of equipments; to attend any emergencies / breakdown wherever and whenever required in a minimum possible time.


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11.3.2.6 To instruct, train and supervise staff under his control and ensure that they shall operate and maintain the equipment properly and in particular they actually observe all prescribed rules and regulations, Joint procedure orders issued time to time, safety precautions, SHE policy laid down, for this to ensure proper training of all the staffs working under him. Ensure provision of Personnel Protective Equipments (PPE) while working on the systems for him and working staff as well.

11.3.2.7 To ensure that special tools and instruments for maintenance, and testing of all installations are healthy and carried for corrective and preventive maintenance, their timely calibration, storing at proper place etc. In addition to ensure that the program of testing and maintenance of protective relays in adhered to and ensure that other safety equipment including bonding and earthing are functioning effectively;

11.3.2.8 To monitor availability of sufficient quantity of spares and other store required for better maintenance and operation of the installations and initiate timely action to recoup of these items. Stock / Non-stock items planning, placement of stocking applications, submission of indents.

11.3.2.9 Ensuring availability of materials at all time and proper accountal and periodical verification of stores and T&P etc.

11.3.2.10 Ensure spare materials, T&P drawings, manuals and all other relevant literature etc. is available with him as per conditions of contract agreement.

11.3.2.11 To depute staff having competency when required for manning switching stations in the event of SCADA failure.

11.3.2.12 To inspect all installations under his charge at least once in three months and or as per prescribed scheduled inspection with particular attention to safety and operational aspects and submit the inspection reports to Employer without fail.

11.3.2.13 To keep Employer fully informed of all important development and seek their guidance when required.

11.3.2.14 To ensure proper taking over of new installation after arranging proper checking, testing, inspection and rectification of all defects, deficiencies and pending works and to ensure himself that installations are as per contract terms and conditions and as per all relevant standards and obtained approval for the same from the Employer.

11.3.2.15 To scrutinize daily reports on corrective and preventive maintenance activities, failures and other defects notices on switching stations, as well as reports from CTPC/TPC, inspection report of Employer’s engineer and arrange prompt rectification of defects pointed out and report compliances to Employer and ensure their implementation.

11.3.2.16 To ensure submission of prescribed periodical reports after careful scrutiny and remedial measures suggested to avoid recurring failures and submit. (a) Failure analysis reports and unusual occurrence reports (b) Preventive and corrective maintenance progress (c) CB tripping reports with detailed analysis (d) Power blocks and PTW reports (e) Accidental reports (f) Staff position report (g) Store position report

11.3.2.17 Submit reports to Employer on compliance of instructions issued by him if any.

11.3.2.18 To ensure proper competency with validity for the staff working under him and arrange training for issue of competency.


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11.3.2.19 To ensure making of each equipment history, technical details updated and submit as and when required by the superior officers promptly.

11.3.2.20 Details of inspection schedules and the limit / tolerances must be displayed and kept ready at site.

11.3.2.21 To carry out all necessary inspections of his assets as per the statuary requirement or otherwise and shall notify and rectify any defects / deficiencies found during such inspections.

11.3.2.22 To follow all statutory regulations in force from time to time.

11.3.2.23 To carry out any other duties allotted by Employer related to work.

11.3.3 Duties and Responsibilities of Field Engineer The Field Engineer/PSI will be under the Sr. Engineer (Switching Stations) and shall be responsible for:

11.3.3.1 Maintenance of the Switching Stations and allied installations in his jurisdiction in accordance with the prescribed schedules.

11.3.3.2 Submission of the requirements of power blocks / track access for Switching Stations maintenance, in co-ordination with OHE maintenance and other departments concerned as far as possible, so as to take maximum advantage of power blocks / track access.

11.3.3.3 Detailed inspection of Switching Stations installations under his charge as per inspection schedules.

11.3.3.4 Scrutiny of daily foot patrol of cable routes, daily reports of defects and take prompt action to remedy the defects brought out.

11.3.3.5 Close supervision of maintenance gang under his control to ensure a high standardof work and compliance with prescribed schedules. To convey each andevery preventive and corrective maintenance progress himself to TPC as well as it should be written in the progress register of his head quarters.

11.3.3.6 Keeping the organization under his control in readiness to deal with break-downs and take prompt action to attend any failure and breakdowns following all safety rules and regulations.

11.3.3.7 Guidance to the maintenance staff for the proper execution of work in accordance with standing instructions.

11.3.3.8 Ensuring that tools and equipments under his charge are properly cared for and maintained in proper condition.

11.3.3.9 Keep watch and take necessary and timely action to recoup stores and spares required for the upkeep of the system under his jurisdiction.

11.3.3.10 Preparation and submission of periodical reports and returns to superior officers as laid-down.

11.3.3.11 Ensure Employer’s Engineer is informed of all important developments and seeking their guidance when required.

11.3.3.12 Ensuring proper cleanliness of each equipment.

11.3.3.13 Keeping proper records of all reference drawings, manuals, maintenance schedule etc. for proper operation and maintenance of equipments.


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11.3.3.14 Ensuring safe working of maintenance personnel at site while doing of maintenance of

equipments.

11.3.3.15 Ensuring proper competency of the maintenance personnel before commencement of maintenance activities.

11.3.3.16 Ensuring proper records of inventory, testing and measuring tools etc.

11.3.3.17 Ensuring periodical checking / inspections of all testing tools, safety equipmentsand measuring equipments etc. timely and their rectification of deficiencies / defects notices, if any, and maintaining their proper records.

11.3.3.18 Carrying out any other duties allotted by Employer’s Representative related to work.

11.3.4 Duties of Working staff (Skilled)

11.3.4.1 All Skilled staff should have requisite competency to enable their working independently and give report in written the work done assigned to them.

11.3.4.2 Every skilled staff should be conversant with the safety rules pertaining to his work and be capable of independently attending minor repair and adjustment work on Switching Stations. For this purpose he is required to always carry his toolbox, communication equipment, other equipments as required for cleaning, measuring, and lighting, safety equipments (such as discharge rod), ladder etc. with him.

11.3.4.3 A skilled staff should be able to carry out operation at switching stations on local control in an emergency under the instructions of TPC.

11.3.4.4 Skilled staff should look for the common types of defects on Switching Stations when they are deputed for patrolling work and to report on defects noticed during such patrolling to the supervisors.

11.3.4.5 Every Skilled staff should develop the ability to carry out temporary repair in the event of breakdowns so as to restore traffic/supply as quickly as possible and todeal with repairs necessary for all types of breakdowns of Switching Stations.

11.3.4.6 Make general check of battery and battery chargers;

11.3.4.7 Make general check of earth connections;

11.3.4.8 The maintenance staff shall carry out the cleaning, oiling, bolting, servicing, minor adjustments and minor repairs, daily checks and other works as part of corrective and preventive maintenance.

11.3.4.9 Carry out any other duty assigned to him.

11.4 MAINTENANCE PROGRAMME (SWITCHING STATIONS)

11.4.1 General

11.4.1.1 Contractor shall develop and submit maintenance program in order to achieve high reliability and ZERO DEFECT, and to ensure effective execution of the maintenance work for the approval of Employer. Document shall be based on the manufacturers’ recommendation and previous experience of the equipment installed in other railways / metros, O&M manuals, ACTM in force, General Rules for Metros, Safety Rules, Applicable Standards etc. Document shall include the but not limited to: (a) Organization Chart for AMC (b) Maintenance activity


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(c) Periodicity (d) Detailed Procedures (e) List of Equipments (T&P), spares to be used for maintenance including measurement

instruments (f) Checklists/ Registers/ Reports Formats (g) Precautions (h) Any other formats

11.4.1.2 The Contractor shall provide free of cost six weeks before start of trial running, spares, special tools and test equipment which are essential for day to day use in both corrective and preventative maintenance and for workshop use in the overhaul of all modules and units likely to be required over the full service life of the installation as below. The Contractor shall submit a schedule of all tools and equipment with details of calibration and supplier and if this list is found insufficient then the same needs to be augmented for preventive and corrective maintenance of all the equipment supplied under the contract without any extra cost. These tools and test equipment shall become the property of Employer at the end of DLP. Table 11.5: Minimum list of tools & test equipment and Spares (for Switching Stations Maintenance Works)

SN Description Quantity

A Tools and Test Equipment

1 Earthing rods 8 nos. for each Switching Station

2 Aluminum extendable ladder 11 mtrs 1 no. for each Switching Station

3 Complete maintainer tool box with all tools of required sizes (spanners, ring spanners, screw drivers, pliers, hack saw, hammers, adjustable wrench, allen key set etc.)

2 nos.

4 Safety belts 2 nos.

B Spare Parts List

1. Set of protection relays consisting of one relay of each type 1 set

2. Set of transducers consisting of one transducer of each type

1 set

3. Set of metering relays consisting of one relay of each type 1 set

4. Voltage transformer / voltage capacitive sensors 2 nos.

5. Length for each type power and control cable

1% of the installed quantity or 100 mtrs. whichever is higher

6. Straight through joint kit of each type 10 nos.

7. Termination kit of each type 10 nos.

11.4.1.3 The above list is indicative and not exhaustive. If any additional spares, Tools & Test

Equipment are required the same may be indicated by the Contractor. However, nothing extra will be paid for any additional spares, Tools & Test Equipment indicated by the Contractor.

11.4.1.4 The cost of spares, Tools & Test Equipment listed above for maintenance during DLP/AMC have to be included in the quoted prices. Nothing extra will be payable for such spares, Tools & Test Equipment.

11.4.1.5 If any additional spares, Tools & Test Equipment apart from the ones mentioned above are required during the DLP/AMC period the same will be arranged by the Contractor, without any extra payments.

11.4.1.6 This will not absolve the Contractor of his responsibility to fulfill the DLP/AMC obligations as per relevant clauses of tender conditions.


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11.4.1.7 Contractor has to ensure availability of above spares, Tools & Test Equipment along with Test certificates, calibration certificates etc.

11.4.1.8 The requirement given above is indicative and minimum in nature (for guidance purpose only). Prior approval of Engineer-in-charge will have to be taken before supply of spares, Tools & Test Equipment along with details regarding the make & model no. of items specified above.

11.4.1.9 Minimum guidelines for Maintenance activities are broadly categorized as Follows: A) Preventive Maintenance B) Corrective Maintenance

11.4.1.10 For better utilization of traction assets, outage of any traction equipment from service should be minimum without compromising on safety of the equipment and personnel. Monitoring of condition of the equipment by reliable means (e. g. Thermographic camera) is essential for following system of need based maintenance i.e. directed maintenance.

11.4.1.11 Recommendations of Original Equipment Manufacturer (OEM) time to time, have to be kept in view while defining the scope and periodicity of the schedules.

11.4.2 Preventive Maintenance

11.4.2.1 Preventive maintenance is applied when equipment is still operative. In all such cases proactive treatment is given consisting of checks, examination and supervisory inspection. The frequency of maintenance given in following para is minimum. It may be increased on the basis of factors such as site condition/ pollution levels and other system specific requirements.

11.4.2.2 In order to achieve high reliability and ZERO DEFECT, and to ensure effective checks on the maintenance work minimum schedules of inspections to be carried out.

11.4.2.3 The inspection schedule should be such as to cover all the installations in their jurisdiction within the stipulated periods and stagger the inspections among themselves to avoid over inspections of the some installations time and again and neglect of other installations. A checklist in brief for various inspections is given.

11.4.2.4 The periodicity of the items of attention listed in the following paragraphs may be modified to suit local requirements with the approval of Employer.

11.4.2.5 As regards new equipment, if schedules have not been drawn up, tentative schedules may be evolved, based on the Original Equipment Manufacturer’s guidelines and or any other benchmark, keeping in view the local conditions also and followed with the approval of Employer.

11.4.2.6 Detailed Check Sheets for maintenance of Switching Stations installations

Location Installation Quarterly 6 monthly Yearly

SP/ SSP/ SS 25 kV VCB / Interrupter and other Installations.

√ X X

SP/ SSP/ SS Motorised Isolators √ X X

SS/ SP/ SSP Thermography Checks X √ X

SS/ SP/ SSP Bonding and Earthing X X √

Via Duct Lighting with Accessories

At Viaduct

As per recommendations of OEM

Note: Scheduled inspections of the equipments above are minimum. However, to ensure zero failure and enhanced reliability, safety, maintainability and economy, same may be reviewed by employer based on field reports, manufacturers recommendation etc.


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11.4.2.7 Check sheet for maintenance of AC distribution box

SN Task Yearly

1 Date 2 Location 3 Equipment No.

4 Check: 1. Status of earthing strip for tightness 2. Check for any sign of rust, apply touch up paint if required.

5 Check the status of door for smooth closing and opening. 6 Check the condition of door gasket, replace if required 7 Clean the exterior of ACDB box 8

Clean the dust, cobweb and foreign materials inside ACDB with the help of vacuum cleaner after switching off supply

9 Check the healthiness of following indication: 1. ON/OFF 2. LED Under voltage relay

10 Check for any flash mark/overheating or other abnormality of components

11 Check and tighten all electrical connections

12 Verify under voltage indication in SCADA from TPC by shorting the contacts as per wiring diagram for ACDB.

11.4.2.8 Check sheet for maintenance of DC distribution box

SN Task Yearly

1 Date

2 Location

3 Equipment No.

4 Check: 1. Status of earthing strip for tightness 2. Check for any sign of rust, apply touch up paint if required.

5 Examine the status of door for closing and opening

6 Examine the condition of door gasket, replace if required.

7 Clean the exterior of DCDB box.

8 Clean the dust, cobweb and foreign materials inside DCDB with the help of vacuum cleaner

9 Check the healthiness of indication 1. ON/OFF 2. LED Under voltage relay

10 Check for any flash mark / overheating / other abnormality of components

11 Check and tighten all electrical connections

12 Verify under voltage indication in SCADA from TPC by shorting the contacts as per wiring diagram

13 Check automatic changeover of Incomers-1&2 and coupler by switching incomers 1&2 off one by one. (During changeover, CB will trip)

14 Check changeover operation of Incomers-1&2 and coupler by push buttons. (During changeover, CB will trip)

15 Verify the change of status of on/off & Semaphore indicators during changeover in above mentioned steps

11.4.2.9 Checksheet for the maintenance of battery bank

SN Task Quarterly Half

Yearly Yearly

1 Date


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2 Location

3 Equipment No.

4 Measure the battery bank voltage after switching off both the battery chargers. It should be more then 110V

5 Before starting maintenance on battery, wear gloves and goggles.

6

Clean the accumulated dust using paint brush & dry cotton cloth over cell terminals, vent plug and cell body, starting from top to bottom row of cells.

7

Check all battery inter cell links, cable connector and earthing connection for tightness. Replace with new/overhauled links if sulphation is found. Treat removed links with warm water & nylon scrubber in workshop.

X X √

8 Check electrolyte level (It should be between Max - Min marks. Top up with distilled water, if required).

9 Check battery bank stand for any rusting, paint if required.

10 Check each cell for leakage and bulging. If found, replace with new cell.

12

After one hour of switching off battery charger, measure and record individual cell voltage. If voltage of any cell is less than 1.0 Volt, replace with new charged cell filled with sufficient electrolyte.

13 Apply thin layer of petroleum jelly on battery terminals.

14

Perform Discharge Test of Battery Bank and record the same. If capacity is less, then defective cell to be located by measuring the voltage of each cell and same cell should be replaced.

X X √

11.4.2.10 Checksheet for maintenance of battery charger

SN Task Quarterly

1 Date

2 Location

3 Equipment No.

4 Observe the charger for any abnormal sound. Rectify the same if found.

5 Measure the output voltage of the battery chargers. (Float voltage = 119.0V and Boost Voltage= 123.25V). Adjust the respective potentiometer, if any deviation is found.

6 Check working of automatic changeover of the charger

7 Check working of alarm, indications, switches (Input, Output, auto/manual, float/boost) ammeter and voltmeter at charger as well as in SCADA.

8 Switch OFF the charger, Open the cover and clean accumulated dust with vacuum cleaner.

9 Check all cables (AC I/P & DC O/P) & earthing connection for tightness.

10 Check the PCB Card and multi pin connector for any damage / heating mark. Clean PCB cards with soft hair brush.

11 Check PCB cards and connections with IR camera for hot spots.


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11.4.2.11 Check sheet for maintenance of 25kV vaccum circuit breaker/ interrupter

SN Task Quarterly

1 Date 2 Location

3 Equipment No.

4 Obtain Power Block and provide earthing rod

5 Open the cover of control box. Clean accumulated dust by vacuum cleaner. Also clean the sight glass.

6 Check the operation in local and remote mode, keeping the front door open, observe whether the mechanism functions smoothly without any rubbing or obstruction.

7 Check the working of counter and record the counter reading.

8 Check electrical interlocking between CB and associated isolators both locally & remotely. Isolators should not operate when CB is in closed condition.

9 Check for moisture entry inside the box. If found examine the door handle/gasket for any damage, replace if required

10 Verify from SCADA status, the change of position of local/remote switch & open/close status.

11 Remove castle key and switch off DC supply. 12 Check the working of heater.

13 Check all electrical connections of control panel for tightness.

14 Check the bushing insulator for any chipping and flash mark and clean with cotton cloth. Anti track paint should be applied on chipping/Flash marks.

15 Check bimetallic strip between CB flange and bus bar connector.

16 Check the incoming & outgoing connections for tightness

17 Check the gap between sensor and sensor plate (Gap should be 1-3 mm )

18 Check Spring stoke adjustment(Gap should be 2.5 - 5 mm in VCB closed condition )

19 Check the IR value of the 110V DC motor with 500 volt megger (min. value - 1 mega ohm). Clean the commutator with muslin cloth. Examine carbon brushes for any damage.

20 Check all nut bolt inside mechanism box for tightness.

21 Apply touch up paint in case of rusting found inside or outside the control box.

22 Check the earth strip connections for tightness.

23 Check nut bolt of support structure for tightness.

24 Check Remote Operation by TPC before cancellation of Power Block

11.4.2.12 Chechksheet for maintenance of Motorised Isolator

SN Task Quarterly

1 Date

2 Location

3 Equipment No.

4 Obtain power block & provide earthing rod

5

Check the operation electrically in local and remote mode, keeping the front door open: a. Observe whether the motor gear mechanism functions smoothly without any rubbing or obstruction. b. Male and female contact should be in aligned position when isolator is closed, if not then adjust limit switch in control box.

6 Check electrical interlocking between Isolator and associated CB both locally & remotely. Isolators shouldnot operate when CB is in closed condition.


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SN Task Quarterly

7 Press Manual push button & remove castle key. Isolator should not operate electrically after removal of castle key.

8 Check operation with handle after placing castle key at other slot provided for opening of door slot for insertion of handle.

9 After checking above operations, make sure that power circuit of motor is switched off.

10 Clean the control box with blower.

11 Check all wiring connection for any looseness and tighten if required.

12 Check nut and bolts for any looseness and tighten if required.

13

a) Check the clearance between male and female blades in open condition it should be ≥ 50 cm for vertical break isolators. Note the distance between male and female contact should be measured perpendicularly in case ofvertical break isolator.

14 Check the pedestal insulator for any chipping and dust. Clean with dry cotton cloth. In case of chipping apply anti track paint.

15 Check alignment of arcing horn provided on male and female contact of isolator. Adjust if required.

16 Check proper alignment of male and female contact on fixed as well as moving end. There should be no air-gap between male contact and female spring leaf in close condition of isolator.

17

Clean the contact with cotton cloth and apply thin film of petroleum jelly to the contact surfaces. Remove excessive jelly.

