Reasoned Document for comments received on draft technical specification for Stationary Flash Butt Welding Plant and

connected machines & accessories, uploaded on RDSO internet website on 09.01.2019.

S. Provisions of Draft Comments of Stakeholders RDSO Remarks Final Draft Technical

No Clause Technical on the comments Specification of Mobile
No. Specification of received from Flash Butt welding Machine
Stationary Flash stakeholders after consideration of the
Butt welding Plant comments, if any.
1. 0.0 General 1.Comments of NER – NER- 0.0 General
0.1 Stationary Flash Butt 0.1 Accepted as 0.1 Stationary Flash Butt
Welding Plants 0.0 General provisions are Welding Plants working in
working in Indian 0.1 Stationary Flash Butt Welding Plants working in Indian elaborated to make Indian Railways are of old
Railways are of very Railways are of very old vintage. These plants are to be clearer. vintage. These plants are to be
old vintage. These replaced with plants of state of art technology prevailing at replaced with plants of state of
plants are to be present. The old plant may have to be continued in service 0.2 At present, 60 art technology prevailing at
replaced with plants as per discretion of Railway administration. It is intended Kg/m rail section present. The old plant may
of technology that suitable layout keeping available infrastructure viz. Rail has been have to be continued in
prevailing at present handling system, Rail loading and unloading system etc. in envisaged for 25T service as per discretion of
view is decided by the supplier of plant. axle load on Indian Railway administration. It is
Railways. intended that suitable layout
0.2 The plant and equipments supplied under these Considering the keeping available
specifications shall be capable of welding rails of section future requirements infrastructure viz. Rail handling
upto 78kg/m with ultimate tensile strength upto 130 kg/mm2. and expected life of system, Rail loading and
The capability of plants and equipments will have to Flash Butt Welding unloading system etc. in view
physically demonstrated for prevalent rail sections on Indian Plant, rail section is decided by the supplier of
Railways. For Rail sections and UTS, which is not in use at and UTS of rail has plant.
present, Theoretical calculations shall be furnished to been kept in the The capability of plants and
demonstrate the capabilities. This is applicable to all the specification; equipments will have to
Plants supplied under this contract. which is considered physically demonstrate for
adequate, hence prevalent rail sections on
2. Comments of M/s Schlatter – Noted. no amendment . Indian Railways. For Rail
M/s Schlatter – sections and UTS, which is not
3. Comments of M/s NENCKI, Switzerland – Noted. No comments in use at present, Theoretical
M/s NENCKI - calculations shall be furnished
No comments to demonstrate the
capabilities.

2. 0.2 This technical 1.Comments of NER - NER - 0.2 This technical specification
specification has 0.3 This technical specification has been drafted to reflect Accepted and has been drafted to reflect the
been drafted to the performance and quality requirements of the Stationary modified. performance and quality
reflect the Flash Butt Welding Plants in a neutral manner without bias requirements of the Stationary
performance and to any specific manufacturer. Bidders are requested to M/s Schlatter – No Flash Butt Welding Plants.
Page 1 of 49 
 
 quality requirements carefully study the specification and ensure that their comments. Bidders are requested to
of the Stationary equipment fully complies with these specifications. carefully study the
Flash Butt Welding Thereafter, if a bidder feels that his equipment can M/s NENCKI- specification and ensure that
Plants in a neutral substantially meet the performance and quality requirements No comments. their equipment fully complies
manner without bias laid down herein but does not fully satisfy a particular item of with these specifications.
to any specific this specification, he shall mention the deviations, if any, in Thereafter, if a bidder feels
manufacturer. the statement of deviation from the specifications, giving the that his equipment can
Bidders are details how the functional requirements of this specification substantially meet the
requested to carefully are going to be met with. performance and quality
study the requirements laid down herein
specification and 2. Comments of M/s Schlatter – Noted. but does not fully satisfy a
ensure that their particular item of this
equipment fully 3. Comments of M/s NENCKI, Switzerland – Noted. specification, he shall mention
complies with these the deviations, if any, in the
specifications. statement of deviation from the
Thereafter, if a bidder specifications, giving the
feels that his details how the functional
equipment can requirements of this
substantially meet the specification are going to be
performance and met with.
quality requirements
laid down herein but
does not fully satisfy
a particular item of
this specification, he
shall mention the
deviations, if any, in
the statement of
deviation from the
specifications, giving
the details how the
functional
requirements of this
specification are
going to be met with.

