expression of interest (eoi) for manufacturing and …

EXPRESSION OF INTEREST (EOI) FOR MANUFACTURING AND SUPPLY OF SUBASSEMBLIES, PARTS, COMPONENTS ETC FOR APPLICATION IN DIESEL LOCOMOTIVES (Development of Specification): Motive Power Directorate of Research, Designs & Standards Organisation (RDSO), Lucknow, under the Ministry of Railways (MOR), is interested in developing sources for subassemblies, parts, components etc for application in diesel locomotives. Details of such items, for which this part of EOI intends to cover the stage of development of specification, are as follows:

S. No.

Description Details of Specification

Contact Details

1. Modified Hand Brake EMD: MP‐MOD‐BK‐14‐49‐10 ALCO: MP‐MOD‐BK‐03‐23‐09 FRS Attached herewith.

S. P. Govil, Dy. Director/Motive Power‐ BK Room No:103 (L3 Hall) Building: Manak Bhawan Telephone no. 0522‐2451200 extention‐42461, Email: [email protected]

2. New generation Water cooled Air Compressor for HHP Diesel locomotive

FRS Attached herewith.

3. Fuel Jumper Bolt 3/8” ‐16 UNC x 11/2‐2A/SAE Grade 8 with anti‐loosening features for ALCo class of Locomotives engines.

FRS Attached herewith.

Vaibhav Sohane, Jt.Director /Motive Power‐ ES Room No:107 Building: Manak Bhawan Telephone no. 0522‐2465733, email: [email protected]

Details of the above‐mentioned Functional Requirement Specification (FRS) are attached herewith.

Firms who have enough experience/capabilities in the field, have ISO certificate and are interested in developing and supply of above items are requested to submit details in the prescribed format attached herewith to the concerned officer mentioned against each item.

In case of any doubt, please contact the concerned officer mentioned against each item in office at Lucknow, on any working day. Annexures: A & AA

Executive Director Motive Power Directorate.

Annexure A

FORMAT FOR LETTER OF RESPONSE

Respondents Ref No.: Date: Designation of officer to whom the respondent replies Room No: , Building: Research Designs & Standards Organization Ministry of Railways Manak Nagar Lucknow, INDIA 226011 Dear Sir, Subject: RESPONSE TO – EOI FOR PARTICIPATION __________________________ 1. We, the undersigned, offer the following information in response to the Expression of Interest sought

by you vide your Notification No._______, dated _____.

2. We are duly authorized to represent and act on behalf of ________________ (hereinafter the “respondent”)

3. We have examined and have no reservations to the EOI Document including Addenda No(s)

______________________. 4. We are attaching with this letter, the copies of original documents defining: ‐

4.1. the Respondent’s legal status; 4.2. its principal place of business; 4.3. its place of incorporation (if respondents are corporations); or its place of registration (if

respondents are cooperative institutions, partnerships or individually owned firms); 4.4. Self‐certified financial statements of Last three years, clearly indicating the financial turn over

and net worth. 4.5. Copies of any market research, business studies, feasibility reports and the like sponsored by the

respondent, relevant to the project under consideration

5. We shall assist MOR and/or its authorized representatives to obtain further clarification from us, if needed.

6. RDSO and/or its authorized representatives may contact the following nodal persons for further

information on any aspects of the Response:

S. No. Contact Name Address Telephone E Mail

1

2

7. This application is made in the full understanding that:

7.1 Information furnished in response to EOI may be used confidentially by RDSO for the purpose of development of the product.

7.2 RDSO reserves the right to reject or accept any or all applications, cancel the EOI and subsequent process without any obligation to inform the respondent about the grounds of same.

