e504 ‘SCHEDULE- (ll) LIST OF MAINTENANCE SPARES SN Description ‘aty Remarks Electrical control — gears (push Uni cost — oF buttons, selector” switches, | 9,4, gy | machine wil be 1 Jcontactors, relays, MOBs, MccBs, | .2"°.°F, | inclusive of cost MPCBs, Mlumination lamps, 'yPe | of spares Emergency switch, meters) ‘SCHEDULE- (II List of Mai ‘S.No. Description ay O1,__| Toolbox (one set Consisting off ‘Tho (02 | DIE Spanners required sizes. TSet 03 | Grease gun No. of ‘can TN. 05 | Serew Driver of required sizes TSet 06 Nose plier No. ‘07 [Insulated plier TNO. 08 | Hammer 2 bs TN. 09 Allen Key required sizes 1 Set 0 | Screw Wrench No 11 | Multimeter "No 72 | Calibrated residual magnetic Weld ndicator inthe in range | 7 set of 0-10 Gauss Ketos ring as per ASTM E1444-05, 13 | Field indicator (pie gauge) as per ASTM E 1444-05 Tho. "r4__| Magnifying glass (magnification 10x) - 2 nos. 2no. 15 _ | Hall Effect Gauss meter (as per ASTME-1444-05 Tho. Standard) Note: ‘One set of above Maintenance Tools is required with each Machine. Unit cost of machine will be inclusive of cost of Maintenance Tools. Be Fer ie eehihray For Chit Mechanical Engineer DENS Viststop Paps ada nem fs < : oes, Indian Ri te AE hays, Patna. (uumen}e | tender no, 2021-WP-BPL-Mech-WT-18(OPEN) gnature of , JSS)000402 esas rhre Spec no. Spec no. WP/Mech/M&P/BPLIMTMCBC tem No. 05 SPECIFICATION FOR MAGNAFLUX TESTING MACHINE FOR CBC DRAFT GEAR OF LHB COACHES 1.0 Scope 4.1 The scope of supply shall include design, manufacturing, supply, installation, testing, commissioning and proving of 01 no, Magnaflux Testing Machine for CBC Draft Gear of LHB Coaches as per parameters specified in Schedule with all accessories, spares etc and shall be supplied at CRWS, Bhopal, WCR, Madhya Pradesh, India as per instuctions and conditions of contract. it shall also include installation and commissioning of related equipment, training of personnel in operation and ‘maintenance of machine and supply of technical documentation. Sources: Likely sources of manufacturers and suppliers are~ (i) M/s ITW Signodes, Hyderabad (il) M/s Toshniwal brothers, Delhi (il) M/s Dyeglo, Pune (iv) Mis Vector Nat., Bangalore (v) Mis K-Electronics, Mumbai Note: Bidders may quote for any of the reputed brands from the above likely sources. However, makes quoted other than ‘Likely Sources’ can also be considered in case enough documentary evidences in support of proven design, successful supply, satisfactory performance in Railway Industry, adequate manufacturing capacity, established quality norms of Railways or similar heavy industries are submitted, 20 General Description and Scope of Supply: 2.1 One (1no) ~ Magnaflux Testing Machine for CBC Draft Gear of LHB Coaches and all accessories, spares and supports structures. 2.2 Allrelated material required for inspection, erection and commissioning of Machine and connecting electrical equipments with cables, cable laying and fixing accessories shall be included in the cost of basic Machine. 2.3 Necessary information regarding the conditions under which the Magnaflux Testing Machine for CBC Draft Gear of LHB Coaches is to be used, together with other particulars necessary for manufacture and commissioning of the machine, are given in ‘Schedule-l. Sub mission of Catalogues, specification and related drawings for approval to Railways by successful bidder. 2.4 tool box containing all tools (Electrical and Mechanical) requited for the maintenance of the Magnaflux Testing Machine for CBC Draft Gear of LHB Coaches should be supplied with the machine. Unit cost of machine will be inclusive of cost of too! box. 2.5 Technical specifications of M&Ps are to be read and followed in unison with Special Conditions of Contract for Mechanical Works specified in Tender Document. 2.6 Civil work including foundation (if any) for said machine shall be in contractor scope. The cost of machine foundation will be inclusive of cost of machine. 3.0 Purpose and Capability: 3.1. The magnetic particle testing equipment shall be capable of testing of CBC Draft Gear of BG- LHB Coaches as per maximum dimensions given in Schedule-I 3.2 The equipment shall be capable of detecting surface and sub surface cracksiMlaws/seamsilapstfatigue cracks up to at least mm as specified in Schedute-t 3.3 The equipment should have suitable arrangements in the form of electrically operated hoist mounted on swivelling arm capable of lifting and loading components. having weight 200 kg max as specified in Schedule-I. The arrangement shall located near the machine head and willing arm capable of rotating in, “8 per iPr MlggeggPonent canbe loaded onthe machine at processing station For Chief Mechanical Engineer \ Fnigearar fait taney 283 '¥e/BPI-Mech-WT-18(0PEN) ighature J ostop Foes, Indian Rays, PalnaPage 335 “400, 4 0 3 ‘The equipment shall be able to produce a tangential magnetic field strength of at least 30 gauss or (30x10'4 Tesla) in unidirectional magnetization on the surface of largest dia. component as specified in specification when measured on the part surface with a hall effect probe gauss meter as per ASTM E 1444-16 or latest. ‘The equipment should have suitable arrangements for loading test component at processing station, clamping in copper pads, magnetisation, spraying of fluorescent magnetic solution, rotation of the test component, inspection under ultraviolet light, demagnetisation, declamping and discharge at single stage. Specific details about lining and positioning of heavy components with the help of swivelling arm or other arrangement shall be clearly defined with diagrams /sketches of the arrangement offered. The equipment should be capable of creating multi directional magnetisation namely, circular magnetisation to detect fongitudinal flaws and longitudinal magnetisation for detecting transverse/circular flaws along with non-contact mode also, ‘The crack detector shall have infinitely variable accurate current range and fast response. The circuit shall be provided with automatic constant current control arrangement so that magnetisation current is maintained at preselected value, within limits of magnetisation circuit capacity to eliminate field changes due to variations in ‘contact resistance between the workpiece and copper pads. The stepless current ‘control should also be usable for ACIHWDC (Half Wave DC)FWDC(Full wave DC) decay demagnetisation. Details of the circuits should be clearly explained. The electric circuit should be designed for a duty cycle factor of 0.5. The circuit should be capable of continuously carrying the maximum current available for a period of atleast 5 seconds without overheating ‘As the temperature at the site may vary up to 50°C andiwith relative humidity of 100%, the tenderer should clearly confirm that the machine would work satisfactory in above environmental conditions without any deterioration of the detection limits. ‘Two axis type U-V lamp assembly should be equipped on machine in such a manner so that it can move along with the object and across as well should be included. Operating panel should be separate. Concomitant Accessories: ‘The machine should be accompanied with the following concomitant accessories. (@) | Pneumaticaily operated Central conductor of copper (for circular = 1500 mm length for magnetization of hollow parts and springs) tno, ASTM Glass centrifuge tube for suspension concentration testing with M.S. stand Copper braided contact pads for components 4sets/Bnos 1 set Black light with swivelling mounting fixtures 1 set A set of single contact prods with § m each of connecting cables | 1 pair Fluorescent magnetic powder (water based) 5 kgs Hand held ultraviolet lamp with 100watt bulb with a Kopp UV filter and spot focused reflector UY protection goggles with double antiglare coating from both sides and black industrial frame with side covers. (| Magnifying glass (magnification 10x) 0) | Plastic squeeze bol for spraying liquid (k) [Black Roxine folding hood ® [pores Cables (Score) stool braided Ea Fea aif ehh «Ea i vi mr snoren| ooosoa ras Calibrated residual magnetic field indicator 0-10 Gauss set Ketos RINGS as per ASTM E1444-16 or latest ino | Field indicator (pie gauge) as per ASTME -1444 16 ino Hall effect gauss meter as per ASTM-1444-16 standard ‘Ano UY protection cream (Make to be specified by the bidder) 5 Kgs. Air Compressor of 2HP, Shaft driven with auto drain facility and cntine fier of Eli 'Vayu’ make or equivalent capable of delivering clean, dry air at a pressure of 6 to 8 kglom’ alongwith tno storage reservoir of capacity not less than 4 litres. Max water content-30PPM, supply line 0.Sinch (8) | Electrically operated Jib crane 1 ton capacity tno. 42 Apart from the above concomitant accessories, any other accessory/equipment essentially required to make the machine fully operationallfunctional when installed and ‘connected to power source, enhance the detection limit or productivity of the machine shall also provided without any extra cost. 43 Performance Standard: ‘a, The performance of the equipment shall be demonstrated as per ASTM E-1444-16, or latest relevant standards. b. The performance of the magnetic particles shall be tested as per ASTM E-1444 -16 or latest. The particle and suspension shall conform to ASTM E-709 or latest relevant standard, 4.4 Productivity RequirementiCycle Time: a. The bidder shall furnish the estimated floor-to-floor time of all operations for the ‘components listed in Specification. ‘The basis of the timing should be clearly given with break up of all the parameters, The timing should be maintainable for regular 08 hrs shift for Double shift working 6 days a week with machine availabilty of 85%. d. ‘The manufacturer! tenderers shall furnish the productivity requirement for complete crack detection operations on different types of Test Components as listed in technical specification 5.0 Basic Design Features: 5:4 Specific Characteristics: 5.1.1. The equipment should be of robust design for heavy duty and continuous working. The structures should be suitably treated (such as phosphating) for rust prevention. The ‘working area and the drip tray should be made of stainless steel. 5.1.2. A separate control cabinet containing PLC based system and complete electrical and electronic components should be provided with clear indication of different functions, operations and adjustment of magnetisation currents, Control console shall be piaced suitably for easy access to the operator. All controls should be ergonomically designed, ‘The control panel should have a lockable plexiglass cover. 5.1.3. The equipment should have, but not limited t, the following safely features: a) Elecironic timers to cut off high current a preset duration, b) Emergency switch off arrangement «)_ Protection against fre/heavy sparks. i) Low and over voltage protection. i) Single phase preventer ii) MoE 4) Any other safely item which the manufacturer considers essen) aa nen alte aR For Chief Mechanical Engineer saree aa incg20@) TOAOPL-Mch:WT-16(OPEN) shag Projets, dan Rays, Pane _dQ “46405 5.2.1 The operation provides clamping of components In copper pads followed by ‘magnetisation, 5.2.2 For clamping of components, the processing station should be provided with suitable shaped fixture, which should be mounted on headstock and tail stock. The tail stock position should be adjustable by means of electrically operated lead screw for catering the different range of test component lengths. The arrangoment provided for tail stock adjustment should be indicated along with description and diagram(s). 52 52.3 For clamping of components the processing station should have headstock and tail stock arrangements. The tail stock position should be adjustable by means of electrically operated lead screw controlled by VFD (Variable frequency drive) for catering the different range of test component lengths. The arrangement provided for tail stock adjustment should be indicated in the offer along with description and diagrams). the following controls should be available: 41. Speed Control 2. Continuous OOf Control 3. Reverse forward control 4. inch forward and reverse control 5.2.4 The headstock should have pneumatically operated cylinders for gtipping the components between replaceable copper pads. The gripping action should be automatic once "Cycle Start Switch” is pressed. In manual mode a foot operated pedal ‘switch shall control gripping action. The foot paddle switch should be designed for safety. Once initiated for gripping, the paddle can be released. A second pressing shall be required for release. Alternative arrangements for gripping of test components between copper pads in manual mode may be offered if considered superior by the bidder. 5.2.5 The induced circular magnetisation shall be provided by means of Threading Bar method, for hollow components, while a circular yoke with adequate number of turns. shall be provided for solid components. The dotalls of the system offered should be explained along with diagram, 5.2.6 The magnetisation current should be switched on after the components have been Stipped (manual or automatic) for a predetermined time period. To avoid peak loading of the main supply, current should gradually achieve preset value in about 20 mill seconds after switching on. Ammeters should be provided at suitable locations, 10 measure magnetisation currents, so that the operator has full view of these during ‘machine operation. The ammeter should have full § digit display. 5.27 The magnetization current should be step less and within requirement of sub-clauses of ASTME 1444-16 with safe open voltage from 6V to 27 volts.. ) 5.2.8 The supplier shall give complete details of a) The type and magnitude of magnetising current used b) Method of establishing the magnetisation using prods, yoke, head shot or coils etc. ©) Direct magnetisation, induced magnetisation, multidirectional _magnetisation, Continuous magnetisation ete, (whichever is most effective for testing components under consideration). 4d) Demagnetisation method used, €)_ Indication of magnetisation current, residual magnetisation and demagnetisation in the control panel, 5.3 Inspectio 5.3.1 This operation provides wetting by manual fluorescent spray and controlled rotation of test components for inspection. 