18 Grease the main bearing in control box through grease nipple. The other rotating parts should be lubricated using mobil oil.

19 Measure and record insulation resistance of motor winding using of 500V megger. (IR>1M Ohm)

20 Check Remote Operation by TPC before cancellation of Power Block

11.4.2.13 Checksheet for thermography of SS/SSP/SP/FP

SN Task Half Yearly

1 Date 2 Location 3 Equipment No. 4

Check the temperature rise of cable termination, connecting jumper and clamps

5 Check the temperature rise of incoming/outgoing clamps of isolator

NOTE: Temperature recorded should not be greater than 15 degree centigrade of ambient temperature, if found same to be treated as hot spot and get it attended.

11.4.2.14 Checksheet for maintenance of Bonding and Earthing

SN Task Yearly

1 Check physically the soundness of bonding and earthing connection to every electrical equipment, structural steel etc. and inter-panel connections

2 Check and record group/ combined earth resistance of the system

3 Check tightness of Earthing strip on MET

11.4.3 Corrective Maintenance

11.4.3.1 Bottom line of carrying out preventive maintenance is that once it is carried out that

equipment should not fail till the next schedule falls due. Generally it shall be carried out during non traffic hours on main line for 25kV Switching stations as per availability of power block at station. Despite of above intense maintenance schedules and different


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proven power supply arrangements installed failures are observed. These failures are to be attended after taking power and traffic block (if required) of affected section / stations.

11.4.3.2 For attending breakdowns Contractor’s Switching Station team should be ready at designated place all the time and immediately move to the place of breakdown / incident.

11.4.3.3 Unusual Occurrence report should also be submitted within 3 days to the Employer in prescribed format.


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CHAPTER 12 12.0 MISCELLANEOUS

12.1 FACILITIES FOR THE EMPLOYER'S REPRESENTATIVE

12.1.1 General

The Contractor shall provide for the use of the Engineer office accommodation, equipment, communication and drawing facilities throughout the course of the Works and for so long a period of time during the defects liability period as the Engineer may require. The details of the accommodation and other facilities are as under:

12.1.2 Site Offices 12.1.2.1 Accommodation for the Employer's Representative in the Contractor's Works area at the

Depot (or other appropriate location) where assembly, testing and commissioning will take place shall be air conditioned, and shall comprise:

Table 12.1: Site Office for Engineer

SN Type

No. of Staff

Area Sq.m

Total Area Sqm

1 Project Manager Office 1 20 20

2 Resident Engineer Office 1 20 20

3 Dy. Project Manager Office 4 10 40

4 Area for Plotter, Printer etc 1 5 5

5 Site Inspectors / Engineers Common Area 12 5 60

6 Conference room 1 30 30

7 General Office / Reception Area -- 15 15

8 Rest Rooms 3 10 30

9 Kitchen 1 10 10

10 Drivers - 10 10

Total 240

Parking for 10 Cars @ 8 m2/ car 80

12.1.2.2 Offices shall be contained in one building and each office shall be accessible only from a

corridor within the building. An external double door with reception area shall be provided to the corridor.

12.1.2.3 Materials used for the construction of the offices shall be new and of good quality.

Materials shall be chosen such that the buildings when erected shall give good temperature and sound insulation, and when combined with the heating and air condition equipment installed by Contractor will enable interior temperatures to be maintained at within a range of 20-24°C at all times. But external and internal walls shall be sound proof.

12.1.2.4 Windows to each room shall be of an area not less then 10% of the floor area. All windows

to ground floor offices shall be fitted with burglar bars firmly attached to the structure of the building. All windows shall be fitted with mosquito netting. All opening windows shall be fitted with locks and all sets of keys shall be delivered to the Employer's Representative. All windows shall be fitted with venetian blinds.

12.1.2.5 Internal doors shall be hollow core flush doors and shall be fitted with door closers, lever

latches, mortise lock and keys.

12.1.2.6 External doors shall have barrel blots top and bottom to one leaf and a Yale lock to the other loaf. External doors shall be of solid external quality and hung with heavy-duty hinges.


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12.1.2.7 All buildings shall be supplied with running hot and cold water to the kitchens and wash rooms. The toilets may use raw water for flushing, shall be equipped with water closets and sitting type stools and shall be adequately ventilated through the ceiling. The Contractor shall also arrange for the constant and hygienic disposal of all effluent, sewage and rubbish from the buildings.

12.1.2.8 All buildings shall be supplied with electricity 240V 50Hz that shall be distributed to each

room in accordance with the Regulations. Lighting and electrical power points shall be provided to each room. The disposition and location of light and power points will be directed by the Employer's Representative.

12.1.2.9 Pantry shall be provided with work tops, a 2-drainer stainless steel double sink, cupboards

beneath the work-top and mounted on the walls, a cooker with 2 No. 2 gas rings and a microwave oven, a 300 litres refrigerator and tea and coffee making facilities for 20 persons shall be provided. Crockery and cutlery for 25 persons. Tiling shall be provided to the walls above the sink, cooker and work-tops.

12.1.2.10 Fire fighting equipment shall be provided in accordance with the recommendations of the

City Fire Brigade.

12.1.2.11 The Contractor shall provide, erect and maintain appropriate name boards as specified for each of the offices. The wording on each name board and its location shall be agreed by the Employer's Representative before it is erected.

12.1.2.12 The building shall be provided with a continuous water supply and drainage to Kitchen,

Washroom and Toilets. The Toilets shall be equipped with low level suites and be adequately ventilated through the ceiling.

12.1.2.13 The Contractor shall provide protective clothing and safety equipment for 10 persons, comprising, as a minimum – Safety Helmets Safety Harness, Steel-toed construction boots (sizes to be notified), Day-Glo waistcoat, Industrial safety goggles, Industrial gloves, Breathing Masks and Filters, Ear protectors, Heavy weight suits (sizes to be notified), Lamps (with batteries).

12.1.2.14 The Contractor shall arrange for upkeep, service and security of the offices and compound. These to be thoroughly cleaned and for rubbish and waste to be removed at least once per day.

12.1.2.15 The Contarctor shall maintain the running cost of the office including electricity, wifi, telephone communication. The Contractor shall provide four desktops for employers in office

12.1.3 Furniture and Equipments

12.1.3.1 The Contractor shall supply new furniture and equipment to the Employer's

Representative offices. The Contractor shall as a minimum provide the following furniture and equipment for the offices subject to acceptance by the Employer's Representative. The furnitures and equipment shall include, but need not be limited to :

Table 12.2: Furniture and Equipment for Site Office

SN Description Nos.

1 Conference table (2400 x 900) 1 No.

2 Conference chairs 10 No.

3 Glass-fronted lockable bookcase 4 No.

4 1500 x 900 double pedestal desk 4 No.

5 1200 x 900 single pedestal desks 8 No.

6 Swivel office chair with armrests 8 No.

7 Swivel office chair without armrests 8 No.

8 Typist chair 4 No.


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SN Description Nos.

9 Visitors chair 8 No.

10 3-shelf bookcase 5 No.

11 4-drawer filing cabinet 5 No.

12 Plan chest (AO size) 1 No.

13 Plan chest (A1 size 4 No.

14 Drawing Table 1 No.

15 1500 x 900 tables 6 No.

16 Lockable cupboard 6ft high with internal shelves 8 No.

17 Heavy Duty Paper Shredders 1 No.

18 Computers with Peripherals like CD Drive, CD Writer, Modems with Internet Connections etc.

3 Nos.

19 Consumables (paper, computer cartridge etc. LS

20 A4 size printer (Laser). 3 Nos.

21 Photocopier capable of reduction and copying A3 and A4 size paper and with document feed Capability and sorter

2 No.

22 Tele-facsimile transmission/reception facility connected to a dedicated line with IDD facility.

1 set

23 Waste paper baskets 10 No.

24 4-hole document punches 2 No.

25 Desk mounted pencil sharpeners 8 No.

26 Desk tray sets 10 No.

27 Fully automatic camera with date and time Recording facility downloadable to a PC

1 No.

28 First aid kits for up to 36 persons 2 No.

29 Safety helmets 10 No.

30 Pairs steel toed construction boots, sizes to be advised 5 pr

31 Day-glow waistcoat 30 Nos.

32 2 L kettles 2 No.

33 Tea & Coffee dispenser 1 No.

34 Potable water dispenser with hot/cold Taps and paper/plastic cups 2 No.

35 Potable water, tea & coffee material for the Employer’s staff LS

36 Cups and saucers 24 No.

37 Side plates 24 No.

38 Fire extinguisher 5 No.

12.1.3.2 The Contractor shall also allocate at his Works, and those of his major sub-contractors,

adequate office space, furniture and equipment for the use of the Employer’s Representative’s Inspection Engineers. Such accommodation shall include secure filing for Contractual and other sensitive documents, and secure telephone and facsimile facilities. Such facilities shall apply equally to the overseas and the local building phases of the Works.

12.1.4 Road Transport

12.1.4.1 The following type of land transport shall be provided for the Depot assembly, testing and

commissioning phases of the Works: (a) One air-conditioned Saloon Car (which shall be provided at the commencement of

the Works) of a type and colour approved by the Employer and having an engine capacity of at least 1600CC.

(b) Two nos. air-conditioned Four-Wheel-Drive vehicles, (Innova / Bolero / Tavera /

Equivalent) (which shall be provided at the commencement of the Works as agreed by the Employer’s Representative). It shall have an engine capacity of not less than 2000CC (nominal) and a seating capacity of no fewer than 8 persons.

12.1.4.2 The vehicles shall be new and delivered and maintained by the Contractor in good road-

worthy condition. All vehicles shall be air-conditioned.


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12.1.4.3 The vehicles shall be licensed and insured for use on the public highway and shall have

comprehensive insurance cover for any qualified driver authorised by the Employer's Representative together with any authorised passengers and the carriage of goods or samples.

12.1.4.4 The Contractor shall provide fuel, oil and maintenance in conformity with vehicle

manufacturer's recommendations and all relevant toll and parking charges incurred in connection with the Works.

12.1.4.5 A suitable replacement shall be provided for any vehicle out of service for more than 24

hours.

12.1.4.6 The Contractor shall employ and make available competent drivers (at least one being English speaking) fully licensed to operate the vehicles as and when required by the Employer's Representative. The Contractor shall replace drivers at the request of the Employer's Representative.


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CHAPTER 11 13.0 CATENARY MAINTENANCE VEHICLE

One 8-wheeler and one 4-wheeler catenary maintenance vehicles (tower wagons) shall be supplied by the Contractor. The delivery of these vehicles shall be planned by the Contractor in a way that these are actually used for installation, testing and commissioning work of OHE/ROCS of project.

13.1 OHE CATENARY MAINTENANCE VEHICLE (8-WHEELER)

13.1.1 GENERAL The scope of this specification is to reflect the performance and quality requirements for an Over Head Equipment (OHE) Maintenance Vehicle, which will also be used as an emergency and rescue Shunter. The vehicle shall be equipped with necessary sensors / instrumentations for integrated OHE / Track geometry measurement system and ultrasonic measuring device.

13.1.2 VEHICLE DESCRIPTION The vehicle will be a self-propelled full rail borne vehicle composed by a steel frame, lying over four axles (8-Wheeler Vehicle).

13.1.2.1 Vehicle frame

13.1.2.1.1 The frame of the vehicle will be composed of standard steel sections and transversal beams. The material will be of standard steel of different qualities, depending on the mechanical requirements over the frame.


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13.1.2.1.2 The frontal parts of the frame will be designed in order to make the assembly of the coupler easier. They are made to support the efforts indicated in the UIC 577 – OR leaflet.

13.1.2.1.3 The vehicle will have a loading platform in the middle part of the vehicle. The height from

the platform surface to the running plane will be 1200 mm when the vehicle is unloaded.

13.1.2.1.4 Regarding to the surface treatment and painting, the following treatment will be applied to the frame and cabin: (a) Sand blasting SA 2.5 according to SIS 055900 standard (b) Primer coat of anticorrosion painting based in zinc phosphate, (c) Final coat treatment composed by an epoxy coating and a finish coating black RAL

9005.

13.1.2.2 Vehicle equipment

13.1.2.2.1 The vehicle will have a working platform in the middle section. The vehicle will include a hydraulic crane for cargo handling. The vehicle will have a measuring pantograph, and measuring equipments for the overhead equipment and track geometry.

13.1.2.2.2 The four axles of the vehicle will be powered with hydrostatic / hydraulic-mechanical transmission and a main diesel engine.

13.1.2.3 Vehicle performance

The vehicle main duty will be:

13.1.2.3.1 To transport material and workers from the maintenance sites in the tracks to the workshops and train depots.

13.1.2.3.2 To tow up to 6 Metro cars (47t each) in rescue mode

13.1.2.3.3 To carry track and OHE test equipment for analyzing the Track and OHE geometry. For the crew and worker transportation, the vehicle will feature a ten people capacity cabin.

13.1.3 GAUGE AND DIMENSiONS

13.1.3.1 The profile and cross section of the Maintenance Vehicle will comply with the Pune Metro

Rail Schedule of Dimensions.

13.1.3.2 Any equipment, structure or element of the vehicle which could infringe the gauge while extended in running condition will be labeled and painted in a bright colour in order to remind the crew about them after the work is finished.

13.1.3.3 The only equipment which could infringe the gauge is the crane, the working platform and the stabilizers, so they will be all retracted and stowed when switching from working speed to running speed. The vehicle will have enough clearance from the rail level to the underside of the vehicle.

13.1.4 OPERATIONAL REQUIREMENTS

13.1.4.1 The vehicle will be able to tow up to 6 Metro cars (47t each) for a total of 280 ton, in a gradient of 4% at least at 8 km/h speed.To perform the towing duty, the vehicle will feature a Rockinger type coupler for towing Metro Cars. For the design and construction of the vehicle UIC and IRS standards will be applied.

13.1.4.2 Maximum admissible axle load for the vehicle will not be higher than 16t per axle. The wheel profile will be as per Metro standard wheel profile.


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13.1.4.3 Track requirements

The vehicle will be capable of travelling through the Curves, Cants and Gradients noted in the Pune Metro Rail Schedule of Dimensions.

Minimum radius of horizontal curves

On main running lines Elevated and At-Grade Sections 120m

On main running lines Underground Sections 200m

Depot and other non-passenger Lines 100m

At passenger platforms 1000m

Minimum radius of vertical curve on main running lines 1500m

Cant and Cant Deficiency

Maximum Cant on curves 125mm

Maximum Cant Deficiency 100mm

Maximum Gradient 4%

13.1.4.4 Speed requirements

The vehicle will be able to circulate at the following speeds:

By its own speed in straight track and curves with a very long radius 50 kmph

Towing 280 ton of Metro cars in 4% gradient 8 kmph

Towing 280 ton of Metro cars in level track 14 kmph

In a train composition being tow 80 kmph

The vehicle will be able to circulate in both directions at the same speed

13.1.5 DRIVE

13.1.5.1 Diesel engine

13.1.5.1.1 The vehicle will be powered by a diesel engine of adequate capacity to meet the performance and operational requirements detailed in the Clause 13.1.4 “Operational Requirements”.

13.1.5.1.2 The proposed power of the engine will be a minimum of 350 kW or more as required for

hauling 6 car train. This proposed power can vary depending on the current state of the diesel engine technology.The diesel engine will be from a top brand OEM, with satisfactory service and repair support facilities available in India.

13.1.5.1.3 The Diesel Engine will have a fuel tank with enough capacity to provide 8 hours of

continuous operation. The engine starter will be electric, powered by batteries.

13.1.5.1.4 The Diesel engine will comply at least with the Euro 4 or equivalent exhaust emissions standard.

13.1.5.1.5 The Driver control panel will have enough monitoring gauges for temperature, rpm, oil

pressure etc. for controlling the engine performance at any moment.

13.1.5.1.6 The engine, as well as the associated elements (compressor, alternator, etc.) will be assembled over its own frame supported by mean of silent blocks by the frame of the vehicle.


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13.1.5.1.7 The engine will be easily accessible by every side, with doors and cabinets on the vehicle floor in order to help maintenance operations and to help in the removal of dust and grease.

13.1.5.1.8 The cooling circuit of the vehicle will be designed with the radiator in horizontal position.

The radiator will have the same performance in both directions.

13.1.5.1.9 The radiator surface for the engine will be enough to keep the engine running in working order even with 30% of the radiator surface chocked, and in any case, the cooling fluids will exceed 95°C temperatures.

13.1.5.1.10 The radiator fan will be of electric nature, which will be feed by the auxiliary alternator of

the engine.

13.1.5.2 Transmission

13.1.5.2.1 The vehicle will have the diesel engine power relayed to the four axles, by means of a hydrostatic / hydraulic-mechanical transmission.

13.1.5.2.2 This hydrostatic drive will be composed of hydraulic pumps, hydraulic motors in each

axle, and the software control.

13.1.5.2.3 The drive mineral oil will be of HLP grade type satisfying DIN 51 524 standards. Every hydraulic systems of the vehicle will be protected by mean of security valves from the pressures in the different working conditions.

13.1.5.2.4 The oil tank of the vehicle will have a capacity to provide 8 hours of continuous

operation. It will be designed to allow changes in the volume of the oil which could take place in every running condition, permitting the air outlet in every moment. The capacity will be enough for the first filling of the circuit.

13.1.5.2.5 The final mechanical connection between the axle set and the hydraulic motor will be

made by mean of an axle gear – box with dual speed.The dual speed selection will allow the vehicle to shift between low speed, high traction force gear for work and shunting duties and a high speed, low fuel consumption gear for transfer duties and faster arrival at the working place.

13.1.6 CABIN

13.1.6.1 The vehicle will have a double cabin with enough space for carrying 10 persons.

13.1.6.2 The cabin will comply with UIC 617 – 6, 625 – 6 y 651 OR leaflets.

13.1.6.3 The cabin will be made of steel profiles, with an interior furnishing of phenolic boards.

13.1.6.4 Enough windscreens and windows will be provided in order to give the best visibility all

around from the cabin, in both directions of driving.

13.1.6.5 Two separate driving desks can be installed, one on each running direction in order to provide good view in both travelling directions.

13.1.6.6 The passenger seats will be ergonomic and will be able to fold to save space when not in movement.

13.1.6.7 The visibility from the driving desk will be according to UIC 625-6 leaflet, and the windshields will have windshield wipers. It will also have rear mirrors in order to control the position of the vehicle.

13.1.6.8 The cabin will have full acclimatization in order to keep the cabin temperature in working levels thought the whole year.


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13.1.6.9 It will include both A/C and heater.

13.1.7 BRAKE SYSTEM

13.1.7.1 The vehicle will be fitted with compressed air brakes commanded from the main cabin

through the driver’s desk.

13.1.7.2 The vehicle should be able to drive as a head in a towing composition, and as a wagon in a larger train composition. The brake system will be able to brake the vehicle when it is part of a bigger composition.

13.1.7.3 The brake system will be capable of braking a full towed composition of 6 Metro Cars with 47t weight each.

13.1.7.4 The minimum percentages of braked mass of the automatic brake will be according to UIC 543 specifications. The braking coefficient will be of the 70% in the most unfavorable load conditions.

13.1.7.5 The parking brake will warranty that the vehicle is stopped on a slope of the 4% with a safety factor of 1.45, without overtake an adherence coefficient rail – wheel of 0.12.

13.1.7.6 The parking brake will work over the same brake blocksor brake cylinder as the service brake by mean of accumulation springs. The service brake will be electro pneumatic, according to UIC 540 to 543 leaflets.