3. 0.3 The bidder shall 1. Comments of M/s Schlatter – M/s Schlatter – 0.3 The bidder shall specify
specify the model of The bidder shall specify the model of Flash Butt Firm has specified the model of Flash Butt
Flash Butt Welding Welding Unit and related equipment’s offered and furnish the the components Welding Unit and related
Unit and related a detailed Technical Description of the same. with his GAAS80 equipments offered and
equipments offered Schlatter GAAS80 with necessary component like machine. The furnish a detailed Technical
and furnish a detailed hydraulic power station; cooling device ; integrated specification is kept Description of the same.
Page 2 of 49 
 
 Technical Description stripping device and weld processing system and Weld generic. Hence, System/sub-systems and
of the same. Analyzer System for quality control and storage data base. suggested working mechanisms of the
System/sub-systems System/sub-systems and working mechanisms of the specification for a machine shall be described in
and working machine shall be described in the “Technical Description” particular model of the “Technical Description” in
mechanisms of the in detail along with the sketches to show the manner machine/firm is not detail along with the sketches
machine shall be in which the requirements of the specifications are accepted. to show the manner in which
described in the accomplished by the offered model of FBW machine. the requirements of the
“Technical 2. Comments of M/s NENCKI, Switzerland – Noted. But M/s NENCKI – specifications are
Description” in detail NENCKI is not the principal manufacturer of Welding Comments are accomplished by the offered
along with the Machine. However, with the expertise from Projects like informative only. model of FBW machine.
sketches to show the Bhilai Steel Plant and Setting up of New FBWP at
manner in which the Sabarmati, NENCKI is able to build the specifications of a
requirements of the Welding Machine too.
specifications are
accomplished by the
offered model of
FBW machine.

4. 0.4 The tenderer shall 1.Comments of NER - NER – 0.4 The tenderer shall furnish
furnish video 0.5 The tenderer shall furnish video compact disc showing Accepted as video compact disc showing
compact disc the working of Machine in real time under field conditions. In provisions are the working of Machine in real
showing the working case, the tenderer intends to offer the improved version of elaborated to make time under field conditions. In
of Machine in real Automatic Flash Butt Welding machine for welding of rails, clearer . case, the tenderer intends to
time under field for which video is not available, he can submit the video of offer the improved version of
conditions. his existing working plant with description of changes Automatic Flash Butt Welding
Photographs of the proposed and a walk through 3-D simulation model of machine for welding of rails,
machines offered and proposed plant. Photographs of the machines offered and M/s Schlatter – for which video is not
technical literature technical literature shall also be enclosed with the offer. The Comments are available, he can submit the
shall also be photographs shall also show close-ups of various working informative only. video of his existing working
enclosed with the assemblies/systems and the full Plant. plant with description of
offer. The 2. Comments of M/s Schlatter – M/s NENCKI – changes proposed and a walk
photographs shall The tenderer shall furnish video compact disc showing the Comments are through 3-D simulation model
also show close-ups working of Machine in real time under field conditions. Informative only. of proposed plant.
of various working Photographs of the machines offered and technical Photographs of the machines
assemblies/systems literature shall also be enclosed with the offer. The offered and technical literature
and the full Plant. photographs shall also show close-ups of various working shall also be enclosed with the
assemblies/systems and the full Plant. offer. The photographs shall
Presentation material included. Available videos CD will be also show close-ups of various
submitted along with tender documents. working assemblies/systems
3. Comments of M/s NENCKI, Switzerland – Noted and the full Plant.
Technical description, Photographs and videos of the
individual working machines (Grinding, Straightening,
Page 3 of 49 
 
 Brushing, Test press) are available and if required can be
submitted with the offer.

5. 0.5 All machines 1.Comments of NER – NER- Accepted as 0.5 All machines including
including Flash Butt 0.6 All machines including Flash Butt welding machine provisions are Flash Butt welding machine
welding machine should be well synchronized, durable, easy to maintain and elaborated to make should be well synchronized,
should be well of robust design. Machines should be able to coup cope up clearer durable, easy to maintain and
synchronized, the forces coming during the operation. of robust design. Machines
durable, easy to M/s Schlatter – should be able to cope up the
maintain and of 0.7 The tenderer shall be either manufacturer of the No comments. forces coming during the
robust design. Automatic Flash Butt Welding Plant for welding of Rails or operation.
Machines should be accredited agent of manufacturer. It shall be clearly M/s NENCKI – The tenderer shall be either
able to coup up the specified whether other equipments are manufactured for Comments are manufacturer of the Automatic
forces coming during tenderer or are bought out item. In case of bought out item, Informative only. Flash Butt Welding Plant for
the operation. the model name and name of manufacturer shall be clearly welding of Rails or accredited
indicated. agent of manufacturer. It shall
2. Comments of M/s Schlatter – be clearly specified whether
O.K Please note point 2.2 Machine body. other equipments are
3. Comments of M/s NENCKI, Switzerland – manufactured for tenderer or
Noted are bought out item. In case of
Nencki Rail Handling machines have been operating in bought out item, the model
multiple shifts for decades name and name of
manufacturer shall be clearly
indicated.
6. 1.0 Description/Scope 1.Comments of NER - NER - 1.0 Description/Scope of
1.1 Flash Butt Welding 1.0 Description/Scope of Work: Accepted as Work:
plant consisting of 1.1 Flash Butt Welding Machine Plant normally provisions are 1.1 Flash Butt Welding
following consisting of following machines/equipments/ components: elaborated to make Plant normally consisting of
machines/equipment (i) Automatic Flash Butt Welding Unit with clearer following machines/
s/ components: (a) Programmable Logic Control (PLC) SCR- equipments/components:
(b) Weld data recorder Accepted as (i) Automatic Flash Butt
(i) Automatic Flash (c) Smoke trapping device provisions are Welding Unit with
Butt Welding (d) Automatic cooling device elaborated to make (a) Automatic stripping/
Unit. (e) Equipment for post weld heat treatment clearer trimming unit.
(ii) Programmable (ii) Standby Diesel generator NR – (b) Programmable Logic
Logic Control (iii) Rail end brushing/ Cleaning machine Hardness and Control (PLC)
(PLC) (iv) Weld profile grinding machine Transverse load (c) Weld data recorder
(iii) Weld data (v) Rail straightening machine testing machines (d) Smoke trapping device
recorder (a) Pre-straightening Machine are independent (e) Automatic cooling
(iv) Smoke trapping (b) Post weld straightening Machine testing machines device
device 2.Comments of SCR and may be (ii) Equipment for post weld
(v) Automatic 1.1(i) Automatic Flash Butt Welding Unit with automatic procured on heat treatment
Page 4 of 49 
 