5.3.2 For spraying fluorescent magnetic particle suspension, a hand held gun should be provided. The gun should be leak proof, to avold electrical shock to the {gun should be placed on a suitably designed anchor/hook when not in ui rd Ba BE REHhoch WT-10(0PEN) For Ciet Mechanical Engineer hop Proje, nan Ratays, Paina5.3.5 536 53.7 53.8 53.9 54 641 54.2 543 5.4.4 545 55 54 For Chief Mechanical’ tama OR APLEPL Mech WT-8(0°EN) op Projects, Ieian Reways, Patné Rt Wor a ager aiPI SOTA withthe help of residual magnetic field indicator provided Page 338 of 445 ‘The manual operation of spray gun, nozzle flow control and safe anchoring of gun shall be ergonomically designed and should be indicated in a sketch, Independent motorised rotation arrangement for test components should be provided through a reduction gearbox towards head stock and tail stock side for easy rotation of the test components in clamped mode. The rotation of head stock and tail stock should be synchronised with interlocks. The speed of controt should be through variable frequency controller. a) For irregular shape of components it should rotate on either side. In the case of heavy component it should not fall on the machine table and b) For round components, it should be resting on three moveable rotating support rollers during inspection. A foot pedal or push button should be provided to start and control the speed of test components rotation. A foot pedal or push button should be provided to start and control the speed of test components rotation. The test component should be rotated at ‘a speed of 0 to10 RPM. The rotation operation takes place only after magnetization ‘operation is over. For effective inspection, the area should be covered with a biack fabric reinforced Rexene hood with exhaust fan. Normal 24 V lights should also be provided for Visibility. The hood shall be of sliding type for easy movement of test components and operator. ‘The ultraviolet light intensity at work should not be less than 2000 W/ cm* when measured with suitable backlight meter. The light shall be as per of ASTM E 709 or related latest standard. To avoid unnecessary reflection of ultraviolet light from the test surface a band pass fiter designed to pass light of wavelengths between 5500 Angstrom to 6000 Angstrom should be provided for use during inspection. Counters should be provided to have a count of total number of components tested clearly giving the break-up of rejected and accepted components during a shift, Each shift comprising of 8 hrs. each. Tank Assembly for Storing Magnetic Suspension: ‘The tank assembly with SS tray for storing the magnetic fluid’ Kerosene suspensions should be fabricated out of stainless stool of not less than SWG14 conforming to IS- 6911-1992 or latest, suitably reinforced so that it is robust and sturdy. The tank shall be provided with a level indicator gauge to indicate the fluid level in the storage tank (capacity approx. 40 liter). The tank shall be provided with proper ports for ease of maintenance, cleaning draining out and replenishments of magnetic fluid. ‘The storage tank shall be provided with a suitable circulationlagitation system capable of maintaining the quality of the magnetic fluid without degenerating the fluorescent particles, Use of air for agitation will not be acceptable. The bidder shall explain the system in details along with supporting literature and diagrams/drawings. ‘The centrifugal pump used in equipment should be of reputed make and shall be specially designed to spray fluorescent magnetic powder suspended in kerosene without any wear and tear. The make of the pump and material of impeller shall be furnished. Main body of the pump and its assembly shall be designed from suitable material to eliminate or reduce the destructive effect of magnetic bath at the working temperature. ‘The type and design of the pump should be indicated. ‘The pipeline used in equipment from pump to spray nozzie shall be flexible type and suitably braided to prevent damage to the pipe due to extensive utilisation. The braiding material shall be such so as to minimise rusting/staining, Demagnetisation: Suitable Dernagnetisation shall be provided to eliminate the residual magnetism in the test components. The effectiveness of demagnetisation operation should bert be 7ee Page 339 of 445 | 000407 5.5.2. The bidder shall clearly indicate the type/method of demagnetisation to be used for test components after testing. The detailed explanation along with diagram(s) to be furnished by the bidder. Controls: A separate ergonomically designed control cabinet, containing the PLC based system; complete electrical and electronic components should be provided. Equipment Maintenance - a) The PLC controller inside the equipment should have automatic self diagnosis system for repair assistance. All the operation of PLC should have closed loop feedback system for checking the stalus of internal components of the equipment, ‘When any component malfunctions the PLC should be able to recognise the problem and provide solution on the display screen. ‘The PLC system should have following feedback system 1) Clamp contact control: for checking the contact of headstock and tail stock with the test component. ii) Head shot AC/ HWDCIFWDC contactor control: for checking the contact of contactors. lil) Induced shot AC/ HWDG/ FWOC contactor control: For checking the contact of contactors. iv) Input supply operation range: Input should be taken from single phase Preventor for the input supply range i.e. 418V 210%. ©) In event of any failure the PLC should be able to recognise the fault and immediately switch the equipment to shut down mode to prevent any accident and provide the solution on the screen for repairs. Suitable audio! visual buzzer should also be provided for the purpose, ‘The control panel should be adequately labelled for various functions being controlled from the panel for ease of recognition and operation by the operators and maintenance staff ‘The control panel should be easily accessible by the operator and maintenance staff ‘a) The control panel should have a lockable plexiglass cover. It should consist of, but ‘ot limited to the following controls: b) Ammeter- to indicate amount of output current. ©) Switch (preferably foot switch) - to control clampingideclamping action of head stock Pump switch - ON/OFF switch to operate the pump motor. Black light switch - ON/OFF selector switch to operate prefocussed black lights (if provided). Magnetising current ‘ON’ Pilot Lamp - to indicate the duration of flow of magnetising current. De-magnetising ‘ON’ Pilot Lamp - to indicate the duration of flow of demagnetising current. ‘h) Supply Pilot light -to indicate input supply. ji) Magnetising current - to increase or decrease the output current switch 1) Master switch - Red coloured mushroom type master emergency switch capable of ‘witching off the machine in any exigency. Equipment operation cycl The general operation cycle sequence of the equipment shall be clearly defined in the offer. Operation cycle sequence for different items shall be described separately. The bidder shall furnish estimated cycle time required for testing components as per maximum dimension indicated under schedule-I, Rl yer aie etitay E tehide Ghietddestwnrost :WT-18(OPEN) Brera vivo, ada ta, Tea000408 ir vohiae 5. 5.8.1 582 59 60 64 62 x wat en aia eaten For Chief Mechanical Engineer y, ae Ra, TET ‘orks Pees ean RORS, RASEPL-MectAVT-16(OPEN) prea afta Component Rotation System: Independent motorized rotation arrangement for various test specimens as specification should be provided through a reduction gearbox towards head stock and tall stock side for easy rotation of these test components in clamped mode. The rotation of head stock and tail stock should be synchronized with interlocks. The speed Of control should be through variable frequency controller. |) For round components, it should be resting on three moveable rotating support rollers during testing/ Inspection |i) For irogular shape of components, it should rotate on either side. In the case of heavy component it should not fal on the machine table. A foot pedal or push button should be provided to start and control the forward, backward, inching and speed of rotation of the test components. The test component should be rotated at a speed of 0 to 10 RPM. The rotation operation takes place only after magnetization operation is over. Component Transfer Devic i) Provision of jib crane of 100 kg capacity with chain and hooks for loading and unloading of the components with required structure to meet the productivity of ‘machine. ji) The device shall be of reputed make like Demag, Ingersoll, DC, Indef etc. and should be able to handle all types of components (within the dimensions) as indicated in the specification General Characteristic: Rigidity and Stability: |) The machine shall be robust, rigid and of sturdy construction. It shall be designed to meet heavy duty demands of various operations on the machine under normal ‘Workshop environment for such machines. It shall be free for vibrations even when ‘working at full capacity. ii) All machine castings shall be made of close grained high grade cast iron like Mechanite or equivalent materials meeting IS-210 Standards to ensure durability and rigidity, The casting shall be thermal stress relieved to ensure stability and continued accuracy. ii) All machine fabrications of critical load bearing assemblies like beds, columns etc. shall be adequately strengthened and stress relieved. iv) Change in ambient temperature shall not affect the performance of the machine. vv) There shall be no change in the performance of the machine either on switching on the machine or after continuous running, vv) There shall be no resonant vibrations throughout the working range of the machine at all load levels. Lighting: |) Integral lighting suitable for the operations concemed where Its lack is likely to ‘cause a risk despite ambient lighting of normal intensity shall be provided. li) The manufacturer must ensure that there is no atea of shadow likely to cause nuisance, that there Is no irritating dazzle and that there are no dangerous stroboscopic effects due to lighting provided by the manufacturer. lil) Integral parts requiring frequent inspection and adjustment and maintenance areas must be provided with appropriate lighting iv) The machine lighting should be of low voltage so as to prevent any hazard to the operator.Seta Page 342 of a5. 000409 63 Machine Maintainability: |) The machine shall be so designed as to require minimum possible maintenance and to give trouble free service. li) All assemblies/parts of the machine shall be easily accessible for maintenance. ili) The machine shall not requite major dis-assembly for checking and replacement of patticular part, especially for parts requiring periodical check up and replacement. |v) The manufacturer must provide means of access e.g. stairs, ladders, cat walks ete. to allow access safety to all areas used for production, adjustments and ‘maintenance operations. 6.4 — Wear Compensation Adjustment: The original built in accuracy of the machine shall be capable of being maintained conveniently and economically by suitable adjustments for taking up wear on slides, bearings and load screws. The system of adjustments incorporated shall be explained inthe offer. 7.0 Technical Literature: 74 One copy of the printed ilustrative catalogue showing features of the machine and its elements shall be furnished 7.2 The technical literature shall be provided for the complete machine, including imported {and indigenously purchased components / sub- assemblies. The successful tenderer will have to furnish 4 (four) copies each of the following manuals directly to the consignee along with the machine, Out of these 04 sets, the bidder shall be required to submit one set of all documents in best available condition one month prior to the training for the machine. One set of technical literature should cover the following details (where ever applicable) a) Operational & Maintenance manual of the machine. b) Operational & Maintenance manual of the servo controlled voltage stabilizer. ©) Operational & Maintenance manual of the ulra-isolation transformer. 4) Instruction & Maintenance manual for Hydraulic Oil Cooling Unit. €) User manual for Tool changer system (if provided). ) Technical & Maintenance manual for Hydraulic System. 9) Technical & Maintenance manual for Lubrication System. hh) Operator Guide for CNC Control System (if provided). i) Programming Guide for CNC Control System (if provided). J) Diagnostic & Trouble shooting Guide for CNC Control Systom (if provided). k) Start-up Guide for CNC Control System (if provided). 1) Machine Software Listing (if provided). m) Soft and hard copies of PLC Program in ladder form with cross reference listing ‘and PLC project fle 1n) Drawings of tooling & fixtures, hard copies in A-2 size as well as soft copy in POF format. ©) Witing diagram, in which length of wires must be mentioned, hard copies in A-3 size as well as Soft copy in POF format. P) Mechanical drawings (spindle assembly, table @ 4) ssombly, column assembly), hard copies in A-1 size as well as soft copy in POF format. 1) Spare part manual including part lists no., hard copies in A-4 size as well as in POF Format 8) Lay out drawings in A-1 size, which clearly shows the position of all type of electrical Components in machine. Note: All manual and literature should be in English/Hindi. Mechanical000410 10.0 104 ae aor Workshop Projets, Idan Ralways, Pato ‘Spares & Maintenance Tools: List of recommended spares required for the maintenance of the machine should be supplied along with the machine as per Schedule-tI. Unit cost of machine will be inclusive of cost of spares, Tool boxes containing all tools (Electrical and Mechanical) required for the maintenance of the machine should be supplied along with the machine. Tools shall be ‘supplied in two different tool boxes, with individual pocket for each item and shall be of MEKASTER/TAPARIA or reputed ISI make as per Schedule-Ill. Unit cost of machine will be inclusive of cost of tool box, Inspection and Testing at Manufacturer's Works 1a) The inspection of machine shall be carried out by Railways/authorized Raiiway Representative. b) A load test and functional test like no load test and maximum Horse Power test must be carried out at the manufacturer's works to check the machine with respect to the purpose and capability requirements to the satisfaction of the appointed Inspecting Agency. Rigidity of the machine shall be demonstrated to the salisfaction of appointed inspector or inspecting agency. ) Manufacturers must have adequate facilities at their works for carrying out the Inspection. The bidder shall clearly confirm that all faciliies exist and shall be made available to the inspecting authority. d) A sample inspection chart for inspecting the machine shall be supplied. The inspection chart shall indicate all tests that are carried out during manufacture. ¢) The bidder shall submit a copy of the quality assurance plan being followed at the ‘manufacturer's works for ensuring quality of the product offered. 