13.1.7.7 The service brake system will allow the coupling of the vehicle to a train composition, in such a way that the brake can be activated from the cabin, and to act over the own vehicle and the rest of the composition.

13.1.7.8 The application of the braking effort will be made by mean of braking blocks or brake cylinder with double effect regulator and antagonist spring. They will act directly over the lathes by mean of braking pads according to UIC 541 – 3 y 541 – 4 and 832 standards.

13.1.7.9 The vehicle will have an emergency brake system installed. These emergency brake buttons will be easily visible and accessible. The emergency brake connects directly the emergency valve to the atmosphere producing an emergency brake.

13.1.7.10 The whole system will be powered by an onboard air compressor which will comply with prEN 14033 – 1 article 9.4, for a minimum number of 16 axles.

13.1.7.11 The tank capacity will allow, in every braking condition, three braking / looses at the maximum pressure, with the vehicle isolated, without production of compressed air and with the maximum stroke of the brake blocks.

13.1.8 DYNAMIC EQUIPMENT

13.1.8.1 The vehicle will be powered by four axle sets.

13.1.8.2 The maximum weight per axle will not exceed 16 Tonne.

13.1.8.3 The four axles will be powered, and be capable of moving the vehicle in both directions at full speed. The wheels will be monoblock, and made of forged steel. The axle grease boxes will be fully sealed, and will have installed long life bearings. The damping system will be designed following the UIC leaflets, and will be composed of elastic steel coil springs between the frame and the axle boxes.

13.1.9 ELECTRIC EQUIPMENT


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13.1.9.1 The electric equipment of the vehicle will comply with all the relevant standards and specifications, and will be suitable for the final destination conditions .The vehicle will be equipped with an electric starter batteries and motor for the diesel engine, capable of starting the engine on its own without any external power.

13.1.9.2 The internal and external lightning will comply with the line standards, and will be enough to work in night time conditions.

13.1.9.3 The working platform will have electric sockets on the cradle, and two manual lights mounted in pivoting mounts, one on each opposing corners of the platform. The circulation lightning will be according to the Metro Line standards.

13.1.10 MISCELANEOUS EQUIPMENT The vehicle will come equipped with the following auxiliary equipment:

13.1.10.1 Sand boxes The vehicle will have sand boxes in both running directions and in every wheel to allow a better traction effort in case of slipping.

13.1.10.2 Driver Safety Device The vehicle will feature a double system for the safety of the driver which will accomplishing UIC 641 – O standard.When activated it will produce an emergency braking (traction cut and maximum service brake).

13.1.10.3 Acoustic signals (Horn) The vehicle will have two pneumatic horns, one for each running directions, audible at a distance of minimum 1000 m, with sound intensity between 120 and 125 dB(A) at 5 meters (according UIC-644 leaflet).

13.1.10.4 Tool Kit The vehicle will include a set of general tools to make urgent reparation.

13.1.11 WORKING PLATFORM

13.1.11.1 The vehicle will have a working platform for inspection and maintenance works in the overhead equipment. The working platform will be constructed by mean of an insulated platform with insulating elements according to DIN standards for the voltage and intensity required.

13.1.11.2 The platform will have handrails of 1100mm height, and dimensions of 2500 x 2500mm. The design and location of the platform, will allow the work with the handrail erected in small gauge tunnels.

13.1.11.3 The access to the platform will be an insulated ladder with the insulating characteristics of the platform, 800mm width. The steps will be anti slipping, with a distance between them of 300mm and a step of 50mm. The access to the platform will be safe and comfortable.

13.1.11.4 The platform will have two movements, elevation and translation. The elevation mechanisms will be hydraulic with a scissors like mechanism powered by cylinders of double effect and piston pump to activate them or hydraulic telescopic type.

13.1.11.5 The platform will be pivot mounted rotating type or translating. The translation system will be powered by a hydraulic motor with negative brake that assures the position of the working platform and a mechanical system with coupler that limits its speed.


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13.1.11.6 The platform floor should be capable of elevating to a maximum height of 5500mm The platform floor when retracted should be at 3000mm from the rail head. The platform will be able to laterally traverse 1500mm to each side of the track axle.

13.1.11.7 The working platform will have an emergency system for its own movement in case of breakdown, consisting of a manual hydraulic pump located in the lateral part of the vehicle. It will allow moving the working platform in case of a failure of the diesel engine.

13.1.12 CRANE

13.1.12.1 The vehicle will have a hydraulic operated crane specific for railway vehicles, with low standstill height.

13.1.12.2 The crane operation should be such that there is no infringement to over head electric equipment during crane maneuvering / extension / shortening and there is no infringement to the Metro Schedule of Dimensions

13.1.12.3 The crane will have the following performance and equipment: (a) Max. Lifting capacity: 10.4 t (b) Lifting capacity at 9.7 m reach: 1000 kg (c) Hydraulic Reach up to 9.7 m (d) Two extensible hydraulic jacks (e) Base of the crane for works with an angle of 10 degree (f) High pressure filter, Oil radiator (g) Working light, installed in articulated arm (h) Spinning and height limiter (i) Emergency stops, piloted valves and torque limiter (j) Limit switches to avoid gauge infringement

13.1.13 MEASURING EQUIPMENT

13.1.13.1 Introduction

13.1.13.2 The Catenary Maintenance Vehicle shall have the following features:

13.1.13.2.1 Multi-function Inspection System The Multi-Function Inspection System will include the following measuring systems: (a) Positioning and localization system (b) Track navigation system (c) Track Geometry Measuring System (d) Simplified Catenary Measuring System(both flexible and rigid) (e) On-board Software Supervision System / Defect Viewer (f) Off-board Software System

13.1.13.2.2 Ultrasonic Rail Inspection System

13.1.13.3 Multi-Function Inspection System

13.1.13.3.1 Multi-Function Inspection Systems onboard the rail vehicle

(a) The different measuring systems shall be installed onboard the CMV. (b) All the measured parameters shall be automatically recorded into an industrial

workstation onboard, allowing real-time and post-processing display in the form of scrolling charts, photos and videos, pictures of defect with their geographical mapping, printed reports or numeric tables.


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(c) For every measured parameter the raw value, averages and RMS shall be available.

13.1.13.3.2 The multi-function inspection system shall be reliable, accurate and shall have been used by railway customers. References shall be provided to the Employer by the Contractor.

13.1.13.3.3 The system shall be capable of integrating onboard all the different Inspection & Recording Systems both for the hardware and the software, implementing a software platform for easy displaying, storing & retrieving / analyzing the different defects, collected from different sources.

13.1.13.3.4 The system use bogie mounted track geometry instrument

13.1.13.3.5 This Multi-Function Recording System, among other systems, shall include Track

Geometry, Rail profile, OHE / Power Rail Measurement Systems, Clearance Measurement, Thermal Scan, Track Component Video Inspection system etc.

13.1.13.3.6 The measurement method shall not require any laser alignment, as use of laser alignment may affect the accuracy of measurement.

13.1.13.3.7 The utilities and supervision equipment installed inside the vehicle shall be: (a) A cabinet containing the power supplies, the controllers and the localization module.

The approx. dimensions are 19” wide by 20U high by 400 mm deep. (b) A chiller (c) All the PC’s used for supervision and control of the entire system. Installing

additional PCs shall be possible at any time without any impact on the existing system.

13.1.13.3.8 For a Track Recording System which is integrating different subsystems (as Track

Geometry, Track Component Monitoring System, OHE geometry, other Video Systems etc., it is necessary to have the same time and space references to all subsystems, for efficient supervision and post-processing tasks. The architecture shall be based on the following:

(a) Every sensor shall have its own embedded CPU with Linux real time running, to

achieve the following advantages:

Data flow reduction, thanks to the real time first processing (filters, image processing, etc.).

Distributed, pipelined computing

Powerful self-diagnostics and activities monitoring. Every software module can send messages to a unique (in the system) log processor.

Connecting the sensors is as simple as an Ethernet connection. No added noise. Inexpensive network wiring (cables, switches, etc.).

Hardware standardization and easy upgrade of the workstations. No special I/O cards installed inside the workstations (PCs);

As a consequence, the workstations are standard, inexpensive PCs. Upgrading to a newer PC is easy, because no special driver is required.

The true real time latency is only required in the kernel layers of the CPU embedded into the sensors. All the rest is asynchronous.

(b) Every sensor shall receive 4 signals in parallel to synchronize the measurements. These signals shall normally be transmitted as a differential RS422 or RS485 pair, for the best noise immunity. The signals are:

Odometer


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Clock

Direction

(c) Event: this signal has multiple usages: it shall strobe the space and time counters, so thatit can be used for improving the localization via balises. It is also useful to start all measurements at the same time (“start on first event” mode)

(d) Every sensor shall have embedded time and space counter. The value of these counters shall be read whenever a new measurement is taken; The counters value shall be associated to the measurement and this association shall go down the entire computing pipeline. Despite the asynchronous pipeline, re-synchronizing the measurements shall be easy thanks to these space/time labels.

(e) Every sensor shall divide the time (clock) or the space (odometer) signal by a programmable value, to create the measurement trigger. But the space / time localization counters shall always use the undivided clock and odometer signals, to guarantee the maximum resolution.

(f) The hardware implementing the above functions shall be Field Programmable Gate Array (FPGA). Adapting to special needs shall never require a hardware change. Reprogramming the FPGA shall ensure the maximum flexibility.

13.1.13.4 Localization

13.1.13.4.1 All the Track Inspection Systems in the inspection vehicle shall be connected to the

automatic localization system.

13.1.13.4.2 In a Multi-Function Track Recording Systems every sensor needs the same time and space references, for efficient supervision and post-processing tasks. The localization architecture shall be based on the following: (a) Every sensor shall receive in parallel 4 signals to synchronize the measurements

(b) Every sensor shall add the time and space stamps to every sample: these stamps

are the odometer and clock counters current values

(c) The GPS coordinates shall be associated to the odometer and clock counters, as every other event or measurement. This way the measurements and the GPS localization shall be perfectly linked

(d) Localization “events” of every type shall also be tagged with space and time stamps: these events can be crossings, switches, balises, bridges, etc.

(e) The infrastructure description shall link the localization events with the line/km. This way every position (line/km) gets linked to an odometer, thus to the corresponding measurements.

13.1.13.4.3 Event Marking System

(a) It shall be possible to for the operators to add auxiliary information to the records

using a keyboard. Most typical events are pre-coded, and can be added just with a pushbutton or a mouse click, but the operator shall also be sbale to add free comments. Among the pre-coded events: road crossings, bridge, tunnel, turn out, new km position (the user adds the km), mast id etc. The events shall be printed in the relevant horizontal axis position in a strip-chart. The language can be selected by the user.

(b) Two keyboards shall be supplied, each for one driving cab (but they can be located

anywhere on the vehicle, through Ethernet communication). The keyboards shall be implemented on a notebook.


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(c) It shall be possible to adopt symbols as per the user needs (d) All localization events shall be automatically linked to the corresponding data in the

data base.

13.1.13.4.4 Navigation System (a) Track navigation system shall make it possible to link the vehicle position to the

tiniest infrastructure detail, due to the need to model the yards and stations for the turnouts and crossings automatic inspection.

(b) In order to operate this system, the schematic model of the infrastructure must be

uploloaded by the Contractor and validated by the Employer. The Contractor shall obtain infrastructure data from Employer.

(c) The measurements shall be localized according to an infrastructure description

(track schematics) consistent with the UIC RailTopoModel. It shall be possible to import the RailML compatible infrastructure description.

(d) The infrastructure description database shall be resident onboard the vehicle and it

should be possible to update the database by the user (manuals and training shall be provided). The localization system shall navigate the database and create the one to one link in between the odometer (unique in every run, regardless to the direction) and the line/km or the detected object.

13.1.13.4.5 It shall be the responsbility of the Contractor to upload the infrastructure data in the

system accurately and this may involve multiple iterations during the course of the project.

13.1.13.4.6 The System disgnostic to include status monitor, local logistics, remote diagnostics and maintenance features.

13.1.14 TRACK MEASURING DEVICE The vehicle will be equipped with the track measuring device.The device is stored into the cargo platform and can be mounted on the track and attached to the vehicle by a single worker.The maximum towing speed for the measuring device is 15 km/h.

13.1.14.1 Track geometry measuring device

13.1.14.1.1 The measuring device it is made of a steel frame with several steel wheels with railway profile, which will mount all the sensors and batteries needed for operation.

13.1.14.1.2 The measuring device will be able to measure the following track geometry parameters: (a) Track gauge: Precision 0.1mm / reproducibility at 95%: ±0.45 mm / Range: 25

mmTrack cant: Precision 0.1mm / reproducibility at 95%: ±0.7 mm / Range: N/A

(b) Track twist: Precision 0.1mm / reproducibility at 95%: ±0.7 mm / Range: ±13 mmRail top level on both rails: Precision 0.1mm / reproducibility at 95%: ±0.7 mm / Range: -3 mm

(c) Versine (alignment) on both rails: Precision 0.1mm / reproducibility at 95%: ±1 mm / Range: ±25 mm All the measuring parameters will have a precision of at least 0.1 mm.

(d) The measuring device will have a numerical display on the own vehicle, with a PC port for exporting data. The device will have an encoder for measuring the track distance travelled by the device.


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(e) The device also has an independent PDA device which will guarantee:

a. Display of all the measures taken in real time b. Processing of the signals, including wave filtering and signaling when the

tolerances are exceeded

(f) Storage of numerical variables every 0.25 m, with a total memory for 2000 km.

13.1.14.2 Track Geometry Measurement System (TGMS)

13.1.14.2.1 The Track Geometry measurement shall:

Filters allowing the measurement down to very-low speed or zero speed

Creating the reference line to evaluate the defects

13.1.14.2.2 The system shall ensure that in curves the layout rules must be taken into consideration. Low pass filters may not give a good reference, especially for the transition curves.

13.1.14.2.3 The Track Geometry Measurement System shall be a contactless measurement system consisting of an inertial system coupled with two Rail Profile Measurement Systems (one for each rail).

13.1.14.2.4 There shall be no moving mechanical parts. All instruments shall be mounted on the primary suspension (no sub frame shall be needed on the axle boxes). The mounting shall be compatible with UIC518, i.e. there should be no need to re-certify the bogie dynamics after the installation of the equipment.

13.1.14.2.5 The software shall be user-friendly and a single monitor shall be sufficient to display all key data.

13.1.14.2.6 Measurement Principle of Track Geometry and Rail Profile (a) Non-contacting measurement, by optical system associated to inertial sensors shall

be provided. No moving mechanical parts shall be used. Navigational GPS system shall also be included.

(b) The Track Geometry Measurement shall fully compliant with the EN-13848

normative and the reproducibility / performance of the system shall be according to EN-13848.

(c) Measurement shall be under true load at all speed, up to 160 Km/h. (d) The Track Geometry and Rail Profile parameter measured by the system are the

following:

The main measured parameters are:

o Speed and Kilometric progressive (chainage) o GPS position o Track gauge o Longitudinal level of left and right rail o Alignment of left and right rail o Super-elevation and Cross Level o Twist o Curvature and radius o Gradient o Turnout geometry

For Rail Profile measurements for both left and right rail are:


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o Speed and Kilometric progressive (chainage) o GPS position (if included) o Rail cross-section o Height and width o Rail inclination o Section wear o Transversal gauge-side wear o Vertical wear o Equivalent Conicity

(e) Every measurement involving a distance base (e.g. twist, dynamic gauge, ...) shall

be user configurable. Multiple twist values, for various base lengths, shall be computed at the same time. The standard deviation of the alignments on a user configurable distance shall be included in the track geometry module.

(f) It should be possible to compute Custom Track Quality Indexes as functions of the measured data. No component of the system shall be subject to any restriction.

(g) The low speed measurement shall be possible with use of very high quality sensors. There should not be any need for adding any sub frame on the axle boxes. The measurement shall be intrinsically insensitive to any deformation of the bogie or the car body.

(h) The instrument output shall be a set of diagrams, or a set of file (binary or ASCII). All the graphs shall be completely user configurable in the Multi-graph module. The track geometry can be plotted along with any other channel / parameter, which is a function of the space or time.

(i) The system shall make it possible to compute the equivalent conicity by analysing the measured profile data.

13.1.14.2.7 Installation of Track Geometry and Rail Profile onboard The Track Geometry and Rail Profile Measuring Instruments shall be integrated in a single beam. This shall be mounted on the vehicle bogie, suspended on the primary suspension (no sub frame shall be added on the axle boxes).

13.1.14.2.8 Track Supervision Software Track supervision software shall be provided. The architecture of this software shall be developed according to the following criteria:

Double stamping, time and space, for every measurement sample, exactly at the time of the acquisition trigger

Asynchronous computing pipeline. In an asynchronous pipeline, the system latency is not important. Only the average computing power matters.

Completely configurable time and space sampling, at different frequencies for different acquisition channels. The time and space stamps shall be used to properly re-sequence the measurements, wherever necessary.

Every algorithm is an independent computing module.

Whenever it makes sense, the computing modules shall be multi-instance.

The entire system configuration is stored in a single file.

It is always possible to store the raw data, for diagnostics and/or for playing back with different configurations

Different configurations can be stored and retrieved (e.g. different display configurations, showing different channels)


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The software shall have GUI visualization module and Report Generation formats. It shall be possible to download the data from Track Supervision Software and transfer to off-board workstation.

13.1.14.2.9 Off-board software system This should be a Web-based, multiuser and multifunction system to collect, process, store and present the data coming from a multitude of sources on a dedicated Workstation in the back office (off-board). It shall manage the raw data, the processed data and the defects. Everything shall be linked in order to deliver a comprehensive and detailed view of every infrastructure component. It shall integrate all the information / date collected from any other source of track data, including the defects detected by the ultrasonic RFD system.

13.1.14.3 Ultrasonic measuring device

13.1.14.3.1 This measuring device is a dual rail inspection system for tracks.

13.1.14.3.2 The device features several ultrasonic sensors which are specialized in detecting defects and cracks in both rails of the same track simultaneously.

13.1.14.3.3 The main characteristics of the device are as follow: (a) Inspection of both rails at the same time and in a single pass. (b) Recording of all the parameters and variables, including defect details, main events

and the sensibility programmed.

(c) Positioning of the defects and cracks due to encoders in the main wheels.

(d) The device allows inspecting tracks of different gauge with a simple manual adjusting, from narrow tracks to wide tracks, and of course standard UIC gauge.

(e) GSM module which will allow direct link communications to a PC in a distant office, in real time.

(f) 3 different ultrasonic visualization modes, with an option for screen shots of the current visualization and storage of critical images into the device internal memory.

(g) PC port to download all the data to other PCs via direct link.

(h) Special channel for manual checking of the events in the track.

(i) It can be towed upto15km/h by a vehicle or it can be handled by a single worker on foot.

13.1.14.3.4 The device is electrically isolated on track. The device works with 9 ultrasonic sensors

located on each measuring wheel. That allows the device to measure dynamically 98% of the rail head and 100% of the rail beam.

13.1.14.3.5 The sensors are disposed in several angles, in order to extend the coverage of the ultrasonic wave to the maximum available. (a) 1 sensor at 0° (b) 6 sensors at 70° in two groups of 3 (c) 2 sensors at 37°


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13.1.15 OHE / OCS MEASURING DEVICE

13.1.15.1 Measuring Pantograph

13.1.15.1.1 The vehicle will have a measuring pantograph, insulated, calibrated and with precision potentiometer, IP65 protected, and with digital display in the cabin, to measure the height and stagger of the catenary, all catenary parameter at crossover / turnout locations.

