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GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

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SPECIFICATION FOR PROCUREMENT OF TELESCOPIC JIB CRANE ALONGWITH

TECHNICAL COLLABORATION (1676 mm GAUGE)

MP – 0.08.00.61 (REV. – 00)

MARCH - 2011

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RESEARCH DESIGNS AND STANDARDS ORGANISATION MANAK NAGAR, LUCKNOW – 226011

C O N T E N T S

Part Description Page No.

I Explanatory 1 - 10

Objective and Scope, Reference & Eligibility Criteria, Examination of Tender offer, Design Development, Contractor’s responsibility, Guarantee, Exhibited drawings and Standard specifications, Service Team, Training, Service manuals and Spare Parts catalogue, Spare Parts, Lifting tackles, Tools, Training kit, Testing kit and Inspection

II Dimensional, Operating & Acceptance Requirements 11 - 18

Operational parameters, Duties, Oscillation trial, Setting up time, Climatic conditions

III Under Carriage and Match Truck Design 19 - 24

Structural design, Underframe, Carriage Bogies, Wheels and axles, Axle boxes, Spring gears, Draw and buffing gear, Outriggers, Rail Clips, Brakes & Compressors and Match Truck.

IV Superstructure, Jib and Drive Equipment 25 - 31

Superstructure, Cab & Controls, Boom, Hoisting gear, Slewing gear, Luffing gear, Traveling gear, Wire ropes, Wire rope sheaves & drums, Hook, Gears, Brakes, Electrical equipment, Horn, V-belts, Piping’s, Lubrication, Instruction plates, Recovery winch.

V Power Equipment 32 – 35

Diesel engines, Fuel, Transmission, Cooling, Control equipment, Instruments & Safety devices e.g. Safe Load Indicator (SLI)

VI Miscellaneous 36 – 38

Lifting tackle, Tools, Painting & Marking, Maker’s Test Certificate, Drawings, Specifications, Tracings & Photographs and Packing for shipment.

VII Collaboration agreement 39 - 40

Appendix Description Page No.

‘A’ Particulars to be supplied by the tenderer 41 - 49

‘B’ List of drawings 50

Sl. No. Description of attached drawing Drawing Nos.

1. Diagram showing MMD for BG locomotives as per SOD, Revised 2004 with latest amendment

Diagram 1D

2. Standard dimensions for tunnels & through girder bridges as per SOD, Revised 2004 with latest amendment

Diagram No. 1A

3. Standard dimensions for tunnels & through girder bridges as per SOD, Revised 2004 with latest amendment

Diagram No. 1A (Modified)

4. Finished IRS tyre profile CSL- 3040

5. Main dimensions of turnouts RDSO SK. DL. 459

6. Diagram of standard covered bogie wagon type “BCNA” WD- 90030 – S-51

7. Diagram of standard “BTPGLN” wagon WD- 93047/51

8. Diagram of standard LHB IR coach SK- 96077

9. Loco Outline Drawing of WAG 9H locomotive SK EL- 4547

10. Diagram showing lifting of LHB coach at 13m outreach Sketch - 1

11. Diagram showing lifting of BCNA wagon at 8.3m outreach Sketch - 2

Specification for procurement of Telescopic Jib Crane Along with Technical Collaboration (1676mm Gauge)

PART – I

GENERAL

1. EXPLANATORY 1.1 RDSO 1.1.1 The Research Design and Standards Organisation (Ministry of Railways),

Manak Nagar, Lucknow – 226011 is hereafter referred to as RDSO. 1.2 OBJECTIVE & SCOPE 1.2.1 Indian Railways are manufacturing 140 tonne capacity Diesel Hydraulic Fixed

Jib BD Cranes in their workshop at Jamalpur. Indian Railways now desire to upgrade the capacity of BD cranes to 175 tonnes.

1.2.2 The specification covers the requirements for design, manufacture, supply and

delivery including commissioning into service of high capacity diesel hydraulic microprocessor controlled telescopic jib breakdown cranes as described in the accompanying schedule for operation on the Broad Gauge (1676 mm gauge) system of the Indian Railways. This also includes assembly of four no. of cranes from completely knockdown kits to be supplied by the contractor as mentioned in para 1.2.8.

1.2.3 In addition to submitting an offer for supply of cranes, the tenderer is required to

quote separately for a collaboration agreement as detailed in Part – VII.

1.2.4 The breakdown crane is to be used mainly for clearing operations at the site of rail accidents and may also be used for general load lifting purposes, including track laying, re-girdering of bridges etc. The crane shall be so designed that it meets the operating requirements given in Part – II of this specification and shall be capable of carrying out clearing operations in long tunnels. Its nominal capacity will be determined based on these requirements.

1.2.5 In case the tenderer needs clarification on any clause of this specification or

regarding the exhibited drawings, the tenderer shall submit each such item to RDSO for immediate clarification.

1.2.6 Scope of supply shall include:

i) Two prototype and another two fully erected cranes, manufactured completely at the manufacturer’s premises

ii) Four cranes to be supplied by the contractor at Jamalpur workshop in completely knocked down (CKD) condition, where assembly will be done.

1.2.7 Fully Erected cranes (4 nos.) 1.2.7.1 Four cranes manufactured and tested completely at the manufacturer’s

premises shall be supplied. For supply of 4 nos. of cranes, the Match Truck, if required, will be deemed to be a part of the crane. The tenderer shall submit the following information-

Motive Power Directorate 1 Spec. No.MP.0.08.00.61 (Rev- 00) March’2011


Motive Power Directorate 2

i) The extent of assembly to be done by the purchaser on fully erected cranes, after they land in India.

ii) The tenderer should indicate the no. of consignments, maximum dimensions, weight of each consignment and the facilities which would be required to be provided by the purchaser for the purpose of final assembly of cranes after landing in India.

1.2.7.2 The contractor shall provide, free of charge, any special facilities and/or

supervision required for assembling parts of fully erected cranes on landing in India.

1.2.8 Cranes in completely-knocked down condition (4 nos.) 1.2.8.1 For cranes to be supplied in completely-knocked down condition, the tenderer

shall indicate in their offer, the following-

i) List of items of assemblies/sub-assemblies / pre-fabricated goods which will be shipped by them separately for assembly into a complete crane at the Jamalpur workshop of Indian Railways.

ii) Price of each item in the above list separately.

iii) Recommendations of the tenderer in regard to items of the list which in their opinion could possibly be deleted from his supply and manufactured at the facilities of the Indian Railways progressively, beginning from the first knocked down crane onwards.

1.2.8.2 The purchaser will reserve the right to order either full set of items constituting a

complete crane to be obtained in semi-knocked down condition or to delete some items of the list as per above requirement, to be decided before the contract is finalized.

1.2.8.3 The facilities and manpower required for the assembly shall be provided by

Indian Railway; however supervision shall be provided by the contractor. 1.2.8.4 The tenderer shall specify the infrastructure and other facilities required for

assembly of the knocked down kits into four fully erected cranes and their testing and commissioning.

1.2.8.5 For a set of components to be supplied for assembly / manufacture of cranes in

Indian Railways workshop, the contractor shall furnish the following information.

i) List of components, sub-assemblies and assemblies per crane set which will be supplied by them.

ii) For items or sub-assemblies to be manufactured either at Jamalpur

Workshop or by some other agency within the Country, relevant information as may be necessary for manufacture, assembly, testing and their fitment in the crane shall be provided by the contractor as a part of collaboration agreement.

iii) Price of each item in the list separately.

Spec. No.MP.0.08.00.61 (Rev- 00) March’2011



iv) Recommendations from the contractor in regard to the items which in his opinion could be manufactured by the Indian Railways workshops and could be deleted from the list.

1.2.8.6 The decision of the Indian Railway with regard to the components and sub-

assembly / assembly which will be imported or will be manufactured within the country either by Indian Railway or some other agency shall be final and binding.

1.3 REFERENCE AND ELIGIBILITY CRITERIA - Refer Bid Document.

1.4 EXAMINATION OF THE TENDER OFFER 1.4.1 To facilitate examination of the tender offer, the tenderer is required to offer

comments clause by clause of this specification either indicating compliance or otherwise against each clause and sub clause of all the parts of the tender document. Comprehensive specification of the crane offered shall also be submitted along with the above commentary.

1.4.2 The tenderer will strictly adhere to the conditions of this specification. However,

in the event of the tenderer being unable to conform to any part of the requirements of this specification, it must be stated specifically what variation there from is desired by the tenderer.

1.4.3 For any deviation(s), the bidder shall enclose a separate clause-wise statement

along with the offer, indicating the deviation(s) and justification for each deviation sought. In case there are no deviations, a “Nil Deviation” statement will have to be furnished by the bidder.

1.4.4 The main particulars of the crane are to be furnished by the tenderer at the time of submitting his quotation / tender as per Appendix ‘A’.

1.5 DESIGN DEVELOPMENT 1.5.1 The contractor shall develop the design based on the details given in this

specification and sound engineering practice following EN 13000 “ Mobile Cranes”, EN 13001 “General Crane Design“ or Equivalent International standards. The components, sub-assemblies and equipment chosen for application on the crane offered should have already been proven in breakdown crane application and particularly in regard to reliability in operation and maintainability.

1.5.2 To the extent possible, the following systems of the offered crane should

preferably be of such a make, whose spares and service are available in India.

a. Diesel Engine (Main & Auxiliary) b. Hydraulic system c. Brake system d. Auxiliary air compressor e. Gear boxes f. Axle box roller bearing g. Slew ring bearing h. Lifting tackles




1.5.3 The design shall be developed in S.I. Units. 1.5.4 Material specifications with Bill of Material (BOM) for each component shall be

indicated on the relevant drawings and copies in English of specifications other than Indian Standard specifications shall be supplied to the RDSO.

1.5.5 “Approval” to the design means the approval to the general adoptability of the

design features. Notwithstanding the approval, the contractor will be wholly and completely responsible for the performance of the crane offered and for demonstrating its compliance to this technical specification. The contractor when submitting proposals on designs for approval of the RDSO shall draw specific attention to any deviation or departure from the specification involved in his proposals or drawing. Manufacture of the prototype shall be started by the contractor only after the said design “approval” is granted by Indian Railways.

1.5.6 The contractor shall submit drawings in duplicate along with main calculation

details including soft models, which are necessary for checking the design of the crane and its components. This shall cover–

i) Finite Element Analysis (Static Load Analysis), Multi-body Dynamic

Loading Analysis, Fatigue Loading Analysis and Stress Analysis of all the major stress-bearing parts / members of the crane like Jib, Bogie frame, Undercarriage, Slewing frame, Operating machinery (including Shafts, Gears, Couplings), Brake rigging and its components, Primary Suspension Springs, Axles etc. to demonstrate the design efficacy. Complete analysis report with all calculations to be submitted.

ii) Balancing calculations & C.G. calculations in longitudinal, transverse and vertical modes.

iii) Life rating calculation of all-important bearings viz. axle box, shaft bearings and slewing ring. Service life curve of slewing ring for 30,000 revolutions.

iv) Life rating of all the gears in accordance with AGMA/DIN or Equivalent

International Standards.

v) Performance calculations to establish the adequacy of installed power to perform different operations with maximum load on the hook.

vi) Calculations for complete load tables indicating the margin of stability

available with the crane operating at different radii both when free on rail and in propped condition on level and super-elevated track.

vii) Braking effort calculations for different operations of the crane with

maximum load. viii) Stress calculations for hooks, tackles and lifting beams.

1.5.7 Drawings and specifications for the hydraulic pumps / motors and control gears shall also be submitted by the contractor along with main calculations for checking their design. The contractor will also provide details of the generic specification(s) on which the design of hydraulics is based. The contractor will ensure that the detailed design of all equipment of non-generic nature




specifically developed by the hydraulic system integrator will be provided and an undertaking of the system integrator (if proposed to be engaged separately by the tenderer in actual manufacture) will be provided in the offer.