 cooling device stripping/ trimming unit. requirement basis, (iii) Standby Diesel generator
(vi) Equipment for 1.1(ix) Fully automatic Weld grinding machine hence not required (iv) Rail end brushing/
post weld heat 1.1(x) Rail Pre-straightening machine & Post weld in this specification. Cleaning machine
treatment straightening machine Capacity of (v) Fully automatic Weld
(vii) Standby 1.1 (xi) Automatic weld identification number punching straightening profile grinding machine
generator machine machines is (vi) Rail straightening machine
(viii) Rail end 3. Comments of NR – already mentioned (a) Pre-straightening
brushing Hardness and Transverse load testing machine should also at Clause 11. Machine
machine be added. Capacity of transverse load testing machine and (b) Post weld
(ix) Weld grinding straightening press should also be compatible to heaviest M/s Mechelonic – straightening Machine
machine section to be welded by welding machine in future. Not accepted as (vii) Automatic punching
(x) Rail straightening 4.Comments of M/s Mechelonic Semi-automatic profile manual operation machine capable for punching
machine grinding machine with manual grinding support is preferred will give less weld identification number as
as a automatic machine will take too long time for grinding, accurate results. per Para 9 of the Manual for
reducing production. Flash Butt Welding of Rails-
5.Comments of M/s Schlatter – Revised 2012.
(i) Automatic Subject of supply All above plant and
Flash Butt equipments shall be capable
Welding Unit M/s Schlatter – of welding/ handling rails of
section upto 68kg/m with
(ii) Siemens S700 machine control Comments are ultimate tensile strength upto
Programmable system and digital Weld Informative only. 130 kg/mm2.
Logic Control processing System SWEP
(PLC) (programmable by weld Studio
Programme
(iii) Weld data Schlatter WeldAnalyzer System
recorder SR –
Such measurement
(iv) Smoke Only the smoke extraction hood.
in welding line is
trapping device Extraction device is part of the not required hence
project scope of Maco
not considered.
Corporation.
(v) Automatic Belongs to the scope of delivery
cooling device point. Will be supplied as
attachment
(vi) Equipment After weld -treatment not
for post weld integrated in the FBW machine; M/s NENCKI –
heat treatment separate air cooling device type Comments are
Voest Alpine and associated Informative only.

Page 5 of 49 
 
 compressor is supplied as a
separate part and must be used /
operated manually.

Standard machine so far

supplied, no customer has
demanded this provision.
On specific requirement,
provision could be made as per
customers requirement.
(vii) Standby not scope of supply by Schlatter.
generator Part of project supply of Maco
Corporation.
(viii) Rail end not scope of supply by Schlatter.
brushing Part of project supply of Maco
machine Corporation.
(ix) Weld not scope of supply by Schlatter.
grinding Part of project supply of Maco
machine Corporation.
(x) Rail not scope of supply by Schlatter.
straightening Part of project supply of Maco
machine Corporation.

6.Comments of SR –
Description/Scope shall include the following additional
features:
Digital Measuring Device for Rail Head Width and Height.
Description/Scope shall include the measurement on head
width or height of the rail etc. for selection or rejection of rail
ends. One equipment for measurement shall be included
under Para1.1.
7. Comments of M/s NENCKI, Switzerland –

ii, v, vi, viii, ix and x are in the scope of Nencki for respective
Machines.
Rest is part of Flash Butt Welding Machine manufacturer.