1) The contractor shall submit test certificates for all electrical equipment, cables, and all parts used in handling loads. g) The contactor shall submit material test certificates for structural steel and ‘mechanical components. h) The Machine shall be inspected and tested during every different stages of its ‘manufacture starting from raw materials tl the completion of the Machine, by the Engineer or his authorized representative at the contractor’s premises as per the QAP approved. However, the purchaser or his authorized representative is free to institute any further checks also, if he so desires, and shall be in no way binding on the Purchaser. 1) The Machine shall be tested in all respects in conformity with QAP in the presence of Railways or his duly authorized representative before dispatch from the ‘contractor's premises. The manufacturer shall inform the Railway at least 4 weeks prior to the testing of the machine at manufacturer's works. )) All electrical and mechanical equipment shall be tested in accordance with the appropriate Indian Standard at either the machine maker's or equipment manufacturer's works and test certificates provided if required by the Purchaser or his representative. k)_ Railways reserves the right for surveillance inspection of firm after placement of ‘order to assess the ongoing process of manufacturing and faciities available with them. In case the inspection team observes the deficiencies! deterioration in infrastructure manufacturing capability at the firm's premises, the action can be initiated as considered appropriate on merit. |) The contractor shall provide, arrange all the facilities for conducting the test. Installati n and Commissioning The contractor shall arrange erection and commissioning of the machine. Adequate number of teams of technical experts will be made available so that erection and commissioning delays are eliminated. Such personnel will be required to be present immediately as soon as the machine has been received. The Contractor or his agent would be required to inspect the consignment at the consignee'’s end beforePage 343 oto. 411 sssfully ‘The contractor or his agent shall commission and prove out the machine suct as per scheduled time frame Following items of work shall be performed by the contractor a. Design and construction of foundation suiting local soil conditions, to match the receiptatrival date of the machine at the consignee’'s premises. Installing of the machine structure and associated machinery in position, ©. Complete fiting and wiring of all electrical items d._The machine performance shall be demonstrated after successful commissioning. Start-up and trail operz ‘The contractor shall carry out the start up trial operation test (commissioning tests) on receipt of authorization from the Engineer. During the trail operation, all necessary adjustments shall be made so as to ensure compliance with the operating characteristic for the complete equipment as stipulated in the Technical specifications. ‘The machine shall be capable of trouble free operation and work satisfactorily over a period one week, during which the machine shall be subjected to the normal work load in the shops in a complete shift during each of the days. n (commissioning) tests: Proving-out Tests: After the satisfactory completion of the start up and trial operation test, the Engineer shall authorize the contractor to carry out the proving-out tests. The contractor shall establish to the satisfaction of the Engineer the performance of the machine with regard to the following: ‘Test for each item of equipment covered under the contract to establish its compliance with the operating characteristics and technical parameters as detailed in the technical specifications. ‘The machine performance shall be demonstrated by the contractor or his agent at consignee's works as per clause 3.0, 4.3 & 4.4. Thereafter the machine performance shall be watched by the consignee for a period of 2 weeks before the final proving test cerificate is issued, Training Freo training by the firm shall be imparted in operation and maintenance of the machine. The training to be imparted shall cover operation, troubleshooting and repair of all mechanical, hydraulic, electrical & electronics equipment's (CNC Control & AC Drives) and CNC/PLC part programming. This training shall be provided to 04 person nominated by the consignee, for a period of one week free of cost at the manufacturer's promises. Subsequentty, technical experts from the manufacturer willfully and adequately provide training to operators and maintenance staff nominated by the consignee at the time of commissioning of the machine. ‘The supplier will be responsible for co coordinating with the consignee the travel plans of trainees to ensure that the training is imparted on the machine at its assembly and testing stage. The bidder shall also submit training schedule along with the offer. Note: All training should be imparted in English/Hindi only. Foundation & Related Drawings For each machine, the supplier shall fist submit 01 copy of foundation drawings with details of construction of foundations, complete layout of machine elements like bed, hydraulic tank, coolant tank, electrical panel, Servo Controlled Voltage Stablizer ete. and ther related’ dagrams (Mechanical, Hydraulic, Electrical & Electronics) along with machine weight, overall dimensions, electrical oad wth length of 3 phase, 415 V AC electric power cable for approval as per tine schedule specied in epeciicaton to Railway for approval and to enable the consignee for making nocessary {for Installation & Commissioning of Machine on receipt. fa srdlas fx? lech. WT-18(OPEN) rkshap rol, din Ralvays Pata008412 142 150 16.0 17.0 17 172 18.0 Page 344 of 44s ‘Ais Gotti Spproval from Railway, the supplior shall supply directly each consignee 4 copies pf approved GA foundation drawings and rolatod diagrams for each machine as ifr time. schedule spectied in the specification fom the date of approval Of GA crawing for information only. This information should be furnished on the pattem indicated in detail in te folowing IS Specifications (Latest) or relovan international standards i) IS: 2974 (PL Para 4.1) fr reciprocating type machine. i) I: 2974 (PLAN Para 3.1) for rotary type machine (medium & high frequency. i) 18:2974 (PLIV para 4.1) for rotary type machines of low frequeney. iv) IS: 2974 (PLV para 3.1) for impact type machines other than hammers. ‘The ralivay shall ether approve the GA drawings or if necessary return thom to the supplir/contracor for correction. Special Features: ‘Special features incorporated in the machine, if any, shall be indicated separately and clearly indicating the advantages. Structural Material: Structural materials (as por IS 2062 with latest edition) wherever used should be of preferred make such as SAILITATA STEEL! JINDAUESSARIVIZAG STEEL. Colour All surfaces shall bo cleaned so as to be free of rust and then painted, except mechanical mating surfaces, with two coats of red-oxide and zinc chromate primer 2s per ISO: 2074, The painted surface of the bought out items shall not be disturbed. ‘The machine and its accessories shall be painted in Apple Green Colour No 281 to 1S:5~ 1978, (it any specific colour code standardized by BIS is available, the same be given):The machine can also be painted in equivalent RAL/DINiother International ‘Standards. If there is a standard color scheme of the manufacturer, the same can also be considered and may be specified. General: Deviations, Warranty [Guarantee and Dispatch of the Machine from Manufacturer Works are to be read and followed in unison with Special Conditions of Contract for ical Works specified in Tender Document. wer aise soiree For Chief Mechanical Engineer arcane eater, AGIA te, er otkshop Projects, nian Raley, Pato E tender no, 2021-WP-BPL-Mech-WT-18(OPEN}Specifications No. WP/Mech/M&PIBPL/NTMCBC Page 345 of aa5 000413 ‘SCHEDULE- (1) SPECIFICATION FOR MAGNAFLUX TESTING MACHINE FOR CBC DRAFT GEAR OF LHB 22 23 24 25 26 ‘COACHES MAJOR PARAMETERS Detecting surface cracksifiaws/seams/laps in the component Maximum test piece length Maximum test piece diameter Maximum AC current (passed through coil spring in head shot mode) Induced magnetization current OTHER PARAMETERS Black light (2) Intensity (©) Wave length range (©) Predominant wave lenath Magnetising voltage range Stainless steel tank sheet thickness Demagnetisation time Input supply ‘Weight of component upto 3mm depth 100mm ‘500mm 6000 Amps 16000 Amps min. at peak level (through threaded bar method) 2000 Wiem*(minimum) 3300-3900 Angstrom 3650 Angstrom 6 Volts to 27 volts SWG-14 conforming to 1$:6911-1992 less than § seconds, 418V210%- 3 phase, S0Hz23% 100 Kgs(max.) Note: No deviation will be accepted in the major parameters. wean ce For Chel Mechanical Engineer ortshop Projets, nan Raoay, alr E tender no, 2021-WP-BPL-Mech-WT-18(OPEN) ‘Signatur000414 Page 246 of 485 ‘SCHEDULE: (Il) LIST OF MAINTENANCE SPARES: SN "Description | Electrical control gears {push buttons, Unit “cost “of 4 Selector switches, contactors, relays, MCBs, | 20, of | machine will be MCCBs, MPCBs, ilumination "lamps, | each type | inclusive of Emeraeney switch, meters) cost of spares ‘SCHEDULE: (ll) List of Maintenance Tools S.No. Description Qty ‘Of. _ | Toot box (one set Consisting of) Dino (02 _| Die Spanners required sizes Set 03 | Grease gun No. 04 | Oilcan No. (05 | Serew Driver of required sizos 1 Set (06 | Nose plier 1 No. 07 | Insulated plier - No. 08 | Hammer 2 Ibs T No. 02_| Allen Key required sizes Set 10 | Screw Wrench ‘No 11 [Multimeter "No Note: One set of above Maintenance Tools is required with each Machine. Unit cost of machine will be inclusive of cost of Maintenance To's. we yer aires schfree For Chief Mechanical Engineer arcana Rector, ATR NS, TE" Workshop Projets, Indian Rainvays, Pat E tender no, 2021-WP-BPL-Mech-WT-18(0PEN)Page 347 of 445 000415 ‘Specification no. WP/Mech/M&P/BPLIACSB. Item No. 08 SPECIFICATION FOR AIRLESS CENTRIFUGAL SHOT BLASTING MAGHINE FOR COIL. ‘SPRINGS 1.0 Scope 1.1. The scope of supply shall include design, manufacturing, supply, installation, testing, commissioning and proving of 01 no. Airless Centrifugal Shot Blasting Machine For Coll Springs as per parameters specified in Schedule-! with all accessories, spares etc and shall be supplied at CRWS, Bhopal, WCR, Madhya Pradesh, India as per instructions and conditions of contract, It shall also include installation and ‘commissioning of related equioment, training of personnel in operation and maintenance of machine and s upply of technical documentation. Sources: Likely sources of manufacturers and suppliers are- () Mis Patel Furnace & Forging (P) Ltd, Vadodara, Gujarat (il) M/s Mecshot, Jodhpur (ii) M/s Nesco-Indabrator, Mumbai (iv) M/s Surface International, Jodhpur Note: Bidders may quote for any of the reputed brands from the above likely sources. However, makes quoted other than ‘Likely Sources’ can also be considered in case enough documentary evidences in support of proven design, successful supply, satisfactory performance in Railway Industry, adequate manufacturing capacity, established quality norms of Railways or similar heavy industries are submitted. 2.0 General Description and Scope of Supply: 2.1 One (1no) — Airless centrifugal shot blasting machine for coil springs and all accessories, spares and supporis structures. The machine shall consist of blast cabinet along with blast wheel, vestibules, service access doors, work conveyor abrasive recovery and reclamation system, abrasive conveyor, bucket elevator, abrasive separator, automatic abrasive replenisher, shot controller & shot classifier of suitable design. The equipment should also have adequate capacity dust collection system, fiter bags, ducting and exhaust system. 22 The scope also covers supply of necessary spares for normal operation and maintenance for two years. Unit cost of machine will be inclusive of cost of spares. 2.3 Allrelated material required for inspection, erection and commissioning of Machine and connecting electrical equipments with cables, cable laying and fixing accessories shall be included in the cost of basic Machine. 