1.5.8 Contractor shall also supply internationally acceptable Load Simulation

Software in addition to load charts for actual assessment of crane duties other than specified in Clause 2.6.9, with different load and radius combinations under different conditions of lifting such as Free on rail or Propped with no. of props actually utilized, Actual Counterweight used, Tail radius used in case of two different tail radii etc., without going in for a field trial for identifying the actual clearances between .1 the lifted stock and crane. .2 the crane and the permanent structures of IR including OHE.

1.5.9 The process of design approval shall be facilitated by holding at least two specific higher level detailed design review meetings between representatives of Indian Railways and the contractor to ensure suitability of design and smooth progress as per collaboration agreement. The first meeting shall be held in the manufacturer’s premises and the venue of second and subsequent meetings shall be decided mutually between IR and the contractor.

1.6 CONTRACTOR’S RESPONSIBILITY

The contractor is to be entirely responsible for the execution of the contract strictly in accordance with the terms of this Specification and the conditions of contract, notwithstanding any approval which RDSO or the Inspecting Officer may have given at any stage.

1.7 WARRANTY 1.7.1 The contractor shall warrant that under normal use of the supplied cranes in the

specified working conditions obtaining on Indian Railway, the cranes supplied under this contract shall not develop any defect arising from design, materials or workmanship or from any act or omission of the contractor.

1.7.2 Any part of the crane failing or proving unsatisfactory in service due to defective design, material or workmanship within 40 months after delivery or 36 months from the date of commissioning, whichever is earlier, shall be replaced by the contractor at his own expense. In the event of immobilization of the crane owing to defect in design, material or workmanship, this warranty period shall be extended for the duration of the said period of immobilization. Further, should any design modification be made in any part of the equipment offered, the period as stated above would commence from the date the modified part is commissioned in service. The cost of such modification is to be borne by the contractor.

1.7.3 If the contractor, having been notified, fails to remedy the defects or replace the

defective components/sub-assemblies within the period specified. IR may proceed to take remedial action as may be necessary at the contractor’s risk and cost and without prejudice to any other rights which IR may have against the contractor under the contract.




1.7.4 For cranes assembled at Indian Railway Workshop, Jamalpur, the contractor shall also stand warranty to the performance and design of the components/assembly/sub-assembly supplied by the contractor. The contractor shall also be responsible for any design defect or any design issue even for the components/assembly/sub-assembly, not supplied by the contractor, but manufactured in India either by Indian Railway or some other agency. Details of warranty obligation of the contractor with regard to cranes assembled/manufactured in India shall be spelt out as per mutual agreement in the contract.

1.7.5 Bidders are also advised to refer to bid document regarding other warranty

conditions and LD for failure during warranty and for type defects.

1.8 EXHIBITED DRAWINGS AND STANDARD SPECIFICATIONS 1.8.1 “Exhibited Drawings” mean the drawings which are exhibited or provided for the

guidance of the contractor. 1.8.2 The exhibited drawings illustrative of a range of standardized dimensions and

fittings are listed in Appendix ‘B’. The design of the crane must comply with the dimensions and fittings included shall be as per the exhibited drawings as far as possible.

1.8.3 The contractor, in preparing his working drawings, shall ensure that drawings

prepared by him are free from discrepancies and shall incorporate all modifications required by this specification or those desired by the RDSO subsequently without prejudice to the date of delivery or contracted price, except as provided for under the conditions of the contract.

1.8.4 Copies of drawings referred to in this specification may be obtained on payment

from RDSO. 1.8.5 Copies of Indian Railway Standard Specification and Schedule of Maximum &

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

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

9, Bahadur Shah Zafar Marg, New Delhi – 110002. 1.8.7 IPR ACT - This specification and all the related reference drawings issued

by any authority of Indian Railway has been prepared by Indian Railways. All rights conferred by the law of copyright and by virtue of International Copyright Convention are reserved to Indian Railways, irrespective of the fact whether the same has been mentioned on any of such documents or otherwise. Re-production in whole or in part requires the prior written consent of Indian Railways. As the drawing / document incorporate confidential information, its disclosure to third parties also requires Indian Railways prior written consent.

1.9 SERVICE TEAM

1.9.1 The contractor shall, at his own expense, provide a competent technical team to

Indian Railways for the following:




i) During assembly & commissioning of cranes in India - Assistance by technicians and Supervision by Engineer.

ii) During full load test / acceptance test and riding test etc. as mutually

agreed upon. (Refer Clause 1.17) - Associating with Indian Railway Personnel by Engineer and Technicians.

iii) During the warranty period of cranes after commissioning - Providing all

the required Man-power for attending to Warranty / Type defects. iv) During the first major overhaul of such numbers of the crane as may be

agreed upon - Complete Supervision by Engineers. The contractor’s service team shall be available in India till completion of warranty period. However, the final number of days may be arrived at after detailed discussion on the subject after finalization of the tender.

1.9.2 Annual Maintenance Contract - Refer Bid Document.

1.10 TRAINING The tenderer shall have to impart training to Indian Railway personnel in design, manufacture, operation, maintenance and periodic overhaul. The following training will have to be provided by the successful bidder: .1 Training at Manufacturer’s/ Sub-Contractors’ / Customers premises: The contractor shall provide training (as quantified in the Bid Document) in his own and his sub-contractor’s office / works as well as in the railroads where cranes listed against eligibility criteria are deployed. Details of training have to be finalized and submitted along with the offer. .2 Training at IR premises: The contractor shall provide training (as quantified in the Bid Document) to IR personnel at a suitable central location in India. The following staff will be covered under this training:

• Crane maintenance staff. • Crane operators and riggers in crane operation and trouble shooting

which will also include hands on training.

The distribution of the number of trainees indicated in the Bid Document may be changed on mutual discussion, within the limit for total numbers and number of batches. Well trained and qualified instructors shall be deputed by the contractor for both the above mentioned trainings.

1.11 SERVICE MANUALS AND SPARE PARTS CATALOGUE

Detailed operating manual, maintenance manual, schedule (time bound) shall be specially prepared for the crane and at least three copies each of the same shall be supplied free of charge per crane ordered. The manuals will include all information relevant to maintenance, servicing and spares provided by the vendors/OEMs as part of their supply to any prudent purchaser. All manuals shall be additionally provided on DVD/ Pen drive in editable format. The draft contents of the manuals shall be submitted for approval of RDSO. Detailed




spare parts catalogues listing all components manufactured or purchased, three copies per crane shall be supplied free of charge. All manuals shall be dispatched to the address of the Director General (Motive Power), Research Designs and Standards Organisation, Ministry of Railways, Manak Nagar, Lucknow – 226011, India.

1.12 SPARE PARTS 1.12.1 The tenderer shall provide an itemized list of life expectations of different

components/assemblies, which are subject to wear and tear during operations. The new and serviceable limits of all wearing parts used should be provided.

1.12.2 In order to secure the highest availability and utilization of the cranes, a certain number of standby units of the principal assemblies, such as the diesel engine, hydraulic pumps, motors, cylinders, gearboxes, joysticks, fuses, seal kits for all hydraulic equipments etc., are required. In addition, it is proposed to stock sufficient minor components and spares to meet the normal renewals and replacements on account of wear or occasional failure, estimated for a period of three years service except for items whose shelf-life is limited. The tenderer shall, therefore, submit classified lists of spares (emergency, standby and normal maintenance), which are recommended to be held in stock by Indian Railways. The lists shall be accompanied by item-wise quotations, drawing reference, specification, source of supply, etc. for each ‘spare’ item will be indicated. Tenderer should also have back to back arrangement for spares with their counterparts in India.

1.12.3 The contractor shall explicitly commit to supply maintenance and stand by

spares for the total ordered quantity of the cranes for the period of validity of the collaboration agreement. The manufacturer shall also be responsible for the subsequent availability of spares to ensure continued trouble-free service for the life of the crane and should indicate what facilities exist or are proposed to be set up to ensure a ready availability of spare parts in India. Items for spares should include the following items: i) Hydraulic valves and seals. ii) Pneumatic valves and seals. iii) Hydraulic cylinders and seals. iv) Pneumatic cylinders and seals. v) Gearboxes and seals. vi) Hydraulic pumps and motors. vii) Wheel and axle assembly. viii) Springs and shock absorbers. ix) Wire ropes x) SLI system

1.12.4 Consumables for the entire system should be available in India as far as

possible or equivalent supplies from India to be specified by the firm. This includes inter-alia filters, lubricants, transmission belts etc.

1.13 LIFTING TACKLE

The tenderer shall quote for the supply of lifting tackle with break-up as detailed in Clause 6 of this specification.

1.14 TOOLS Lists of tools with quotations wherever necessary shall be submitted by the tenderer in accordance with Clauses 6.2.1 to 6.2.3 of this specification.




1.15 TRAINING KIT

Tenderer will submit along with his tender a complete list of equipment required for purposes of training the Indian Railways’ maintenance, operational and executive staff along with quotations. OEM shall also supply video display of maintenance schedule and virtual training package for drivers and maintenance staff.

1.16 TESTING KIT

Tenderer shall specify the testing equipments as may be required for ensuring optimum performance and trouble-free service of the crane as well as their major assemblies and sub-assemblies. Details of this testing equipment shall be submitted by the tenderer with complete quotations. The supply shall include those equipments as specified by the tenderer.

1.17 INSPECTION

The inspection of the cranes shall be carried out as indicated in the following clauses. The inspection procedures and test schemes will be submitted to RDSO and after discussions, the final approval of RDSO for the same will be obtained before implementation. In addition to standard inspection requirements stipulated at Clause 7 of IRS R 37, the scope of inspection by the inspecting officer will also cover the following:

1.17.1 The contractor shall, after receiving design approval from IR, manufacture two prototype cranes as per the agreed specification and offer them for inspection. The inspection and acceptance tests (detailed in para 1.17.2) on these prototypes will be conducted at the works of the manufacturer by RDSO, Lucknow (or any other nominated representative of Indian Railway).

1.17.2 INSPECTION AND ACCEPTANCE TESTS

i) Dimensional check of loading gauge, i.e. maximum moving dimensions,

coupler heights, clearances, length of the crane over headstock etc. ii) Mechanical and electrical functioning test including safety devices. iii) Rated load and speed test and overload test. iv) Brake functioning test for each motion. v) Weighment test of axle / wheel loads in train running order. vi) Stability and slewing tests on level track and super-elevated track.

vii) Tests for checking setting up time of the crane. viii) Test for negotiability on 10º curve and 1 in 8½ turnout. ix) Traveling speed test of crane with capacity load, no load and jib

lowered on match truck.

x) General inspection for any defects in welding, misalignment etc. 1.17.3 Subject to their successfully passing the tests specified in Clause 1.17.2, the

two prototypes shall be despatched for Oscillation trials and site tests in India.




One of the prototype cranes shall be subjected to site tests as per clause 1.17.4, and the other shall be offered for Oscillation trial as per clause 2.7 of this specification.

1.17.4 The cranes shall be subjected to inspection and acceptance tests mentioned at clause 1.17.2 as well as the following site tests in India after commissioning and before final acceptance:

.1 Weighment test On completion of the first crane, the weights upon each wheel of the complete crane measured at the rail in full working order with the jib resting on the Match truck, if applicable shall be ascertained by load cell. The weights upon the two wheels on the same axle shall be within a tolerance of ± 5% and the total weight on each axle shall be within a tolerance of ± 2% of the specified axle load. However, the total weight of the complete Crane and Match truck shall be within the tolerance ± 2 % of the designed weight. .2 Stability test

The cranes shall be tested in accordance with Clause 28 of IRS specification no. R 37 on track under normal maintenance conditions to establish their stability as specified in Clause 2.6.16 of this specification.

.3 Operational and Over Load Test a) Operational test: The crane shall be subjected to complete testing to establish their performance as specified in Part - II of this specification. b) Over Load test: 25% over load test on the crane shall be carried out in accordance with Clause 28 of IRS specification no. R-37.