13.1.15.1.2 The actuator of the pantograph will be pneumatic, with pressure regulator.

13.1.15.1.3 The pantograph will be able to measure both the lateral and the height deviation of the

overhead line, which the driver will be able to check thought a TV camera supplied with the system. This camera will be pointed at both the rules, and the video feed will be shown in a colour monitor in the driving cabin.

13.1.15.1.4 It will also have a linear inductive detector in the pantograph which will continuously

show in the screen the current height of the pantograph in real time, and will be able to either print the height profile in real time or store the measures in a computer memory.

13.1.15.1.5 For the lateral deviation, the pantograph will feature a laser sensor which will provide

accurate lateral deviation, also shown in real time in the driver desk screen and with the option to either print the lateral deviation profile in real time or store it in a computer memory.

13.1.15.2 OHE / OCS Measurement System

13.1.15.2.1 A colour camera and illuminator shall be installed in front of the pantograph, approximately at the same height as the pantograph base.

13.1.15.2.2 It should be possible for the user to change the camera orientation via a joystick and zoom in and out

13.1.15.2.3 The image of the ruler shall appear on a computer screen, in the vehicle cabin, allowing the operator to watch the pantograph and check the lateral position visually.

13.1.15.2.4 The software shall be configured to automatically stop recording whenthe vehicle stops; and automatically restart recording when the vehicle restarts.

13.1.15.2.5 Header data (Location, time, comments, ...) shall be recorded when starting the operations. These data shall stored as a header in the text file and also superposed to the images.

13.1.15.2.6 The wire height shall be automatically measured by measuring the height of the stripes. A wire sensor shall be installed in the pantograph base. The height shall be constantly shown on the screen, superposed on the pantograph image.

13.1.15.2.7 It should be possible for the user to set tolerance thresholds (low and high). Whenever the height is outside the limits, an event shall be generated and the height shall be shown in red (or other colour as preferred by Emploter), until it goes back into the accepted values. The event shall be also managed as every other event.

13.1.15.2.8 The km shall be shown on the screen, superposed to the image. The km may be incremental or decremental, starting from the value set by the user along with the header data, when starting the operations; the km can be changed at any time via the virtual keyboard.

13.1.15.2.9 It should be possible for the user to also record his voice. The voice record shall be played back synchronized with the video. The system shall record two files, at the same time: video and audio.


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13.1.15.2.10 Km and height shall be superimposed on the images

13.1.15.2.11 Text: after the header, where the user can record location, time, etc., the file shall be

composed by one line every sample. The data sampling shall be synchronized in space. The space interval can be selected by the operator (system configuration menu). Every line shall be composed by: km, Z height, event (if it exists; it comes from the virtual keyboard).

13.1.15.2.12 The virtual keyboard shall allow the operators to add auxiliary information to the records. Most typical events shall be pre-coded, and can be added just with a pushbutton or a mouse click, but the operator can also add free comments. Among the pre-coded events: road crossings, bridge, tunnel, turnout, new km position (the user adds the km), mast id etc.

13.1.15.2.13 The events shall be printed in the relevant horizontal axis position in the strip-chart.

13.1.15.2.14 When playing back the images, the events shall be superposed to the images for a few

seconds. 13.1.15.2.15 The language shall be selected by the user

13.1.15.2.16 In the text output files, the events shall be recorded in a dedicated column, in the last

record before the relevant user action

13.1.15.2.17 The virtual keyboard can be opened on the main screen, or on a separate notebook connected to the Ethernet network.

13.1.15.2.18 The events (regardless to the event source:be it automatically or manually generated) shall also be inserted in the video stream as "markers" allowing the user, when playing back, to jump straight to the selected marker (the markers shall be shown as a list in the playback software). The system, if so configured by the user, can also automatically insert markers every 10, or 20, or 50 or 100, or 500 meters: these markers shall be named with the relevant km post.

13.1.15.2.19 Deliverables

Video and voice file

Text file: header data, followed by columns recording: km, Z position, events (from keyboard).

The position of stagger shall be extracted from the digital video by suitable detecting software in post-processing

13.1.16 RESCUE EQUIPMENT

The vehicle will be equipped with the following rescue equipment, which will include rerailing hydraulic equipment, hydraulic rescue tools, inflatable rescue air bags, and all the power units and control units needed.

13.1.16.1 Air Bags

13.1.16.1.1 One set of air bags comprising two bags of each of the following sizes shall be provided.

13.1.16.1.2 Size of approx. 600x600mm to 650x690mm with 300kN lifting capacity and 350mm lifting height and an Insertion Height of 25 mm. Weight shall be max. 13kg

13.1.16.1.3 Size of approx. 900x900m to 950x950 mm with 670kN lifting capacity and 500mm lifting height and an Insertion Height of 28 mm, Weight shall be max. 25 kg


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13.1.16.1.4 The set of air bags shall be complete with an air compressor of minimum 230 lpm at 10 bars. The air compressors shall be driven by 4-stroke petrol engine. One control box connecting and operating each set of air bags at a time and reinforced air hoses of required numbers of 10 m length. The air hoses shall be capable of reaching 10m into tunnel beyond the entrance for connection between the air compressor and the air bags.

13.1.16.2 One Rescue Device Set

13.1.16.2.1 The rescue device set shall comprise of hydraulically operated one cutter of minimum

392 kN and one spreader of minimum 230 kN powered generally from the re-railing system complete with a pair of 10 m long high pressure hoses, one pair of replacement blades for cutter, one set (one pair of) pulling chains for attachment to spreading arms, one pair of spare tips for the spreading arms and one pair of peeling tips for spreading arms.

13.1.16.2.2 The hydraulically operated cutters shall be powered generally from the re-railing system but if a separate Power Pack required for the same then the cost of the power pack will be added to the offer rate for rescue device set.

13.1.16.3 Power Pack for Rescue Device Set

13.1.16.3.1 The tenderer may quote for a rescue device set.

13.1.16.3.2 A small power pack of 4-stroke petrol engine of suitable capacity for the use for rescue

device with a minimum operating pressure of 630 bar Suitable for simultaneous and independent operation of 2 rescue tools and weight shall not be more than 25 Kgs. Rescue Tools can be connected and disconnected, even under running engine.

13.1.16.4 One Hydraulic Pump Set

13.1.16.4.1 The hydraulic pump set shall be of 4-stroke petrol engine driven. The engine shall

develop at least 4.5 - 5.0 BHP. The pump shall be capable of operating on unleaded petrol readily available in India.

13.1.16.4.2 Portable two stage radial pistons pump capable of generating pressure of 30 MPa (300 bars) or higher, and the system should have an output of at least, 2.5 l/min at high pressure. Power Pack should have built in pressure shut-off valve, pressure relief valve and venting valve etc, or any bypass valve shall be switched to idle position when jack was not in operation

13.1.16.4.3 Oil tank shall have a minimum usable capacity of 20 liters and an oil filter with optical clogging indicator, a filling filter with integral venting filter, oil sight glasses and oil drain screw.

13.1.16.4.4 The weight shall be less than 105 kg.

13.1.16.5 One Auxiliary Hand Pump

13.1.16.5.1 Auxiliary hand pump shall have a minimum pressure rating of 30 MPa and be complete with minimum 2 connections and minimum 10-litre tank. The hand pump should be capable to work a complete rerailing procedure including lifting, lowering in dangerous areas where any pump unit cannot be used.

13.1.16.5.2 Portable hand pump with minimum two connections shall be suitable for two jacks operation. Oil tank shall have a minimum capacity of 10 liters and a filling filter with integral venting filter. The weight shall be less than 40 kg.

13.1.16.6 One Control Console


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13.1.16.6.1 The control console shall be complete with all necessary valves, controls and safety features including dead man switch operable with automatic spring reset in the event of operator inabilities.

13.1.16.6.2 The control console shall have a minimum of four control valves for simultaneous/ independent operation of lifting, lowering and moving horizontally, up to 4 lifting and displacing operation. Safety valves, pressure gauges for pressure monitoring and color coded hose connections shall be provided.

13.1.16.6.3 A high-pressure filter shall be used to prevent the dust and sand from the pump unit to get into the hydraulic system during lifting, lowering and displacing procedures.

13.1.16.6.4 The control console shall have a sturdy portable frame/stand shall be light in weight and the weight of control console shall be less than 70 kgs.

13.1.16.7 High Pressure Hoses

13.1.16.7.1 Pairs of high-pressure hoses each 10m long of required numbers to connect the jacks

between the power pack and control console (bound in pairs) with quick connect couplings / screwed couplings, including oil retaining valves to prevent the leakage of oil when uncoupled and protective caps to prevent soiling shall be provided. The hoses shall be color coded and capable of withstanding a working pressure provided by hydraulic pump. The hoses shall be equipped with non-interchangeable safety couplings.

13.1.16.7.2 Tenderer shall be the manufacturer of quick connect coupler. However if tenderer is not the manufacturer of the same, then same shall be procured from a proven source and shall take approval of the same from MAHA-METRO before supply. Tenderer shall provide complete credential of the proven source in their technical proposal along with the address and telephone number of the end user to whom the high pressure hose have been supplied for use in the re-railing equipment.

13.1.16.7.3 Tenderer shall provide complete technical details of hoses & safety couplings including the company catalogue in their offer.

13.1.16.8 Telescopic Jacks

13.1.16.8.1 The following telescopic jacks having the following nominal ratings shall be provided.

The working pressure shall be 30 MPa or above. 2 nos. of maximum close height including Piston protection plate 250mm, minimum stroke 185mm Capacity: Piston-1: 55 – 65 tons and Piston-2: 25 – 25 tons. Stacking set of 260mm shall be provided if required to achieve maximum closing height of second jacks. 2 nos. of maximum close height including Piston protection plate 495 mm, minimum stroke 500mm.

13.1.16.8.2 Capacity: Piston-1: 55 – 65 tons and Piston-2: 25 – 25 tons

13.1.16.8.3 The jacks with similar overall rating will also be considered. The telescopic jacks shall have hydraulically releasable non-return valves for safe holding of the load even in the event of hose ruptures. Pressure relief valves shall also be provided.

13.1.16.8.4 The jacks shall have coupling connector with overload valves to prevent an overpressure on pressure line.

13.1.16.8.5 Jacks with integrated Base Plates and separate Base Plate are acceptable.

13.1.16.8.6 The maximum stroke including supporting set of the smaller jack types shall be more than the maximum closed height of the taller jack types to make sure that the higher jacks can be used for a continuous lifting operation when the lower jacks have reached their limits.


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13.1.16.8.7 The telescopic jacks shall have carrying handles, colour coded connections, and the weight shall be less than 40 kg.

13.1.16.8.8 Displacement Jacks and Roller Carriages

13.1.16.8.9 Pair of displacing jacks shall be provided each with 12/6 tones (pushing force 12 tones and pulling 6 tones) capacity, maximum closed height 580mm, minimum stroke 300mm with steel counter support.

13.1.16.8.10 The displacing jacks shall have color coded connections and the weight shall be less than 20 kg. The working pressure shall be 30 MPa or above.

13.1.16.8.11 Four roller carriages shall be provided each with 60-ton or above capacity, and removable top plate. The height shall be less than 110mm (without plate) - 140mm (with plate) and the weight less than 60 kg (without plate) and 85 kg (with plate). The width shall be 260mm.

13.1.16.8.12 The roller carriages shall have carrying handles, shall be equipped with low friction rollers and guiding pin to ensure a linear movement.

13.1.16.8.13 The following accessories shall be provided: (a) Four counter supports, (b) One stopping device with carrying handle, (c) One distance bar having an adjustable length from 1,050mm up to 2,600 mm and

weight less than 50 kg

13.1.16.9 Re-railing Bridges and Couplers

13.1.16.9.1 Re-railing bridge of carrying capacity 60 tones at a free span of 1.5m shall be provided for each of the following sizes. (a) 3.30m Long (one no.) or ( 2.5m + 1.0m) (b) 2.20- 2.5 m Long

13.1.16.9.2 The Re-railing bridges shall be manufactured out of high quality light metal alloy in

hollow body construction designed to ensure ability to couple one bridge with another. Construction height shall not exceed 180 mm and width shall be between 250 - 350mm. The load capacity of re-railing bridges shall be tested to 25% overload capacity.

13.1.16.9.3 The re-railing bridges shall be fitted out with carrying handles and mounting points for bridge couplings.

13.1.16.9.4 The maximum weight for the longest bridge shall not be more than 135 kg.

13.1.16.9.5 Pair of bridge couplers / one set of connection element shall be provided and coupler shall be designed for joining together two re-railing bridges. The coupler weight of one set of connection element shall be less than 40 kg.

13.1.16.9.6 The bidder shall indicate the test facilities available at manufacturer’s site / third party test laboratory to carry out the load test conforming the load carrying capacity of re-railing bridges at a free span of 1.5 meters as per details above and tenderer shall submit details in the technical offer as per the Bidder’s technical submission.

13.1.16.10 Single Piston Step Jack (claw jack)

13.1.16.10.1 The Piston Step Jack shall have a capacity of minimum 30 tonnes, minimum working

pressure 35 Mpa, height of 1000 mm to 1150 mm or to approx. 850 mm with claw and stroke of 825mm including accessories:


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(a) Integrated high capacity claw (b) One round Head Piece for single piston step jack (c) Radius plate as swivel base plate for the above claw jack. (d) The single piston step jack shall have carrying handles, Colour coded connections

and the weight shall be max. 70 kg.

13.1.16.11 Two Lifting Cable Ladders The lifting cable ladders shall be provided complete with accessories. The carrying capacity shall be 35-40 tones with a factor of safety not less than 3. The length shall be at least 3m.

13.1.16.12 Generator

13.1.16.12.1 One generator shall be provided along with the equipment. The generator shall be a portable petrol engine driven unit, skid mounted with protective frame.

13.1.16.12.2 The output rating shall be not less than 3.2kW, 220V, 50Hz single phase. The unit shall be manually started by means of a retractable toggle starter. A minimum of two panels with three in panel mounted industrial waterproof socket outlets shall be provided. Equipment of lighter weights are preferable.

13.1.17 TECHNICAL ALTERNATIVE

Minor deviation in technical specification is permitted. However,minor deviation shall not affect SOD and performance parameter of machines.

13.1.18 RAMS REQUIREMENTS The Plant is expected to meet the RAMS target of 96% Availability, which will be calculated excluding the downtime planned for Preventive Maintenance Services. Note: The bidder shall submit the complete technical detail of offered 8-wheeler Tower Wagon for technical evaluation.

13.2 CATENARY MAINTENANCE VEHICLE (4-WHEELER)


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13.2.1 GENERAL

The scope of this specification is to reflect the performance and quality requirements for an Over Head Equipment (OHE) Maintenance Vehicle, which will also be used as an emergency and rescue Shunter. The vehicle shall be equipped with necessary sensors / instrumentations for integrated OHE / Track geometry measurement system and ultrasonic measuring device.

13.2.2 VEHICLE DESCRIPTION The vehicle will be a self propelled full rail borne vehicle composed by a steel frame, lying over two axles (4-Wheeler Vehicle)

13.2.2.1 Vehicle frame

13.2.2.1.1 The frame of the vehicle will be composed of standard steel sections and transversal beams. The material will be of standard steel of different qualities, depending on the mechanical requirements over the frame.

13.2.2.1.2 The frontal parts of the frame will be designed in order to make the assembly of the coupler easier. They are made to support the efforts indicated in the UIC 577 – OR leaflet.

13.2.2.1.3 The vehicle will have a loading platform in the middle part of the vehicle. The height from the platform surface to the running plane will be 1200 mm when the vehicle is unloaded.

13.2.2.1.4 Regarding to the surface treatment and painting, the following treatment will be applied

to the frame and cabin: (a) Sand blasting SA 2.5 according to SIS 055900 standard (b) Primer coat of anticorrosion painting based in zinc phosphate, (c) Final coat treatment composed by an epoxy coating and a finish coating black RAL

9005.

13.2.2.2 Vehicle equipment

13.2.2.2.1 The vehicle will have a working platform in the middle section. The vehicle will include a hydraulic crane for cargo handling. The vehicle will have a measuring pantograph, and measuring equipments for the overhead equipment and track geometry.

13.2.2.2.2 The two axles of the vehicle will be powered with hydrostatic / hydraulic-mechanical transmission and a main diesel engine.

13.2.2.3 Vehicle performance

The vehicle main duty will be:

13.2.2.3.1 To transport material and workers from the maintenance sites in the tracks to the workshops and train depots

13.2.2.3.2 To tow up to 6 Metro cars (47 t each) in rescue mode

13.2.2.3.3 To carry track and OHE test equipment for analyzing the Track and OHE geometry. For the crew and worker transportation, the vehicle will feature a five people capacity cabin.

13.2.3 GAUGES AND DIMENSIONS


Feb 2018 Page 197 of 202

13.2.3.1.1 The profile and cross section of the Maintenance Vehicle will comply with the Pune Metro Rail Schedule of Dimensions.

13.2.3.1.2 Any equipment, structure or element of the vehicle which could infringe the gauge while extended in running condition will be labeled and painted in a bright colour in order to remind the crew about them after the work is finished.

13.2.3.1.3 The only equipment which could infringe the gauge is the crane, the working platform and the stabilizers, so they will be all retracted and stowed when switching from working speed to running speed. The vehicle will have enough clearance from the rail level to the underside of the vehicle.

13.2.4 OPERATIONAL REQUIREMENTS

13.2.4.1 The vehicle will be able to tow up to 6 Metro cars (47t each) for a total of 280 ton, in a

gradient of 4% at least at 8 km/h speed.To perform the towing duty, the vehicle will feature a Rockinger type coupler for towing Metro Cars. For the design and construction of the vehicle UIC and IRS standards will be applied.

13.2.4.2 Maximum admissible axle load for the vehicle will not be higher than 16t per axle. The

wheel profile will be as per Metro standard wheel profile.

13.2.4.3 Track requirements The vehicle will be capable of travelling through the Curves, Cants and Gradients noted in the Pune Metro Rail Schedule of Dimensions.

Minimum radius of horizontal curves

On main running lines Elevated and At-Grade Sections 120m

On main running lines Underground Sections 200m

Depot and other non-passenger Lines 100m

At passenger platforms 1000m

Minimum radius of vertical curve on main running lines 1500m

Cant and Cant Deficiency

Maximum Cant on curves 125mm

Maximum Cant Deficiency 100mm

Maximum Gradient 4%

13.2.4.4 Speed requirements

The vehicle will be able to circulate at the following speeds:

By its own speed in straight track and curves with a very long radius 50 kmph

Towing 280 ton of Metro cars in 4% gradient 8 kmph

Towing 280 ton of Metro cars in level track 14 kmph

In a train composition being tow 80 kmph

The vehicle will be able to circulate in both directions at the same speed

13.2.5 DRIVE

13.2.5.1 Diesel engine

13.2.5.1.1 The vehicle will be powered by a diesel engine of adequate capacity to meet the performance and operational requirements detailed in the Clause 13.2.4 “Operational requirements”


Feb 2018 Page 198 of 202

13.2.5.1.2 The proposed power of the engine will be a minimum of 200 kW or more as required for

hauling 6 car train. This proposed power can vary depending on the current state of the diesel engine technology. The diesel engine will be from a top brand OEM, with satisfactory service and repair support facilities available in India.

13.2.5.1.3 The Diesel Engine will have a fuel tank with enough capacity to provide 8 hours of continuous operation. The engine starter will be electric, powered by batteries.