24 Tool boxes containing all tools (Electrical and Mechanical) required for the ‘maintenance of the machine should be supplied along with the machine as per schedule-Il. Tools shall be supplied in two different tool boxes, with individual pocket {for each item and shpll be of MEKASTER/TAPARIA or reputed ISI make. Unit cost of machine will be inclusive of cost of tool box 2.5 Submission of GA Drawings and related drawings for approval to Railways by successful bidder. Civil work including foundation (it any) for said machine shall be in contractor scope. ‘The cost of machine foundation will be inclusive of cost of machine. Technical specifications of M&Ps are to be read and followed in unison with S: Conditions of Contract for Mechanical Works and General specification for ‘supply of MBP specified in the Tender Document Standard specifi ‘The machine shail be designed, manufactured, erected and tested as per the latest relevant IS specifications, Z\ jon (Mechanical): E tender no! 207WP-PL-Mech:WT-18(OPEN) ay yea aif gif arent Ararat, TRA a, TE Worst Projets ian Rabies, Pe000816 34a 34.2 40 4a 42 43 4a 45 = ‘gh oe te ttre, For Chiet Meanabiah i WP-BPL-Mech-WT-18(OPEN) ‘Si arearh after, wit ta, ve ‘Weiksnop Peels tnan Rabays, Pot — — —— Page 348 of 445 ‘The airless centrifugal shot blasting machine for coil springs shall be complete in all respects. The tenderer shall furnish complete details regarding types, materials of construction, specifications and special features, if any for the main items, constructing the equipment and detailed in this clause, any variations from the specification contained in this tender shall be brought out with reasons for the same. Any variations involving lower standards of design performance and rating are not acceptable. ‘The scope of supply shall include the following along with the necessary fittings and ancillaries: a) blast cabinet along with blast wheel, b) vestibules, ©) service access doors, ) work conveyor abrasive recovery and reclamation system, e) abrasive conveyor, ) bucket elevator, 9) abrasive separator, h) automatic abrasive replenisher, i) shot controlier & shot classifier of suitable design. The equipment should also have adequate capacity dust collection system, k) iter bags, 1) Ducting and exhaust system, The airless centrifugal shot blasting machine for coll springs is required for shot blasting of all types of coil springs components as mentioned in Annexure-I_ used in ICFIRCFILHB Coaches in Indian Railway. Performance Standards, a) The machine shall be capable of performing automatic airless centrifugal shot blasting and-peening of coil springs as per indicated in specification and shall be designed as per parameters given in leading parameters of this specification ) The shot biast plant shall be capable of blasting on the springs to prepare the surface finish shall conform to SA- 2 as per IS: 9954-1981(Para 4.1.2.2) ©) The plant shall be capable of recycling and cleaning the used shots, 4) The machine shall be capable of the operating under ambient conditions of 48°C. and 98% relative humility, e}Peening intensity-and-coverage-for-items-+ to-43- mentioned in-spesification-shall be-checked. with-Almena-strip-in-accordance-with 4S 7001(Almena-stip-type “As, ‘minirsum-coverage:90%- intensity =minimum-0-40(0.046") Purposes and Capability: The shot blasting machine shall be capable of automatic airless centrifugal shot blasting of coil springs as per details indicated in Annexure-| and shall be designed as per parameters given under ‘Leading Parameters’ in Schedule-| ‘The shot blasting plant shall be capable of blasting on the springs to prepare the surface to SA 2% as per IS: 9954-1981 ‘The design of the plant shall be roller conveyor type with one or two blasting turbine fixed on roof of the cabinet. The coil springs shall be conveyed and rotated through biast zone by power driven spinner rolls and a chain conveyor equipped with fingers which pushes the call springs along the rotational rolls, ‘The plant shall be capable of recycling and cleaning the used shots The coil springs shail be shot blasted on all its surfaces. Minimum blasting capacity shall be approx. 30 coil springs per hr. This shall be ffoved for 16t axle box spring, drawing no.WTAC-O-1-202 and for 16t bolster spring, drawing fo. WEAC-0,5-202 for @ period of six days of two 8 hrs. shift per day. The tme required Jor loading, ard Unloading of the coll spring should be taken into consideration while indicating the blasting and-peening capacity. aSPage 349 of aa5 00041 4.6 Reening-intensity-and-coverage-for-items—t_to-43-mentioned-in-Annexure-|-shall-be hecked-with- Almen-strip-in-accordance-with-1S-700+(Almen- strip-type"A’,-minirnum soverage-00%, Intensity--minimum-0.40-40.016"). 4.7 Tenderer shall indicate the total cycle time as well as break up in the following format a. Loading time b. Blasting time © Unloading time 4.8 — The bidder shall furnish the estimated floor to floor time of all operations for the components listed in Annexure-| 4.9 The basis of the timing should be clearly given with break up of al the parameters. 4.10 The timing should be maintainable for regular 08 hrs shift for single shift working 6 days ‘week with machine availability of 85%. 5.0 Concomitant Accessories: ‘The Concomitant Accessories should accompany along with the machine. The scope of supply shall include the following concomitant accessories whose price shall be included in the basic price of the machine: @) | Abrasive Shots ur | (®) | Electrical Wiring | 1 lot © | Foundation and Teveling bots [eet (@ | A suitable air cooled screw type air compressor along with ol {tee air drier to meet machine requitement as per leading tno parameter. —_ (© | Alb crane-1500kg inclucing instalation ‘no (® [Any other accessory/ equipment, which the manufacturer considers essential to make the machine fully operational, improve reliability and capabiliy of the machine when installed ‘and commissioned connected to power source and give the specified output/productivity 6.0 Basic Design Features: 61 Safety features: The machine shail incorporate all safety devices so as to provide Complete protection to the operator and machine. 62 Specific Characteristic: The supply shall include all equipment and concomitant accessories as detailed in the specification 6.24 General a) The material of coll springs shall be rolled silico manganese steel to IS specification No. 3195-92.The coil springs shall be cleaned of cil, grease, scale etc. by degreasing agents and rinsing with hot water/steam before shot blasting, ) The design of the machine shall be roller conveyor type with one blasting turbine fixed on roof of the cabinet. The coil springs shall be conveyed and rotated through blast zone by power driven manganese spinner rolls and a chain conveyor equipped with fingers which pushes the coll springs along the rotational rolls. 6.2.2 Blast Cabinet a) The blast cabinet shall be of sturdy fabricated construction with M.S. plates not less than 6mm thick suitably reinforced to combine strength and ultlty. The overall dimensions of the blast cabinet shall be such as to enhance shot blasting efficiency. Length, breadth and height of the cabinet shall be indicated, b) The area of the cabinet directly exposed to the shot stream shall be lined with hardened long life alloy liners of 11-14% austenitic manganese steel of minimum. ‘2mm thickness. ‘The fer shal be prehardened trough work hardegjg pease in order to avoid any warping during blasting operation. A E tender no. 2921-WPRIG Most WYI:14(0PEN) I yee arcane Raker, aA "a te = shop Projects, Indian Raltways, P=*000418 a Page 350 of 44s The thickness, material composition, life of liners in terms of machine hours of Utilization and hardness of liners shall be indicated in the offer. Vulcanized rubber liners should not be used at any location in Blast Cabinet, instead only Manganese steel liners shall be used, ©) The cabinet floor shall be of minimum 6mm thickness M.S. plates. Arrangements should be made to protect unnecessary wear to the cabinet floor and screw conveyors, 6.2.3 Vestibules a) Two vestibules one at the inlet and one at the outlet side of blasting chambers shall be provided. The vestibules shall extend to an adequate length to avoid leakage of shots. The length of vestibules should be clearly given. The vestibules shall be fabricated, suitably reinforced and mounted on structural frame of robust construction. Each vestibule shall be provided with four sets of rubber strip curtains made out of wear resistant rubber of minimum thickness 3mm. The construction shall permit easy passage of work piece while effectively preventing leakage of shots. The vestibules should be fabricated from minimum 4mm thick stee! plates. The spent abrasive should be trapped within the vestibules and returned to the main abrasive system through hopper. 6.2.4 Service Access Door ‘The service access doors shall be provided at strategic location so as to facilitate servicing of the interior of the chamber. The door shall be equipped with safety limit switches so as to prevent accidental starting of the turbine with door in open position These doors shall be fabricated from six mm thick mild steel and lined with 6mm thick 14-14% Austenitic Manganese steel. 6.2.5 Work Conveyor The work conveyor shall be such that coil springs to be shot blasted are loaded on one side on the conveyor and shot blasted coll springs shall come out from the ather side. The col springs should not fall of from the conveyor during its journey The length and wicth ofthe conveyor shall be ccary indicated b) The work conveying and rotating device shall consist of power driven manganese steel rolls which support and rotate the coll springs while the pusher chain moves them through the cabinet. Steel conveyor chain shall be fited with pusher dogs of cast 11-14% Austenitic Manganese steel for protection, Design features of rotating and conveying device and method of shot blasting to be carried out on the springs inside the cabinet shall be explained in detail with sketches and diagrams ¢) The spinner with (rotating device) and the pusher chain shall be ariven by suitable drive motors having AC variable Drives, inftely variable. Arrangements for reversible rolercrive shall also be mage and available so that RH. ang LH. wound springs can be handled on the machine. HP. of the dfive motors shall the ! indicated. In case the values are less than that indicated in leading parameters ! reasons shall be furishea | @) Loading Area: - A Loading area shall be provided before the entrance vestibule. This area shal be open on one sid fo alow the springs fo be moved laterally ino | the position on the spinner rolls. A fat apron, which shall be part of loading station permits the springs to be positioned parallel to line of work travel before they shall | be placed on work rolls/push fingers. ! ©) Unloading Area: - An Unioading area shal be provided after the exit vestibule. Tis area shall be open on one side to alow the springs to be unloaded laterally by an air cylinder operated mechanism or any other suitable system, which moves the springs onto an incined unloading table. Unloading table has to be supplied by the bidder Bidder shal submit the complete design detail with drg./sketch a Ba yen aif goithray ; , | For Chief Mechanical E hota Te (X Bra ofa’ 3PL-Mech-WT-18(0PEN) Signifture of Ten ‘Workshop Projects, tadian Rabways, Po”Page 351 of a ‘0b4i9 6.2.6 Abrasive Recovery and Reclamation System ‘The spent abrasive shall be collected in the hopper below the floor gtid. The hopper shall be of fabricated construction suitably reinforced to combine strength and rigidity. ‘The abrasive shall be transferred by screw conveyors to the bucket elevator, which shall discharge the shots to the abrasives separator where dust and fines shall be removed. The clean usable abrasive shall drop into a storage hopper after which the abrasive shall be fed to the turbine. The design of the system provided shall be clearly shown in detail through diagrams and schematic views. 6.2.7 Media Conveyor This shall consist of screw conveyors. The screw conveyors shall discharge the charge to the boot section of the elevator and shall be driven through chain and sprocket transmission. The number and complete details of screw conveyors used in the system shall be indicated, 628 Abrasive Conveyor This shail consist of helicoid screw conveyors. The screw conveyors shall discharge the charge to the boot section of the elevator and shall be driven through chain and sprocket transmission. The number of scrow conveyors used in the system shall be indicated 6.2.9 Bucket Elevator a) The bucket elevator shall be of fabricated construction with suitable access for ‘maintenance located at convenient points. Access door for bucket elevator shall be provided. The buckets shall bo of MS fabricated construction and attached to belt with spike bolts. ‘The elevator head shall have removable top cover for belt inspection or installation. The discharge spout shall also be provided with an inspection door. The bearings of the elevator in the head and boot area shall be prelubricated and sealed for life. Make of bearings shall be only SKF/FAGIKOYOINTNITATA. b)_ The elevator drive unit shall be located at the top. ©) The abrasive shall be centrifugally discharged from the head through the discharge spent to the abrasive separator. 4) A tensioning arrangement shall be provided at the top of the bucket elevator to faciltate ease of adjustment of belt tension. 6.2.10 Abrasive Separator a) The abrasive separator shall consist of wind siting arrangement which works on the principle of blowing air across the cascading stream of shots. b) The bucket elevator shall discharge shots and dust into the wind sifting arrangement through a screw, which removes large size particles. In the wind sifting arrangement, the material shall be allowed to fall by gravity. The shots shall be arranged to fall in several cascades so as to increase the contact time with the cleaning air through a series of baffles. The arrangement shall ensure even ‘istrbution of shots across the full width of the separator. ‘The chamber shall be connected to the dust extractions system of ensure collection of thoroughly cleaned shots into storage hopper. The residual dust contents in the blasting abrasives after sifting must be indicated. ©) The arrangement shall be such that wear and tear on the separator is negligible. ‘An abrasive trap shall be provided to prevent small abrasives from being carried into dust collector. 