1.17.5 The contractor shall, at his own cost, carry out any modifications deemed necessary as a result of the acceptance tests. The contractor shall also bear all costs for inspection and testing as required by the purchaser or his representative, as per terms and conditions of the contract.

1.17.6 Supply of the balance two fully assembled cranes and of knocked down

components for assembly of the four cranes shall commence only on receiving written clearance from IR, which shall be granted after the prototypes successfully pass the oscillation trials and site tests. The knocked down cranes components shall be supplied with manufacturers / supplier’s test certificates, and contractor shall be fully responsible for their performance in the crane

1.17.7 The two assembled and four knocked down cranes (other than the prototype

cranes) to be supplied against this contract, shall also be inspected at the manufacturer’s works by a nominated representative of IR before they are despatched. The inspection of these cranes would be as per clause 1.17.2 or as per mutually agreed upon inspection procedure.




PART – II

2.0 DIMENSIONAL, OPERATING AND ACCEPTANCE REQUIREMENTS: 2.1 The diesel powered self-propelling type rail crane along with single match truck

shall be of a modern design extremely reliable and robust, suitable for breakdown work and other general load lifting work. It should also be capable to handle rolling stocks in terms of both volume and weight as per Sketch – 1 & Sketch - 2 respectively indicated in Appendix - B.

2.2 The crane shall also be suitable for operation in tunnels on the Broad Gauge

(1676 mm gauge) section of the Indian Railways. The dimensions in tunnel are as per diagram 1A and 1A (Modified) of “Indian Railway Schedule of Dimensions 1676 mm gauge (BG) Revised-2004 with latest addendum & corrigendum slip”.

2.2.1 The crane shall be designed to have special type attachment like Tunnel Fork/ Hammerhead or any suitable equipment for working in tunnels. It shall be attached to jib of crane and shall have following features:-

• It shall be capable of lifting and holding a load of 80 t or more.

• It shall have provision to prevent slipping of load under lifted condition.

• Lifted load (Wagon / Locomotive as indicated in Appendix-B) can easily be pulled out off the tunnels or from top of underslung Girder Bridge in FOR condition. Wheel loads in any case shall not exceed specified limit.

• Main hoist pulley shall be capable of withstanding the forces as well as intensive wear/tear associated with pulling of entangled wagons / locomotives, including that with telescopic action of boom. Pulley shall be designed to withstand such use and rope should not jump out of the sheave.

• An anchor shall be provided to the crane to counteract the forces during pulling operation.

• Time required for attachment/detachment of tunnel fork/equipment and the location for keeping it while moving in train formation may be indicated.

• The procedure for attachment / detachment to jib may be illustrated. 2.2.2 The crane shall be of modular design with easy maintainability of assemblies for

repairs and adjustments and have features incorporated to protect the drive and control equipment to the maximum extent possible from heavy rain and dust storm prevalent in the area of operation.

2.2.3 Telescopic crane shall have provision for independent slewing of the boom

irrespective of position of counterweight. It should be possible to slew the boom to a certain angle with a counterweight staying in line with the track. This angle (maximum) and the load which can be lifted in such conditions with different positions of the counterweight and different boom radii should be specified in the offer. The microprocessor based control system should be provided with inbuilt working charts which could indicate the counterweight requirements as well as extent of telescoping on being fed with the operational requirements. In




case of overloading the microprocessor based control system should be able to invoke the safety features automatically.

2.2.4 The crane shall be with telescopic boom to have varying boom length so as to

provide versatility at breakdown site, especially in cuttings, tunnels, and under OHE, etc.

2.2.5 The crane should be provided with automatic leveling device as a safety feature. However, its control should be through a switch and not by default. It should normally be kept as by-passed.

2.2.6 The crane should be equipped with microprocessor based control and a central

monitoring system, collecting and displaying all relevant data from engine, transmissions, drives and overload protection systems. The system must be equipped with data logging for at least one month. Warning & faults when displayed must be linked to instructions for rectification through microprocessor control.

2.3 The crane should be so designed that there should normally not be a need for

slewing/ dropping of the OHE / Catenary of the adjoining track at the back end (i.e. end opposite to the jib). The relevant dimensions of the OHE used on IR is as under:

2.3.1 Minimum distance center to center of tracks: 4265mm

2.3.2 Maximum variation of live conductor wire on either side of C.L. of track: on straight: - 200

mm on curve: - 300 mm 2.3.3 Minimum height from R.L. to the underside of live conductor wire: 4580 mm 2.4 Crane shall be built to symmetrical arrangement with equal outreach in both fore

and aft directions and shall be suitable for hauling “in train” alongwith match truck on Indian Railways at operating / hauling speed as indicated in Clause 2.6.19 in either direction, without exceeding the acceleration, flange force, vertical dynamic augment 45% (1.45) and ride index limit as indicated in clause 2.7.

2.5 The crane shall be designed without relieving bogies. 2.6 The crane shall be designed to conform to the principal dimensions /

requirements etc. specified hereunder:-

Items Dimensions / Requirements .1 Track gauge 1676 mm .2 Overall Moving

dimensions (MMD) “In train” running order i.e., with jib fully retracted & lowered, the whole crane in new condition shall be within the dimensions as shown on Diagram 1D of Indian Railways Schedule of Dimensions 1676 mm gauge (BG) Revised-2004 with latest addendum & corrigendum slip when standing centrally on a level tangent track. The whole crane shall be kept within the clearances (including extras) allowed over the moving dimensions when the crane is negotiating the maximum specified




curve and 1 in 8½ turnout. .3 Schedule of Dimensions Indian Railways Schedule of Dimensions 1676 mm

gauge (BG) Revised-2004 with latest addendum & corrigendum slip.

.4 Sharpest curve to be negotiated

175 m radius. The structural component of the crane & match truck shall not infringe with wheels while negotiating the curve. Negotiability diagram for crane and match truck to be provided. The crane shall also be checked in both directions for passage over IR Standard 1 in 8½ turnout and also on 1 in 8½ turnout taking off from inside of 245 m radius curve. Drawing showing I.R.S. turnouts is appended to this specification.

.5 Super-elevation 165 mm

.6 Clearance above Rail Level

Adequate clearance shall be allowed on the crane “as built” in order that no component shall infringe the minimum clearance of 102 mm from rail level when the crane is in running condition with fully worn wheels. The tenderer shall indicate the extent of reduction in this clearance in the event of spring rigging components failure.

.7 Axle load i) Max. axle load 20t with the jib in ‘in-train’ running order ii) TLD i.e. Load per meter not to exceed 7.67 t inclusive of Match Truck.

.8 Duties for which required Mainly breakdown work; also general load lifting work including track laying of bridge girders and re-girdering, capable to work in tunnels as well as under OHE.

.9 Capacity of crane The capacity i.e. load versus outreach / radius characteristic of the crane propped up and free-on –rail condition shall be such as to meet the following duty requirements:

a) The crane in propped condition on a prop base of 6m should have a minimum designated crane capacity of 175t at 6.5m radius for 360 degree slew.

b) The crane in propped condition on a prop base of 6m shall be capable of lifting a fully loaded BCNA wagon (Ref. Diagram WD – 90030 –S-51 attached for dimensions) of 91.28t gross weight plus weight of lifting tackles in front of the crane head stock at an outreach of 8.3m with limited slewing range of 30 degree on either side of track centre line. The minimum lift required is 500mm above rail level and with this lift no part of wagon shall foul the jib or crane underframe.

c) The crane in propped condition on a prop base of 6m shall be capable of lifting a fully loaded BTPGLN wagon (Ref. Diagram WD – 93047 / 51 attached for dimensions) of 79.2t gross weight plus weight of lifting tackles in front of the crane head stock at an outreach of 10.5m with limited slewing range of 30 deg. on either side of track centre line. The minimum lift required is 500mm above rail




level and with this lift no part of wagon shall foul the jib or crane underframe.

d) The crane in propped condition on a prop base of 6m shall be capable of lifting a LHB Genset coach (Ref. Diagram SK -96077 attached for dimensions) of weight 56.6t plus weight of lifting tackles in front of the crane head stock at an outreach of 13m with limited slewing range of 30 degree on either side of track centre line. The minimum lift required is 500mm above rail level and with this lift no part of coach shall foul the jib or crane underframe.

e) The crane in propped condition on a prop base of 6m shall be capable of lifting an empty BTPGLN wagon (Ref. Diagram WD – 93047 / 51 attached for dimensions) of 41.6t tare weight plus weight of lifting tackles in front of the crane headstock at an outreach of 10.5m with slewing range of 360 degree. The minimum lift required is 500mm above rail level and with this lift no part of wagon shall foul the jib or crane underframe.

f) The crane in FOR condition shall be capable of lifting an empty BTPGLN wagon (Ref. Diagram WD – 93047 / 51 attached for dimensions) of 41.6t tare weight plus weight of lifting tackles in front of the crane head stock at an outreach of 10.5m with limited slewing range of 30 degree on either side of track centre line. The minimum lift required is 500mm above rail level and with this lift no part of wagon shall foul the jib or crane underframe.

g) The crane in FOR condition shall be capable of lifting one end of a standard diesel / electric locomotive (WAG9H / WAG7H attached for dimensions) of 66t plus weight of lifting tackles on the same track in front of the crane head stock at an outreach of 5.1m with limited slewing range of minimum 10 degree on either side of track centre line.

h) Tenderer shall submit a separate load chart for the capacities (b), (c) & (d) in propped condition using 2 props keeping all other parameters same for faster restoration while working owing to lesser set up time. In the event of manufacturer not being able to meet this requirement, he would advise the reduction in capacities with maximum achievable slew angle in each case.

i) It is desired that the capacities (f) & (g) should be available on super elevated track upto a maximum of 165 mm super elevation. The tenderer in his offer should confirm the possibility of propping the crane level on the maximum super elevated track.

j) Tenderer shall submit a separate load chart for




propped condition without any counterweight. k)

Main hoist pulley and wire rope system shall be designed to enhanced capacity for side dragging.

l) Recovery winch capacity should not be less than 80 KN pull. The tenderer must provide anchor points to connect an additional pulley to triple the capacity to 240 KN. The safety factor of the winch rope to be used must be greater than 3. The tenderer may also indicate what capacity be made available while working in a tunnel.

.10

Maximum permissible Wheel load for crane operated free – on – rail, with any capacity load at its corresponding radius

27.5 t

.11 Range of lift from throat of hook to rail level at an outreach of 13 m

Above rail level

Below rail level

10 m 4 m

.12 Tail radius 7m maximum when the crane is at 90 degree to track C.L. Counterweight shall be of telescopic design to increase the capacity and stays in line with the track when required.

.13 Propping Base & Props i) Propping base

(Width across track C.L.) 6m for all specified crane duties from (a) to (e) with intermediate propping bases of 5m and 3m with proper marking and positive locking arrangement. However, provision shall be made to extend the propping base to 7m. Load chart for the same may also be submitted.

ii) Number of Props Minimum 4 .14 Bottom of propping

cylinder in retracted condition above R.L.

Shall not exceed more than 200 mm with minimum stroke of 500 mm.

.15 Wheel diameter i) New a) 914 mm is preferred.

b) In case, a wheel of lower diameter is offered, then it should not be less than 840 mm.

ii) Condemning a) For a new wheel diameter of 914mm, the wear allowance should be minimum 80 mm on diameter. b) In case, new wheel diameter offered is less than 914mm, then the wear allowance is to be indicated by the tenderer.

.16 Margin of stability As per EN 13000 & EN 13001 or Equivalent International standard. Free on Rail 40% i) Forward stability on level

track with most adverse load and radius combinations

Propped 40%

ii) Backward stability The crane free on rail shall be stable on 165 mm super-elevated track with jib at minimum radius at right angles to the track pointing away from center of curve and snatch block resting on the ground.




.17 Operating / Motion speeds of Crane

i) Hoisting speed with capacity load upto 25t on hook.

Maximum speed not less than 15 m / min.

ii) Hoisting speed with capacity load more than 25t & upto 100t on hook.