13.2.5.1.4 The Diesel engine will comply at least with the Euro 4 or equivalent exhaust emissions standard.

13.2.5.1.5 The Driver control panel will have enough monitoring gauges for temperature, rpm, oil pressure etc. for controlling the engine performance at any moment.

13.2.5.1.6 The engine, as well as the associated elements (compressor, alternator, etc.) will be assembled over its own frame supported by mean of silent blocks by the frame of the vehicle.

13.2.5.1.7 The engine will be easily accessible by every side, with doors and cabinets on the vehicle floor in order to help maintenance operations and to help in the removal of dust and grease.

13.2.5.1.8 The cooling circuit of the vehicle will be designed with the radiator in horizontal position. The radiator will have the same performance in both directions.

13.2.5.1.9 The radiator surface for the engine will be enough to keep the engine running in working order even with 30% of the radiator surface chocked, and in any case, the cooling fluids will exceed 95°C temperatures.

13.2.5.1.10 The radiator fan will be of electric nature, which will be feed by the auxiliary alternator of the engine.

13.2.5.2 Transmission

13.2.5.2.1 The vehicle will have the diesel engine power relayed to the two axles, by means of a hydrostatic / hydraulic-mechanical transmission.

13.2.5.2.2 This hydrostatic drive will be composed of hydraulic pumps, hydraulic motors in each axle, and the software control.

13.2.5.2.3 The drive mineral oil will be of HLP grade type satisfying DIN 51 524 standards. Every hydraulic systems of the vehicle will be protected by mean of security valves from the pressures in the different working conditions.

13.2.5.2.4 The oil tank of the vehicle will have a capacity to provide 8 hours of continuous operation. It will be designed to allow changes in the volume of the oil which could take place in every running condition, permitting the air outlet in every moment. The capacity will be enough for the first filling of the circuit.

13.2.5.2.5 The final mechanical connection between the axle set and the hydraulic motor will be made by mean of an axle gear – box with dual speed.The dual speed selection will allow the vehicle to shift between low speed, high traction force gear for work and shunting duties and a high speed, low fuel consumption gear for transfer duties and faster arrival at the working place.

13.2.6 CABIN

13.2.6.1 The vehicle will have a single cabin with enough space for carrying 4 passengers + the

driver seated on the Driver’s seat.


Feb 2018 Page 199 of 202

13.2.6.2 The cabin will comply with UIC 617 – 6, 625 – 6 y 651 OR leaflets.

13.2.6.3 The cabin will be made of steel profiles, with an interior furnishing of phenolic boards.

13.2.6.4 Enough windscreens and windows will be provided in order to give the best visibility all

around from the cabin, in both directions of driving.

13.2.6.5 Two separate driving desks can be installed, one on each running direction in order to provide good view in both travelling directions.

13.2.6.6 The passenger seats will be ergonomic and will be able to fold to save space when not in

movement.

13.2.6.7 The visibility from the driving desk will be according to UIC 625-6 leaflet, and the windshields will have windshield wipers. It will also have rear mirrors in order to control the position of the vehicle.

13.2.6.8 The cabin will have full acclimatization in order to keep the cabin temperature in working

levels thought the whole year.

13.2.6.9 It will include both A/C and heater.

13.2.7 BRAKE SYSTEM

13.2.7.1 The vehicle will be fitted with compressed air brakes commanded from the main cabin through the driver’s desk.

13.2.7.2 The vehicle should be able to drive as a head in a towing composition, and as a wagon in a larger train composition. The brake system will be able to brake the vehicle when it is part of a bigger composition.

13.2.7.3 The brake system will be capable of braking a full towed composition of 6 Metro Cars with 47t weight each.

13.2.7.4 The minimum percentages of braked mass of the automatic brake will be according to UIC 543 specifications. The braking coefficient will be of the 70% in the most unfavorable load conditions.

13.2.7.5 The parking brake will warranty that the vehicle is stopped on a slope of the 4% with a safety factor of 1.45, without overtake an adherence coefficient rail – wheel of 0.12.

13.2.7.6 The parking brake will work over the same brake blocks as the service brake by mean of accumulation springs. The service brake will be electro pneumatic, according to UIC 540 to 543 leaflets.

13.2.7.7 The service brake system will allow the coupling of the vehicle to a train composition, in such a way that the brake can be activated from the cabin, and to act over the own vehicle and the rest of the composition.

13.2.7.8 The application of the braking effort will be made by mean of braking blocksor brake cylinder with double effect regulator and antagonist spring. They will act directly over the lathes by mean of braking pads according to UIC 541 – 3 y 541 – 4 and 832 standards.

13.2.7.9 The vehicle will have an emergency brake system installed. These emergency brake buttons will be easily visible and accessible. The emergency brake connects directly the emergency valve to the atmosphere producing an emergency brake.

13.2.7.10 The whole system will be powered by an onboard air compressor which will comply with prEN 14033 – 1 article 9.4, for a minimum number of 14 axles.


Feb 2018 Page 200 of 202

13.2.7.11 The tank capacity will allow, in every braking condition, three braking / looses at the

maximum pressure, with the vehicle isolated, without production of compressed air and with the maximum stroke of the brake blocks.

13.2.8 DYNAMIC EQUIPMENT

13.2.8.1 The vehicle will be powered by two axle sets.

13.2.8.2 The maximum weight per axle will not exceed 16 Tonne.

13.2.8.3 The two axles will be powered, and be capable of moving the vehicle in both directions at

full speed. The wheels will be monoblock, and made of forged steel. The axle grease boxes will be fully sealed, and will have installed long life bearings. The damping system will be designed following the UIC leaflets, and will be composed of elastic steel coil springs between the frame and the axle boxes.

13.2.9 ELECTRIC EQUIPMENT

13.2.9.1 The electric equipment of the vehicle will comply with all the relevant standards and specifications, and will be suitable for the final destination conditions.The vehicle will be equipped with an electric starter batteries and motor for the diesel engine, capable of starting the engine on its own without any external power.

13.2.9.2 The internal and external lightning will comply with the line standards, and will be enough to work in night time conditions.

13.2.9.3 The working platform will have electric sockets on the cradle, and two manual lights mounted in pivoting mounts, one on each opposing corners of the platform. The circulation lightning will be according to the Metro Line standards.

13.2.10 MISCELANEOUS EQUIPMENT The vehicle will come equipped with the following auxiliary equipment:

13.2.10.1 Sand boxes The vehicle will have sand boxes in both running directions and in every wheel to allow a better traction effort in case of slipping.

13.2.10.2 Driver Safety Device The vehicle will feature a double system for the safety of the driver which will accomplishing UIC 641 – O standard.When activated it will produce an emergency braking (traction cut and maximum service brake).

13.2.10.3 Acoustic signals (Horn) The vehicle will have two pneumatic horns, one for each running directions, audible at a distance of minimum 1000 m, with sound intensity between 120 and 125 dB(A) at 5 meters (according UIC-644 leaflet).

13.2.10.4 Tool Kit The vehicle will include a set of general tools to make urgent reparation.

13.2.11 WORKING PLATFORM

13.2.11.1 The vehicle will have a working platform for inspection and maintenance works in the overhead equipment. The working platform will be constructed by mean of an insulated


Feb 2018 Page 201 of 202

platform with insulating elements according to DIN standards for the voltage and intensity required.

13.2.11.2 The platform will have handrails of 1100 mm height, and dimensions of 2500 x 2500 mm. The design and location of the platform, will allow the work with the handrail erected in small gauge tunnels.

13.2.11.3 The access to the platform will be an insulated ladder with the insulating characteristics of the platform, 800 mm width. The steps will be anti slipping, with a distance between them of 300 mm and a step of 50 mm. The access to the platform will be safe and comfortable.

13.2.11.4 The platform will have two movements, elevation and translation. The elevation mechanisms will be hydraulic with a scissors like mechanism powered by cylinders of double effect and piston pump to activate them or hydraulic telescopic type. The platform will be pivot mounted rotating type or translating.

13.2.11.5 The translation system will be powered by a hydraulic motor with negative brake that assures the position of the working platform and a mechanical system with coupler that limits its speed.

13.2.11.6 The platform floor should be capable of elevating to a maximum height of 5500 mm The platform floor when retracted should be at 3000 mm from the rail head.The platform will be able to laterally traverse 1500 mm to each side of the track axle.

13.2.11.7 The working platform will have an emergency system for its own movement in case of breakdown, consisting of a manual hydraulic pump located in the lateral part of the vehicle. It will allow moving the working platform in case of a failure of the diesel engine.

13.2.12 CRANE

13.2.12.1 The vehicle will have a hydraulic operated crane specific for railway vehicles, with low standstill height.

13.2.12.2 The crane operation should be such that there is no infringement to over head electric equipment during crane maneuvering / extension / shortening and there is no infringement to the Metro Schedule of Dimensions

13.2.12.3 The crane will have the following performance and equipment: (a) Max. Lifting capacity:10.4 t m (b) Lifting capacity at 9.7 m reach: 1000 kg (c) Hydraulic Reach up to 9.7 m. (d) Two extensible hydraulic jacks (e) Base of the crane for works with an angle of 10o (f) High pressure filter, Oil radiator. (g) Working light, installed in articulated arm. (h) Spinning and height limiter. (i) Emergency stops, piloted valves and torque limiter. (j) Limit switches to avoid gauge infringement.

13.2.13 MEASURING EQUIPMENT Refer to Para 13.1.13

13.2.14 TRACK MEASURING DEVICE Refer to Para 13.1.14

13.2.15 OHE / OCS MEASURING DEVICE


Feb 2018 Page 202 of 202

Refer to Para 13.1.15

13.2.16 TECHNICAL ALTERNATIVE Minor deviation in technical specification is permitted. However,minor deviation shall not affect SOD and performance parameter of machines.

13.2.17 RAMS REQUIREMENTS The Plant is expected to meet the RAMS target of 96% Availability, which will be calculated excluding the downtime planned for Preventive Maintenance Services. Note: The bidder shall submit the complete technical detail of offered 4-wheeler tower wagon for technical evaluation.

MAHA-METRO Contract No. P1/TR-02/2018 Particular Specification Appendix A: Interfaces




DESIGN, SUPPLY, INSTALLATION, TESTING & COMMISSIONING OF 25KV FLEXIBLE & RIGID OVERHEAD CATENARY SYSTEM (OCS / OHE) AND SECTIONING POSTS FOR PUNE METRO

RAIL PROJECT




APPENDIX A: INTERFACES



Table of Contents

1.0 INTRODUCTION ........................................................................................................................... 3

1.1 OBJECTIVE ................................................................................................................................... 3

1.2 INTERFACE WITH CIVIC / GOVERNMENT AUTHORITIES ....................................................... 3

1.3 INTERFACE WITH OTHER CONTRACTORS .............................................................................. 4



1.0 INTRODUCTION

1.1 OBJECTIVE

1.1.1 The design and construction process for Metro Project involves multidisciplinary agencies, which shall take up the design and construction of various systems like Civil Works, Track Works, Train Control Works, Telecom System works, Traction System works, Electrical Power Works etc. The successful implementation of the Project will require close interaction and co-ordination among the various agencies.

1.1.2 It shall be the responsibility of the Contractor to interface with all the agencies involved in

the project for the successful completion of all activities assigned to the Contractor. This Chapter defines as the Scope of Work of different agencies, in respect of interface required with OCS Contractor, so that the problems which could arise during the execution stage are greatly minimized, if not eliminated. However, it shall be the responsibility of the Contractor to maintain a close interface with the other concerned contractors and design consultants, so that the problems anticipated/faced during design/design review, procurement and execution at site are communicated through ‘interface documents’ and discussed in periodical lnterface meetings, to arrive at logical and expeditious solutions, to ensure smooth progress of the physical works and realization of the scheduled dates for completion of Works.

1.1.3 The Contractor shall submit an Interface Management Plan in accordance with Clause

3.3.2 of the GS.

1.1.4 This Chapter defines the interface requirement with the following agencies:

(a) Civic / Government authorities (b) Power Supply Contractor (PST) (c) Trackwork Contractors (TRW) (d) Station Building Contractors (SBC) (e) Underground Tunnels / Station Contractors (f) Viaduct Contractors (VIA) (g) Depot Contractors (DEP) (h) Rolling Stock Contractor (RS) (i) Train Control / Signaling Contractor (SIG) (j) Telecom Contractors (TEL) (k) Any other contractor/agency designated by Employer

1.2 INTERFACE WITH CIVIC / GOVERNMENT AUTHORITIES

1.2.1 The OCS Contractor, in the course of survey, execution, testing and commissioning shall

maintain constant interface with Pune Development Agencies / Muncipal Corporation / other Civic Authorities to obtain:

All permissions and approvals including payment of fees/ restoration charges/ penalties/ demurrages.

Clearances for digging along pavements / roads, as necessary

Restoration of the sites, as required under terms of agreement with Pune Development Agencies / Muncipal Corporation / other Civic Authorities and final clearance to be obtained.

Interface with the civic authorities to obtain water, sewerage connection as required.

1.2.2 Interface with IGL /BSNL and other Utilities authorities The OCS Contractor, in the course of survey, execution and testing and commissioning shall maintain constant interface with IGL/ BSNL and other utilities authorities to ensure that:

The functioning of the utilities is not jeopardized by the actions of the OCS Contractor

No damage is caused to the utilities



If any work is carried out in the vicinity or on the utilities; the status-quo-ante is restored to the satisfaction of the Utilities.

Obtaining ‘No objection ‘and final clearance as required including payment of fees / restoration charges / penalties / demurrages.

1.2.3 Interface including all documentation, coordination and necessary tests for obtaining

statuary approval and clearance of Electrical Inspector to the Government.

1.2.4 Interface, including all documentation, coordination and necessary tests, for obtaining statutory approval and sanction of Commissioner Metro Rail Safety to the Government for opening the system for public carriage of passengers

1.3 INTERFACE WITH OTHER CONTRACTORS

Refer ‘Project Wide Interface Document’

MAHA-METRO Contract No. P1/TR-02/2018 Particular Specification Appendix B: Technical Sheets





RAIL PROJECT




APPENDIX B: TECHNICAL SHEETS



Table of Contents

1.0 INTRODUCTION ........................................................................................................................... 3

2.0 OVERHEAD CONTACT SYSTEM ................................................................................................ 3

2.1 Contact Wire .................................................................................................................................. 3

2.2 Messenger Wire ............................................................................................................................. 3

2.3 Overhead Protection Conductor (OPC) & Buried Earth Conductor (BEC) .................................... 4

2.4 Jumper Wire................................................................................................................................... 5

2.5 Dropper Wire ................................................................................................................................. 6

2.6 OCS Support Structures (for depot) .............................................................................................. 6

2.7 Insulators (for bracket, stay arm, conductor anchor …) ................................................................ 7

2.8 Short Neutral Section ..................................................................................................................... 8

2.9 Section Insulator (conventional type) ............................................................................................ 8

2.10 Light weight section insulator....................................................................................................... 9

2.11 Rigid Overhead Collection System (ROCS) .............................................................................. 10

2.12 Working Vehicle ......................................................................................................................... 11

3.0 CABLES ...................................................................................................................................... 12

3.1 25kV Cables ................................................................................................................................ 12

4.0 25KV SWITCHGEAR .................................................................................................................. 14

4.1 25kV Circuit Breaker .................................................................................................................... 14

4.2 25kV Interrupters ......................................................................................................................... 15

4.3 25kV Isolator ................................................................................................................................ 16

4.4 25kV Current Transformer ........................................................................................................... 17

4.5 25kV Voltage Transformer ........................................................................................................... 18

4.6 25kV Lightning Arresters ............................................................................................................. 19

4.7 25kV Isolator (opening or closing manual or motorized, pole mounted) ..................................... 20

4.8 25kV Motorized Circuit Breaker (pole mounted).......................................................................... 20

4.9 25kV Gas Insulated Switchgear (GIS) for Underground ............................................................. 22

5.0 BATTERY SUPPLY .................................................................................................................... 24

5.1 110V DC Battery .......................................................................................................................... 24

5.2 110V DC Battery Charger ............................................................................................................ 24



1.0 INTRODUCTION Expected values given in this Appendix are tentative and shall be updated as per Contractor’s detailed design with notice of no-objection from Employer’s Representative

2.0 OVERHEAD CONTACT SYSTEM

2.1 Contact Wire

SN Indications Unit Expected values

Values submitted

1 Manufacturer

2 Place of manufacture

3 Manufacturer drawing reference

4 Standard EN 50149, UIC 870

5 Material Copper

6 Cross section type BF-150

7 Maximum linear weight Kg/m 1.374

8 Minimum linear weight Kg/m 1.293

9 Coefficient of linear expansion Per °C 17 ∗ 10−6

10 Minimum breaking load daN 5265

11 Elongation factor 91 ∗ 10−6

12 Equivalent copper conductivity 98%

13 Maximum resistivity at 20°C μΩ.cm 1.777

14 Minimum diameter of contact wire drawn out of continuous cast rod

mm 21

15 Length of wire per drum m

16 Weight of drum with contact wire kg

17 Drum type Wood with mild steel frame

18 Drum tested as per EN 50149

2.2 Messenger Wire


Values submitted

1 Manufacturer





Values submitted


4 Standard RDSO spec ETI/OHE/50

5 Material Cadmium Copper

6 Nominal cross section Sqmm 65

7 Diameter mm 10.5

8 Composition 19 strands, each of 2.1mm dia








16 Weight of drum with messenger wire kg


2.3 Overhead Protection Conductor (OPC) & Buried Earth Conductor (BEC)


Values submitted

1 Manufacturer



4 Standard IS 398 (Part II)

5 Material ACSR

6 Nominal cross section Sqmm 93.3

7 Diameter mm 12.5




Values submitted

8 Composition (of aluminium) 12 wires, each of 2.5mm dia

9 Composition (of steel) 7 wires, each of 2.5mm dia







16 Weight of drum with messenger wire kg


2.4 Jumper Wire

SN Indications Unit Expected values Values submitted

1 Manufacturer



4 Material Annealed copper

5 In-span jumper

a. Nominal cross section Sqmm 26

b. Diameter mm 7.5

c. Type 19 strands, each containing 7 wires each of 0.5mm diameter

d. Linear weight Kg/m 0.232

e. Coefficient of linear expansion 1/°C 17 ∗ 10−6

6 Continuity jumper


b. Diameter mm 12.7







7 Feeder jumper


b. Diameter mm 18.10




2.5 Dropper Wire


1 Manufacturer



4 Material Bronze

5 Nominal cross section sqmm 12

6 Diameter mm 5

7 1 wire type One wire of 7 strands, each of 0.65mm diameter

8 6 wire type 6 wires of 7 strands, each of 0.65mm diameter

9 Linear weight Kg/m 0.103

10 Coefficienct of linear expansion 1/°C 17 ∗ 10−6



2.6 OCS Support Structures (for depot)


1 Manufacturer



4 Standard IS 2062, IS 800, IS 808 RDSO spec no. ETI/OHE/13




5 Galvanization standard IS 209

6 Zinc coating size of galvanization Microns 85 to 100

7 H type mast BFB 152*152mm RSJ 203*153mm BFB 206*204mm

8 Length m 8.5

9 Plate welding standard ISO-TC-44

10 Portal

a. Galvanization standard IS 209

b. Zinc coating Microns 85 to 100

c. Welding standard ISO-TC-44

2.7 Insulators (for bracket, stay arm, conductor anchor …)


1 Manufacturer



4 Standard RDSO spec no. TI/SPC/ OHE/INSCOM/1070

5 Type Silicone composite insulator

6 Nominal voltage at 50Hz (line to earth)

kV 25

7 System voltage can go upto kV 30

8 Creepage distance of insulator mm 1600

9 Creepage value of insulator mm/kV 31

10 Shed and sheath material of insulator

Made of HTV type silicone rubber having silicon content between 40-50% and preferably alumina tri hydrate as filler