6.2.11 Media Separator ) A sullable abrasive separator should be provided to remove sand, scale abrasive fines and other contaminants from the abrasive operating mix so than only proper size clean abrasive shall roturn to the blast wheel turbine for reuse, b) The abrasive separator shall consist of wind sifting arrangement which works on the ade of blowing air across the cascading stream of shots. bucket elevator shall discharge shots and dust into the wind sifting qe ah hinge through a screw which removes large size particles. Int ng stra LR & Gist Eine Eagnoangerent, the materia shall be allowed to fall by gravity, ( "BENS Gor enw sore ronstp Pes nah 4| 000420 ae f ‘The shots shall be arranged to fall in several cascades so as to increase the contact time with the cleaning air through a series of baffles. ‘The arrangement shall ensure even distribution of shots across the full width of the separator. The chamber shall be connected to the dust extractions system of ensure collection of thoroughly cleaned shots into storage hopper. The residual dust contents in the blasting abrasives after sifting must be indicated 4) The arrangement shall be such that wear and tear on the separator is negligible. An abrasive trap shall be provided to prevent small abrasives from being carried into dust collector. Blasting Turbine Wheels fa) The plant shall be provided with ono turbine whee! with its position so arranged as. to ensure coverage of entire area of coil springs for complete blasting to the desired standard finish in one setting. The turbine blades should be self-locking type to minimize time and effort during blade changing. However, the bidder should furnish H.P, shot throw speed and shot throw capacity per minute of turbine wheel with calculations etc. in the offer. In case the values are less than that indicated as leading parameters, reasons shall to be furnished, The bidder shall also indicate the number of blasting turbine actually proposed for the operation and their layout in the blasting cabinet through sketches, b) All parts of the turbine wheel coming into contact with shots should conforms to the following: () Bare Wheel ~ SAE 8620 oF its equivalent (i) Blade hardness ~ 64-66 HRC, a solf locking type blade (ii) Impellers/Accelerators 52-56 HRC (iv) Control cage 82-56 HRC ‘The bidder shall identify the material used for the above parts and their method of hardening. Note: The max. variation in the hardness for the above components should be ¥: 3 HRC. ©) The wheel shaft should run on dust proof ball bearings of make ‘SKFIFAG/KOYOINTN/TATA. a) The turbine wheel should be dynamically balanced. 6.2.13 Shot Controller: The flow of shots to the turbine unit shall be controlled by an air cylinder operating shut off valve which operates through a solenoid valve and a selector switch located near the operator's control panel. 6.2.14 Automatic Abrasive Replenisher a) One automatic abrasives replenisher shall be provided having suitable shot abrasive capacity complete with air operated abrasive gate, and diaphragm operated bin indicator for replenishing new abrasive to the system. Bidder shall Indicate the capacity of abrasive replenisher. b) In operation, when the level of abrasive in the main storage bin reaches a point below the bin indicator, the pneumatically operated abrasive control valve at the bottom of the abrasive replenisher shall automatically open thus, replenishing new abrasive to the system. c) When the level of the abrasive reaches a point above the bin indicator in the main storage bin, the abrasive control vaive shall automatically close. 62.48 Shot classifier: Vibrating shot classifier shall be provided to constant classify the shots and return to this to abrasive system via the elevator. The classifier will be driven by suitable capacity motor. Bidder shall indicate the motor power. The sy Mexnclude $n gate and spout to meter and contol shat fow from the sto HA EY aise goin { For Chief Mechanical Engineer ‘Rae, Se FATE. PL-Mech.WT-18(OPEN)Page 353 of 445 000421 a) Dust collector and extraction unit of wear resistant design of suitable thickness of stee! sheet and capacity should be provided. Tho air exhaust into atmosphere must rot contain more than 80 miligram of dust per cubie meter of ar. 6.2.16 Dust Collector: b) The dust extraction unit shall be such, as to ensure that adequate fresh air Circulation is maintained in the chamber for clear visibility and to prevent dust deposition on the blast cleaned surfaces. ©) Complete technical details, specifications and make of the equipment like fans, fiers, duct etc. working parameters like exhaust air capacity, static pressure at fan inlet, operating pressures and power equipments should be furnished. d) The exhaust fans should be made of sturdy stool sheet construction of sultable thickness not less than 3mm. it should have dynamically balanced impellor. The air volume capacity, RPM, pressure and HP requirement should be indicated. e) Facility for automatic continuous by Hi-Pulse jet cleaning of the filter bags shall bo provided. The system should be explained in detail. The bidder shall provide drawers type of bin at the bottom of the hopper for removal of dust. 1) Ducting between dust collector and cabin should be of minimum 2.6mm thickness galvanized steel sheets. The ducting provided should be from dust collector to fan and to chimney at least 3m above the roof of the shed which will be of about 8-10, ‘meter height as per pollution control norms. 6.2.17 Shots: The steel shots shall conform to SAE J827/J444 or its equivalent with hardness value ranging between 40 to 50 HRC. The bidder shall clearly indicate material composition of shots to be used, its density, hardness and size otc. 6.2.18 Noise Level The noise level of the plant shall not exceed 85 db at 1 meter distance in any case during working of the machine. The system adapted for controlling the noise level shall be indicated in detail 7.0 General Characteristic 71 Rigidity and Stability a) The machine shall be robust, rigid and of sturdy construction. it shall be designed to meet heavy duty demands of various operations on the machine under normal Workshop environment for such machines. It shall be free for vibrations even when working at full capacity b) All machine castings shall be made of close grained high grade cast iron tke Mecanite or equivalent materials meeting IS-210 Standards to ensure durability and rigidity. The casting shall be thermal stress relieved to ensure stabllty and continued accuracy. ©) All machine fabrications of critical load bearing assemblies like beds, columns ete shall be adequately strengthened and stress relieved. 4) Change in ambient temperature shall not affect the performance of the machine. €) There shall be no change in the performance of the machine either on switching on the machine or after continuous running. 4) There shall be no resonant vibrations throughout the working range of the machine at all oad lovets. 7.2 Operational Controls 7.2.1 The operation of the machine shall be by push buttons or levers. The basic rules for the rection of operation of controls and the corresponding direction of movements of the machine tools shall be as per IS: 2987-1985. ea yea ahh gui SGA ERR weron s,inian9.0 10.0 110 114 11.2 ‘Wrkshop Projects, dan Relays, Patna 000422 Page 354 of. 7.2.2 The control devices shail be a) Clearly visible and identifiable b) Ergonomically positioned for safe operation without hesitating or loss of time, and without ambiguity. 7.2.3 CNCIPLC Controls (where applicable) -The general requirements of CNC/PLC controls shall be submitted. Technical details including make and model should be furnished. Lighting: 1a) Integral lighting suitable for the operations concemed where its lack is likely to cause a risk despite ambient lighting of normal intensity shall be provided. b) The manufacturer must ensure that there is no area of shadow likely to cause nuisance, that there is no irritating dazzle and that there are no dangerous stroboscopic effects due to lighting provided by the manufacturer. ¢)_ Integral parts requiring frequent inspection and adjustment and maintenance areas must be provided with appropriate lighting. 4d) The machine lighting should be of low voltage so as to prevent any hazard to the operator. Machine Maintainat fa) The machine shall be so designed as to require minimum possible maintenance and to give trouble free service. b) Allassemblies/parts of the machine shall be easily accessible for maintenance. ©) The machine shall not require major disassembly for checking and replacement of particular part, especially for parts requiting periodical check up and replacement. d) The manufacturer must provide means of aocess e.g. stairs, ladders, cat walks etc. to allow access safety to all areas used for production, adjustments and maintenance operations. Wear Compensation Adjustment: The original built in accuracy of the machine shall be capable of being maintained conveniently and economically by suitable adjustments for taking up wear on slides, bearings and load screws. The system of adjustments incorporated shall be explained in the offer. Inspection and Testing at Manufacturer's Works The inspection of machine shall be carried out by Railways/authorized Railway Representative. A no load test must be carried out at the manufacturer's works for testing of individual equipment not the complete plant i.e. turbine wheels, blast cabinet, dust collector and fan bucket elevator, abrasive separator and abrasive conveyor etc. Rigidity of the machine shall be demonstrated to the satisfaction of appointed inspector or inspecting agency. Manufacturers must have adequate facilities at their works for carrying out the inspection. The bidder shall clearly confirm that all facilities exist and shall be made available to the inspecting authority. ‘A-sample inspection chart for inspecting the machine shall be supplied. The inspection chart shall indicate all tests that are carried out during manufacture. ‘The bidder shall submit a copy of the quality assurance plan being followed at the manufacturer's works for ensuring quality of the product offered. ‘The contractor shall submit test certificates for all electrical equipment, cables, and al parts used in handling loads. ‘The contactor shall submit material test certificates for structural steel, somponents. (dR, BORER WT-16(0PEN)Page 355 of. 00423 11.8 The Machine shall be inspected and tested during every different stages of its manufacture starting from raw materia, til the completion of the Machine, by the Engineer or his authorized representative at the contractor's premises as per the QAP approved. However, the purchaser or his authorized representative is free to institute any further checks aiso, if he so desires, and shall be in no way binding on the Purchaser. 11.9 The Machine shall be tested in all respects in conformity with QAP in the presence of Railways or his duly authorized representative before dispatch from the contractor's, promises. The manufacturer shall inform the Railway at least 4 weeks prior to the testing of the machine at manufacturer's works. 11.10 All electrical and mechanical equipment shall be tested in accordance with the appropriate Indian Standard at either the machine maker's or equipment manufacturer's works and test certificates provided if required by the Purchaser or his representative 11.11 Railways reserves the right for surveillance inspection of firm after placement of order to assess the ongoing process of manufacturing and facilties available with them. In case the inspection team observes the deficiencies! deterioration in infrastructure manufacturing capability at the firm's premises, the action can be initiated as considered appropriate on merit. 11.12. The contractor shall provide, arrange all the faciities for conducting the test. 12.0 Installation and Commissioning 124 The contractor shall arrange erection and commissioning of the machine. Adequate umber of teams of technical experts will be made available so that erection ‘and commissioning delays are eliminated. Such personnel will be required to be present immediately as soon as the machine has been received. The Contractor or his agent would be required to inspect the consignment at the consignee’s end before unpacking is done and carry out a joint check of the receipt of components to avoid subsequent complaints regarding short shipment or transit damages. 12.2 The contractor or his agent shall commission and prove out the machine successfully as per scheduled time frame 12.3 Following items of work shall be performed by the contractor ‘a, Design and construction of foundation suiting local soll conditions, to match the receipVarrival date of the machine at the consignee’s premises b. Installing of the machine structure and associated machinery in position. c. Complete iting and wiring of all electrical items d. The machine performance shall be demonstrated after successful commissioning. 13.0 Start-up and trail operation (commissioning) tests: 43.1 The contractor shall carry out the start up trial operation test (commissioning tests) on receipt of authorization trom the Engineer. 13.2 During the trail operation, all necessary adjustments shall be made so as to ensure compliance with the operating characteristic for the complete equipment as stipulated in the Technical specifications. 