Page 6 of 49 
 
7. 1.2 Specification also 1.Comments of NER – NER- 1.2 This specification broadly
covers installation of 1.2 All above plant and equipments shall be capable of 1.2 Provisions covers the Working
the plant, Training of welding rails of section upto 78kg/m with ultimate tensile covered under Mechanism & Functional
the staff, Layout, strength upto 130 kg/mm2. clause 0.1 Requirements. The scope of
Foundation of the 1.3 This specification broadly covers the Working 1.3 Accepted as work under this specification
machines, Instruction Mechanism & Functional Requirements. The scope of work provisions are also covers installation of the
manuals, Inspection, under this Specification also covers installation of the plant, elaborated to make plant, Training of the staff,
Additional Training of the staff, Layout, Foundation of the machines, clearer. Layout, Foundation of the
information, Instruction manuals, Inspection, Additional information, machines, Instruction
Equipment Equipment Environment, Warranty, etc. SCR – manuals, Inspection,
Environment, 2.Comments of SCR - Standardization of Additional information,
Warranty, etc. Specification also covers installation of the plant, welding parameters Equipment Environment,
commissioning of the plant including standardization of weld by RDSO already Warranty, Annual Maintenance
parameters by RDSO, Training of the staff, Layout, mentioned in Contract (AMC), etc.
Foundation of the machines, Instruction manuals, Manual for FB
Inspection, Additional information, Equipment Environment, welding of rails-
Warranty, etc. 2012. Hence not
3. Comments of M/s Schlatter – considered.
Maco Corporation (India) Private Limited having adequate
experience in setting up of FBW plants (latest being SAIL
Bhilai Long Rail Welding Line – 02 Numbers), will do the
installations, commissioning, AMC as well as provide all the M/s Schlatter –
support mentioned above. Comments are
4. Comments of M/s NENCKI, Switzerland – Noted Informative only.

M/s NENCKI-
No comments.
8. 2.0 Working 1.Comments of NER – NER – 2.0 Automatic Flash Butt
Mechanism & 2.0 Considered. Welding Machine:
Functional 2.0 Automatic Flash Butt Welding Machine: 2.1 Not accepted
Requirements: 2.1 General: as provisions have
Automatic Flash Butt Welding machine complete with already given in
integral upset removal device, automatic rail alignment subsequent
crown adjusting and de-twist unit, power transformers and clauses.
02 years maintenance spares for welding rails up to 78
Kg/m (including special high wear resistant steel rails having
tensile strength up to 130 Kg/mm²).
9. 2.1 Weldability and 1.Comments of NER- NER- 2.1 Weldability and range of
range of application 2.2 Weldability and Range of application: Accepted except application :
: The FBW Machine should be designed for welding rails rail section 78 Kg/m The FBW Machine should be
The FBW Machine up to 78 Kg/m having ultimate tensile strength up to 130 and modified as designed for welding rails up
should be designed Kg/mm². provisions are to 68 Kg/m having ultimate
Page 7 of 49 
 
 to weld new rails/ The plant shall be capable to weld new rails/ released but elaborated to make tensile strength up to 130
released but serviceable rails of various sections and metallurgies clearer. Kg/mm².
serviceable rails of specified in Indian Railway’s Standard Specification for Flat The post weld heat The plant shall be capable to
various sections and Bottom Rails (IRS-T-12-2009) with up to date Addendum treatment facility is weld new rails/ released but
metallurgies specified and Corrigendum slips (hereinafter called Specification of covered in clause serviceable rails of various
in Indian Railway’s Rails) viz. 52/60/68Kg/m of grades 880 (C-Mn, Cu-Mo, Ni- 7.0. sections and metallurgies
Standard Cr-Cu, Niobium, Vanadium), 1080(HH, Cr). Plant would also specified in Indian Railway’s
Specification for Flat be capable of welding of 60/68 Kg/m rails having SCR- Standard Specification for Flat
Bottom Rails(IRS-T- mechanical & chemical properties of R350HT of BS EN Abbreviation of Bottom Rails(IRS-T-12-2009)
12-2009) with up to 13674-1:2011+A1:2017. elements are well with up to date Addendum and
date Addendum and The machine should incorporate special post heat known, hence full Corrigendum slips (hereinafter
Corrigendum slips treatment facilities necessary to ensure quality welding name is not called Specification of Rails)
(hereinafter called results on special grade steels. required. viz. 52/60/68Kg/m of grades
Specification of Rails) The machine should have facility for traversing by atleast NR – 880(C-Mn, Cu-Mo, Ni-Cr-Cu,
viz. 52/60/68Kg/m of 500mm to facilitate central positioning of the ends of long At present, 60 Niobium, Vanadium),
grades 880(C-Mn, welded rails Kg/m rail section 1080(HH, Cr). Plant would
Cu-Mo, Ni-Cr-Cu, 2.Comments of SCR- has been also be capable of welding of
Niobium, Vanadium), Cr may be written as Chromium envisaged for 25T 60/68 Kg/m rails having
1080(HH, Cr). Plant 3. Comments of NR - axle load on Indian mechanical & chemical
would also be Plant should be capable to weld rails upto 75 Kg/m and Railways. properties of R350HT of BS
capable of welding of 12000 sqmm area. Considering the EN 13674-1:2011+A1:2017.
60/68 Kg/m rails 4.Comments of M/s Schlatter - future requirements The machine should have
having mechanical & Standard by Schlatter and expected life of facility for traversing by at least
chemical properties 5.Comments of SR – Flash Butt Welding 500mm to facilitate central
of R350HT of BS EN Additional Para to be included as below: Plant, rail section positioning of the ends of long
13674- The Flash Butt welding Machine should be capable for and UTS of rail has welded rails.
1:2011+A1:2017. welding of new rails/released serviceable rails of sectional been kept in the
area upto 12,000 Sq.mm. The recommended butting specification;
pressure for different types of rails are included below: which is considered
 72 UTS Rails: 5 Kg/Sq.mm on cross sectional area. adequate, hence
 90 UTS & HH Rails: 6 Kg/Sq.mm. no amendment .
 110 UTS Rails: 7 Kg/Sq.mm. M/s Schlatter -
6. Comments of M/s NENCKI, Switzerland – No comments
Not applicable for Nencki. SR –
Part of Flash Butt Welding manufacturer Rail sections
specified in Indian
Railway’s Standard
Specification for
Flat Bottom
Rails(IRS-T-12-
2009) have been
incorporated in the
Page 8 of 49 
 