Maximum speed not less than 4 m / min.

iii) Hoisting speed with capacity load above 100t on hook.

Maximum speed not less than 3 m/min.

iv) Rapid lowering speed (min.) with capacity load upto 25t on hook.

Speed not less than 30 m / min.

v) Rapid lowering speed (min.) with capacity load more than 25t on hook.

8 -10 m / min.

vi) Slewing speed 0.5 to 1 rpm vii) Luffing speed

(Time taken for Max. to Min. Radius)

Maximum 2 minutes

viii) Telescopic speed with capacity load in horizontal position

To be indicated by tenderer

.18 Self-propelled/ Travelling speed

i) Self-propelled/ Travelling speed with jib fully retracted in horizontal position alongwith match truck.

Maximum speed not less than 20 km / h

ii) Self-propelled / Travelling speed with no load on hook


iii) Self-propelled / Travelling speed with capacity load on hook


.19 Hauling speed Speed at which crane and match truck both can be hauled in “in-train” formation.

.1 on track maintained to other than C&M -I Vol.-I standard

100 km/h and test speed 10% higher i.e. upto 110 km/h on track comprising of 52 Kg rail, M+7 sleeper density and 250 mm thick ballast cushion. The crane shall be subjected to oscillation trials as per clause 2.7 with track tolerances given below from (a) to (d) :-

a) Un-evenness (rail - joint depression)

15 mm (inclusive) (on 3.6 m chord)

b) Twist 2.78 mm/ metre (on 3.6 m base) c) Gauge variation within + 6.00 mm d) Alignment Up to 10 mm (versine on 7.5m chord)




.2 on track maintained to C&M – I Vol.- I standard

100 km/h and test speed 10% higher i.e. upto 110 km/h on track comprising of 52 Kg rail, M+7 sleeper density and at least 250 mm thick ballast cushion. The crane shall be subjected to oscillation trials as per Clause 2.7 with track tolerances as recommended in report no. C&M - I Vol. – I.

2.7 OSCILLATION TRIAL The oscillation trial test shall be carried on Indian Railways standard track.

Track structure is given at Clause 2.6.19. The crane shall be tested at a test speed 10% higher than the operating speed as indicated above. The oscillation trials shall have to be conducted in following conditions: -

a) New wheel profile as per CSL- 3040 with Crane leading & Match truck

trailing condition and vice versa. b) Worn wheel profile with Crane leading & Match truck trailing condition

and vice versa. c) Long confirmatory run under both conditions (a) and (b). The criteria to assess the performance of the breakdown crane in oscillation trials will be as under:

.1 A lateral force lasting more than 2 metres should not exceed the Prud

Home’s limit of 0.85 (1 + P/3) tonnes, where P is the axle load in tonnes. .2 Isolated peak values exceeding the above limit are permissible provided the

record shows stabilizing characteristics of the vehicle subsequent to the disturbances.

.3 A derailment coefficient should be worked out in the form of ratio between

the lateral force (Hy) and the wheel load (Q) continuously over a period of 1/20th second, the value of Hy / Q shall not exceed 1.

.4 The values of acceleration recorded in the cab at location as near as

possible to the bogie pivot (as near as possible to axle in case of 4-wheelers) shall be limited to 0.55 g both in vertical and lateral directions.

.5 Isolated peak values up to 0.60 g may be permitted, if the records do not

indicate a resonant tendency in the region of peak value.

.6 In case of such vehicles where measurement of forces is not possible, evaluation shall be in terms of ride index, based on the accelerations measured as detailed in para 2.7.4 above, which shall not be greater than 4.50, but a limit of 4.25 is preferred.

.7 A general indication of stable running characteristics of the whole vehicle as

evidenced by the movements of the bogie in straight, station yard and curved track and lateral force and derailment coefficient or accelerations as the case may be.




2.8 SETTING UP TIME One of the important requirements of the breakdown crane is minimum set-up time for operation. The tenderer shall indicate the time required for setting up the crane in blocked condition with jib in position, from the time of arrival at the working spot, till the crane is ready to perform the following operations. Time to be shown separately for

a) Attaching the removable counterweight

b) Removing match truck and c) Setting up the outriggers.

i) Ready to lift any empty BCNA wagon (Ref. Diagram WD-90030-S-51 attached for dimensions) FOR on the same line at either end of the crane;

ii) Ready to lift a loaded BCNA wagon (Ref. Diagram WD-90030-S-51 attached for dimensions) on the same line at either end of the crane.

The Crane shall be so designed that the set up time is kept as low as possible, given that it should not be more than 45 minutes. The tenderer will be required to indicate setting up times and to demonstrate the same in actual operation. The contractor shall indicate what other measures have been taken to minimize the set up time after reaching the site.

2.9 CLIMATIC CONDITIONS The crane should be capable of continuous operation during the varying

atmospheric and climatic conditions occurring throughout the year. The range of climatic conditions is:-

Ambient temperature : -10°C to 55°C Altitude : Sea level to 1850 m. Humidity : 40 % to 100 % Dust particle in air High The contractor shall ensure that the de-rating of the diesel engine (s) is such

that the power developed at site does not under any climatic conditions indicated above, fall below the minimum required for operating conditions of the crane.




PART – III

UNDER-CARRIAGE AND MATCH TRUCK DESIGN

3.0 STRUCTURAL DESIGN 3.1 The design and permissible stresses of structural portion of the cranes shall

comply with EN -13000 & EN -13001 or equivalent International Standard.

3.1.1 Welding sequences of major structural parts of welded fabrication such as crane underframe; superstructure, jib, bogie frame etc. and radiographic standards for acceptance of welded joints in these parts shall be submitted along with the tender offer.

3.1.2 The successful bidder should provide the certificate/documents confirming to material /welder traceability of the fabrication, flaws detected in welded joint if any and corrective action thereon to the inspecting officials at the time of inspection of cranes at the bidders premises.

3.1.3 The stress relieving of welded structures should be carried out in electric or gas

fired furnace. The furnace should have the provision for automatic temperature recording. Such records should be shown to the inspecting agency.

3.1.4 In case the bidder’s design does not provide for stress relieving in an electric or

gas fired furnace, the bidder should indicate the mechanism/provisions made in the design/manufacturing process to eliminate related defects such as stress, distortion, twist etc. It should furnish the details that no crack in structures on account of these defects should be developed in future.

3.1.5 All surface to be painted should be cleaned by grit/shot blasting as per DIN

55928 Pt.4 or sand blasted to SA 2 ½. 3.1.6 Adequate structural clearance shall be ensured to avoid infringement with

moving parts. 3.2 UNDERFRAME 3.2.1 The underframe shall be constructed from rolled steel sections and/or plates

and shall be designed to withstand a maximum static squeeze test load of 400 tonnes without any signs of permanent distortion.

3.2.2 The ends of the underframe shall be designed to accommodate center buffer

coupler with transition gear generally to RDSO Sketch No. 62723 to 62727 as well as Indian Railways Standard hook type draft gear to IR Drg. No.2000/8A/M with side buffers.

3.2.3 Provision shall be made on the under – carriage to facilitate lifting by overhead

cranes, the crane complete with its under-carriage and equipment. The lifting points shall be clearly marked.

3.2.4 Crane shall be equipped with state of the art suspension blocking system when

the crane is in FOR operation. Apart from hydraulic system manual blocking




system shall also be provided. Use of wedges for this purpose shall not be permitted.

3.2.5 On both sides of the underframe collapsible / folding type platforms are to be

provided for attending crane repairs. 3.3 CARRIAGE BOGIES 3.3.1 Bogies to be provided shall be of a design well proven in service. 3.3.2 The suspension of the crane carriage shall be of a design as indicated in

Clause 2.6.19 suitable for satisfactory riding of the crane while being hauled in ‘in-train” formation, the un-sprung masses being kept as low as possible.

3.3.3 The axle-loads of each bogie shall be equalized by means of a well-tried

system of compensation. 3.4 WHEELS AND AXLES 3.4.1 Solid rolled multi-wear type heavy-duty steel wheels to IRS Specification R-19

(Latest) shall be provided. 3.4.2 For diameter of wheels of crane, refer clause 2.6.15. The use of a standard

wheel to I.R. Drg. No. W/WL- 4771 may be checked by the tenderer as a reference.

3.4.3 Thick flanges as shown on Drawing No. CSL- 3040 shall be provided on all

wheels. 3.4.4 The wheel hubs shall be provided with a device to facilitate extraction of wheels

from the axle by fluid pressure. 3.4.5 The axles shall be made in accordance with IRS Specification R-43 (Latest) and

shall be finished in consultation with the Axle Roller Bearing manufacturers. 3.5 AXLE BOXES 3.5.1 Roller bearing, grease lubricated axle boxes, shall be provided on all axles. The

roller bearing shall be designed for a L10 minimum life of 25 years, taking into account vertical dynamic augment of 50%.

3.5.2 Makes of Bearings well proven in rail traction in tropical countries will be

acceptable. It would be expected that normally bearings should not require to be attended before 8 years.

3.5.3 Special attention shall be given to the design of the labyrinth seal at the ends of axle boxes to prevent ingress of water and dirt. 3.5.4 The guides shall be fitted with manganese steel liners and the horn clearances

shall be kept to the minimum necessary to permit negotiation of the crane over the sharpest curve and turn-out specified. The clearance shall be determined in consultation with the manufacturer of the roller bearing axle boxes.




3.6 SPRING GEAR 3.6.1 The suspension system shall be such that the resonant speeds (min. & max.)

do not occur within the operating range. It shall also ensure that various modes of exciting frequencies and ride index values are within the acceptable limits (see Clause 2.7).

3.6.2 Laminated bearing springs, if used, shall conform to IRS Specification R-8 (Latest). Working stresses in such springs shall not exceed 45 kg / mm². The spring plates shall bear identification grooves in accordance with IS Specification No. 3885 or equivalent International Specification.

3.6.3 Helical springs shall be made of ground bar and shall be shot-peened after

coiling. The design stress of the spring shall be subject to approval of RDSO. 3.6.4 Consideration shall be given to the provision of safety straps or other

arrangement to prevent spring or spring-gear fittings fouling the track in the event of failure of any part of the spring gear. The springs should not home under test conditions.

3.7 DRAW AND BUFFING GEAR 3.7.1 The crane shall be fitted with IRS draw hook and side buffers, which shall be of

hinged type. 3.7.2 The draft gear arrangement shall be to Drg. No. 2000/8A/M. 3.8 OUTRIGGERS 3.8.1 The out-riggers of the pull out / swing out beam type shall be fitted with

hydraulic power operated mechanism, to enable them to be easily and quickly extended or stowed. The number of beams and locations shall be such that in one setting of the outriggers or props, a full 3600 swing with load should be possible.

3.8.2 The out-riggers shall be capable of being locked both in closed and extended

positions effectively. 3.8.3 If the out-riggers are provided with power-operated jack, they should be

additionally fitted with permanently attached screw jacks to be used in emergency.

3.8.4 Swing out type props hydraulic power operated, are also acceptable provided

they are fitted with robust hinges and stiffer and longer jacks, and lightweight support pyramids also supplied therewith.

3.8.5 Positive locking shall be provided for outrigger beams and jacks in closed

position to prevent coming out while being hauled in train formation. 3.8.6 Prop sinking indicator shall be provided. 3.9 RAIL CLIPS 3.9.1 Adjustable rail clips shall be fitted, two at each end of the under carriage on

buffer/coupler beam of the crane.




3.10 BRAKES AND COMPRESSORS

The braking system shall in general comply with EN13000 or equivalent international standard and shall also meet the following requirements

3.10.1 Air brakes capable of being operated through a control valve in the cab shall be provided on the crane for application and release of brakes when the crane is self propelled, i.e. travels under its own power.