13.3 The machine shall be capable of trouble free operation and work satisfactorily over a period one week, during which the machine shall be subjected to the normal work load in the shops in a complete shift during each ofthe days. 14.0 Proving-out Tests: 14.1. After the satisfactory completion of the start up and trial operation test, the Engineer shall authorize the contractor to carry out the proving-out tests. The contractor shall | ‘establish to the satisfaction of the Engineer the performance of the machine with regard to the following: 14.2 Test for each item of equipment covered under the contract to establish its compliance wh the operaing charade and ocal prartrs as deta puree cestions. Ganev S oN (7 yy 32 Se Bvrs(or ara arforeg)S « eee HEOFEN ‘Stonatury BE (ond } ‘workshop Projects, Indian Raiays, Paina000424 Pee udda 150 154 162 163 16.0 161 16.2 170 18.0 19.0 19.4 192 « Be gE Seas snoren aL ORs, ee Se. Page 356 of 44s ‘The machine performance shall be demonstrated by the contractor or his agent at consignee's works as per clause 3.1.3 & 4.0. Thereafter the machine performance shall be watched by the consignee for a period of 2 weeks before the final proving test certificate is issued. Training Free training by the firm shall be imparted in operation and maintenance of the machine. The training to be imparted shall cover operation, troubleshooting and repair of all mechanical, hydraulic, electrical & electronics equipment’s (CNC Control & AC Drives) and CNCIPLC part programming. This training shall be provided to 04 person nominated by the consignee, for a period of one week free of cost at the ‘manufacturer's premises. ‘Subsequently, technical experts from the manufacturer will fully and adequately provide training to operators and maintenance staff nominated by the consignee at the time of ‘commissioning of the machine. ‘The supplier will be responsible for co coordinating with the consignee the travel plans of trainees to ensure that the training is imparted on the machine at its assembly and testing stage. The bidder shall also submit training schedule along with the offer, Note: All training should be imparted in English/Hindi only. Foundation & Related Drawings For each machine, the supplier shall frst submit 01 copy of foundation drawings with details of construction of foundations, complete layout of machine elements like bed, hydraulic tank, coolant tank, electrical panel, Servo Controlled Voltage Stabilizer etc. and other related diagrams (Mechanical, Hydraulic, Electrical & Electronics) along with machine weight, overall dimensions, electrical load with length of 3 phase, 415 V AC electric power cable for approval as por time schedule specified in specification to Railway for approval and to enable the consignee for making necessary arrangements for Installation & Commissioning of Machine on rece! After getting approval from Railway, the supplier shall supply directly to each consignee 4 copies of approved GA foundation drawings and related diagrams for each machine as per time schedule specified in the specification from the date of approval of GA drawing for information only. This information should be furnished on the pattern indicated in detail in the following IS Specifications (Latest) or relevant international standards 1) IS: 2974 (Pt. Para 4.1) for reciprocating type machine. Ii) IS: 2974 (PLlll Para 3.1) for rotary type machine (medium & high frequency. lil 1S:2974 (PLIV para 4.1) for rotary type machines of low frequency. IS: 2974 (PLY para 3.1) for impact type machines other than hammers. The railway shall elther approve the GA drawings or if necessary return them to the ssuppliericontractor for correction. Special Feature: ‘Special features incorporated in the machine, if any, shall be indicated separately and Clearly indicating the advantages. ‘Structural Material: Structural materials (as per IS 2062 with latest edition) wherever used should be of preferred make such as SAILITATA STEEL/ JINDAUESSARIVIZAG STEEL. Colour All surfaces shall be cleaned so as to be free of rust and then painted, except mechanical mating surfaces, with two coats of red-oxide and zinc chromate primer as, per ISO: 2074. The painted surface of the bought out items shall not be disturbed. ‘The machine and its accessories shall be painted in Apple Green Colour No.281 to IS:5- 1978, (if any specific colour code standardized by BIS is available, the same be given).The machine can also be painted in equivalent RAL/DIN‘other Intemational Standards. If there is a standard color scheme of the manufacturer, the say e considered and may be specified.Page 357 ol a | 000425 20.1 One copy of the printed illustrative catalogue showing features of the machine and its elements shall be furnished. 20.2 The technical literature shail be provided for the complete machine, including imported and indigenously purchased components / sub- assemblies. The successful tenderer wil have to furnish 4 (four) copies each of the following manuals directly to the consignee ‘along with the machine. Out of these 04 sets, the bidder shall be required to submit one set of all documents in best available condition one month prior to the training for the machine. One set of technical iterature should cover the following details (where ever applicable) 2) Operational & Maintenance manual of the machine b)_ Operational & Maintenance manual of the servo controlled voltage stabilizer. ©) Operational & Maintenance manual ofthe ultra-isolation transformer. @) Instruction & Maintenance manual for Hydraulic Oil Cooling Unit. @) User manual for Tool changer system (if provided) 4) Technical & Maintenance manual for Hydraulic System, 9) Technical & Maintenance manual for Lubrication System. hh) Operator Guide for CNC Control System (if provided). ’) Programming Guide for CNC Control System (if provided) }) Diagnostic & Trouble shooting Guide for CNC Control System (i provided). k) Start-up Guide for CNC Control System (if provided). 1). Machine Software Listing (if provided). Im) Soft and hard copies of PLC Program in ladder form with cross reference listing and PLC project file 1) Drawings of tooling & fixtures, hard copies in A-2 size as well as soft copy in PDF format. ©) Witing diagram, in which length of wires must be mentioned, hard copies in A-3 size as well as Soft copy in POF format. ) Mechanical drawings (spindle assembly, table a 4) ssembly, column assembly), hard copies in A-1 size as well as soft copy in POF format. 1) Spare part manual including part lists no., hard copies in A-é size as well as in PDF Format. 8) Lay out drawings in A-1 size, which clearly shows the position of all type of ‘electrical Components in machine. Note: All manual and literature should be in English/Hindi, General Deviations, Warranty /Guarantee and Dispatch of the Machine from Manufacturer Works are to be read and followed in unison with Special Conditions of Contract for Mechanical Works specified in Tender Document x ea aie Sohn For Chief Mechanical Engineer oRGrT Wate, anda te, TET. ‘Workshop Projects, Indian Raitways, Patna tender no. 2021-WP-BPL-Mech-WT-18(OPEN)000826 Page 258 of 85 Pint Annexui List of components to be loaded on the machine ~~) Total quantity ie. all t Machining | components from 8.1. ‘Sno. ‘Component Drawing No Operations to ig is +22) tor [Berisha ecard out | blasted in shit of § re | with 85% availability of themochine A. Spring of ICF Coaches ‘ate Box Spingon | F-70068 | Shot ising ne 7) alte Sring ron | oSS002 | ShatBasing AC 3 [Axle Box Spring- AC WTAC-0-1- 202 _| Shot Blasting 4 |B.G. Bolster AC WTAC-0-5- 202 _| Shot blasting 5 [Pimary sprinter] ROSOISKVL-000-| Shot stg [Pinar sping ROSOISKOL 3472 | shat basing fate bow tor gnaraar | WLRRME--1202 | Shot blasting | 8 | Bolster for power car WLRRM8-0-5-802 | Shot blasting LHB SPRINGS Tia Bogie Pimary ‘6747 [shat ising outer pring 10 rat Boge rary ‘aeraig | hat ising inner spring | 77 Bat Bogie saandary | 1260618 | Shot ising cuter soa 2 | het Bogie scordary | 1060573 Shoring trorseha 13° ‘| Fiat Bogie Primary 1277142 ‘Shot blasting 150 nos cur asi | Pet Bog Bary iarrae | shot basing tnersaing 6 fat gio secondary | Taras) Sor aing tutor oping oe 16 | Fiat Bogie secondary 1277145 ‘Shot blasting imer spas! 7 Bat Begs scondary | 10686068 | Shot ang ue sping it-2 18 _| Fiat Bogie secondary 1268837 ‘Shot blasting Inner se sao i | Pat oi Pinay veorioo —| stetsing butersung 20_| Fiat Bogie Primary LGOTi01 ‘Shot blasting inser eota Fi] Pat Bogle secondary | —USOBTOT —} Shor BaetnG suis tai “ | Fa Bele tooonday | ucosto0 —] Soros ter sph a yer ae WR For Chet Mechanical Engineer apreearay kata, ARGTRT Net, Te" Workshop Projects, dian Ralls, Pr tender no, 2021-WP-BPL-Mech-WT-18(OPEN)aoa SCHEDULE: (I) ‘Technical Specifications No. WP/Mech/M&P/BPLIACSB: Leading Parameters of Airless Centrifugal Shot Blasting Machine for Coil Springs (Supplied by consignee for guidance of manufacturer) Coil Springs : Free Height 150 to 900mm Spring dia (max.) 7010 475mm Dia of wire 16 to 60mm Weight of springs 3.3 to 200 kg Shot flow rate 160-200 kg/min ‘Shot throw velocity 70-80 meters/sec Conveyor speed 0. meter to 1.0 meterimin HP. of motors for Blasting turbine wheel 2 1SHP Spinner Rolls 2HP Chain/Roller conveyor 3.0 HP Elevator 2 2HP Sorew conveyor for transferring spent abrasive . 3yp from hopper to bucket elevator Dust collector fan 7.5HP Rotary valve 1.0HP Blasting intensity ‘As lald down in 1S: 9954-1981 Suitable for operation on 415 V +10% AC 50 Electrical cycles + 3%, 3 phase. Note: Tho values of parametprs shown at 3 fo 6 are not mandatory but indicative minimum. The design of the machine should be such that it should be capable of automatic airiess ‘centritugal shot blastingfpeening of coil springs. ax a qerdire gohan For Chief Mechanical Engine. arcana afta, RA tt, Te E tender Warahoy Mojuene Siac Raa BREPEN)Page 360 of 445, ‘SCHEDULE: (I) ist of Maintenance Tools Description — Qty Tool box (one sel Gonsisingo) ——~—~—~—~S~™ «tn Fixed Spanners-t no each (6-7, 6-9, 10-11, 12513, 14-18, | 1Set_ , 14-18, 21-23, 25-28) | No — No. | Allen Key required sizes Tester ‘Multimeter One set of above Maintenance Tools is required with each Machine. Unit cost of ‘machine will be inclusive of cost of Maintenance Tools. tender no. 2021-WWP-BPL-Mech-WT-18{OPEN) & of TenderPaee 3613 9.94.99 ‘Specification no. WP/Mech/M&P/BPLIRRSV lem No. 07 RAIL CUM ROAD SHUNTING VEHICLE Scope of supply ‘The scope of supply shall include design, manufacturing, supply, installation, testing, commissioning and proving of 01 no. Battery Operated Rail cum Road shunting vehicle 485 per parameters specified in Schedule with all accessories, spares etc and shall be supplied at CRWS, Bhopal, WCR, Madhya Pradesh, India as per instructions and conditions of contract: It shall also include installation and commissioning of related equipment, training of personnel in operation and maintenance of machine and supply of technical documentation Source: Likely sources of manufacturers and suppliers are- Mis HYT Engineering Co. Pvt Ltd, Pune (i) Mis BEMO, Netheriand Note: Bidders may quote for any of the reputed brands from the above likely sources. However, makes quoted other than ‘Likely Sources’ can also be considered in case enough documentary evidences in support of proven design, successful supply, satisfactory performance in Railway Industry, adequate manufacturing capacity, established quality norms of Railways or similar heavy industries are submitted, Purpose and Capability Battery Operated Rall cum Road shunting vehicle capable for on Track Shunting of Coaches. General Design Features ‘The following key features shall be provided: a) The Battery Operated Rail cum Road shunting vehicle shall meet the broad technical parameters of operation and Railway Vehicles having track gauge 1676 mm, vehicle weight up to 135 Tones, draw bar pull force of 15 KN (min.), safe speed of steplessly variable from 0 to 2 km/h (approx.) when loaded and 0 to 4 km/h (approx.) when solo, gradient / slop from 0 to 2.5 per 1000, curve radius of 90m including tumouts & crossings, power supply 3Phase, 415V + 10%, 50 Hz + 3% with neutral for battery charging, ‘The Scope Covers Complete Battery Operated Road Cum Rail Shunting Vehicle along with the following standard accessories and items required to make it fully functional (i). First fi of oils and lubricants (ii) On Board battery charger ~ One No. (ii) A set of maintenance tools - One Set. (iv) Electrical cables for connecting battery charger to electrical power source ~ 1 lot. (v) CBC coupler suitable for IRS rolling stocks -1 No. (vi) Remote control for Vehicle opération- 1 No. For Vehicle's movernent on road oF rail, Vehicle shall be equipped with four nos. traction wheels, each equipped with individual variable speed AC motor. These traction wheels shall be of Polyurethane for higher co-efficient of friction. Each traction wheels shall have individual steering mechanism with individual variable speed AC motor. It shall be able to make 360 deg. rotation about its own axis. Travelling speed of Vehicle shall be infinitely variable within the speed limit. aye i oir For Chief Mechanical Engineer Rear Hara, RCT Ret, SEAT oe RP SASSER GAPS ocopeny000830 soe amos 4) In addition to four number traction wheels, Vehicle shall be equipped with retractable flanged steel wheels for guiding the Vehicle during its rail mode operation. Wheels shall be lowered during rail mode and shall run safe and comfortable in turnouts and crossings. These wheels shall be mounted on suitable bearing arrangement for durable performance. These wheels shall be retracted up by hydraulic cylinders during road mode of operation. ©} Super structure shall be torsionally rigid box structured frame made out of mild stool plates as per IS 2062. ) Battery Operated Road Cum Rail Shunting Vehicle shall be equipped with PLC controls from Siemens / Allen Bradley / Parker/Fanuc of latest design. All the controls of vehicle shall operate through the PLC system. PLC shall be equipped with remote diagnostic feature, a) Vehicle shall be equipped with hydraulic system for the retraction of flanged wheels. Hydraulic system shall be equipped with necessary safety equipment’s. Hydraulic system shall be mounted within superstructure. h) Battery capacity shall be sufficient for travelling at least 20 Kms under solo condition or for travelling at least 9 Km under fully loaded condition on single charging basis straight and flat track conditions, |) Radio remote controlled operator pendant shall be equipped with necessary ‘switches / buttons for selecting direction, speed control, steering control, horn, flanged wheel up/down, emergency Switch, Speedometer, Indication for mode of ‘operation (railroad & remote manual), Other standard indications etc. The remote control shall operate from maximum distance of 200 meters in open field conditions. J) Vehicle shall be equipped with electrically controlled breaking. In addition, manually releasable, failsafe spring applied parking brake shall also be provided k). The followings protection shall be included in the working of Battery Operated Road Cum Rall Shunting Vehicle as mentioned below:- (Low battery vottage alarm. (il) Low ol levet in hydraulic system alarm. (i) Over current of drive motor alarm. (iv) Provision of auto parking brake. (V) Provision of dead man switch. (vi) No traction with parking brakes on. 1) Operate on rail tracks as well as roads: maximum mode changeover time from rail toroad is 2 minutes. m) The Vehicle shall be painted in Golden Yellow shed No. 356 to | n) License. 