11 Core material of the insulator Boron free, electrically corrosion resistant grade fibre reinforced epoxy resin rod having at least 70% fibers by




weight

2.8 Short Neutral Section


1 Manufacturer



4 Standard IEC 61109/ EN 50119

5 Type Automatic Switched NS

6 Current carrying capacity A 1000

7 Maximum short circuit current capacity

kA 40

8 Maximum short circuit current time

ms 80

9 Insulator Fiber coated with self cleaning PTFE

10 Application Outdoor / tunnel

11 Spark extinguishing 100% when locomotive is not switched off while passing neutral section

12 Insulation resistance (insulator without skids)

Ohm >= 1000 million

13 Creepage distance (insulator without skid)

mm 2500

14 Power frequency dry withstand voltage (insulator without skids)

kV >= 600

15 25kV, 50Hz Vacuum switch

a. Manufacturer

b. Manufacturer location

c. Manufacturer drawing reference

d. Application Outdoor / tunnel

e. Power frequency wet withstand voltage

kV >= 90

f. Short time current rating kA 500 for 3 seconds

g. Actuation of the system

2.9 Section Insulator (conventional type)





1 Manufacturer



4 Standard RDSO Spec no. ETI/OHE/27

5 Type Composite insulator


kV 25


2.10 Light weight section insulator


1 Manufacturer



4 Standard Prototype RDSO Spec no. TI/PC/OHE/LWTSI /0060

5 Type Silicone Composite insulator


kV 25

7 System voltage can go upto kV 30


9 Creepage value of insulator mm/kV 31

10 Shed and sheath material of insulator

Made of HTV type silicone rubber having silicon content between 40-50% and preferably alumina tri hydrate as filler

11 Core material of the insulator Boron free, electrically corrosion resistant grade fibre reinforced epoxy resin rod having at least 70% fibers by weight




12 Breaking load kN 80

13 Dry condition of flashover kV 78.3

14 Wet condition flashover kV 64.5

2.11 Rigid Overhead Collection System (ROCS)


1 Manufacturer



4 Standard and regulations UIC 606-1 and/or UIC 505-5-OI, EN 755-2/9, EN 573, SAC 2200

5 Type Conductor rail having aluminium profile and copper conductor inserted in it.

6 Designed speed of the system and support

kmph 90 + 10%

7 Length of conductor rail (aluminium profile)

a. Minimum m 8

b. Maximum m 15

8 Conductor rail (aluminium profile) cross section

sqmm 2200

9 Conductor rail (aluminium profile) weight

Kg/m 5.91

10 Conductor rail (aluminium profile) current carrying capacity (continuous)

A 3500

11 Conductor rail (aluminium profile) resistivity

μΩ.m 15

12 Conductor rail (aluminium profile) resistivity with contact wire

μΩ.m ≤14

13 Conductor rail (aluminium profile) horizontal moment of inertia

cm4 338.14

14 Contact wire cross section sqmm 150

15 Supporting steel structure safety factor

3 times the yield strength of steel




16 Copper aluminium clamp Should have teflon bearing to allow movement (3mm) of aluminium profile with contact wire

17 Minimum curve m 200

2.12 Working Vehicle


1 Crane for pole lifting

a. Vehicle type 10t crane on rail vehicle

b. Manufacturer

c. Number of vehicles proposed to be used

2 Vehicle used for wiring the OCS

a. Vehicle type Rail vehicle with working platform and carrying contact with drum

b. Manufacturer


2 Vehicle used for wiring the ROCS

a. Vehicle type Rail vehicle with arrangement of Wire mounting trolley, contact wire, contact wire drum, greasing device, pulling cable etc.

b. Manufacturer




3.0 CABLES

3.1 25kV Cables


Values submitted

1 Manufacturer

2 Cable size Sqmm 400/240

3 Cable type XLPE/PVC

4 Voltage grade (Uo / U (U2) kV 26/45 (52)

5 Reference standard IEC 60840

6 Operating voltage kV 27.5

7 Conducting core Annealed copper

8 Shape Circular compact stranded

9 Class / standard Class 2 / IEC 228

10 Nominal diameter of conductor mm

11 Conductor screen materials Extruded semi conducting compound

12 Nominal thickness of conductor screen mm

13 Insulation material Extruded solid dielectric made of XLPE with tolerance as per IEC 502-1

14 Nominal thickness of insulation mm

15 Nominal diameter over insulation mm

16 Insulation screen material (non-metallic) Non-metallic part of semi-conducting material plus metallic part consisting of standard wire and copper tape, rated to carry a short circuit current




Values submitted

of 14kA

17 Nominal thickness of insulation screen mm

18 Insulation screen material (metallic)

19 Nominal thickness of tape mm

20 Nos. and diameter of wires No. / mm

21 Cross sectional area Sqmm

22 Outer sheath material Flame retardant polyvinyl chloride (FRLSOH for UG section)

23 Nominal thickness of outer sheath mm

24 Nominal overall diameter (+/- 2mm) mm

25 Minimum bending radius mm

26 Max DC conductor resistance at 20°C Ω/km

27 Max AC conductor resistance at 65°C Ω/km

28 Approx weight of cable Kg/km

29 Max current rating in air A

30 Max current rating in ground A

31 Max conductor temperature on continuous °C 90

32 Max conductor temperature in short circuit °C 250

33 Max short circuit current rating

a. t = 0.1 sec kA

b. t = 0.2 sec kA

c. t = 0.3 sec kA

d. t = 0.4 sec kA

34 Length marking (length shall be marked with number at one meter intervals on the sheath)



4.0 25KV SWITCHGEAR

4.1 25kV Circuit Breaker


Values submitted

1 Manufacturer



4 Standards IEC 62271-100

5 Type Outdoor

6 Rated voltage kV 25

7 Rated frequency Hz 50

8 Number of phases 1

9 Type of mechanism Spring or magnetic actuator

10 Maximum service voltage (permanent) kV 27.5

11 Rated insulation voltage level kV 40

12 Rated current A 1250

13 Rated power frequency withstand voltage for 1 minute

kV rms 95

14 Rated impulse withstand (1.2/50 μs) voltage for primary winding

kV peak 250

15 Rated short circuit making capacity kA 40

16 Rated short circuit current breaking capacity

kA 16 (3 sec)

17 Rated operating sequence CO-15sec-CO

18 Maximum closing time ms 100

19 Maximum opening time ms 70

20 Insulation material Composite / Ceramic

21 Motor power W 250

22 Motor service voltage V dc 110




Values submitted

23 Auxiliaries contacts 8NO + 8NC

24 Maximum starting current at 110V dc A

25 Mechanical life time Cycles

26 Temperature range °C

27 Maximum weight kg

28 Degree of protection IP 55

4.2 25kV Interrupters


Values submitted

1 Manufacturer




5 Type Indoor / outdoor




9 Type of mechanism Spring





kV rms 95


kV peak 250



kA 16 (3 sec)





Values submitted



20 Insulation material Composite

21 Motor power W




25 Mechanical life time Cycles 50000


27 Maximum weight kg 160


4.3 25kV Isolator


Values submitted

1 Manufacturer




5 Type Indoor / outdoor







12 Rated busbar current A 1250


kV rms 95




Values submitted


kV peak 250


16 Opening / closing mode Motorized / Manual

17 Auxiliary supply voltage V dc 110





22 Maximum weight kg


4.4 25kV Current Transformer


Values submitted

1 Manufacturer




5 Type Indoor / Outdoor



8 Transformer type Cast resin



11 Rated insulation voltage kV 40

12 Rated power frequency withstand voltage one minute for primary winding

kV rms 95

13 Rated lightning impulse withstand voltage for primary winding (1.2/50 μs)

kV peak

250

14 Rated secondary current A 1




Values submitted

15 Creepage distance mm/kV 31

16 Secondary core, CT between transformer and 25kV breaker side

a. Core 1 (Protection) 1250-625/1A 5P15, 30 VA

b. Core 2 (Protection) 1250-625/1A 5P15, 30 VA

c. Core 3 (Metering) 2500-1250/1A Cl 0.5, 20 VA

17 Secondary core, CT between 25kV breaker and 25kV busbar side

a. Core 1 (Protection) 1250-625/1A 5P15, 30 VA

b. Core 2 (Metering) 1250-625/1A Cl 0.5, 20 VA

18 Withstand overcurrent (Is peak) kA 20/40


20 Degree of protection for auxiliary circuit IP55

4.5 25kV Voltage Transformer


Values submitted

1 Manufacturer




5 Type Indoor / Outdoor



8 Transformer type




12 Rated power frequency withstand voltage one minute for primary winding

kV rms 95

13 Rated lightning impulse withstand voltage kV 250




Values submitted

for primary winding (1.2/50 μs) peak

14 Resistance of primary winding Ω Not less than 27000 Ω at 10°C

15 Creepage distance mm/kV 31

16 Actual transformation ratio

a. Primary winding kV 25/√3

b. Secondary winding V 110/√3

17 Secondary core winding

a. Core 1 30 VA, Cl 1

b. Core 2 30 VA, Cl 1


19 Degree of protection for auxiliary circuit IP55

4.6 25kV Lightning Arresters


Values submitted

1 Manufacturer




5 Type Outdoor

6 Type of substation Open

7 Lightning arrester type Nonlinear metal oxide resistor type, gapless

8 Nominal system voltage phase to earth kV

9 Nominal system voltage phase to phase kV

10 Rated voltage for lightning arrester kV 35

11 Line discharge class 3

12 Nominal discharge current kA 10

13 Max discharge voltage at nominal discharge current

kV 125

14 Power frequency withstand voltage for arrester housing

kV 105




Values submitted

15 Pressure relief class A

4.7 25kV Isolator (opening or closing manual or motorized, pole mounted)


Values submitted

1 Manufacturer




5 Type Outdoor






11 Rated operating current A 1250

12 Rated busbar current A 1250


14 Rated power frequency withstand voltage for one minute

kV rms 95


kV peak

250

16 Auxiliary contacts 8NO + 8NC

17 Auxiliary supply control voltage V dc 110




4.8 25kV Motorized Circuit Breaker (pole mounted)


Values submitted

1 Manufacturer




Values submitted




5 Type Outdoor




9 Type of mechanism Spring





kV rms 95


kV peak 250



kA 16 (3 sec)




20 Insulation material Ceramic

21 Motor power W 250



24 Maximum starting current at 110V dc A 7A max at 110V dc

25 Mechanical life time Cycles 50000

26 Temperature range °C 20-60




Values submitted

27 Maximum weight kg 140


4.9 25kV Gas Insulated Switchgear (GIS) for Underground


1 Standard IEC 62271

2 Busbar Copper

3 Service voltage kV 25

4 Maximum service voltage (permanent) kV 31


6 Frequency Hz 50 ± 5%

7 Rated AC withstand voltage kV 95

8 Rated lightning peak withstand voltage kV 200kV as per EN50124-1

9 Continuous current rating A 1250

10 Rated peak current kA 40

11 Short time current rating kA 16 (for 3 sec)

12 Overload current rating (5 & 10 minutes) A

13 Degree of protection of gas compartment

IP 64

14 Degree of protection for drive cabinet IP 3X

15 Degree of protection for low voltage cabinet

IP 3X

16 Nos. of switching cycles at rated service current

10000

17 Type of circuit breaker Vacuum

18 Auxiliary voltage for closing coil, tripping coil, spring charge motor

110V dc

19 Metal enclosure busbar chamber cubicle SS Sheet metal / powder coated

20 Loss of gas <1% per annum; gas charging equipment to be




supplied

21 Rated short circuit current switching cycles

100 cycles at 16kA

22 Sequence on short circuit CO-15sec-CO



25 No. of pole 1

Notes:

One set of gas charging equipment to be supplied Clear visual indications of isolator and earthing switch



5.0 BATTERY SUPPLY

5.1 110V DC Battery


Values submitted

1 Manufacturer



4 Standards IEC 622

5 Type Ni-Cd

6 Stationary compact

7 Maintenance free Yes

8 Capacity offered for 10 hours discharge duration

Ah

9 Voltage per cell V

10 Number of cells

11 Rated operating voltage V dc 110

12 Maximum output current A

13 Dimensions

a. Length mm

b. Width mm

14 Total weight kg

5.2 110V DC Battery Charger


Values submitted

1 Manufacturer



4 Standards IEC 146

5 3-phase power supply V ac 415

6 Frequency Hz 50

7 Rated direct voltage V dc 110

8 Allowable output voltage variation

a. For +10% variation of supply voltage +1%

b. For +5% variation of frequency +1%




Values submitted

9 Maximum output current in permanent duty A

10 Residual ripple ratio

11 Dimensions

a. Length mm

b. Depth mm

c. Height mm

12 Total weight kg

MAHA-METRO Contract No. P1/TR-02/2018 Particular Specification Appendix C: Test Sheets





RAIL PROJECT




APPENDIX C: TEST SHEETS



Table of Contents

1.0 OVERHEAD EQUIPMENT ............................................................................................................ 3

1.1 Contact Wire .................................................................................................................................. 3

1.2 Messenger Wire ............................................................................................................................. 3

1.3 Aerial Earth Cable (AEC) ............................................................................................................... 3

1.4 Buried Earth Cable (BEC) .............................................................................................................. 4

1.5 Jumper Wire................................................................................................................................... 4

1.6 Dropper Wire ................................................................................................................................. 5

1.7 Mast and Portal .............................................................................................................................. 5

1.8 Insulators (for bracket, stay arm, conductor anchor and section insulator) ................................... 5

1.9 25kV Short Neutral Section ........................................................................................................... 6

1.10 Rigid OCS Test Sheet ................................................................................................................. 7

2.0 TRACTION SWITCHGEARS ........................................................................................................ 8

2.1 25kV Circuit Breaker ...................................................................................................................... 8

2.2 25kV Interrupters ........................................................................................................................... 8

2.3 25kV Isolators ................................................................................................................................ 9

2.4 25kV Current Transformers ........................................................................................................... 9

2.5 25kV Voltage Transformer ............................................................................................................. 9

3.0 AUXILIARY EQUIPMENT ........................................................................................................... 11

3.1 Battery Charger ........................................................................................................................... 11

3.2 Battery .......................................................................................................................................... 11

3.3 AC and DC Auxiliary Cabinets ..................................................................................................... 11



1.0 OVERHEAD EQUIPMENT

1.1 Contact Wire

SN Description Type of tests

Type Routine On site After shipment

1 Test standard as per EN 50149, UIC 870, RDSO Specification ETI/OHE/76

X X

2 Determination of copper and other elements of raw material

X

3 Electrolytic analysis for chemical composition of copper

X X

4 Tensile testing X X X X

5 Hardness test X X X X

6 Compression test X X

7 Bend test X X

8 Metallurgical test on conductor X

9 Profile measuring device X X

10 Breaking load X

11 Elongation and contraction X

12 Resistivity X X

13 Flaw detection in contact wire drawn out of continuous cast rod

X

14 Visual examination of drum and contact wire

X X X

15 Visual checking of packaging including drum

X X X

1.2 Messenger Wire



1 Test standard as per EN 50182, RDSO Specification ETI/OHE/76

X X

2 Determination of copper and other elements of raw material of copper and cadmium

X X

3 Electrolytic analysis for chemical composition of copper and cadmium

X X

4 Tensile testing X X X


6 Breaking load X


8 Resistivity X X

9 Wrapping test of wire X

10 Visual examination of drum and messenger wire

X X X


X X X

1.3 Aerial Earth Cable (AEC)





1 Test standard as per IS 398 (Part II)

X X

2 Determination composition of aluminium and steel

X



5 Breaking load X X

6 Resistivity X X


8 Visual examination of drum and aluminium core steel reinforced (ACSR) wire

X X X


X X X

1.4 Buried Earth Cable (BEC)



1 Test standard as per ETI/OHE/3, IS 9968 Part 2

X X

2 Current carrying capacity test X

3 Maximum short circuit current capacity

X

4 Visual examination X X X

5 Packaging visual examination X X X

6 Leakage current X

7 Insulation resistance X

8 Power frequency dry withstand voltage

X

9 Power frequency wet withstand voltage

X

10 Dielectric strength X X

1.5 Jumper Wire



1 Test standard as per RDSO Specification ETI/OHE/3

X X

2 Determination of copper and other elements of raw material of copper and composition of number of strands

X

3 Electrolytic analysis for chemical composition of copper

X X



6 Breaking load X


8 Resistivity X X


10 Visual examination of drum and jumper wire

X X X

11 Visual checking of packaging X X X





including drum

1.6 Dropper Wire



1 Test standard as per RDSO Specification ETI/OHE/3

X X

2 Determination of bronze and other elements of raw material of bronze and composition of number of strands

X

3 Electrolytic analysis for chemical composition of bronze

X X



6 Breaking load X


8 Resistivity X X


10 Visual examination of drum and dropper wire

X X X


X X X

1.7 Mast and Portal



1 Test standard as per IS 2062, IS 800, IS 808, RDSO Specification ETI/OHE/3

X X

2 Hot dip galvanization (EN ISO 1461, IS 209)

X

3 Zinc coating size of galvanization X X X

4 Plate welding standard (ISO-TC-44) X X X X

5 Loading test (IEC 60652, IEC 60826)

X

6 Bending test X

7 Mast dimension tolerances (EN 10034)

X X


1.8 Insulators (for bracket, stay arm, conductor anchor and section insulator)



1 Test standard as per RDSO Specification TI/SPC/OHE/INSCOM /1070

X X

2 Mechanical failing load test X

3 Mechanical load time test (clause 6.4 of IEC 61109)

X





4 Analysis of material properties (housing material silicone compound, core material)

X

5 Visible discharge test X

6 Dry lightning impulse withstand voltage test (clause 6.1 of IEC 61109)

X

7 Wet power frequency test (clause 6.2 of IEC 61109)

X

8 Wet power frequency maximum withstand voltage test

X

9 Visual examination (clause 8.2 of IEC 61109)

X X X

10 Mechanical load test X X

11 Visual examination of packaging X X

12 Recording of standard atmospheric condition

X X X

13 Verification of dimension X X X

14 Bending load test X X

15 Hardness (Shore A) (As per ASTM D 2240)

X X

16 Specific gravity (as per ASTM D 792)

X X

17 Sudden load release test X

18 Water immersion test X

19 1000 hours, 5000 hours – tracking and erosion test

X

1.9 25kV Short Neutral Section



1 Test standard as per product standard (IEC 61109, EN 50119)

X X

2 Current carrying capacity test X

3 Maximum short circuit current capacity with duration test

X

4 Pollution index text (as per DIN 50022)

X X

5 Vibration intensity (maximum horizontal accleration)

X X

6 Static withstand contact pressure (80N ± 10N)

X

7 Insulator (as per RDSO Spec TI/SPC/OHE/INSCOM/1070)

X

8 Spark extinguishing X


10 Packaging visual examination X X X

11 Leakage current X

12 Insulation resistance (insulator without skids)

X

13 Creepage distance (insulator without skids)

X

14 Power frequency dry withstand voltage

X





15 Lightning impulse withstand voltage X

16 Power frequency pollution withstand voltage (as per IEC 61109)

X

17 25kV, 50Hz vacuum switch X

a. Current working range X X

b. Power frequency wet withstand voltage

X

c. Short time current rating X

d. Maximum short circuit current with duration

X

e. Maximum opening and closing time X

1.10 Rigid OCS Test Sheet



1 Standard and regulations UIC 606, UIC 505, EN 755, EN 573, SAC 2200

X X

2 Composition of the material as per EN 573-3

X X

3 Tensile strength X X

4 Mechanical failing load test X

5 Mechanical load test X X X

6 Insulator as per IEC 383 X X X

7 Supporting steel structure – yield strength

X

8 Steel structure – Galvanization X X X

9 Bending load test X X

10 Hardness of surface X

11 Tightening torque of the bolt / screw X X

12 Movement (3mm) of aluminium profile with contact wire

X

13 Conductor rail (aluminium profile) – continuous current carrying capacity – as per DIN 43670

X

14 Conductor rail (aluminium profile) resistivity

X

15 Conductor rail (aluminium profile) resistivity with contact wire

X

16 Current carrying capacity of power feed block

X

17 Current collection including transition from rigid to flexible OCS

X X

18 Visual inspection X X X

19 Visual inspection of packaging X X X



2.0 TRACTION SWITCHGEARS

2.1 25kV Circuit Breaker



1 Temperature rise X

2 Mechanical operation X X

3 Lightning impulse withstand voltage test

X

4 Short circuit current making and breaking capacity

X

5 Magnetizing & small inductive current switching

X

6 Peaks and short time current withstand

X

7 Auxiliary circuits dielectric withstand X

8 Main circuits resistance value X

9 Withstand voltage at 50Hz X

10 Mechanical operations at rated, max and min voltage

X X

11 Functioning times X

12 Interlocking X X

13 Visual inspection X X

2.2 25kV Interrupters




2 Mechanical operation X X


X

4 Short circuit current making and breaking capacity

X

5 Magnetizing & small inductive current switching

X


X




10 Lightning withstand voltage X

11 All devices operation checking X

12 Functioning times X

13 Wiring X X

14 Interlocking X X

15 Panting and external visual inspection

X X

16 Exchangeability of similar devices X

17 Auxiliary circuits insulation X

The Mechanical operation test to be done as a Routine test and shall comprise of five opening and five closing operations at each of the rated, maximum and minimum control voltages. The contact travel characteristics shall be recorded for each closing and tripping operation.