3.10.2 When the crane is running in train formation, brake application shall take place

on crane carriage and match truck in train equipped with twin pipe graduated release air brakes. For this purpose the brake pipe and feed pipe of conventional standard dia. size and shall run throughout the length of the crane, terminating below each buffer/ coupler beam. The ends shall be provided with standard flexible hosepipes and end fittings. The necessary distributor along with brake cylinders and reservoirs shall be provided for operation of brakes. The tenderer may consider using the standard graduated release type distributor valve. The air brake system of the crane should be compatible with air brake system of locomotives, coaches and wagons being used on Indian Railways. The air brake valves should be mounted on a panel with internal grooves.

3.10.3 With full brake pressure, the nominal force on the brake shoes shall be 80% of

the maximum of the designed weight of the crane in working condition free on rails.

3.10.4 A hand brake actuated from either side shall be provided on crane as well as on

match truck for holding them on a grade of 1 in 37 while operating there on. It shall act on the wheels through the brake shoes and rigging provided for air brakes. Hydraulic brakes are not acceptable.

3.10.5 The match truck shall be equipped with automatic air brakes only. 3.10.6 Clasp type brakes with Composite shoes / Disc Brakes shall be provided. 3.10.7 The brake adjuster shall be designed with sufficient range so that the maximum

life can be obtained from brake blocks with maximum worn wheels. 3.10.8 In arranging the brake rigging, care shall be taken that it does not approach too

close to other parts of the crane/match truck or infringe the maximum and minimum moving dimensions with worn wheels.

3.10.9 Adequate safety straps shall be provided below the moving components of

brake rigging to prevent fouling of the track in the event of failure of any component.

3.10.10The hand brake shall be fitted with a safety catch to retain the brake in ‘OFF’

position and shall be fitted with indicators to show the direction for ‘OFF’ and ‘ON’ positions.

3.10.11The contractor shall submit details of brake system covering brake schematic

diagram indicating part no./ drg no. of each brake equipments / valves in the Bill of Material, working principal, literature of brake equipment, calculation of brake




power, braking distance and compressor capacity proposed, along with offer and get approval from RDSO before manufacturing of the prototype.

3.10.12 An air compressor with appropriate drive shall be provided to meet the

demands of braking, controls and other auxiliaries. The capacity of the compressor may be decided in consultation with RDSO. The drive shall be so arranged as to ensure adequate output even at engine idling speed. It is also to be ensured that a compressor governor for loading and unloading of compressor as per requirement is provided. Main/auxiliary reservoirs of adequate capacity shall be provided. In case compressor is driven separately standby should also be provided to ensure reliability.

3.10.13 Provision of air dryer of approved make confirming to Spec. No. MP-0.01.00.06

(Rev-03), March 2007 and automatic drain valve in addition to manual drain cock in main reservoir will be essential, to drain of the condensate collected in the reservoir.

3.10.14 Brake valves/equipments should be in accordance with RDSO General Spec. No. MS 005 (Revised) of brake equipments. The pneumatic valves should preferably not require overhauling before 8 years.

3.11 MATCH TRUCK 3.11.1 The match truck, if a part of crane design, will be deemed to be a part of scope

of supply for all the cranes (prototype, fully erected and in CKD condition). 3.11.2 To expedite restoration work at site, tenderer may look into the possibility of

elimination of match truck. If it is impossible to eliminate the same, then there should be only one match truck. There should be sufficient room for accommodating slings and other accessories on the crane, and the axle load shall be within specified limits. If match truck is provided, the same shall be designed to meet the following.

3.11.3 The match truck shall be a bogie type equipped with Indian Railways Standard

buffing and draw gear suitable for attaching to trains running up to operating speed as indicated in Clause 2.5.19.

3.11.4 The weight of the match truck shall be kept as low as possible so that it can be

cleared off the track by the crane free on rail in a single lift, in minimum time. The detailed procedure for this operation should be clearly indicated by the tenderer.

3.11.5 Underframe, wheels and axles, axle boxes, springs, draw and buffing gear shall conform to the requirements of Clause nos. 3.1 to 3.7.

3.11.6 Adequate attention shall be given while fixing the height of the trestle, if

provided so that moving dimension are not infringed and sufficient clearance is available between the side of the well and the jib while negotiating the curves and turnouts.

3.11.7 A toolbox of adequate size shall be provided for storing the tools and small

material handling equipment. 3.11.8 Footsteps on the sides at convenient locations with hand - rails shall be

provided.




3.11.9 Suitable storage space shall be provided on the match truck for storage of complete set of lifting tackles and outrigger pads.

3.11.10 Suitable drain holes shall be provided where rainwater is likely to collect. 3.11.11Safety chains shall be provided at suitable location.




PART – IV

SUPERSTRUCTURE, JIB AND DRIVE EQUIPMENT

4.1 SUPERSTRUCTURE 4.1.1 The platforms shall be of chequered steel plates. 4.1.2 The superstructure shall be supported on a ball or roller bearing slewing ring.

The life rating of the slewing ring shall be commensurate with the life of the crane. Attention shall be given to the method of mounting and to bolting requirements as recommended by the manufacturer of the slewing ring.

4.1.3 The superstructure sides and tail shall be rigidly connected and suitable

locking device, without chains or straps, shall be provided for locking the superstructure in position, when attached to trains. Provision shall be made on the superstructure to facilitate lifting by overhead cranes.

4.1.4 Suitable drainage arrangement shall be provided where rainwater is likely to

collect. 4.1.5 Suitable arrangement shall be provided to protect the engine and drive

equipment from heavy rain and dust storm prevalent in the area of operation. 4.1.6 Detachable or adjustable counterweights are acceptable for meeting the lifting

requirements [Clause 2.6.9 (a) to (i)]. Full details of the method of transfer of the detachable counterweight from its normal position to the tail of the crane superstructure should be furnished showing the various equipments and details needed for this transfer operation. The procedure should be amply illustrated by sketches; the time required for the operation should be stated. Standby arrangements should be provided for manually raising and attaching the counterweight in case of malfunctioning of the equipment like hydraulic jacks, Jib etc. normally used for transfer of detachable counterweights. The counterweight securing arrangement should be robust enough to withstand sudden jerk during operation with load.

4.1.7 The counterweight shall be telescopic design as already explained in para

2.2.3. 4.2 CAB AND CONTROLS 4.2.1 A stainless steel all weather proof cab fitted with safety glass suitably located

on the crane affording an unobstructed view of the load on the hook at all positions of the jib, shall be provided. The cab design should conform to EN 13000 & EN13001 or equivalent standard

4.2.2 It shall be ensured that ample headroom is provided for the operator in the

cab. Adequate ventilation and protection against sun and rain shall be ensured for the operator to enable him to work the crane under all climatic conditions. The cab should be air conditioned with provision of heater.

4.2.3 Cab should be provided with TFT display screen interfaced with the

microprocessor based control system. It is envisaged that a single display system in the form of pre configured TFT screen on the control stand, which




provide all the displays of instruments and gauges that are constantly required to be watched by the driver is provided in front of the driver at a convenient location without the driver having to move from his seat. (See Clause 5.5)

4.2.4 TFT screen with high brightness capability shall be used. Display should have

good visibility in daylight with following specification.

Resolution 800X600 pixels or better Luminance (Brightness) 400 cd/m² or better Colours 256 colours or better Visibility angle 140/120 Brightness control Manual and automatic brightness control

(based on light sensor input) 4.2.5 All control levers; foot brakes etc. shall be placed in a convenient location in

the driver’s cab within easy reach of the driver. 4.2.6 The foot pedals shall have non-slip surfaces and their travel shall not be more

than 250 mm. 4.2.7 Each control shall have an appropriate marking indicating the operation it

controls and where practicable provided with a locking device to prevent accidental engagement of the control.

4.2.8 One upholstered seat capable of horizontal and vertical adjustment shall be

provided in the cab for the driver. 4.2.9 Suitable handrails and footsteps, rigidly fixed, shall be provided to allow-easy

access to the driver’s cab. 4.2.10 An electrically or compressed air operated windscreen wiper shall be provided

on the front window. 4.2.11 One portable fire extinguisher of suitable capacity shall be provided in the cab

and one fire extinguisher in the engine and machinery compartment. 4.2.12 A lockable toolbox with a complete set of tools, for attending to power pack

and machinery shall be provided suitably in the cab. 4.2.13 The maximum noise level inside the cabin should not exceed the limit of 78

dB (A), when operated at full load. 4.2.14 A suitable communication system with latest technology with a speaker and

microphone arrangement in the cabin and single ear piece headphone and microphone arrangement for ten crane staff shall be provided so that the crane operator and staff should be able to communicate with each other simultaneously at the time of crane operation.

4.3 BOOM 4.3.1 The boom shall be of telescopic type designed to withstand all stresses

arising from service conditions including allowance for inertia or swinging of




the loads during slewing. The boom design shall take into account side dragging, which the crane may be subjected to in service.

4.3.2 The boom shall be provided with suitable arrangement for resting of the boom

on match truck, if provided, and slewing frame under running conditions, so that the boom is fully relieved of all stresses arising from the crane passing over the curves with buffers in fully compressed position and boom resting on match truck.

4.3.3 Attention will be paid to ensure that visibility of the crane driver is not

obstructed with the load on the hook at any radius on account of the boom design.

4.3.4 A complete calculation of the boom design shall be submitted for scrutiny of

RDSO in the event of an order being placed. 4.4 HOISTING GEAR 4.4.1 An efficient brake for holding the suspended load in any desired position shall

be provided in addition to an arrangement for power lowering of the loads. The arrangement should be provided for quick / emergency lowering also.

4.4.2 Additional suitable locking arrangement shall be provided for locking the

hoisting drum for holding the load in any position. 4.5 SLEWING GEAR 4.5.1 An effective slewing mechanism, capable of slewing in either direction with

maximum load on the hook even while the crane is on super-elevated track or gradient shall be provided. The slewing gear shall be capable of working in both the direction.

4.5.2 The slewing gear shall be provided with suitable brake arrangement capable

of being notched down in the ‘ON’ position so as to ensure the crane when under load will not slew of its own accord when working on a steep gradient or track with super elevation.

4.6 LUFFING GEAR (Derricking Gear) 4.6.1 Provision for gradual rising / lowering of the boom with safe load on the hook

and holding the boom in any desired position shall be made. 4.6.2 An efficient fail-safe brake capable of quick operation for controlling the luffing

gear shall be provided. 4.7 TRAVELLING GEAR 4.7.1 The crane shall be fitted with self-propelling gear capable of permitting the

crane to travel under its own power with maximum safe load permitted in free on rail condition, on the hook.

4.7.2 The traveling gear shall be provided with disengaging clutches for hauling of

the crane in train formation.




4.7.3 Arrangements to keep the disengaging clutch securely fixed while traveling coupled to a train shall be provided.

4.7.4 An indicator suitably located shall be provided on the crane clearly indicating

the sense of direction in which the disengaging clutch gets engaged and disengaged respectively.

4.7.5 The propelling mechanism shall be able to function satisfactorily:

i) When the driven axles are at maximum angularity with respect to the underframe while negotiating sharp curves and turnouts.

ii) When the wheel tread and flanges are worn out to the maximum permitted limit.

iii) When the combination of (i) & (ii) occurs.

4.8 WIRE ROPES The wire ropes fitted on the crane for hoisting shall be preferably of standard

6 x 37 {18/12/6/ 1 / F(C)} construction to IS Specification No. 2266 (Latest) or equivalent International Specification. The breaking strength of the ropes shall not be less than six times the maximum static load on the rope. Test certificate/necessary documents for the same shall be submitted by the contractor.

4.9 WIRE ROPE SHEAVES AND DRUMS 4.9.1 All the sheaves used will be made of nylon (or equivalent synthetic material)

of ample diameter and strength for the rope. The radius of the sheave groove will be just large enough to provide clearance for the rope without pinching, the pitch diameter of the sheave being more than 18 times of the nominal outside diameter of the rope. The hoisting sheaves will be provided with antifriction bearing.