2007. ‘It shall be the responsibilty of the contractor to obtain frequency allocation and required permission and license on behalf of Raitways from the license issuing authority. ‘The initial conse fee ie. One year from the date of commissioning and acceptance shall be borne by the contractor. Technical specifications of M&Ps are to be read and followed in unison with Special Conditions of Contract for Mechanical Works specified in Tender Document. Safety Equipment shall be incorporated with all safety featuresisafety devices for complete pe ‘of operator & equipment from all possible operational failures. ah aor alfre gore For Chief ‘Mechanical Engineer ‘BWA FY AORT WINER Ae HAA-1(OPEN) workshop Projet, lian Raways, ParsPage 363 of 445. | Concomitant Accessories 000431 Machine should be accompanied by the all concomitant accessories, and their cost should be included in the basic price of the machine. ‘Any other concomitant accessories required to make the machine/equipment fully operational on installation when connected to mains power source. Optional Accessories ‘Any optional accessories, which, in the opinion of the tenderer can contribute to higher production rate, better precision or quality level should be quoted separately and shall ‘not be included in the price of the machine/equipment. Spares ‘The supplier should give the price list of recommended spares, which will be purely need based and therefore, their rate shall not be taken for evaluation. Installation and Commissioning Joint chock :- The contractor/supplier would be required to carry out a joint check at the consignee’s end, along with the consignee, before unpacking is done, to avoid subsequent complaints regarding short shipmentitransit damages. It is necessary that this joint inspection be done immediately on receipt of the machine by consignee to avoid commissioning delays due to shortages/transit damages. The contractor/supplier or his agent will commission the machine/equipment. The machinefequipment performance shall be demonstrated by the contractor or his agent after successful commissioning at the workshop site and prove out the claimed capability, to the satisfaction of consignee. After such successful demonstration, the consignee shall take over and watch the machine/equipment performance before the final acceptance certificate is issued. Provision of all tools and equipment, technical and unskilled manpower, material handling equipment and all materials for installation and commissioning by ccontractor/supplier. Loading/unloading of the equipment on receipt and its movement to the site of installation by contractorisupplier. Training The contractor shall fully and adequately train the staff nominated by Railways free of ‘cost in the proper operation and maintenance of the machine/equipment at site during ‘commissioning of the machine/equipment. ‘The training for maintenance of the equipment will include troubleshooting and repair of the machine and accessories. The training to be imparted will cover all mechanical / electrical / electronic equipment / part programming, Technical Literature The contractor shall supply four sets of technical literature preferably in English/Hindi language, which shall comprise of all the user and maintenance manuals supplied by OEM's of different equipment used in the plant and a soparate user and maintenance ‘manual for the complete system prepared by the contractor/supplier. Proving Test ‘The vehicle performance shall be demonstrated by the contractor or his agent for a period of two shift of 8 hrs during commissioning at the consignee's works. After such ‘successful commissioning the machine performance shall be watched for a period of 01 (One) month. Inspection of Equipment Inspection should be carried out by Railways or Authorized Representative golfer For Chief Mechanical Engineer E Pha legh We &(OPEN) Indian Raways, PatniPage 364 of 445 Schedule(!) ‘Specification no. WP/Mech/M&P/BPLIRRSV Leading parameters of Battery Operated Rail cum Road shunting vehicle (Supplied by consignee for guidance of manufacturer) 1 [Type Rail cum road vericle Z_| Senvice weight BUA 10% 3__ [Max wheel foad ‘Approx. 7.257 4 | Gauge 4676 mm 11435 mim 5 | Max. Speed Vi loaded 0-2 kmir V2 solo 0~4 kmfhr 6 | Max. tract. effort ~|ASKN at whee! rim at adhesion p =0.5 in dry (03 in wet) 7 | Towing capacity 135T locomotive 7 other rolling stock at gradient from 0-2.5 per 1000. @_| Wheelbase 1880 mm 3 |Wieth £7300 (2420) min 72060 (2180) mim 40 | Height max 1420 (560mm including antenna) mm for visibility 41_| Total length (without couplers) | 3080 mm 12_| For Up railing ‘approx. 3.5m x Sm 73 | Gulding wheels 4 Nos. Stecl flanged wheel, profile according to IR. CSL ~ 3040 or UIC 510, dia. 330mm Ta | Traction steering wheels | 4 Nos. Vuikolan / Polyurethane dia. 304 x 140 mm, 15 | Steoring ‘urheel crab side way, perpendicular, “croular, “360 degrees rotating on own axle 16 | Battery capacity ‘B0V, 460A waterless, with electoiye mixing for less maintenance 17 | Battery charger Charging time max 10 hours, 416V, 3 Phase + earth, fused at 168 18 [Esystem 24 V PLC Igan Safety integrity Level sis For Chief Mechanical Engineer Workshop Projects, Idan Relays, Pats tender no, 2021-WP-BPL-Mech-WT-18(0PEN)FSH Page iin 53 Specification No- WP/MechiM&P/BPLICMTWM Item No. 08, SPECIFICATION FOR COLD METAL TRANSFER WELDING MACHINE ‘Scope The scope covers inspection, supply, commissioning, Proving-Out Test, training and handing over of Intelligent Monitor (Linux/Others based) Mulli-Process Welding Machine preferably with Touch Screen Panel with language change options, compatible for upgradation to Robotic and Mechanization options for future use, digital microprocessor-contralled inverter based synergic pulse MIG/ MAG Cold Metal ‘Transfer Welding Machine with powder coated sheet metal body and consisting of inverter-based power source, wire feeder unit, torch gun, argon regulator, in-built digital ammeter, voltmeter and interconnecting cables along with standard accessories and items necessary to make unit fully functional when connected to power source and other utilities, Sources: Likely sources of manufacturers and suppliers are- () Mis Fronius India Ltd, Pune; Note: Bidders may quote for any of the reputed brands from the above likely sources. However, makes quoted other than ‘Likely Sources’ can also be considered in case enough documentary evidences in support of proven design, successful supply, satisfactory performance in Railway Industry, adequate manufacturing capaclty, established quality norms of Railways or similar heavy industries are submitted. General Description and Scope of Supply: Specification covers supply, installation, testing, commissioning of Cold Metal Transfer Welding Machine. The supply shall include all cables, cable laying, earthing and all fixing accessories, standard accessories, which are essential to make the Welding ‘machine fully operational, All related material required for inspection, erection and commissioning of Machine and connecting electrical equipments with cable, cable laying and fixing accessories shall be included in the cost of basic Machine. Tool boxes containing all tools (Electrical and Mechanical) required for the maintenance of the machine should be supplied along with the machine. Tools shall be ‘supplied in two different too! boxes, with individual pocket for each item and shall be of MEKASTERV/TAPARIA or reputed ISI make. Unit cost of machine will be inclusive of cost of tool box. ‘Submission of GA Drawingsirelated drawings (if any), Make-Model & QAP for approval to Rallways by successful bidder. Civil work including foundation (if any) for said machine shall be in contractor scope. ‘The cost of machine foundation will be inclusive of cost of machine. Technical specifications of M&Ps are to be read and followed in unison with Special Conditions of Contract for Mechanical Works and General specification for ‘Supply of M&P speoified in the Tender Document. Broad Paramete: ‘The welding plant should be capable of welding in steel plates of 2-30 mm thick. Welding plant shall meet broad technical parameters detalled hereunder. Technology Digital microprocessor controlled mull pulse MIG Welding ‘Type of Inverter ieaT ‘Current Range 5-400 A000834 pages ores Main Voltage ~ |S phase, 380-460 V— OO Mains Frequency ‘50/60 Hz Welding Current (minimum) | 360A @ 60% Duty Cycle 320@ 100% Duty Cycle (D.C. calculated at 10 min bbase and 40°C ambient condition) Type of coating “Forced air cooled ‘Open Circuit Voltage 60-58 V Efficiency > B5% Power factor 0.99 Protection Class 125, Tasulation Class F or botter Wire Feeder | Feed Mechanism “Troll with quick change over Wire feed range 4-24 mimin | Wire filer diameter ‘08-1.6 mm (roller set for 0.8.1.2 1.6 mm wire tobe supplied) ‘Gun connestor Euro or better (OEM should specify on this) Degree of Protection 123 Water cooled Welding Gun , Type | Euro or better (OEM should specity on this) ‘Current rating(minimum) [320A @ 100% duty cycle DC Lenath of Torch 3m Filler wires 08-16 mm Gable construction Integrated type with cover 4.0 Standard accessories: 7 [lnterconnection cable assembly comprising of power cable with | 1m ‘copper cable connectors for welding current, gas hose, coolant Circulation hose, control cable inserted in flexible heat ‘resistant sleeve to mest 100% Duty Cycle load requirement. 2 |4 core copper cable flexible PVC insulated & sheathed conforming | 15m to 1S 694 (or latest) for input connection from main power supply point to the plant 3 |Earthing copper cable ISI marked 50 mmP"P with heavy duly | 15m clamps 4 | Leather hand gloves as per IS 2573-1986 (or latest) 1 Pair 5_| Operation and maintenance tools including screw drivers 1 Set 6 _| Argo shield gas pipe line connecting regulator to welding plant 15m 7_| MIGIMAG welding torch water cooled as per specification ino [8 _| Wire feeder unit as per specification ino 9_| Trolley forthe welding plant tno 70 | Cooling unit (integrated with power source as a module) suitabie for | 1 no welding plant with fitter, flow and thermal sensor connected to ‘power source and controlled through power source T_| Remote control 10m Tho 12 | Additional coolant 10 liter in container Tecan 13 | Consumables (contact tip-50 no, gas nozzles-10 no, diffuser- 10 no, splatter ‘guard-10 ino, liners-25 no, insulating rings-10 nos. Consumables are to be provided for 0.8 mm,1.2 mm and 1.6 mm electrode in ratio of 40%,50% and 410% of the mentioned quantity where applicable) wa ger aie SAR For Chief Mecherical Engineer JRC) RE aD. Bele HEPP-BPL-Mech-WT-16(OPEN) Projects, ian Ralways, PatsPage 367 G4 35 Welding plant should be capable of synergic pulsed MIG welding with adjustable arc force, crater current, crater voltage, crater fil, welding current, voltage, with 2/4 step welding modes switch. Plant should have bright digital display for Amp and Volt meters for easy viewing in sunlight, and pre-settable for precise control of various welding parameters. Machine should be capable of storing pre-set welding programs for various welding (100 programs minimum) which can retrieved to set the welding parameters by the welder easily. Plant should have soft start ignition function and protection to over temperature, over current, under voltage and power phase absence. Welding machine should be capable of control through a remote control by welder. Dust fiter cables should be inserted in floxiblo heat resistance hosel sleeve to avoid damage to cables. Machine should have 1000 Job stores capacity Design Features: Industry 4.0 -Machine supplied should be Industry 4.0 compliant and ready. The data feedback speed should be min 100 MBPS or better .The data documentation should be stored in the machine for a min period of 30 days Proving Out Test:~ ‘The successful tenderer shall guarantee the workmanship, material and satisfactory operation of all individual and collective items of the equipment offered, ‘The guarantee for performance shall cover Individual items, systems for their accuracy 4s well as for the integrated operation of the machine and its ancillaries as a whole, ‘The equipment shall be put into trial for proving performance guarantee parameters after continuously working for 10 days, After-Sales-Service: The supplier shall offer maintenance support including calibration for the machine in the form of Annual Maintenance Contract after satisfactory completion of above warranty period at mutually agreed terms. General: Deviations, Warranty /Guarantee and Dispatch of the Machine from Manufacturer Works are to be read and followed in unison with Special Conditions of Contract for Mechanical Works and General specification for supply of M&P specified in the Tender Document. For Chief Mechanical Engineer ‘Workshop Projets, Indian Ralways, Pate E tender no. 2021-WP-8PL-Mech- WT-18(OPEN)000436 Page 368 of 45 "UB pecification no. WP/MechiM&PIBPLIICSSLTM. tem No. 09 SPECIFICATION FOR COIL SPRING SCRAGGING & LOAD DEFLEXTION TESTING MACHINE FOR LHB AND IRY COACHES 1.0 Scope 4.1. The scope of supply shall include design, manufacturing, supply, installation, testing ‘commissioning and proving of 01 no. Coll Spring Scragging and load deflection Testing Machine for LHB and IRY Coaches as per parameters specified in Annexure-X with all accessories, spares etc and shall be supplied at CRWS, Bhopal, WCR, Madhya Pradesh, India as per instructions and conditions of contract. It shall also include installation and commissioning of related equipment, training of personnel in operation and maintenance of machine and supply of technical documentation. Sources: Likely sources of manufacturers and suppliers are- () Mis Asco Rail Sp. Zoo, Poland (il) Mis Enkay Enterprises, New Delhi (il) Mis M/s MARWAHA MFG, CO, New Delhi Noto: Bidders may quote for any of the reputed brands from the above likely sources. However, makes quoted other than ‘Likely Sources’ can also be considered in case enough documentary evidences in support of proven design, successful supply, satisfactory performance in Railway Industry, adequate manufacturing capacity, ‘established quality norms of Rallways or similar heavy industries are submitted. 2.0 General Description and Scope of Supply’ 2.1. One (no) ~ Coll spring scragging and load deflection testing machine for LHB and IRY Coaches including frame, working table, Composite ram cylinder assembly, hydraulic assembly, measuring system, recording system, control and operation, lubrication & ‘spring handling system and all other accessories, spares and supports structures etc. 22 Allrelated material required for inspection, erection and commissioning of Machine and connecting electrical equipments with cables, cable laying and fixing accessories shall be included in the cost of basic Machine. 2.3 Necessary information regarding the conditions under which the Coil Spring Scragging and load deflection Testing Machine for LHB and IRY Coaches is to be Used, together with other particulars necessary for manufacture and commissioning of the machine, are given in Schedule-I. Sub mission of Catalogues, specification and related drawings for approval to Rallways by successful bidder. 