 specification.
M/s NENCKI –
Comments are
Informative only.

10. 2.2 Machine Body : 1.Comments of NER - NER – 2.2 Machine Body:
The Machine body 2.3 Machine Body: Modification The Machine body should be
should be preferably The Machine body should be preferably of a frame type accepted to preferably of a frame type
of a frame type construction capable of taking clamping and upset force to facilitate welder for construction capable of taking
construction capable their axes of action. The machine frame should have large quick replacement clamping and upset force to
of taking clamping openings in front of the welder to facilitate quick removal of dies/electrode their axes of action. The
and upset force to and replacement of welder dies and clamps and to provide and to provide machine frame should have
their axes of action. maximum visibility for operation and maintenance. The maximum visibility large openings in front of the
The machine frame machine frame assembly should be sturdy, all welded steel for operation and welder to facilitate quick
assembly should be fabrication suitably braced and stiffened at points of stresses maintenance. removal and replacement of
sturdy, all welded to minimize deflection and thermally stress relieved. The welder dies and clamps and to
steel fabrication machine frame top should have a single continuous beam M/s NENCKI – provide maximum visibility for
suitably braced and structure to minimize welded joints, so that deflection/ Comments are operation and maintenance.
stiffened at points of distortion/ cracks may be avoided. The weld zone should be Informative only. The machine frame assembly
stresses to minimize fully covered with spatter guards to trap the flash and a fume should be sturdy, all welded
deflection and extractor to be provided to exhaust this chamber. Guides steel fabrication suitably
thermally stress should be provided at entry, and within the machine, to braced and stiffened at points
relieved. The enable free passage for rails during entry and transport. The of stresses to minimize
machine frame top welding standard followed for manufacturing of machine deflection and thermally stress
should have a single should be to ISO:3834, EN:15085 or any other equivalent relieved. The machine frame
continuous beam standard for welding railway vehicles and components. The top should have a single
structure to minimize manufacturer should specify the standard followed and continuous beam structure to
welded joints, so that certify that it meets the welding standard mentioned above. minimize welded joints, so that
deflection/ distortion/ 2. Comments of M/s NENCKI, Switzerland – deflection/ distortion/ cracks
cracks may be Not applicable for Nencki Machines. may be avoided. The weld
avoided. The weld Part of Flash Butt Welding manufacturer zone should be fully covered
zone should be fully In general: with spatter guards to trap the
covered with spatter Our machines are produced according to the standard ISO flash and a fume extractor to
guards to trap the 3834. For us it would also possible to manufacture the steel be provided to exhaust this
flash and a fume structures according to the EN 15085, since we are a EN chamber. Guides should be
extractor to be 15085-certified company. A production according to EN provided at entry, and within
provided to exhaust 15085 is connected with additional costs and is not our the machine, to enable free
this chamber. Guides basic standard. passage for rails during entry
should be provided at and transport. The welding
entry, and within the standard followed for
machine, to enable manufacturing of machine
free passage for rails should be to ISO:3834,
Page 9 of 49 
 