4.9.2 The drums will be of alloy cast steel or rolled steel welded construction. The

hoisting drums will be constructed to accommodate, the sufficient length of ropes for the range of lift specified.

4.10 HOOK 4.10.1 The main hoist of the crane shall be provided with a Ramshorn hook of

maximum suitable capacity of crane supported on thrust ball bearing to allow free swivel even under loaded hook.

4.10.2 The hook shall be made of steel and shall be of forged construction to IS:

5749 (Latest) and IS: 3815 (Latest) respectively or equivalent International specification. Cutting of hooks from slabs shall not be permitted. Test certificate/necessary documents for the same shall be submitted by the contractor.

4.11 GEARS 4.11.1 All gears shall be machine finished and shall be designed for strength and

adequate life in accordance with AGMA/DIN standards / codes. Detailed calculations for gear stress and also heat treatment procedures, surface




hardness and surface finish values and tooth profile drawings will be submitted.

4.12 BRAKES 4.12.1 Brakes for crane motions shall be governed by EN 13000 or equivalent

International Standards. 4.12.2 The brakes provided for the different operations shall be protected from

ingress of water, grease, oil or other substances, which may have an adverse effect on them.

4.12.3 The brake lining shall be suitable for high ambient temperature of 55°C and a

suitable device shall be provided to compensate for the wear of the lining. 4.12.4 The force required for operating the brakes shall not exceed 15 kg at the

handle when applied by hand and 30 kg on the pedal when applied by foot. 4.13 ELECTRICAL EQUIPMENT 4.13.1 The electrical equipment to be provided on these cranes shall conform to

relevant standard specifications and shall be suitable for Indian climatic conditions.

4.13.2 The crane shall be provided with a generator of suitable capacity working at

maximum 32 volts (24 V Battery) for the flood lights, inspection lamps, etc. as described in the following clauses.

4.13.3 One 200 watt floodlight preferably metal halide or Tungsten Halogen type with

a diverging lens suspended in the upper part of the jib so as to light the hook and the load in all positions.

4.13.4 Two 200 watt focusing and swiveling floodlights preferably metal halide or

Tungsten Halogen type to be fitted suitably at the front of the superstructure to light the working area.

4.13.5 One 100 watt floodlight preferably metal halide or Tungsten Halogen type at

the rear end of the crane. 4.13.6 Sufficient lights complete with switch, holder, bulb and leads to illuminate the

cab machinery and engine room. 4.13.7 Suitable means shall be provided, to illuminate the instruments, gauges,

switches, etc. in the operator’s control stand. The lighting shall be glare free. 4.13.8 All wiring from the generator to the light points and plug points with the

exception of connection between superstructure and jib shall be encased in steel or plastic conduits securely clamped in suitable position.

4.13.9 Sufficient lights complete with switch to illuminate the outrigger operation and

setting area (Minimum 100 Lux). 4.13.10 Two plug points shall be provided on either side of the crane at a suitable

location for use of portable inspection lamps. Two portable electric 25 Watts




hand inspection lamps, each complete with a 20 metre flexible cable and plug shall also be supplied. The sockets provided for plugging shall be watertight.

4.13.11 Heavy duty maintenance free batteries of reputed make shall be provided for

starting the engine and other electrical load. 4.13.12 Alternator capacity should be ensured at more than the maximum electric

load in the crane to prevent battery drain with prolonged full load operation of the crane.

4.13.13 The electrical / electronic box should be stored in a dedicated compartment

conforming to IP: 65 standards. The compartment should be provided on the sides for easy access and battery maintenance. The relevant test certification for the components conforming to IP-65 standards should be provided.

4.13.14 The contractor shall provide the details of standards to which the wires and

cables used in the crane shall conform. 4.14 HORN 4.14.1 Electric horns shall be provided facing outwards at each end of the crane at a

suitable location. The horns shall be distinctly audible from a distance of at least 100 meters from the crane.

4.14.2 Press buttons placed next to each other shall be provided so that one horn or

both horns at a time could be blown by the driver. 4.14.3 The two horns will have different tones, but in harmony when blown together. 4.15 V-BELTS

In case V-belts are used, the following shall be adhered to, wherever V-belts are used.

4.15.1 Special attention shall be paid to all belt arrangements, which shall permit

easy, and quick replacement when required and which can be adjusted and replaced in service. Adequate safety guards for the belts shall be provided.

4.15.2 The size and shapes of belts selected shall be to IS Specification No. 2494

(Latest) or equivalent International standards. 4.16 PIPINGS 4.16.1 Pipes other than those subjected to hydraulic oil pressure shall conform to IS

Specification No. 1239 (Latest) medium or equivalent International standards. It will be preferable, if sizes of pipes are limited to a minimum. Sharp bends must be avoided and when necessary standard connection shall be used.

4.16.2 Pipes and conduits shall conform to standard identification colour schemes. 4.16.3 A plaque showing the identification colour scheme of the above shall be fitted

in the cab at a prominent location.




4.17 LUBRICATION 4.17.1 Provision shall be made for the lubrication of bearings and all wearing

surfaces with either grease or oil. The grease nipples shall be suitably grouped at convenient locations so as to facilitate grouped lubrication.

4.17.2 Grease nipples shall be to IS Specification No. 4009 (Latest) or equivalent

International standards. 4.17.3 Grease nipples and adaptors wherever used, shall be tack welded to prevent

them from unscrewing and falling off in service. 4.17.4 Flexible pipes used for lubrication purpose shall be suitable to withstand high

temperature conditions.

4.17.5 Automatic lubrication system should be offered alternatively.

4.18 INSTRUCTION PLATES 4.18.1 Suitable instructions plates shall be provided on the crane at convenient

locations as may be specified in the event of an order being placed. 4.19 RECOVERY WINCH 4.19.1 A recovery winch as per clause 2.6.9 (l) shall be provided with rope length of 60

m on the superstructure with suitable brake.




PART – V

POWER EQUIPMENT 5.1 DIESEL ENGINES 5.1.1. The diesel engines (Main & Auxiliary) selected shall be well proven and reliable

in service in tropical countries and preferably shall be of same manufacturer. Robust construction and low maintenance costs are of a particular importance. The make, model and series of the diesel engine selected should be reputed one and one being manufactured in India. The tenderer may either procure the engine from India or its identical equivalent manufactured elsewhere. If procured from elsewhere, the tenderer must offer an engine, which is an exact equivalent of one being made in India and further ensure that all the spares for the engine offered will be available from the Indian manufacturer.

5.1.2. The engine shall be provided with either common rail direct injection system or

high pressure electronic fuel injection system, and digital speed governing system.

5.1.3. Adequate allowance shall be made for derating of the diesel engine under the

most adverse climatic conditions stated in Clause 2.9 of this specification. 5.1.4. The tenderer shall indicate the steps taken to help in cold start while working

under sub zero condition. 5.1.5. Filters for engine intake air shall be of adequate efficiency and capacity to

ensure satisfactory performance under duty conditions. 5.2 FUEL 5.2.1 The diesel engine shall work satisfactorily with fuel oil to IS Specification

No.1460 (Latest). 5.2.2 A minimum fuel capacity sufficient for continuous operation for 24 hours shall

be provided. Higher tank capacity shall be of advantage. Sight glass type fuel measuring gauge shall be provided on the fuel tank. It should be possible to clean fuel tank conveniently. The details shall be submitted with the offer.

5.3 TRANSMISSION 5.3.1 Only hydraulic (i.e. hydro-static) transmission of approved design and proven

reliability in breakdown crane application in tropical countries will be acceptable. The gearboxes, hydraulic pumps and motors used in the transmission shall preferably be suitable for replacement by equivalent equipment / models manufactured in India without any major modification on the crane.

5.3.2 Adequate cooling capacity for the transmission unit shall be arranged so that

the maximum temperature of the medium at any time under continuous rating conditions, in the ambient temperatures as laid down does not exceed that stipulated by the Makers.

5.3.3 The components of the transmission drive system such as gearbox, etc. shall

be of robust and well-proved design. Consideration shall be given to the lubricating system so as to ensure efficient lubrication of the gears at all times.




5.3.4 The hydraulic equipment used in the crane shall comply with the requirements

of EN 13000 or equivalent International standards. The tenderer shall submit a hydraulic circuit diagram.

5.3.5 The hydraulic system should be so designed that there should be no necessity

to disconnect and connect the hoses carrying hydraulic oil under pressure for carrying out any crane operation including transfer of counterweight etc.

5.3.6 The pneumatic equipment used in the crane shall comply with the requirements

of EN 13000 or equivalent International standards. The tenderer shall submit a pneumatic circuit diagram.

5.3.7 All valves, components used should have interchangeability from outside

sources. There should be at least two sources for the same component. 5.3.8 The hydraulic system should be maintenance friendly. It should be possible to

check the hydraulic oil level with the crane in folded up condition. 5.4 COOLING 5.4.1 The cooling equipment shall be of an approved make and shall be designed for

maximum ambient temperature of 55° C. 5.4.2 The diesel engine shall be water-cooled, equipped with an overdesigned

radiator and radiator fan to cope with the service demands under the severest temperature conditions. The details of the radiator and radiator fan shall be submitted with the offer. The maximum water temperature shall not exceed 850C. The system must be adequately pressurized and vented to avoid all possibilities of cavitations. Margin in cooling capacity shall be kept for fouling of radiators in service.

5.5 CONTROL EQUIPMENT, INSTRUMENTS AND SAFETY DEVICES 5.5.1 The control system including its components should be designed to work in

Indian climatic conditions as indicated in clause 2.9. The system should have provision for fault diagnostic so that the fault can be clearly identified and corrective action taken. An internationally accepted open protocol like CANBUS should be adopted to interlink different systems like engine, transmission, joystick, hydraulic system etc. The contractor shall furnish details of the protocol to be used.

5.5.2 Adequate control equipment including gauges, instruments and safety devices

shall be provided for safe and satisfactory operation of the crane. (See Clause 4.2.3).

5.5.3 The following parameters are necessarily required to be displayed in the TFT

screen /Gauges. .1 Diesel engine:

i. Lubricating oil pressure ii. Lubricating oil temperature. iii. Cooling water temperature. iv. Service hour-meter. v. Fuel gauge. vi. Engine RPM.




.2 Hydraulic i. Transmission oil temperature. Transmission ii. Transmission oil pressure.

.3 Other gauges i. Battery charge and discharge ammeter.

.4 Indicators i. Inclinometer. ii. Radius indicator pendulum type on side of the jib

for both main hoist. iii. Safe load – Radius indicator for both free-on-rails

and propped up (on level as well as super-elevated track) conditions in side the cab will be provided.

iv. An additional lifting capacity table outside the cab is also to be provided.

5.5.4 All the parameters including those as mentioned above shall be in metric units. 5.5.5 The following audio visual signals or reference panel lights shall be provided in

the cab: i. Lubricating oil temperature too high; ii. Radiator water temperature too high; iii. Transmission hydraulic oil temperature too high.

5.5.6 The following safety devices for the engine shall be provided:

.1 No water in radiator Power to transmission cut off and engine shut down after time delay.

.2

Low lubricating oil pressure Power to transmission cut off and engine shut down immediately.

.3

Engine speed too high

Power to transmission cut off and engine shut down immediately.

5.5.7 The following safety device for safe working of crane shall be provided:

i. Microprocessor based safe load indicator with automatic cut out for working radius and conditions of utilization. The system should also give direct reading of important parameters like jib load, jib length, working radius, integrated display for SLI data, engine parameter data, counterweight position and load cum radius data, prop position data and hydraulic and pneumatic data. Option of touch screen input and display system must also be given in the offer. Manual bypass switch to be provided. The safe load indicator shall be robust and reliable in design and shall be capable of working without problem in tropical climate.

The SLI system should be mounted in a sealed box (preferably

in two units) one as a main processor and data storage unit and the second as a junction box positioned at an appropriate location in proximity to the sensors. Option of an event recording system also to be given in the offer. Recording of date and time of SLI system as bypassed and all other operating data should be possible to be recorded.

ii. Slewing angle indicator. iii. Hoist limit switch for main hoist. iv. Limit switch for luffing. v. Lowering check valves, pressure relief valves and lock valve for

hydraulic system.