24 A tool box containing all tools (Electrical and Mechanical) required for the maintenance of the Coll Spring Scragging and load deflection Testing Machine for LHB and IRY Coaches should be supplied with the machine. Unit cost of machine will be Inclusive of cost of tool box. 2.8 Technical specifications of M&Ps are to be read and followed in unison with Special Conditions of Contract for Mechanical Works specified in Tender Document. 2.6 Civil work including foundation (if any) for said machine shall be in contractor scope. ‘The cost of machine foundation will be inclusive of cost of machine. 3.0 Standard specification (Mechanical): 3.1. The machine shall be designed, manufactured, erected and tested as per the latest relevant IS specications. 32 The scope of supply shall include design, supply, and installation, testing, commissioning and proving of machine. The machine shall have folowing configuration 2) Frame, Working Table b) Composite Ram cylinder Assembly ©) Hydraulic System & Lubrication System 4) Measuring System & Recording System AE _ 8} Control and Operation ae yea aiIw yeh Handling System For Chief Mechanical Engineer rcearat GRP eT HRN 2 AF-BPL-Mech-WT-18(OPEN) Workshop Projects, incian Ralways, PatnaPage 369 of 445 000437 a) Machine shall be capable of Scrag testing & load deflection testing of coll springs for LHB & IRY, high-speed coaches Parameters of springs to be tested are indicated In Annexure-X. The machine shall be supplied in accordance with parameter given in Schedule-t Generating and effective ram force of at least 25 T as per Schedule-1 ‘Working in normal indian Railway workshop environment with ambient temperature Up to 48 degree C and relative humidity up to 98%, ‘The following type of tests will be conducted on the coil springs:- Axial Spring Stifmess Transverse Spring Stiffness Bowing deflection. Bowing angle, Bowing force. Force Deflection diagram Productivity a) The bidder shatl furnish the estimated floor-to-floor time of all operations for the components listed in Annexure-X. b) The basis of the timing should be clearly given with break up of all the parameters. ©) The timing should be maintainable for regular 08 hrs shift for three shift working 6 days a week with machine availabilty of 85%. Performance Standard: Purposes and Capability: The machine shall be capable of: a) Scragging and load deflection testing of coil springs for LHB and IRY Coaches having parameters indicated in Annexure-X The following type of tests will be conducted on the coll springs Spring Stiffness, Transverse Spring Stiffness Bowing deflection, Bowing angle Bowing force. /. Force Deflection diagram, a) Generating the effective ram force of at least 25 t as per leading parameters of sschedule-1 Concomitant Accessories ‘The machine should be accompanied with the following concomitant accessories: a) First fill of oils and lubricants for intial commissioning Alot b) Electrical cables tot ©). Maintenance tools 1 set 4) Fasteners for installation of the machine ‘tet ) Plugs and bushes for holding coil springs as per 1 set spring parameters indicated in Sch.-1 ) Spring Handiing System (Ref.clause.8.10) 1 set 9) Load calibration unit, tet h) Electrically operated jib Crane one ton capacity 1 no. i) Computer and peripherals as per relovant clause. 88 1 set i) Any other accessory besides those given above which in the opinion of the bidder is essential to make the machine fully operational when installed and connected to Power source shall be provided as concomitant accessory. Cost of such accessories shall be included in the basic price of the machine, at ithe gohan 5 Weshanical Engineer oe tere oreofeatures, which should be available on the machine, are mentioned below- 4) The test piece should not get unclamped in the event of power failure. b) Load meter should be provided to indicate the load on Machine, so that the load on the Machine can be maintained within the safe limits. ©) The machine dosign shall ensure safety of the operator and the machine at all times including accidental slipping of the spring under test. Details of safety features provided in the machine shall be furnished. d) To eliminate the possibilty of injury to operator due to breaking of spring under testing, suitable guards shall be provided and interlocked with ram movement. e) Suitable interlocks should be provided to protect the machine in the event of hydraulic oil failure, lubrication failure, pneumatic system failure, fluctuation in voltage and frequency. f) The safety feature shall include safety device against over loading of any drive, over travel of any slide and interlock against conflicting motions. 19) Mushroom type emergency stop shall be provided on the machine, which shall be easily accessible and capable of disabling the machine in case of any emergency. hh). The noise level should not exceed 85 dB at full load when measured at distance of 1 meter away from the periphery of the machine. Noise measurement should be carried out as per NMTBA noise measurement Technique! IS0-3746, |) A detailed list of all alarms / indications provided on machine should be submitted by the supplier. |) All the pipes, cables etc. on the machine should be well supported and protected. These should not create any hindrance to machine operator’s movement for effective use of machine. ) All the rotating parts used on machine should be statically & dynamically balanced to avoid undue vibrations & noise. 1) OIL 8 water pipe lines should not run with electrical cable in the same tray/trench. m) No hazardous chemicals shall be required to be used in the machine, rn) The machine during operation shall ensure safety of the operator at all times. Details of safety features must be explained. 8&2 Specific Characteristic Page 370 of 445 Basic Design Features: Safety features: The machine shall incorporate all safely devices so as to provide complete protection to the operator and machine. Some of the important safety ‘The supply shall be include all equipment and concomitant accessories as detailed in the specification and any other equipment, which the manufacturer considers essential ‘to make the machine fully operational when installed and connected to power source. 83 Frame ‘a, The machine frame shall be a rigid and robust, stress relieved, Meehanite cast iron casting conforming to IS: 14329-2000 (or latest) or fabricated steel conforming to IS: 2062, grade - B duly stress relieved structure capable of withstanding 1.6 times the normal developed force. b. The structure should be thoroughly stress relieved. Method and necessary certiication/documents of stress relieving should be furnished. . All weldments shall be checked for weld defects. Methods of checking weld defects shall be indicated along with a brief write up, 84 Working Table ‘a, The machine table shall be a rigid and robust, stress relieved, Meehanite cast iron ‘casting conforming to IS: 14329-2000 (or latest) or fabricated steel conforming to 1S; 2082, grade ~ B duly stress relieved. It shall have an arrangement for ensuring that the axes of load cell and springs are coincident for all types of spi 4 in to Schedule-l . Arrangement provided shall be explained Ba Ra Vifae sah For chet wep mide ¥P-BPL-MectWT-10(0PEN) ftatorn, area Ya, TEN ‘Workshop Projecs, indian’ 7(abe Page 371 of a 0043 b. Provision shall be made in the working table to hold all types of coil springs as indicated in Schedule-t securely to the working table with plugs and bushes offered 88 concomitant accessory. 8.5 Ram-Cylinder Assembly ‘a. The main cylinder shall be machined out of stee! forging or seamless stool tube and ultrasonically tested for cracks. The cylinder shall be honed to 0.3 microns surface finish. Material specification of the cylinder along with surface finish offered shall be indicated, b. The ram shall be machined out of steel forging hardened, ground and hard chrome plated. Surface finish of the ram shall be 0.3p. Surface hardness of the ram shall be HRC 65 minimum. Minimum thickness of chrome piating shall be 25y. Material ‘specification of the ram, thickness of the chrome plating and surface hardness shall be indicated ©. The cylinder shall be double acting and provided with proper rear guiding arrangement for the ram, The piston assembly shall be effectively pressure sealed at both ends to prevent leakage of ol The cylinder gland packing shall be designed for almost dry rod operation, Arrangement provided for relieving the piston seals of any lateral loading along with anti rotation or angle shifting of ram during load applied shall be explained. The sealing arrangement shall be explained with a sketch and a brief write-up. d. Hydraulic seals, “O' rings and packings under compression shall be made from Teflon/PTFENViton. Rubber seals shall be of Neoprene. e. Piston slide rings and gland packing liners shall be of Turcite / Turcon / Bronze impregnated PTFE. {The ram shall be able to generate an effective force of at least 25 T in accordance to schedule-I parameters. Design calculations taking into consideration frictional losses in the ram-cylinder assembly and the hydraulic circuit shall be furnished for motor power, speeds, pump capacity and hydraulic pressure. g. The ram end shall carry @ moving platen of highly wear resistant alloy steel Method of coupling the moving platen to the ram and material of the platen shall be Indicated, 8.6 Hydraulic System . A suitable positive displacement pump shall be provided for the high-pressure cil circuit. Type, make and model number of the pump shall be indicated in the bid. Only Rexroth / Vickers / Yuken / Mico Bosch/Polyhydron make pumps shall be accepted. The hydraulic elements shall be of the same or compatible make as the Pump Make of each hydraulic element shall be indicated in the bid. 8.7 Measuring System a. A load cell shall be provided for precise measurement of the force applied. The load cell shall have replaceable wear plates to ensure continued accuracy of ram stroke measurement. Least count of the load cell shall be 0.01t and accuracy shall bbe +/-0.5% (RDV, Read down value). b. It shall be possible to cutout the load cell during Scragging of springs. Arrangement provided shall be explained. Arrangement provided shall be explained in the bid in ase of Schedule-I parameter machine. ©. Arrangement shall be provided to measure the ram stroke with an accuracy of O.1mm. It shall be possible to select the zero datum at any ram position. The arrangement provided shall be explained in the bid d. It shall be possible to preset the ram force anywhere from zero to maximum, Arrangement provided shall be explained. fe. Arrangement shall be provided to indicate the spring height before and after testing, ma 6 i if Ea Ei Mgea 48(OPEN) Patna ca ‘id| o00440 OO aman * | t {. The machine shall be capable of recording, storing and displaying the following Ss i. Actual free height ii Actual height under tare. il Actual home height iv, Stiffness between two given heights. v. Bowing at a given load. vi. Plot load vis deflection & Stiffness vs deflection vii Table of results for single or group of springs. Vii Free alignment deviation and angle of deviation atthe specified load. ix. Lateral Stiffness between two prescribed (vertical) load. x. Plot of lateral displacement vs lateral load and lateral stifiness wis lateral displacement. xi. Tabular results indicating vertical as well as lateral characteristics. xii, Data shall be recorded in the computer as well as on the portable data analysis system. 8&8 Recording System ‘The computer based recording system shall comprise of the following a. Industrial PC of IP 65/NEMA 4 capable of working in shop floor in the temp range of 0- 50° C of Seimens / Beckoff/ Fanuc make. Printer LaserJet 1000 plus / P 1505 or with simiar feature of HP make only. 1000 VA UPS of Einova/Bluebird/APC/Elent/Logicstat make only. J. The software shall be designed specifically for spring testing machine and shall be capable of machine control, data collection and result evaluations. It shall be flexible and suitable for accurate spring testing system and capable of streamlined. e. The software shall be capable of measure, display and evaluate spring center of force, side load movements. It shall have the provision of bowing and bowing angle measuroment automatically. Details for the same shall be explained in the offer. f. The software shall be Windows based latest version. It shall be capable of statistical calculations on the recorded values for standard deviation, median and coefficient of variation. The software shall be loaded on the computer hard disc and a set of CDs containing the software shall be supplied with the machine. ‘a. The software shall be capable of auto-calibration of the machine. The values of load indicated and recorded by the computer shall be identical b. The bidder shall explain in detail the flow chart of the application/analytical software to be provided for recording and analyzing the data collected during the testing of springs. 89 Controls and operation a. Operation of the machine shall be through electronic soft touch Keypad and selector switches provided on an ergonomically designed centralised control panel, ‘which shall allow a full view of the working area, Details of controls shall be furished in the bid ». It shal be possible to preset the ram force anywhere between 10% to maximum through a pressure selector switch with tonnage. The precise range of conto! shall be ingicated in the bid. Faclity for inching, single cycle and continuous cycle shal be provided. c. The total ram force being applied when the machine is working shall be provided at 2 suitable location so that iis easly visible to the operater. Least count for force and pressure shall be 0,01 and 5 Kg/om2 respectivoly. 4. Inthe testing cycle, deflection shall be measured during loading and unioading for which inching of the ram shell be possible beyond the preset limit forthe test load. The load shall be gradually reduced to reach the preset value of test load for recording of deflection. It shall be possible to hold each load for at least § minutes x ater which the corresponding height of the spring under load shall be determined. Electrical limit switches shall be provided for stopping the rage e. aa en aif eae ForGh et Mea Bap oP. ‘Mech WT-18(OPEN) Paina