 during entry and EN:15085 or any other
transport. The equivalent standard for
welding standard welding railway vehicles and
followed for components. The
manufacturing of manufacturer should specify
machine should be to the standard followed and
ISO:3834, EN:15085 certify that it meets the welding
or any other standard mentioned above.
equivalent standard
for welding railway
vehicles and
components. The
manufacturer should
specify the standard
followed and certify
that it meets the
welding standard
mentioned above.
11. 2.3 Production 1.Comments of NER NER – 2.3 Production Capacity:
Capacity: 2.4 Production Capacity: Considered. The hourly output in terms of
The hourly output in The hourly output in terms of number of welded joints should Specification number of welded joints
terms of number of be more than 20 for 60 kg 90UTS rails in continuous rail reviewed and should not be less than 20 for
welded joints should panels including all activities from Pre-Straightening of rail modified. 60 kg 90UTS, 13m rails
be more than 20 in ends to Post Straightening of produced welded joints. The including insertion of rails,
continuous rail panels plant should be capable of welding 260m long rail panels by clamping and aligning rail
including all activities continuous welding of 13/26/65m rail lengths. ends, matching rail ends
from Pre- The actual welding cycle (insertion of rails, clamping and through power adjustment,
Straightening of rail aligning rail ends, matching rail ends through power welding cycle, stripping of
ends to Post adjustment, welding cycle, stripping of upset, unclamping upset, unclamping and
Straightening of and resetting of machine) should not take more than 120 SCR- resetting of machine. The plant
produced welded seconds for 60kg/m 90 UTS Rails. The time in seconds for Provision has been should be capable of welding
joints. The plant various operations per joint like positioning of welding made clear for 60 260m long rail panels by
should be capable of machine, Clamping and aligning the rail ends, matching rail kg/m 90 UTS rails. continuous welding of
welding 260m long ends through powered adjustments, welding cycle, placing 13/26/65m rail lengths.
rail panels by stripper in position, stripping of upset metal, unclamping and The time in seconds for
continuous welding of resetting of machine etc. shall be indicated. various operations per joint
13/26/65m rail Total rail usage per weld should be within 30mm. like positioning of welding
lengths. The actual 2.Comments of SCR machine, Clamping and
welding cycle Production Capacity: aligning the rail ends,
(insertion of rails, The hourly output in terms of number of welded joints should M/s Schlatter - matching rail ends through
clamping and aligning be more than 20 in continuous rail panels including all Considered. powered adjustments, welding
rail ends, matching activities from Pre-Straightening of rail ends to Post Specification cycle, placing stripper in
Page 10 of 49 
 
 rail ends through Straightening of produced welded joints. The plant should reviewed and position, stripping of upset
power adjustment, be capable of welding 260m long rail panels by continuous modified. metal, unclamping and
welding cycle, welding of 13/26/65m rail lengths. The hourly output may resetting of machine etc. shall
stripping of upset, slightly vary in case of 65m rail lengths. The actual welding be indicated.
unclamping and cycle (insertion of rails, clamping and aligning rail ends, Total rail usage per weld
resetting of machine) matching rail ends through power adjustment, welding cycle, should be within 30mm.
should not take more stripping of upset, unclamping and resetting of machine) SR –
than 120 seconds. should not take more than 120 seconds. Total rail usage per 30 mm rail usage
Total rail usage per weld should be within 30mm. per weld is
weld should be within maximum. This can
30mm. 3.Comments of M/s Schlatter - be less also.
Schlatter Industries AG offer a welding machine, which
according to the construction and the design is able to
produce 20 welds on rails UIC60 (thermal design of the
components). In reality, the hourly output depends on the
time which is the slowest machine in the welding line. As a
rule (existing welding plants), it is the grinding machine
which carries out the fine grinding at the end of a line. This M/s NENCKI –
operation takes approx. 5 - 6 minutes and thus determines Considered and
the hourly output of a long rail welding plant. provisions have
The hourly output can also be affected by the length of rails, been modified.
speed of the conveyor system, handling and human
interference.
An overview / description of the time schedule for one weld
with GAAS80 are included in the attached presentation.
The ideal welding cycle is 180 seconds (right from entry of
rails inside the FBW machine till its exit).
As a rule, no more than 30 mm of rail material including
upsetting length is required for welding. Slight differences -
depending on rail type and welding program or national
standard (determination of the upsetting way) can occur in
a span of 28 mm to 36 mm.
4.Comments of SR –
The rail usage is given as within 30mm appears high.
The aspect may be brought under Forging unit under Para
2.6 also.
5. Comments of M/s NENCKI, Switzerland –
It is not realistic to have an hourly output of 20 welds.

Machine cycles (for example welding machine, grinding) and

the necessary unforced cooling time (avoidance of micro
structural changes) demand a minimum of time which
Page 11 of 49 
 
 succeeds 120 seconds per cycle.