7.3 We confirm that we are interested in participating in development of the product.

8. We certify that our turnover and net worth in the last three years is as under:

Financial Year Turn over Net worth

9. In response to the EOI we hereby submit the following additional details annexed to this application.

9.1 Details of various items being manufactured/consultancy undertaken. 9.2 Details of customer(s) and supplies made in the field of item under EOI. 9.3 Experience and expertise for the items proposed in EOI. 9.4 Details of man‐power with their qualification and experience. 9.5 Detailed proposal for items proposed in EOI including alternative proposal, if any. 9.6Details of Intellectual Property Rights (IPR) held, patent filed/held and MOU/agreement signed. 9.7 Details of ISO certification. 9.8 Undertaking as per Annexure‐AA

10. The undersigned declare that the statements made and the information provided in the duly

completed application are complete, true, and correct in every detail. We also understand that in the event of any information furnished by us being found later on to be incorrect or any material information having been suppressed, RDSO may delete our name from the list of qualified Respondents. We further understand that RDSO will give first preference to the applicants considered relevant for the purpose.

11. Our response is valid till (date in figures and words):_______________________________________

Yours sincerely,

(Sign) Name In the Capacity of Duly authorized to sign the response for and on behalf of Date

Annexure-AA

(To be taken on non-judicial stamp paper of appropriate value as applicable in the respective state and duly notarised and witnessed)

UNDERTAKING I, son of ……………… aged about …..... Years resident of ………….. do hereby solemnly affirm as under: 1. That the deponent is the Authorised signatory of (Name of the Sole Proprietorship Concern/Partnership Firm/

Registered Company/ Joint Venture). 2. That the deponent declares on behalf of (Name of the Sole Proprietorship Concern/ Partnership Firm/ Registered

Company/Joint Venture) that:

a) In regard to matters relating to the security and integrity of the country, no charge sheet has been filed by an agency of the Government and/or conviction awarded by a Court of Law for an offence committed by the -----------------------------------(name of the entity) or by any sister concern of the ----------------------------------(name of the entity) which would constitute disqualification of-----------------------(name of the entity or any of it’s sister concerns).

b) In regard to matters other than the security and integrity of the country, ---------------(name of the entity) has

not been convicted by a Court of Law or indicted / passed any adverse order by a regulatory authority against it or it’s any sister concern which relates to a grave offence, or would constitute disqualification. Grave offence is defined to be of such a nature that it outrages the moral sense of the community.

DEPONENT

VERIFICATION

I declare that the contents of para 1 to 2 above are true as per my knowledge and nothing has been hidden.

DEPONENT

of 9

Functional Requirement Specification (FRS) for Modified Hand Brake Assembly for ALCo

and HHP Locomotives on Indian Railways

1. Introduction: The FRS covers description of equipment, functional, technical, testing, maintenance, and environmental requirements for the Modified Hand Brake Assembly for ALCo and HHP Locomotives on Indian Railways. The device broadly consists of i. Modified Hand Brake Assembly ii. Pulley iii. Chain iv. Weight

v. Rubber ring

2. Requirements:

i. Service Conditions: The Modified Hand Brake Assembly shall be capable of working satisfactorily under service conditions indicated below:

a) Altitude: - Mean sea level to an altitude of 1000 meters above mean sea level. b) Relative Humidity: Up to 100 % c) Temperature: 00C to 550C. The air temperature around equipment may reach as high as 700C. d) Ambient conditions:- The equipment shall be capable of operating efficiently in spite of dust,

dirt, mist, torrential rain, heavy sand or snow storms, presence of oil vapors and radiant heat, coastal area etc. to which rolling stock is normally exposed in service.

e) Vibrations and shocks: The Modified Hand Brake Assembly should be capable to withstand, without damage, the vibrations and shocks normally encountered during service. The conditions are indicated below: 1. Maximum vertical acceleration = 1.0 g 2. Maximum longitudinal acceleration = 3.0 g 3. Maximum transverse acceleration = 0.5 g (‘g’ being acceleration due to gravity)