5.5.8 The following safety interlocking devices shall be provided:

i. Luffing and brake. ii. Hoist clutch and brake.

5.5.9 Makers will clearly indicate the necessity of providing interlocking between the various motions, i.e. luffing, hoisting, slewing and traveling for the design of crane being offered by them. A chart showing possibilities of simultaneous operation of the motions shall be submitted by the tenderer.

5.5.10 A pump operated by an auxiliary diesel engine shall be provided to permit the crane being brought to train hauling condition in case of main diesel engine failure.




PART – VI

MISCELLANEOUS 6. LIFTING TACKLE 6.1 The following lifting tackle to be supplied along with each crane: 6.1.1 Lifting Beam

(i) One lifting beam of 140t capacity to suit Ramshorn hook, shall have sling center position at 3.4m to take Double leg wire rope or Nylon / Polyster sling & also 2 Single leg wire rope or Nylon / Polyster slings.

(ii) One lifting beam of 70t capacity to suit Ramshorn hook, shall have sling

center position at 3.4m to take Double leg wire rope or Nylon / Polyster sling & also 2 Single leg wire rope or Nylon / Polyester slings.

6.1.2 Wire Rope Slings Sl.No. Description of Wire Rope Quantity Specific Lifting Purpose 1. Special Drawbar, 4m long,

certified for safe working load of 70t to suit Ramshorn hook.

2 nos. One end of a locomotive from coupler end & other works.

2. Single leg complete with oblong link at one end & hook at other end, 6m long, certified for safe working load of 50t to suit Ramshorn hook.

4 nos. i) Overload test ( ~ 220t) ii) Capacity Load (175t) iii) One end of a loco.

3. Single leg complete with oblong link at one end & hook at other end, 6m long, certified for safe working load of 25t to suit Ramshorn hook.

4 nos. + 4 spare

i) Loaded BOY (91.4t) ii) Loaded BCNA, BOXNHS (91.28t) iii) Loaded BTPGLN (79.2t) iv) ICF Genset (63.5t) & other ICF coaches v) LHB Genset (56.6t) &

other LHB coaches. vi) Empty BTPGLN (41.6t)

4. Double leg complete with oblong link at one end & hook at other end, 6m long, certified for safe working load of 15t at an included angle of 90° to suit Ramshorn hook.

2 nos. + 4 spare

i) Loco bogies (~ 25t) ii) Empty BCNA (24.6t) iii) Empty BOXNHS (23.1t) iv) Empty BOY (20.7t) v) Match Truck of the Crane. vi) Counterweights.

6.1.3 Tenderer shall alternatively quote separately for complete sets of nylon sling/

polyester sling / equivalent as indicated in Clause 6.1.2. Nylon / Polyester slings shall have same characteristics and design parameters as existing steel wire rope slings. Tenderer should also indicate total weight of each type of sling including individual weight of its components.

6.1.4 In addition to above, the items considered essential to facilitate lifting operation

shall also be supplied with the crane. The details of such items shall be submitted to RDSO for approval.




6.1.5 The contractor shall also submit test certificates pertaining to all type of lifting tackles (complete with hook and rings) provided with each crane of this category.

6.1.6 Successful bidder will also have to provide details of indigenous sources for the

complete set of slings detailed in clause 6.1.2. 6.2 TOOLS 6.2.1 Each crane shall be supplied with a complete kit of tools, and spare parts

required by the driver in an emergency and for normal working of the crane. This will be arranged in a toolbox provided on the cab.

6.2.2 The complement of tools to be provided shall include all tools necessary for

maintenance and repair of the entire crane including specialized equipment for auxiliary and ancillary equipment.

6.2.3 All special tools shall be listed and catalogued illustrating the method of

application. 6.3 PAINTING AND MARKING 6.3.1 The crane shall be delivered fully erected and painted. 6.3.2 Specification for paints and method of painting the exterior and interior of the

crane shall be submitted to RDSO for approval. 6.3.3 The colour scheme for the exterior and interior of the crane and particulars for

marking and number plates will be supplied later. The builder shall supply colour scheme for approval of RDSO.

6.4 MAKER’S TEST CERTIFICATE 6.4.1 Copies of Maker’s certificate indicating the performance of the crane shall be

supplied in duplicate along with the delivery of each crane. 6.5 DRAWINGS, SPECIFICATIONS, TRACINGS AND PHOTOGRAPHS 6.5.1 In order to facilitate subsequent maintenance and service, the Contractor shall

supply complete set of “as made” drawings as mentioned in the table below. In case the drawings are supplied in any other version than *DWG, then the software for its conversion / reading purpose should also be supplied which would cover all the items of his manufacture. All the drawings shall be dimensioned in metric units.

Sl.No. Description Required Copies

i) Soft copies of “as made drawings” in AUTOCAD Version (*.DWG) or in Equivalent Version, Material list, Material specifications, Spare parts catalogue, Trouble shooting manual and SLI manual in DVDs/PEN drive in PDF format.

1 set each for RDSO & JMP

ii) Hard copies of “as made drawings” in superior quality Transparent Tracings.

1 set each for RDSO & JMP

iii) Hard copies of “as made drawings” in A3 size in a box folder (for reference purpose), Material list, Material specifications, Spare parts catalogue, Trouble shooting manual and Safe load Indicator (SLI) manual etc.

1 set each for RDSO & JMP & 2 sets per crane

for consignee




The drawings shall exhibit clearly the complete bill of materials (BOM) including tolerances and surface finish as per the format given below and the specifications that are necessary for maintenance, overhaul and assembly of these items by the Railways for their own use. All specifications and drawings should be hyper linked to the BOM.

Main Group Group Code Item Description

Sub-Group Sub-group Code Item Description Code template

A component classification system, if used by the contractor should be provided.

6.5.2 In case there are any proprietary items in respect of which the Contractor is unable to supply the drawings as detailed above, the Contractor shall indicate terms and conditions under which such drawings and technical know-how can be made available to the Indian Railways.

6.5.3 The drawings shall be indexed on lines of RDSO Drg. No. CS.CR – 193, copy

of which will be issued by RDSO on application. 6.5.4 Sizes of drawing sheets, general make up, nomenclature of items, schedule of

material particulars, method of projection of end and plan view etc., shall be in accordance with RDSO SK. No. CR – 424, copy of which will be issued by RDSO on application.

6.5.5 Weight of each component and of each major assembly shall be indicated on

the “ as made” tracings. 6.5.6 Welding symbols are to be in accordance with IS Specification No. 813.

Drawings on which such symbols appear are to bear a note on the bottom left hand corner “WELDING SYMBOLS to IS SPECIFICATION NO. 813 (Latest) or equivalent EN”.

6.5.7 All the detailed drawings and specification are to be dispatched with the first lot

of cranes and such delivery will not be considered complete until the same are delivered.

6.5.8 The following photographs (along with negatives) shall be supplied with each

set of “as made” tracings:-

i) Photographs of the crane with the boom resting on Match truck and with the jib raised for operations. Side and end views shall incorporate as many details as possible in the photographs.

ii) Photographs are to be taken (while the cranes are under construction) of the various assemblies and sub-assemblies. The views shall be such as to incorporate as many details as possible in the photographs.

iii) The photographs shall be of 330 mm x 250 mm size.

6.6 PACKING FOR SHIPMENT The packing shall comply with requirements of Clause 30 of IRS R –37.




PART -VII

COLLABORATION AGREEMENT 7.1 The collaboration agreement is required to transfer knowledge from the

contractor to ensure complete know-how for maintenance, trouble-shooting, overhauling and assembly of the cranes and to enable manufacture of the selected components/assembly or sub-assembly by the Indian Railways in a phased program (increasing level of local value addition during major maintenance schedules requiring replacement of the selected components/ assembly or sub-assembly) and will cover the following items –

A. Assistance in Assembly and Maintenance schedules.

Development of facilities: .1 After finalization of the contract the contractor shall depute their team of

expert to Jamalpur Workshop of Indian Railways and shall carry out a detailed study in association with Indian Railways Engineers. Based on the study, the contractor shall submit a project report within 3-6 months of the finalization of the contract. The report shall contain complete details required for limited manufacture of selected items and assembly of the offered crane at Jamalpur Workshop such as upgradation to the facilities, modification in the layout, manpower requirements, list of machines, tools, Jigs and Fixtures, test benches etc. required for assembly of the crane. The Contractor shall provide complete information required for their procurement. Contractor shall also supply activity chart for assembly clearly indicating completion time for each stage.

.2 The Contractor shall supply the BOM of crane with their Part Number

and corresponding Vendor’s Part Number for Assembly of the Crane. The Contractor shall also give source of supply of Component/Subassembly for procurement. The Contractor shall give drawing/specifications required for procurement/manufacture of the selected components/subassemblies. The drawings inter-alia would have requisite critical information for inspection of bought out items.

.3 The contractor shall give complete manufacturing drawings and

technical details of the bogie of the crane and the complete match truck.

.4 The Contractor shall give drawings/instruction sheets for the assembly of the crane. The Contractor shall give the Electrical, Pneumatic and Hydraulic circuit schematic and physical drawings for assembly of the crane. The contractor shall also give welding methods and type of electrode and complete details of other consumable required.

.5 The BOM shall be in Excel or Database format and all the

drawings/specifications shall be in PDF format. Drawing and specification shall be hyper linked with BOM or organized with some document management system. All the above documents including internationally accepted specifications shall be in English, or in case, English version is not available, a translated English version shall be provided.




B. Milestones of the Collaboration Agreement .1 Completion of design, drawings, specification etc. to the extent required

by the collaboration agreement for assembly, part manufacture and maintenance of cranes in India. The completion of this milestone shall be certified by Executive Director Standards (Motive Power)/ RDSO/ Lucknow .

.2 Successful assembly and commissioning of four cranes in India from

knocked down components supplied by the contractor. The completion of this milestone shall be certified by Chief Works Manager/ Jamalpur.

.3 Completion of the duration of the agreement viz. 10 years from the date

of signing the agreement of successful POH of first 2 Cranes at Indian Railway Workshop, whichever is later. The completion of POH shall be certified by Chief Workshop Manager/ Jamalpur.

These milestones shall be used for determining stage-wise payment against the Collaboration Agreement between IR and the contractor.

C. Training (Price to be quoted separately) .1 Training of Indian Railway Engineers in the manufacturer’s design

offices. The number of Engineers to be trained will be mutually decided before the contract is finalized.

.2 Training of Indian Railway Engineers and Artisans in the works of the

crane manufacturer and sub-contractors’ Works for limited Manufacture of selected components

.3 On the job training in solid models and drafting, specially related with re-

engineering work of the crane for Broad Gauge application.

The man days for this training as quantified in the Bid Document should be catered for under this clause. It may be made amply clear that this training is in addition to the training specified in Clause 1.10.

7.2 The collaboration agreement shall be for a period of 10 years. After the expiry

of this period, if the Indian Railways are desirous of being technically associated for a further period with the contractor, this will be so done through an agreement for such period on mutually agreed upon terms.

7.3 Deputing suitably competent Engineers to assist Indian Railways in setting up

the maintenance infrastructure of the crane. Such Engineers should be available for a period of time to be mutually agreed upon between the purchaser and contractor.

7.4 The contractor shall supervise the (assembly) and commissioning of the four

knocked down cranes in India besides carrying out quality audit and assessment of progress of crane assembly schedule, as and when required by IR.

7.5 During the assembly / maintenance of the cranes at Indian Railways Workshop

wherein items / components / spares used are as per newly identified local vendors, the crane OEM shall get the vendors assessed by their technical




delegate in terms of quality / fabrication process till first two cranes undergo Periodic Overhaul in Indian Railway Workshop. They shall also suggest remedies in case of any deviation.