12. 2.4 Quality of Weld: 1.Comments of CTE/NER - 2.4 Quality of Weld:

Quality of weld 2.5 Quality of Weld: The welded joint produced by
produced by the The welded joint produced by the Machine should meet the NER – the Machine should meet the
Machine should meet various test standards and geometrical tolerances specified Accepted as various test standards and
the various test in the Manual for Flash Butt Welding of Rails-Revised -2012 provisions have geometrical tolerances
standards and and amended up to date. The machine offered shall be been elaborated to specified in the Manual for
geometrical capable of producing consistently and fully automatically make clearer. Flash Butt Welding of Rails-
tolerances specified weld to meet these stipulations. The joint shall be capable of Revised -2012 and amended
in the Manual for being placed on a PSC sleeper rail seat. up to date. The machine
Flash Butt Welding of The machine should be controlled by a PLC of latest version offered shall be capable of
Rails-Revised -2012 of a reputed manufacturer which monitors all the vital producing consistently and
and amended up to parameters of the process such as the current, velocity and fully automatically weld to
date. duration of flashing etc. The parameters are also recorded meet these stipulations.
The machine should on a weld data recorder as required. The PLC should also The machine should be
be controlled by a have a self diagnostic arrangement. If the rail welder does SCR – controlled by a PLC of latest
PLC of latest version not meet the preset values, the operation should stop Accepted as version of a reputed
of a reputed automatically after execution of the weld provisions have manufacturer which monitors
manufacturer which 2.Comments of SCR - been elaborated all the vital parameters of the
monitors all the vital Following lines may be added after last line: further. process such as Voltage,
parameters of the The software deciding the acceptance of welds based on Current, Displacement,
process such as the different weld parameters should be tailor made. Bandwidth Pressure, Time intervals,
current, velocity and for different rail sections and chemistry should be specific velocity and duration of
duration of flashing and narrow one. flashing etc. The parameters
etc. The parameters are also recorded and
are also recorded on 3.Comments of M/s Schlatter - displayed on a Weld Data
a weld data recorder Quality of Weld: Recorder as required. The
as required. The Quality of weld produced by the Machine should meet the PLC should also have a self
PLC should also various test standards and geometrical tolerances diagnostic arrangement. If the
have a self diagnostic specified in the Manual for Flash Butt Welding of M/s Schlatter – rail weld does not meet the
arrangement. If the Rails-Revised -2012 and amended up to date. preset values, suitable error
rail welder does not RSDO Permission existent for 3 active GAAS80 in India. Comments are indication shall be shown
meet the preset Another GAAS80 machine will be put up at Sabarmati by Informative only. whether the weld joint is
values, the operation “Good” or “Bad” and the
RITES this year. The complete reference List of GAAS80
should stop operation should stop
automatically after installed and operating satisfactorily. automatically after execution
execution of the weld. The machine should be controlled by a PLC of latest of the weld.
version of a reputed manufacturer which monitors all the SR – The software deciding the
vital parameters of the process such as the current, velocity Accepted and acceptance of welds based on
and duration of flashing etc. The parameters are also modified. different weld parameters
should be tailor made.
Page 12 of 49 
 
 recorded on a weld data recorder as required. Bandwidth for different rail
Fulfilled – Schlatter WeldAnalyzer system sections and chemistry should
The PLC should also have a self- diagnostic arrangement. be specific and narrow one.
If the rail welder does not meet the preset values, the
operation should stop automatically after execution of the
weld.
The digital, PLC welding processor system SWEP is the
only system that monitors the welding process during the
process in real time (self-diagnosis) and in case of
deviations from the set parameters can independently
interrupt the welding process until before the moment of
upsetting. The WeldAnalyzer system displays the
erroneous value in red on the monitor. A new welding can
only be started after the cause of the error has been
eliminated. The incorrect welding remains in the database
for evaluation / quality control of the system / job. When the
welding is restarted, the welding number is automatically
reset so that the welding numbering of the long rail remains
consistent.
4.Comments of SR –
Existing Para shall be revised as below:
The machine should be controlled by a PLC of latest version
of a reputed manufacturer which monitors all the vital
parameters of the process such as Voltage, Current,
Displacement, Pressure and Time intervals, etc. at each
stage. The parameters are also recorded and displayed on a
Weld Data Recorder as required. The PLC should also have
a self diagnostic arrangement. If the rail weld does not meet
the preset values, suitable error indication shall be shown
whether the weld joint is “Good” or “Bad”.