3. Technical and functional Requirement: a) The Modified Hand Brake Assembly shall confirm to drawings as follows:

S. No. Drawing No. Description

1. SKDP-3947 For Alco locos 2. SKDP-4089 For HHP locos

b) Arrangement shall be such that clockwise movement of the handle causes brake

application and anticlockwise movement causes brake release. c) There shall be provision for locking the handle to maintain brake application/ release as

required. d) The link chain shall be maintained as follows:

S. No. Type of Loco Link

1. Alco locos 85 2. HHP locos 191 3. HHP locos with dual cab 251

of 9

e) Modified hand brake assembly should be working smoothly in clock wise and anticlockwise direction with minimum 2.2 ton force available in connecting chain.

f) Chain shall be round steel short link chains (Electric Butt Welded) grade L(3) part-1 non-calibrated load chain for lifting purposes as per IS-2429.

g) The system shall be of simple design, light in weight, robust in construction. The design shall be compact for ease of interfacing with brake rigging.

h) Mounting arrangement of Modified Hand Brake Assembly shall be secured against severe vibrations.

i) Manufacturers shall guarantee availability of spares throughout the life of the equipment. List of recommended spares too shall be submitted by the manufacturer.

4. Installation and Acceptance test: The supplier shall supply the complete layout drawings for

the Modified hand brake assembly (Assembly and components) indicating the overall dimensions and get them approved from RDSO before supply of Modified hand brake assembly to IR. The acceptance test shall be governed by the attached document.

5. Maintenance requirements:

The supplier shall provide the maintenance manual for Modified hand brake assembly detailing maintenance procedure, schedule/ frequency, list of spares required during routine maintenance/ overhauling.

of 9

Check sheet for Modified hand brake assembly for ALCo and HHP locos

Item Modified hand brake assembly

Spec no. Nil. Drg. No. & Alt. SKDP-3947 for ALCo locomotive and SKDP-4089 for HHP locomotive

1. Firm’s Name:- 2. Date (period) of Inspection:- 3. P.O. Details:-

a) P.O. no. and date:- b) Order placing authority:- c) Specification no: (As mention in P.O.)-- d) Drawing no. :- (As mention in P.O.) e) Quantity on order:- f) Quantity offered for inspection on date:- g) Consignee :- h) Delivery Period:

4. Sampling Plan/Lot Size: - As per Table given below (As per IS-2500 Part-I)

Lot size For Tests Sample size Number of rejection

acceptable Up to 25 3 0

25-50 5 0

50-75 8 0

75-100 10 0

More than 100 10% of the lot 0

Table‐1

5. Types of Tests: A. Material Test : All internal parts specified i.e. IS standard in RDSO drawing no. SKDP-

3947 for ALCo locomotive and SKDP-4089 for HHP locomotive should be complied.

B. Visual Check (Ref; Table-1for sampling plan):

Sr. No. Specified Standards Observed Remarks

a) Month & Year of Manufacturer Yes

b) Name of Manufacturer Yes

c) Surface Finish No any cut mark or debarring in any place

of 9

C. Dimension Check(Ref; Table-1for sampling plan):

(i) Over all dimension check as per SKDP-3947 for ALCo locomotive and SKDP-4089 for HHP locomotive.

(ii) Dimension check for internal parts as per manufacturer drawings

D. Performance Test (Ref; Table-1for sampling plan): Modified hand brake assembly should be working smoothly in clock wise and anticlockwise direction in a test bench with minimum 2.2 ton force available in connecting chain.

of 9

Draft Specification for development of specification of New generation Water cooled Air Compressor for HHP Diesel locomotives

1. Purpose of Use: 1.1 The purpose of the Air compressor is to compress the air taken at atmospheric

pressure to the pre-determined gauge pressure i.e 10.0 kg/cm² and also to maintain the pressure of that compressed air between 8.0 kg/cm² to 10.0 kg/cm² in the main reservoirs of locomotive, for use in train braking and operation of auxiliary equipment(s).

1.2 The New generation Water cooled Air Compressor shall be directly driven by diesel engine of the locomotive at varying speeds w.r.t various notches of the diesel engine.