2.3 25kV Isolators





X


X




7 All devices operation checking X

8 Operation times X

9 Wiring X X

10 Interlocking X X

11 Panting and external visual inspection

X X


13 Auxiliary circuits insulation X

2.4 25kV Current Transformers





3 Short circuit withstand X

4 Primary windings power frequency withstand voltage test

X

5 Secondary windings power frequency withstand voltage test

X

6 Between section power frequency withstand voltage test

X

7 Transformer ratio X

8 Temrianl marking X X



2.5 25kV Voltage Transformer





3 Short circuit withstand X

4 Primary windings power frequency withstand voltage test

X

5 Secondary windings power frequency withstand voltage test

X

6 Between section power frequency withstand voltage test

X

7 Transformer ratio X

8 Temrianl marking X X









3.0 AUXILIARY EQUIPMENT

3.1 Battery Charger



1 Temperature rise* X

2 Power frequency withstand voltage test

X

3 Floating operation mode test X

4 Equalization operation mode test X

5 Direct operation mode test X

6 Protection devices operation X

7 Setting test X


*For this type test, the Contractor could provide a report of less than 5 years on similar equipment

3.2 Battery



1 Electrical specifications checking (on one call)

X


3 Capacity measurement X

4 Endurance test X

5 Overload aptitude test X

3.3 AC and DC Auxiliary Cabinets



1 Rated short circuit duration power frequency withstand voltage test

X X

2 Operation checking X


MAHA-METRO Contract No. P1/TR-02/2018 Particular Specification Appendix D: Safety Requirements





RAIL PROJECT




APPENDIX D: SAFETY REQUIREMENTS



Table of Contents

1.0 INTRODUCTION ........................................................................................................................... 3

2.0 APPLICABLE STANDARDS ........................................................................................................ 3

3.0 ACRONYMS .................................................................................................................................. 3

4.0 DEFINITIONS ................................................................................................................................ 4

5.0 SCOPE OF THE SAFETY MISSION ............................................................................................ 5

6.0 SCOPE OF THE SAFETY STUDIES ............................................................................................ 6

6.1 General .......................................................................................................................................... 6

6.2 Internal interfaces and interfaces with other Contractors and external agencies .......................... 6

6.3 Hazardous situations not involved ................................................................................................. 7

7.0 SAFETY ORGANIZATION AND RESPONSIBILITIES OF THE CONTRACTOR ....................... 7

7.1 System safety organization of the Contractor................................................................................ 7

7.2 Links with Quality ........................................................................................................................... 8

7.3 Links with Indian safety authorities ................................................................................................ 8

7.4 Responsibilities of the Contractor .................................................................................................. 9

8.0 SYSTEM SAFETY DESIGN REQUIREMENTS .......................................................................... 10

8.1 Qualitative safety requirements ................................................................................................... 10

8.2 System safety objectives ............................................................................................................. 11

8.3 System Safety program management requirements ................................................................... 13



1.0 INTRODUCTION This document describes the general safety management specifications to be applied by the Contractor to reach the requirements that are specified in the present document for the Traction System equipment. This document stipulates the requirements in term of: (a) organization to be set up by the Contractor and its responsibilities towards reliability,

availability, maintainability and safety, (b) safety tasks to be carried out, (c) documents related to safety process, management, studies and analyses that must be

provided by the Contractor during the project. This document also specifies:

The scope of the safety mission for the Contractor,

The safety process (main ideas and concepts), The Contractor shall note that the Employer shall put in place an appropriate mechanism for overall system safety assurance for whole project. The system safety requirement defined in this document relates to OCS system and it shall be Contractor’s responsibility to appropriately interface with other relevant agencies to ensure that safety requirements of the OCS subsystem fits with the overall context of the project level system safety requirements.

2.0 APPLICABLE STANDARDS The following regulations and standards are applicable to the project:

[A1] IEC 62278 / CENELEC EN 50126

Railway Applications – The specification and demonstration of reliability, availability, maintainability and safety (RAMS)

[A2] IEC 62279 / CENELEC EN 50128

Railway Applications – Communication, signalling and processing systems – software for railway control and protection systems

[A3] IEC 62425 / CENELEC EN 50129

Railway Applications – Communication, signalling and processing systems – safety related electronic systems for signalling

[A4] CEI 61508 Functional safety of electrical/electronic/programmable safety-related systems

[A5] Railway (Operation and Maintenance) Act 2002

[A6] Electricity Act 2003

[A7] ISO 9001:2000 Quality management systems - Requirements

3.0 ACRONYMS

IEC International Electrotechnical Commission

CEIG Chief Electrical Inspector to Government

CMRS Commissioner of Metro Railway Safety

D&B Design & Build

FMEA Failure Modes and Effects Analysis

FTA Fault Tree Analysis

GC General Consultant

LRU Line Replaceable Unit

O&M Operating and Maintenance

PHA Preliminary Hazard Analysis

RAM Reliability, Availability and Maintainability



SHA System Hazard Analysis

SRU Shop Replaceable Unit

SSHA Sub-system Hazard Analysis

SIL System Integrity Level

4.0 DEFINITIONS

Term Definition Reference

Accident An unintended event or series of events that results in death, injury, loss of a service or service or environmental damage.

EN50129

Apportionment

A process whereby the dependability (RAMS) elements for a system are sub-divided between the various items which comprise the system to provide individual targets

EN50126

Assessment

The process of analysis to determine whether the Design Authority and the Validator have achieved a product that meets the specified requirements and to form a judgement as to whether the product is fit for its intended purpose.

EN50129

Dependability The ability of a system to perform one or several required functions under given conditions

External protection

All risk reduction facilities external to the supplied system, enabling to reduce or mitigate risks

Failure A deviation from a specified performance of a system. A failure is the consequence of a fault or an error in the system

EN50129

Hazard A physical situation with a potential for human injury EN50126

Hazard analysis The process of identifying the hazards which a product or its use can cause

EN50129

Hazard log

The document in which all safety management activities, hazard identified, decisions made and solutions adopted are recorded or referenced. As known as Safety log

EN50126

Internal protection Physical measure internal to the studied system, taken to reduce or mitigate the risk

LRU The smallest replacement item at first line maintenance

Railway Safety

Railway Safety (or Product Safety) aims to reduce potential hazards from technical failure or use of the railway system that may harm people during operation.

Reliability The probability that an item can perform a required function under given conditions for a given time interval.

EN50126

Residual risk. Any risk that can not be adequately eliminated (possibly because it is outside the scope of the studied system).

Risk The probable rate of occurrence of a hazard causing harm and the degree of harm

EN50126

Safety Freedom from unacceptable levels of Risks EN50126

Safety requirements

A requirement issued as an output of a safety analysis and aimed at managing Safety of an item which carries responsibility for Safety.

System

System comprises Sub-systems that are combined to fulfil a required function under given condition. It is the highest level of description.In this document, the system considered covers the entire scope of the Contractor’s contract, that is to say the



Term Definition Reference

power supply and the overhead equipment

Safety Case (sometimes called a proof of Safety) is the demonstration that the design of the studied system complies with the specified Safety Requirements.

EN50126

Safety Integrity

The likelihood of a Safety related system achieving its required Safety features under all the stated conditions within a stated operational environment and within a stated period of time

EN50126

Safety Integrity Level (SIL)

One of the numbers of defined discrete levels for specifying the safety integrity requirements of the safety functions to be allocated to the safety related systems. Safety Integrity level with the highest figure has the highest level of safety integrity

EN50126

Safety plan

A documented set of time scheduled activities resources and events serving to implement the organisation structure, responsibilities, procedures, activities, capabilities and resources that together ensure that an item will satisfy given safety requirements relevant to a given contract or project

EN50126

Safety related function

A function where a hazard has been identified with a category in a range predefined by the Safety regulatory authority

Safety regulatory authority

Often a national government body responsible for setting or agreeing the safety requirements for a railways and ensuring that the railway complies with the requirements The body responsible for certifying that a safety related system is fit for service and complies with relevant statutory and regulatory safety requirements

EN50126 EN50129

Security Aptitude to establish protection against personal attack, theft of personal property

Transportation system

The Pune Metro Rail Project is the transportation system considered in this document.

Validation

The objective of validation is to demonstrate that the system under consideration, at any step of its development and after its installation, meets its requirement in all respects. Confirmation by examination and provision of objective evidence that the particular requirements for a specific intended use have been fulfilled.

EN50126

Verification

The objective of verification is to demonstrate that, for the specific inputs, the deliverables of each phase meet in all respects the requirements of that phase. Confirmation by examination and provision of objective evidence that the specified requirements have been fulfilled.

EN50126

5.0 SAFETY OBJECTIVE The Contractor shall consider that the safety mission, within the framework of the study and the construction of the project is to ensure and guarantee the safety of each person that could be affected during the operation of the Pune Metro Rail Project. The Contractor shall consider that the people that are concerned by the safety are: (a) The users: all people travelling in the Pune Metro Rail Project, (b) Other people: in particular residents or users of the roadways in the elevated sections



The Contractor shall take measures to ensure the safety of the operator staff (drivers, maintainers, etc.) depending on the local safety regulation.

6.0 SCOPE OF THE SAFETY STUDIES

6.1 General

6.1.1 The Safety studies shall apply to equipments & systems supplied by the Contractor. Contractor’s safety studies shall cover the design, development, manufacturing, test, installation, commissioning, operation and maintenance phases of the system.

6.1.2 The safety studies shall include all the life cycle phases as described in the IEC 62278 / EN 50126, according to the following diagram showing the ”V” representation of the lifecycle:

6.1.3 The Contractor shall apply this safety diagram for all configurations of the system delivered according to the sections defined in the project, and for all intermediate deliveries of any specific configuration.

6.1.4 The Contractor shall consider in his safety program the operational modes (including degraded modes) and failures (both random and systematic) that may lead to a catastrophic or critical hazard.

6.1.5 The Contractor shall consider in his safety studies the operating conditions of the Operating and Maintenance concept plan, as well as other information provided by the Employer during the detailed design phase.

6.2 Internal interfaces and interfaces with other Contractors and external agencies



6.2.1 The Contractor shall take into account that the entire Pune Metro Rail Project includes other contracts (see Appendix A Interface Specifications) and liaison with external agencies. Therefore, the Contractor shall: (a) identify the safety critical issues which may arise from interaction with the other

contracts and liaison with external agencies, (b) identify the input data provided by systems or equipment delivered under the other

contracts and liaison with external agencies, which may impact the safety of system equipment,

(c) answer to the concerned Contractors questions about the data and failure modes of system equipment they would identify as safety critical for their works.

6.2.2 In order to ensure the whole safety process, management and studies, the Contractor

shall establish all the safety requirements that applies to others Contractors, and particularly to: (a) its sub-contractor(s), (b) the Civil work contractors, (c) the Tunnel / UG contractors (d) the depot contractor (e) the Track Works Contractor, (f) the rolling stock Contractor, (g) the Signalling Contractor, (h) the Telecommunications Contractor, (i) the depot machine contractor (j) other contractors

6.2.3 The Contractor shall make sure that the safety requirements from his scope of work but applicable to other Contractors have been properly taken into account.

6.2.4 The Contractor shall take into account safety requirements from other systems and give the proofs of their implementation to the other Contractors and the Employer.

6.3 Hazardous situations not involved The following hazardous situations are excluded from the safety studies of the Contractor: (a) Declared national disaster such as: cataclysm, overall flooding, etc. (b) Terrorism, vandalism, acts of God, madness (c) Environmental conditions exceeding those specified in the contract (d) Diverted use of the system (e) Incorrect maintenance done by other than personnel or subcontractor working for

them (f) Infringement to Safety and Health regulations (g) Infringement to procedures and orders (h) Faults attributed to equipment not of the responsibility of the Contractor such as:

debris on the track, signals failure, etc. (i) Over-accident due to Rolling Stock breakage, if operation is not stopped immediately

on the line.

7.0 SAFETY ORGANIZATION AND RESPONSIBILITIES OF THE CONTRACTOR

7.1 System safety organization of the Contractor

7.1.1 The Contractor shall set up an appropriate safety organization.

7.1.2 The Contractor shall carry out safety activities by the safety organization team (para 7.1.1 above) which shall be independent of the project delivery team of the Contractor.



7.1.3 The safety team of the Contractor shall be represented by the Contractor’s Safety

engineer who shall have adequate experience in dependability.

7.1.4 The Contractor shall make sure that the people in charge of the safety on the project has the authority, the responsibility and the means necessary to guarantee the quality of the tasks to carry out.

7.1.5 The Contractor shall establish safety roles and responsibilities for each subcontractor, and shall coordinate and monitor the OCS equipment safety activities of all subcontractors to ensure the safe interface and integration of subcontractor products and the proper integration of all safety activities for the entire system. Contractor activities shall include flowing down all applicable safety requirements; coordinating all safety analyses, verification and validation activities including testing for products being provided; establishing a schedule consistent with that of the Contractor’s safety activities / deliverables; and monitoring the progress and results of safety activities for integration into the Contractor’s hazard tracking and safety reporting process.

7.1.6 The Contractor shall include system safety program progress summaries with Project monthly reports. At a minimum, these summaries shall address: (a) The status of system safety activities with respect to the Project and its schedule, (b) Identified hazards for which adequate mitigation has yet to be provided, in the form of

an updated Hazard Log, (c) Safety issues requiring discussion with the Employer, (d) System safety incidents which have occurred on the Project since the last report.

7.1.7 The Contractor shall conduct periodic internal, documented audits to ensure that the Contractor’s System Safety Plan is followed. All detected non-conformances shall be addressed and cleared. The internal safety reviews/audits shall: (a) Address system safety concerns in a timely fashion as identified through their safety

activities or by other Project participants. (b) Discuss possible means of resolving those concerns through the incorporation of

special system features, design/procedural changes, or other means, and assign action items for the resolution of those concerns.

(c) These reviews/audits shall also be used to track progress, track problems related to the implementation of the system safety program by Contractor and subcontractor personnel, and to allow all contractor/subcontractor personnel to remain closely informed of safety activities and responsibilities.

(d) The Contractor shall carry on the audits in respect to the EN ISO 19011.

7.2 Links with Quality

7.2.1 The Contractor shall consider that the Safety of the system is based upon its level of Quality: the Contractor shall define a Quality Management system in order to identify errors and control their impact throughout the life-cycle of the system.

7.2.2 The Contractor shall define Quality requirements in order to control the Quality of the design.

7.2.3 The Contractor shall led Safety related Activities such as testing and verification in accordance with the Quality Assurance Procedures (refer to Chapter 5 of General Specifications).

7.3 Links with Indian safety authorities

7.3.1 Access shall be granted to the Employer to any facilities where installation, cutover work, or other tests are in progress and to all inspection and test and commissioning records.



7.3.2 The Contractor shall support any testing required by the Commissioner of Metro Railway Safety or the CEIG in order to obtain approval for Revenue operation.

7.3.3 The Contractor shall provide any support or documentation requested by the Commissioner of Metro Railway Safety or the CEIG in order to obtain approval for Revenue operation.

7.3.4 The Contractor shall assist the Employer during the Commissioner of Metro Railway Safety or the CEIG inspections. Therefore, representatives of the Contractor with adequate competencies shall be present during these inspections.

7.4 Responsibilities of the Contractor

7.4.1 The Contractor is responsible for providing a system designed and built that satisfy the safety requirements.

7.4.2 The responsibility of the Contractor in the system safety program shall be: (a) To implement the following major system safety program activities throughout the

design, manufacture, installation, test, and commissioning phases of the Project, consistent with this Section and the Safety Program Plan for Power supply equipment, including:

a. Definition, documentation, and internal audit of its Safety Program. b. Identification and assessment of hazards at the system, subsystem, and unit

levels. c. Resolution of hazards by specific mitigation activities. d. Identification of system items/elements required to mitigate hazards. e. Identification of safety design requirements. f. Demonstration of compliance of the system with the identified system safety

requirements through Safety Verification and Safety Validation activities as specified below.

g. Documentation of the hazard identification, resolution, compliance review, and system safety approval process.

(b) To maintain complete responsibility for the safety of the System and verify that the

System satisfies the required safety assurance levels. (c) To participate in meetings, present, discuss, and resolve (where appropriate) issues

regarding the safety of the system.

7.4.3 The Contractor shall put in place the safety process necessary to answer to the Employer’s safety requirements.

7.4.4 The Contractor shall manage the safety process of his furniture within its organization (entities of the Contractor, sub-contractors ) and with the others actors of the project.

7.4.5 The Contractor shall create, maintain and regularly update the Hazard Log and make sure that the safety objectives and the safety requirements identified during the Preliminary Hazard Analysis or specified by the Employer are respected. The Contractor shall regularly organise reviews to present the progress of the status of the Hazard Log.

7.4.6 The Contractor shall carry out the safety studies defined below, as well as all those which he considers useful to guarantee the project’s safety.

7.4.7 The Contractor shall identify and analyze the possible unsafe situations caused under normal or downgraded operating mode, as well as the possible dysfunctions being able to lead to the unexpected generation of unsafe situations.