7.6 Any other data / assistance necessary as per mutual agreement for assembly/Maintenance of the cranes in India.

7.7 All technical upgrades to be transferred by OEM to Indian Railways during the

currency of Collaboration Agreement. A review of technical upgrades will be carried out after every 5 years.




Appendix –A

PARTICULARS OF THE CRANE TO BE FURNISHED BY THE TENDERER AT THE

TIME OF SUBMITTING QUOTATIONS. A1 The following particulars of the crane offered shall be furnished. A.1.1 An outline diagram of the crane offered showing the main design features

indicating following particulars: - .1 Length of Crane complete and Match Truck over head stocks

……mm

.2 Length of Crane undercarriage only over head stocks

……mm

.3 Length of Match Truck over head stock

……mm

.4 Distance between axle centres of Crane

……mm

.5 Distance between axle centres of Match Truck

……mm

.6 Total wheel base of crane

……mm

.7 Fixed wheel base of crane

……mm

.8 Crane maximum width and height in relation to diagram of moving dimension and other principal dimensions

……mm

.9 Minimum height above rail level of any component of the crane in loaded worn condition

……mm

.10 Wheel diameter New/ Worn

……mm

.11 Tail radius

……mm

.12 Block up base

……mm

.13 Length of jib from centre at foot to centre of pulley at top

……mm

.14 Minimum working radius of crane

……mm

.15 Maximum working radius of crane

…mm

.16 Maximum working radius of crane with maximum load

……mm

.17 Distance between the pivot centre and the jib foot centre

……mm

.18 Distance between the jib foot center and match truck trestle center (if trestle exists).

……mm

.19 Coupler heights of the crane and match truck in running order

……mm

.20 Buffer heights of the crane and match truck in running order

……mm




.21 Position of the center of gravity both longitudinal and vertical of the crane in working order for blocked up, free on rails on level track and free on rails on 165 mm super-elevated track conditions

……mm

.22 Estimated axle loads for all the axles individually with the crane in running order & jib in fully retracted condition in “in train” running order

…….t

.23 Estimated axle loads for all the axles individually with jib in line with track center line with no load on main hook

….t

.24 Total weight of crane in running order and jib in fully retracted condition in “in train” running order

….t

.25 Total weight of crane in working order

….t

.26 Fuel capacity

….ltrs

.27 Maximum Tractive effort and Braking force for crane and its C.G height above Rail Level

.28 Maximum Braking force for Match Truck and its C.G height above Rail Level

.29 Maximum Design speed of Crane

.30 Proposed Track Loading Density for Crane and Match Truck

.31 Wheel load calculation for 0º, 20º, 30º, 90º and 180º slew

A.2 The following general particulars will be indicated separately by the tenderer: .1 Table of height of point of hook at various radii from rail level. .2 Maximum permissible side dragging angle without endangering safety.

.3 Particulars of weights of superstructure complete with boom hinge load, under carriage complete with bogies, boom tip weight and counterweights on slewing frame and undercarriage and the longitudinal position of center of gravity for each of these assemblies.

.4 Polar diagram indicating the maximum and minimum wheel/axle loads at

the various slewing positions for crane with load on hook for free on rail conditions (both on level and 165 mm super-elevated track).

.5 Propping reactions for various slewing positions of the crane with load

on hook for blocked up condition. .6 Type, quantity, location, method of storing and stowing the mobile

ballast weight, if provided. .7 Alignment of crane complete with; match truck on curves and turnout as

described in Clause 2.6.2 indicating the movement at jib foot end, if any.




.8 Visibility diagram of the load on the crane hook. .9 Stability diagram with calculations of the crane for blocked up base. .10 Stability diagram with calculations of the crane free on rails on level

track. .11 Stability diagram with calculations of the crane free on rails on 165 mm

super-elevated track. .12 Table of outreach of the jib in both fore and aft direction.

A.3 Diesel Engine(s) .1 Make …. .2 Type …. .3 Number(s) installed per crane …. .4 Operating speed at each notch and maximum speed rating ….

.5 Horse Power (Designated – short term/continuous rating) ….

.6 Horse Power at site (continuous rating) …. .7 Horse Power for auxiliaries with breakup …. .8 Horse Power available for crane operating requirements (standard and site conditions) …. .9 Maximum permissible temperature of lubricating oil …..°C .10 Maximum permissible temperature of circulating water …..°C .11 Type and details of air intake filter .12 Types and details of oil and fuel filters

.13 Characteristic fuel consumption, torque and horse power

curves over the operating speed range of the engines .14 Engine consumption of fuel oil under idling 0.25, 0.50, 0.75 and full load condition .15 Type of supercharger, if any. Supercharger characteristics

and matching engine to supercharger .16 Weight of the engine in dry and working order .17 Lubricating oil consumption figures .18 Lubricating oil sump capacity




A.4 Transmission (s) A.4.1 Hydraulic Motor and pumps .1 Make …. .2 Type …. .3 Number(s) installed per crane ………

.4 Maximum input horse power at 15 mts., ½ hour ……… and 1 hour rating. .5 Efficiency curves for 0.25, 0.50,0.75 and full load from --------- zero to 100% of main shaft speed

.6 Maximum permissible transmission oil temperature …..°C .7 Maximum pressure of hydraulic fluid …. .8 Maximum temperature d during continuous working of

15 mts., ½ hour and 1 hour. …..°C

.9 Type of relief valve provided ….. .10 Weight of transmission, empty and in working condition ------ .11 Specifications for hydro-static pumps and motors …. .12 Specification of hydraulic oil …. .13 Specifications of hoses, seals land other rubber items …. .14 Permissible leakage rate …..

.15 Approximate life from point of view of wear of plunger/piston ….. .16 Items requiring renewal during major overhaul ….

A.5 Drive Equipments

.1 Torsional vibration analysis and matching calculations of diesel engine with rotating components

.2. Mode for transmission between different drives for various motions with schematic diagram of the complete drive indicating the ratio of speeds …. .3 Methods of reversing the motions …. .4 Make and type of clutches including details of application release …. .5 Make, type and friction coefficient of clutch lining, if provided ….




.6 Make and type of brakes for automatic/ manual braking for each motion and interlocking provided …. .7 Make and type of brake lining, if provided …. .8 Expected life in working hours of the gears used ….. .9 Table of make and type of shaft bearings used and their expected life. A.6 Cooling Equipment .1 Make and type (both for diesel engine and transmission) …. .2 Heat dissipation requirements of the diesel engine …. .3 Heat dissipation requirements of the transmission …. .4 Make and type of thermostatic controls, if any, brief description …. .5 Weight .…Kg A.7 Bogies A.7.1 Crane and Match Truck Bogie

1. Detailed drawings of the bogie fully illustrating the system of suspension ….

2. Weight of bogie ….Kg A.8 Axle Boxes .1 Make .2 Type .3 Bearing particulars A.9 Boom .1 Type of construction …. .2 Particulars of boom foot …. .3 Material …. .4 Weight and C.G. location …..Kg ….m




A.10 Ramshorn Hook .1 Make and type ….. .2 Material ,…. .3 Mode of manufacture ….. A.11 Wire Rope (Hoisting)

S.No. Item Hoisting

.1 Diameter of rope

…… mm

.2 Number of strands

…..

.3 Number of wires in each strand

……

.4 Diameter of each wire

….mm

.5 Breaking load of each wire

……Kg

.6 Description of core in strand

……

.7 Description of core in rope

……

.8 No. of twists per 300 mm of strand

……

.9 No. of twists over 300 mm of finished rope

……

.10 Breaking stress in each strand

……N/mm²

.11 Diameter of drum round which the rope will safely work

.…mm

.12 Diameter of drum of reel round which the rope will be coiled for shipment

.…mm

.13 Ratio of diameter of drum to rope size

……

.14 Ratio of diameter of pulley to rope size

……




A.12 Out - Riggers .1 Type – Pull out or Swing out …… .2 Time required to extend the outriggers from closed position to specified block up base …… .3 Method of locking the outriggers, both in closed and open position …… A.13 Buffers & Couplers .1 Make and Type …… A.14 Compressor(s) .1 Make …… .2 Type …… .3 Number(s) installed per crane …… .4 Maximum pressure …… .5 Capacity (litres/minute-swept volume) at idling speed of the engine and at full speed …… .6 Speed ratio to engine speed …… .7 Method of drive …… .8 Weight …… .9 Power consumption …… A.15 Crane Brakes A.15.1 Air Brake

.1 Make .2 Type .3 Number of cylinders .4 Diameter and stroke of cylinders .5 Brake power .6 Schematic diagram .7 Weight




A.15.2 Hand brake .1 Schematic diagram .2 Ratio of leverage .3 Brake power .4 Weight

A.16 Control Equipment

Complete description / schematics of working of control system for the hydraulic system. .1 Make and type .2 Table of applied torque and restraining torque on brake drums of

hoisting, luffing and slewing mechanism.

.3 Schematic diagram for operation of various clutches indicating leverage ratios, if lever used.

.4 Schematic diagram for operation of various drive brakes indicating

leverage ratios, if lever used.

.5 Method of interlocking between luffing clutch and brake, slewing clutch and brake, travel clutch and brake.

A.17 Electric Lighting Equipment

.1 Make, type and wattage of jib flood light …… .2 Make, type and wattage of side flood light ……

.3 Detailed schematic diagram ……

A.18 Batteries

.1 Make …… .2 Type ……

.3 Number of cells per battery and total no. of batteries ……

.4 Capacity in ampere-hour of the battery on 10 hr. rating basis. …… .5 Size (overall dimensions) ……

A.19 Operating Performance of Crane

.1 Table of radius and safe load, which can be lifted and slew for propped condition.




.2 Table of radius and safe load, which can be lifted, slewed and traveled with free on rails, on level track and free on rails on 165 mm super-elevated track conditions.

.3 Table of load, Radius and Hoisting speed.

.4 Table of load, Radius and Slewing speed.

.5 Table of load, Radius and Travelling speed with load on hook.

.6 Table of Radius and Travelling speed, without any load on hook.

.7 Table of time taken to luff the boom from one radius to the other and

from maximum radius to minimum radius and minimum to maximum angle, for both, with and without load conditions.

.8 Horse power analysis, engine output, input to transmission and

horsepower for auxiliaries.

.9 Engine consumption of diesel fuel oil under idling 0.25, 0.50, 0.75 and full load condition.

A.20 Name & address of manufacturers of the following components /

assemblies

.1 Wheels and Axles. .2 Roller bearings (separately for axle journals and other locations)

.3 Important steel castings

.4 Telescopic Boom

.5 Hooks

.6 Wire ropes, Wire rope slings & Chain slings

.7 Outriggers

.8 Compressor (s)

.9 Brake equipment

.10 Cooling equipment

.11 Storage batteries

.12 Diesel engines

.13 Alternator and Transmission equipment

.14 Drive equipment and Control equipment

.15 Safe load indicator

.16 Match truck




Appendix – ‘B’

List of Drawings

S.No. Description Drawing Nos.

1. Diagram showing MMD for BG locomotives as per SOD, Revised 2004 with latest amendment.

Diagram 1D

2. Standard dimensions for tunnels & through girder bridges as per SOD, Revised 2004 with latest amendment.

Diagram No. 1 A

3. Standard dimensions for tunnels & through girder bridges as per SOD, Revised 2004 with latest amendment.

Diagram No. 1A (Modified)

4. Finished IRS tyre profile CSL-3040

5. Main dimensions of turnouts RDSO SK. DL. 459

6. Diagram of standard covered bogie wagon type “BCNA” WD- 90030 –S-51

7. Diagram of standard “BTPGLN” wagon WD - 93047/51

8. Diagram of standard LHB IR coach SK- 96077

9. Loco Outline Drawing of WAG9H locomotive SK EL - 4547

10. Diagram showing lifting of LHB coach at 13 m outreach Sketch - 1

11. Diagram showing lifting of BCNA Wagon at 8.3 m outreach Sketch - 2


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