2. Objectives and Scope: This draft specification covers the purpose of use, design, functional and test requirements of New generation Water Cooled Air Compressor to be used in HHP Diesel locomotives of Indian Railways for the purpose of framing the specification.

3. Terminology / Abbreviations Abbreviations Full form/Description RDSO Research Designs & Standards Organization ISO International Standards Organisation IS Indian Standards I R Indian Railways FAD Free air delivery M.R. Main Reservoir RPM Revolution per minute LPM Litre per minute

4. Design Requirements: 4.1.1 The air compressor shall be positive displacement, two-stage, water-cooled type.

The compressor shall have its own gear driven type lube oil pump and forced feed lubricating system.

4.1.2 This compressor shall have two low-pressure cylinders and one high-pressure cylinder. All the pistons shall be reciprocating through their individual connecting rods, oscillated on a common crankshaft. Crank shaft is directly driven by diesel engine of locomotive through a shaft coupling arrangement.

4.1.3 The compressor shall have combined concentric suction & discharge valve on each cylinder. The valves shall preferably be identical in low pressure and high pressure cylinder.

4.1.4 The compressor shall have Light weight welded plate type inter-cooler. 4.1.5 Compressed air from Low pressure cylinder after passing through the inter-cooler

shall enter the high pressure cylinder. 4.1.6 Compressed air from high pressure cylinder through connecting pipe shall be stored

in the main reservoirs and maintained generally between 8.0 to 10.0 kg/cm². 4.1.7 The compressor shall have inbuilt un-loader arrangement with the combined

concentric suction & discharge valve to load and unload the compressor at a preset pressure.

of 9

4.1.8 The cooling water circulation arrangement shall cool the different components of the compressor (cylinders, heads, valves, valve plug and inter cooler etc. where by compressed air passes).

4.1.9 Forced feed lubrication system comprising of positive displacement type of lube oil pump shall be provided. The system shall have lube oil level and pressure indicator & relief valve.

4.1.10 The compressor must be capable of being driven by diesel engine over a speed of 200-1100 rpm and maximum service speed of 950 rpm.

4.1.11 Duty cycle - The compressors are subjected to run for 22 hours a day. 4.1.12 Loading / unloading - The compressor will be loaded at 8.0±0.1 kg/cm² and get

unloaded at 10.0±0.1 kg/cm². Pressure relief valve set at 10.7±0.1 kg/cm² is provided in loco air brake system to safeguard the main reservoir of locomotive and compressor if loading/unloading mechanism fails.

4.1.13 Maximum weight – 1000 kg (excluding air suction filter) 4.1.14 Maximum space –

Space Length along locomotive

Width across the locomotive

Height

Maximum envelop dimension for compressor general arrangement

1368 ± 5 mm 662 ± 5 mm 1065 ± 5 mm

4.1.15 Mounting and interfacing dimensions should be suitable for HHP diesel locomotive and should also conform to RDSO drawing SK.DP NO.-3842, (annexure –I).

4.1.16 Cooling of compressor - The compressor shall be provided with the cooling water received from radiator of locomotives during running of engine at following conditions.

i. Minimum water flow-amount of cooling water flow will be of 68 lit/min to 122 lit/min at 950 rpm in compressor system.

ii. Minimum water flow-amount of cooling water flow will be of 18 lit/min at 200 rpm in compressor system.

4.1.17 Lubricating oil conform to SAE-30 / IOC SERVO-100 RR approved for compressor shall be used.

4.1.18 The arrangement for the cooling piping system and loading unloading piping system shall be such that it does not fail during the service of the locomotives due to vibrations.

4.1.19 Reconditioning of valves and Un-loader – reconditioning/ replacement period of un-loader & valves shall be at least six year of service.