7.4.8 The Contractor shall take into account the interfaces of the scope of his furniture.



7.4.9 In order to ensure the safety of the Pune Metro Rail Project, the Contractor shall generate

a traceability process between the various safety analyses of the Pune Metro Rail Project.

7.4.10 The Contractor shall refer to a management process of any modifications in order to control the safety impacts of the various developments on the other contributors.

7.4.11 The Contractor shall draft all the recommendations related to operation and maintenance which he could consider as necessary to reach the specified security levels.

7.4.12 The Contractor shall specify how he will manage:

the issues following an anomaly linked with safety,

the exemptions,

the non conformities.

7.4.13 The Contractor shall collect all the safety proofs or elements and establish the Safety Case that he shall present to the Employer, and the Commissioner of Metro Railway Safety.

7.4.14 The Contractor shall submit the safety case to the Employer for approval: (a) in case of non-consistency, the Employer will return the Safety Case with

recommendations for modification, (b) in case of consistency, the Employer will forward the Safety Case to the

Commissioner of Railway Safety for his instruction. In case of a negative conclusion, the Safety Case will be returned with recommendations for modification.

7.4.15 Requirement verification shall be performed during the testing periods before commercial

operation. If this verification fails, the Contractor shall review the design and implement improving design changes at no cost for the Employer.

7.4.16 The Contractor shall respect the deadlines defined in the calendar of the Contract. For the various stages of the project, the Contractor shall respect the following key dates for the delivery of the safety documentation:

Submittals Schedule

Safety Assurance Plan 2 months after commencement date of the works

Design safety case End of each detail design phase

Construction safety case 6 months before each service revenue

Test & Commissioning safety case 3 weeks before each service revenue

8.0 SYSTEM SAFETY DESIGN REQUIREMENTS

8.1 Qualitative safety requirements

8.1.1 The system shall meet or exceed the requirements of CENELEC Standards EN50126, EN 50128 & EN 50129 or equivalent international standards (IEC 62278, IEC 62279 & IEC 62245) for Reliability, Availability, Maintainability and Safety.

8.1.2 The Contractor shall accomplish the design and implementation of the system including the development of procedures and other means in such a manner to assure that: (a) The system safely performs the correct safety critical functions within the normal

operating conditions and with no component failures. This includes showing to the extent reasonably possible that the system is free of unsafe systematic failures - those failures which can be attributed to human error that could occur throughout the design/implementation process and result in an unsafe condition. This also requires



that all applicable hazards are shown, via the Hazard Log, to be eliminated or having their associated risks mitigated to acceptable levels.

(b) The system performs the correct safety critical functions under external influences such as electrical, mechanical and environmental factors as specified in these Technical Specifications. This requires that all applicable hazards are shown, via the Hazard Log, to be eliminated or having their associated risks mitigated to acceptable levels.

8.1.3 Safety-critical functions are those identified by performing the required safety analysis

activities.

8.1.4 During normal operation of the system, system safety shall not depend on the correctness of actions taken or procedures used by operating personnel. Procedures shall not be considered as a substitute for safety functions that are to be vested in specific components, equipment, or facilities. The impact of the safety of processes and procedures which relate to the installation of the system shall be analyzed as part of the system safety program.

8.2 System safety objectives

8.2.1 Risk classification and assessment (a) The Contractor shall classify risks by combination of the hazard consequence and the

hazard probability (b) The Contractor shall use the table 3 below for risk classification. (c) Safety analysis will be conducted in accordance with the required level of Safety

defined in the Hazard Analysis and Assessment documentation.

8.2.2 Risk categorization

8.2.2.1 The hazard severity levels will be classified into the following categories: Table 1: Hazard Severity Levels

Interpretation Severity Level following [A1]

Category Severity Level

Consequence to persons or environment

Consequence to service

I Catastrophic Fatalities and/or multiple severe injuries and/or major damage to the environment

Loss of all the system

II Critial Single fatality and/or severe injury and/or significant damage to environment

Loss of a major system

III Marginal Minor injury and/or significant threat to the environment

Severe systems damage

IV Insignificant Possible minor injury Minor system damage

8.2.2.2 The probabilities of occurrence will be classified according to the categories shown in the

following table: Table 2: Hazard Probability Levels

Interpretation Frequency level following [A1]

Category Frequency

level Description

A Frequent Likely to occur frequently. The hazard will be continually experienced.

B Probable Will occur several times. The hazard can be expected to occur often.



Interpretation Frequency level following [A1]

Category Frequency

level Description

C Occasional Likely to occur several times in the life of the system. The hazard can be expected to occur several times.

D Remote Likely to occur sometime in the system life cycle. The hazard can reasonably be expected to occur.

E Improbable Unlikely to occur, but possible. It can be assumed that the hazard may exceptionally occur.

F Incredible Extremely unlikely to occur. It can be assumed its occurrence may not be experienced

8.2.3 Risk evaluation

8.2.3.1 The risk classification is the combination of the hazard consequence and the hazard

probability. The Contractor shall apply the following tables: Table 3: Risk Classification Matrix

Risk Level Severity level of hazard consequence

I II III IV

Fre

quency o

f

occurr

ence

of

hazard

ous

event

A Frequent Unacceptable Unacceptable Unacceptable Undesirable

B Probable Unacceptable Unacceptable Undesirable Acceptable

C Occasional Unacceptable Undesirable Undesirable Acceptable

D Remote Undesirable Undesirable Acceptable Acceptable

E Improbable Undesirable Acceptable Acceptable Acceptable

F Incredible Acceptable Acceptable Acceptable Acceptable

Decision Table

Risk evaluation Risk reduction / control

Unacceptable Shall be rejected, eliminated

Undesirable Risk reduction to the acceptable level shall be engaged and with agreement of the Employer and the Indian Safety Rules

Acceptable Acceptable; suitable for requirements and with the agreement of the Employer and the Indian Safety Authority

8.2.3.2 For the mitigation of the potential or actual hazard identified through analyses, the

following criteria, as a minimum, shall be adopted by the Contractor with the following order or preference: (a) Use of design techniques (b) Use of safety devices (c) Use of warning devices (d) Use of special procedures

8.2.4 Safety Integrity level

8.2.4.1 Contractor’s activities related with safety assurance for SIL 1 and 2, and for SIL 3 and 4 shall include verification, validation and demonstration of safety in the sense of the standards EN 50126 (IEC 62278).

8.2.4.2 For Safety relevant function, the Contractor shall mitigate random and systematic failures by use of adequate design principles / methods as defined by the CENELEC Standards EN50128 and 50129 (IEC 62278 and IEC 62279) according to the SIL identification.

8.2.4.3 The Contractor shall study the contribution of any sub-system to the operation (including degraded modes). To this purpose, all the functions, even those which can not cause by themselves hazardous situations shall be analyzed; the consequences of their degradation on the system safety level will be taken into the final risk level quantification.



8.2.4.4 The Contractor shall categorize all Identified hazards into levels of severity and frequency by using the EN50126 [A1] and CEI 61508 [A4] standards as a guidelines. The Contractor shall use the risk assessment matrix based on these levels.

8.2.4.5 The Contractor shall assign SILs to each item (sub-system, equipment, hardware or software components) of the System during Safety studies.

8.2.4.6 The Contractor shall determine SILs using the methodology defined in the EN50126 standard: for each accident severity, the maximum frequency leading to an acceptable hazard is considered and converted to a SIL using the “continuous/high demand mode of operation”. The result is as follow:

Severity Level

SIL Tolerable Hazard Rate (THR) per hour

Consequence to Service

Catastrophic 4 10−9 ≤ 𝑇𝐻𝑅 < 10−8 Loss of all the system

Critical 3 10−8 ≤ 𝑇𝐻𝑅 < 10−7 Loss of a major system

Marginal 2 10−7 ≤ 𝑇𝐻𝑅 < 10−6 Severe system(s) damage

Insignificant 1 10−6 ≤ 𝑇𝐻𝑅 < 10−5 Minor system damage

8.2.5 Hazard list

8.2.5.1 The Contractor shall at least consider this list of undesirable events:

N° Undesirable event

01.01 Rear end collision of two trains

01.02 Side on collision of two trains

01.03 Frontal collision of two trains

01.04 Collision of a train with a fixed obstacle

01.05 Collision of a derailed train with a passing trains

02 Train derailment without collision

03 Electrocution of person(s)

04 Fall of people: on the track, on the platform, into the trains, during evacuation,

05 Dragging people

06 Contact, trapping, crush people

07 Panic

08 Fire

09 Intoxication, asphyxiation, suffocation, burn

10 Explosion

8.2.5.2 The undesired events of this list are considered at a very high level. The Contractor shall

complete and detail this list and submit it to the Employer for approval before starting through its Safety Assurance Plan.

8.3 System Safety program management requirements

8.3.1 General

8.3.1.1 The Contractor shall describe in his Safety Assurance Plan the tasks and activities required to meet the Safety Requirements defined through system Safety analysis. The Contractor shall submit his Safety Assurance Plan for approval by the Employer.

8.3.1.2 Proper management techniques shall be used by the Contractor to maximize the visibility of system safety activities and associated results to each Contractor/subcontractor as well as to all Project participants. This shall facilitate the timely identification and resolution of hazards and help minimize the existence of unsafe system aspects.

8.3.1.3 The Contractor shall document all analysis in a format approved by the Employer.

8.3.1.4 The Contractor shall justify the origin of all the data used.



8.3.1.5 The Contractor shall describe all methods that will be used.

8.3.2 Submittals

8.3.2.1 The Contractor shall submit the following documents as a minimum in support of the

System Safety Program. Any other documents or safety demonstration that the Contractor would consider necessary to demonstrate the compliance with the System Safety Requirements and/or to ensure the satisfaction of the system safety level shall also be provided by the Contractor.

8.3.2.2 The Contractor shall submit: (a) A System Safety Assurance Plan (SAP) that shall be compliant with the Employer

specifications and the Pune Metro Rail Project local standards and regulations. It shall describe in particular:

a. the safety approach, showing how the Contractor shall verify attainment of

system safety requirements during design and test phases b. the safety organization of the Contractor, sub-contractors, and the

management process of their relationships. c. the description of the safety management procedures to ensure that the

Contractor’s system safety personnel participate in all design reviews and approve all safety-related elements of this Contract.

d. the description of hazard categorizations and safety design standards as required by this document,

e. the task listing and time phasing for each task, and the list of Safety documents,

f. the description of Safety analysis that the Contractor will employ, g. the description of the method of verification, h. a description of the process by which the Contractor will certify the safety of

the system, i. the tools and methods used. j. a quality control report for each step with no observation status of the

contractor quality team. (b) A Preliminary Hazard Analysis (PHA) that shall provide a systematic, high-level

examination of the proposed system in order to identify and classify potential hazards

a. The PHA shall address the vulnerability of system functions, rather than assess any particular design. The PHA shall be qualitative and shall be conducted using experienced engineering judgment.

b. The PHA shall develop safety design requirements for the system and establish the framework for subsequent safety analyses. It shall provide information about potential hazards and assign a hazard severity and hazard probability categories to each as detailed in §8.2.

(c) A Hazard Log that shall identify all safety related items and hazard requiring solutions

a. The Hazard Log shall initially summarize results of the functional level analyses (PHA, SHA), including all safety-critical items which could result in personal injury, system damage, or loss of operation.

b. The Hazard Log shall identify the Project participant assigned to resolve the hazard, and provide an audit trail from initial identification of the critical item to the point of adequate resolution. Each dated entry shall note the measures that have been taken to either eliminate the hazard or to minimize the magnitude and severity of the hazard for those which cannot be completely eliminated.



c. The final resolution actions shown in the Hazard Log should be sufficient to meet all safety assurance requirements. Closing of the Hazard Log by the Contractor shall be a condition of final system acceptance.

(d) A System Hazard Analyses (SHA) that shall identify in detail the Power supply and

Overhead equipment system and interface level fault contributions to the system hazards and their potential effect on the metro system, customers or third parties.

a. The SHA shall describe the functional faults and the proposed resolution of

each fault in terms of design requirements, which are referenced to safety- critical subsystem design documents. The resolutions become vital requirements for that subsystem.

b. The SHA shall cover interface failure modes, effects and analysis and shall investigate the criticality (risk) of unsafe conditions at the interfaces and identify resolutions proposed to eliminate or mitigate unacceptable risks to acceptable levels.

c. Hazards and resolutions from the SHA shall then be summarized in the Hazard Log for action, tracking, and review.

(e) A List of the safety components and equipments

The Contractor shall identify in this document every safety-related function, component or equipment, specify their safety level and the recommendations to follow in order to maintain their required safety level.

(f) A List of safety critical points to control during manufacturing and installation

a. The Contractor shall define the requirements that he intend to respect in order to ensure the safety level of the system during the manufacturing and installation phases.

b. The Contractor shall provide, for the critical components, a manufacturing and installation control plan.

(g) List of the safety tests plans and procedures

a. The Contractor may need to perform some tests in order to verify some Safety functions, components or equipments. Therefore, the Contractor shall provide tests procedures.

b. The Contractor shall provide the tests reports. c. The Contractor shall include the procedures and test reports in the safety

case. d. The Contractor shall establish the traceability between the safety

requirements defined in the PHA and the tests he has defined as necessary. The tests shall confirm that the safety requirements have been taken into account in the design and properly implemented.

(h) Safety requirements for operation and maintenance

a. For the critical points that could not be closed by the Contractor’s furniture, the Contractor shall draft a document describing

i. The requirements to be applied by the operation to ensure the safety of the system,

ii. The requirements to be applied by the maintenance to ensure the safety of the system.

b. The Contractor shall submit these documents to the Employer and the Operation and Maintenance setup for approbation.

c. The maintenance requirements shall establish the link with the part list of the system and the designation of the list of the safety components and equipments.



(i) System Safety case that the Contractor shall produce and that shall include all documentary evidence required to demonstrate the safety of the system.

a. The Contractor shall build the system safety case in respect of the CENELEC

50129 standard. b. The Contractor shall update the safety case during all the course of the

project and provide at least three versions of the safety case: i. A design safety case that shall provides the design evidences of the

mitigation of the hazards and concludes on the safety level of the design.

ii. A Construction safety case that shall provide the evidence of the mitigation of the hazards and concludes on the safety level as it is build.

iii. A Test and commissioning safety case that shall provide the evidence of the mitigation of the hazards and concludes on the safety level to be commissioned, and give the proof that all the system successfully passed all the safety tests.

MAHA-METRO Contract No. P1/TR-02/2018 Particular Specification Appendix E: Key Dates & Access Dates





RAIL PROJECT




APPENDIX E: KEY DATES & ACCESS DATES

MAHA-METRO Contract No. P1/TR-02/2018 Particular Specification Appendix E: Key Dates & Access Dates


APPENDIX E

Refer to Part 3, Section IX. Particular Conditions Part A – Contract Data ‘Table – Summary of Sections’

MAHA-METRO Contract No. P1/TR-02/2018 Particular Specification Appendix F: List of Deliverables





RAIL PROJECT




APPENDIX F: LIST OF DELIVERABLES



DOCUMENTS SUBMISSION

The Contractor shall supply to the Engineer duly indicating the documents required for information and the documents required for notice of no-objection for the procurement, design, manufacture, Inspection, testing, installation, training, maintenance and operation of the Works as detailed hereunder. The Contractor list of deliverables shall at least cover all documents required in General Specification and cover the following items: 1. Preliminary list of design documentation / reports / drawings / submissions

a. Full dimensioned General Arrangement drawings indicating clearances, fixing arrangement of the mounting structure on the foundation

b. Schematic drawings c. List of essential plant, machinery and testing facilities d. Type test report for various equipment of relevant rating e. Construction drawings of indoor and outdoor installations, equipments and facilities f. As-built drawings g. List of Sub-Contractors / Suppliers / Vendors for all the items h. The proposed planning and programming of manufacturing and execution of the work

suiting to the procurement / availability of the equipment, and achieving the completion of the work as per technical specifications within the stipulated period of completion

i. List of supplies and performance report for the tendered equipment from user railway / other customer

j. Pert, CPM and Bar chart for the sequence of activities to complete the project as per Time Schedule

k. Weekly / Monthly Progress Reports. l. Progress monitoring, monthly report including earned value report m. Electromagnetic compatibility report n. Work programme. o. Design, procurement, manufacturer and manufacturing tests programme p. Procurement of material, Installation, Quality procedures and test programs

2. Design documentation

The Contractor shall submit following details / dimensioned drawings in sizes of Scale 1:200 thereof for getting notice of no objection from Engineer.

a. Various simulations (e.g. dynamic simulation between contact line and pantograph) and other study reports including RAMS documentation / reports

b. General assembly showing mounting arrangement and overall dimensions c. Technical solution including design of the contact system d. Designs of tubular portal structures e. Plain mass concrete foundation drawing and design calculations f. Design calculation for structural safety along with details of supporting structure g. Estimation of implementation period h. Summary report of the design of the project i. Schematic and wiring diagram with explanation sheet j. Details of main parts / sub-assembly k. Name / Rating plate of the equipments l. Characteristics of the adopted design of overhead contact system m. Explanation report covering overhead line and civil engineering aspects n. Overhead contact line layout plans o. Transverse profile for inter station lines and stations and depot p. Longitudinal profile for overhead contact line height reductions q. Project specific structures with drawings and calculations r. Cantilever and dropper length calculation s. Polygon calculation for head span structures t. Earthing plans



u. Cable layout plans for the cables of disconnector and remote control v. Complete parts lists consisting of pole and foundation tables, overhead contact line tables

and list of materials w. Details of main, fixed and moving contacts and arcing contacts of CBs x. Operating and coupling mechanism of complete CB along with schematic diagram

showing the mechanical linkages with explanation sheet y. Details of insulators for support of Overhead equipment z. Identification of constraints such as points, sub sectioning, structures, railway crossings

etc. aa. Preparation of wiring design with pole locations at consultant such as crossings, turn out

etc. bb. Preparation of wiring design with pole locations other than constraints locations. cc. Any other drawing considered necessary

Note: Certain design documents shall be live throughout the project cycle and will need to be updated accordingly. For example, Hazard analysis, EMC/EMI documentation, Test Schedules etc. The Contractor shall take care of these requirements.

3. Manuals

a. Installation / Erection manual b. Operations manual c. Maintenance manual d. Training manual e. Preventative / Routine Maintenance Manual f. Systems Manual g. Test Data Manual h. Trouble shooting Manual i. Testing & Commissioning j. Parts list of equipment / system with appropriate codes (detailed according to

maintenance management system) 4. Eligibility Criteria for Designer

The Contractor shall meet, either by its own in-house setup or by engaging a suitable agency, the following qualification for design works: The work involves designs/drawing of the following core areas:

Traction system

Overhead Catenary System

Earthing and bonding works on MRTS viaduct

Interface with civil works such as: o Earthing arrangements o OHE mast drop arm holding arrangements on stations/viaduct.

The Firm to be engaged for this Design work shall meet the following criteria:

Should have experience of preliminary design, detailed design or design review of metro railway power supply and traction system for at least two metro project

Should have experience of preliminary design, detailed design or design review of at least 30 track kms. of 25 kV ac OHE works of metro railway or mainline railways

Should have experience of preliminary design, detailed design or design review of interfaces with civil works in at least one metro project

Kindly note that it is desirable that the designer has design competence in all the above core areas. However, in case, he has competence two of the three areas, the contractor would be required to clearly explain the proposal for the balance area along with proof of his meeting the



above requirement in the relevant field. The documentary evidence of the design experience in all the core areas shall be submitted. The design firm shall be in business of rendering metro / railway system consultancy for minimum 5 years preferably in India.