4.1.20 Overhauling Period – Overhauling period of the complete compressor shall be after six years of service.

4.1.21 The compressor should be capable of working satisfactorily under the service conditions indicated below:

i. Altitude - An altitude between 0 and 1000 meters above mean sea level. ii. Relative Humidity - Up to 100 % in rainy season. iii. Temperature (Ambient air) -5 to 80 deg C. iv. Ambient conditions - The compressor shall be capable of operating efficiently in spite

of dust, dirt, mist, torrential rain, salt taken in coastal area, heavy sand or snow

of 9

storms, presence of oil vapours and radiant heat etc. to which rolling stock is normally exposed in service.

v. The ambient temperature around the compressor and inlet air temperature to the air filters can vary between -5º C and 70º C with a maximum of 80º C for approximately 9 minutes

4.2 Functional Requirement: 4.2.1 FAD should not be less than 5677 LPM and 990 LPM at maximum speed of 950 rpm

and idle speed 200 rpm of drive of compressor respectively. 4.2.2 Discharge compressed air temperature at HP outlet may be allowed up to 200 degree

centigrade maximum. 4.2.3 Power consumption should conform to following table:

Sr. No.

Speed, rpm

Loaded/Unloaded condition

Minimum consumable Horse Power, HP

(indicative)

Maximum consumable

Horse Power, HP

1 200 Unloaded condition 1.8 2.2

2 200 Loaded condition 18 22

3 950 Unloaded condition 19 23

4 950 Loaded condition 59 70

5. Test Requirement: 5.1 Preliminary testing: These comprises of tests to carried out by vendor, at locomotive

operating conditions at firm’s premises under design development. 5.2 Prototype testing: These comprises of tests to carry out by IR, at firm’s premises

during design development as required. 5.3 Reliability Verification Testing ( Testing on locomotive / Field Trial). 5.4 Quality acceptance / routine tests 5.5 Additional Testing, if any

I

uItdil4

*J:

of 9

Functional Requirement Specification (FRS) for Fuel Jumper Bolt 3/8”- 16 UNC x 1 ½" – 2A/SAE Grade 8 with anti-loosening features for ALCo class of locomotive engines: 1. General: Hexagonal head cap screws 3/8”‐16 UNC x 1 ½" – 2A/SAE Grade 5, commonly known as fuel jumper bolts, have been in use in fuel circuit of ALCo locomotive engines in IR. Problems with the bolt like loosening, shearing, breakage etc have been reported. Therefore, superior bolts with anti‐loosening features are considered for application. 2. Requirements: 2.1 Bolt Details: • Hexagonal head bolt size equivalent to 3/8”‐16 UNC x 1 ½" • Class of fit (tolerance standard) – 2A • Material – equivalent to SAE J429 Grade 8. • Coating – equivalent to MAGNI 567 or superior providing minimum 1500 hours salt spray corrosion protection as per standard ASTM B – 117. The coating material shall be environment friendly eg the same shall be free from chrome, boron etc. • The bolt shall have inbuilt with anti‐loosening feature. 2.2 Other requirements: • Supplier shall provide technical details, drawings etc of the bolt. • Supplier of bolt shall clearly mention the torque value for the application. • The bolt shall cause no damage to the engine components like fuel T‐jumper etc during normal fitment. The bolt shall be able to be worked with normal torque wrench. • The bolt manufactured as per above details shall be proven to be resistant to loosening, shearing, breakage etc due to vibration and shock. • The bolt shall have suitable coating to withstand the corrosive environment which corresponds to the fuel system of locomotive engine. • At least 10 loco sets (ie 10 x 32 nos) of bolt shall be subjected to the field trials for 24 months. • The supplier shall submit undertaking in respect of ensuring regular supply of bolts over IR against purchase orders. • The bolts shall have markings for identification in respect of make, date of manufacturing etc for facilitating failure investigation and compilation of life cycle data. 3. Warranty: The warranty clause shall apply as per standard IRS conditions.

…………….

expression of interest (eoi) for manufacturing and …

Documents