13. 2.5 Clamping Units 1.Comments of NER - NER – 2.5 Clamping Units:
Multiple clamps to be 2.6 Clamping Units Accepted except The clamping unit should be
provided for holding The clamping unit should be capable of applying a load rail section 78Kg/m. capable of applying a load
the rails to prevent suitable for different section of rails i.e. upto 78 kg/m. suitable for different section of
slippage during Multiple clamps to be provided for holding the rails to rails i.e. upto 68 Kg/m. Multiple
butting operation and prevent slippage during butting operation and to prevent clamps to be provided for
to prevent abnormal abnormal indentation of the rails. The tenderer should holding the rails to prevent
indentation of the specify the details of clamping cylinders and ratio of slippage during butting

Page 13 of 49 
 
 rails. The tenderer Clamping and forging force M/s Schlatter – operation and to prevent
should specify the 2.Comments of M/s Schlatter – Comments are abnormal indentation of the
details of clamping An overview / description of the clamping system with Informative only. rails. The bidder should
cylinders. GAAS80 are included in the attached presentation. specify the details of clamping
3.Comments of SR – SR – cylinders and ratio of Clamping
Existing Para shall be revised as below. Considered and and forging force.
The Tenderer should specify the details of clamping modified.
cylinders to indicate the type of clamping, number of
clamping cylinders and interfacing with the Brushing
machine.
The clamping force should be sufficient enough to withstand
the butting forces to avoid slippage of rails during butting.
There should be no clamping marks on the rail head and rail
foot to avoid fatigue break of the rail.
14. 2.6 Forging Unit: 1.Comments of NER NER – 2.6 Forging Unit:
Forging unit should 2.7 Forging Unit: Accepted except Forging unit should be of air/oil
be of air/oil intensified Forging unit should be of air/oil intensified type capable of rail section 78Kg/m, intensified type capable of
type capable of applying forging force suitable for welding rails up to 68 78 as it is not available applying forging force suitable
applying forging force Kg/meter. The rams of forging unit shall be so placed so as in worldwide. Other for welding rails up to 68
suitable for welding to ensure equal distribution of the forging load across the changes made the Kg/meter. The rams of forging
rails up to 68 interfaces. The control includes a servo system, which provisions more unit shall be so placed so as to
Kg/meter. The control should be controlled by the PLC for fine control on the clear. ensure equal distribution of the
includes a servo velocity of flashing. The forging action, which has to be as forging load across the
system, which should fast as possible, should be accomplished with the help of a SCR – interfaces. The control
be controlled by the gas charged accumulator. The accumulator system must be Suitable Hydraulic includes a servo system,
PLC for fine control connected to filled/charged Nitrogen cylinder with required circuits may be which should be controlled by
on the velocity of pressure gauge and other necessary fixture. If any used for welding of the PLC for fine control on the
flashing. The forging deficiency of nitrogen gas is observed in accumulator, then it rails upto 68 Kg/m velocity of flashing. The
action, which has to must be easily recouped by nitrogen cylinder. The unit and upto 65m forging action, which has to be
be as fast as should be capable of delivering suitable force for welding 68 length. Hence, as fast as possible, should be
possible, should be 78 Kg/m rails with UTS of 130Kg/mm2. comments not accomplished with the help of
accomplished with In view of the heavy force involved, certain interlocks should considered. a gas charged accumulator.
the help of a gas be incorporated in the system. The weld initiation should not The accumulator system must
charged accumulator. be done without clamping. Similarly, the machine should not be connected to filled/charged
The accumulator retract after welding unless declamped. This is to avoid Nitrogen cylinder with required
system must be application of tensile force on the still plastic joint pressure gauge and other
connected to inadvertently after welding. necessary fixture. If any
filled/charged deficiency of nitrogen gas is
Nitrogen cylinder with 2.Comments of CTE/SCR observed in accumulator, then
required pressure Following lines may be added after last line: it must be easily recouped by
gauge and other Forging unit’s hydraulic circuit should be isolated from other nitrogen cylinder. The unit

Page 14 of 49 
 
 necessary fixture. If hydraulic circuits consisting of clamping, de-twisting, lifting should be capable of
any deficiency of cylinders, etc. as mentioned in para 2.11. delivering suitable force for
nitrogen gas is 3.Comments of M/s Schlatter – welding 68 Kg/m rails with
observed in Fulfilled - An description and picture of the forging UTS of 130Kg/mm2.
accumulator, then it accumulator system with GAAS80 are included in the In view of the heavy force
must be easily attached presentation. M/s Schlatter – involved, certain interlocks
recouped by nitrogen Comments are should be incorporated in the
cylinder. The unit Informative only. system. The weld initiation
should be capable of should not be done without
delivering suitable clamping. Similarly, the
force for welding 68 machine should not retract
Kg/m rails with UTS after welding unless de-
of 130Kg/mm2. In clamped. This is to avoid
view of the heavy application of tensile force on
force involved, the still plastic joint
certain interlocks inadvertently after welding.
should be
incorporated in the
system. The weld
initiation should not
be done without
clamping. Similarly,
the machine should
not retract after
welding unless de-
clamped. This is to
avoid application of
tensile force on the
still plastic joint
inadvertently after
welding.

15. 2.7 Electrodes 1.Comments of NER NER - 2.7 Welding Electrodes:

These are to be of
copper alloy, water
cooled with quick
release facilities for
maintenance before
replacement. Suitable
welding electrodes
should be provided
for the rail sections to
2.8 Welding Electrodes: Partially accepted These are to be of copper
These are to be of copper alloy, water cooled with quick and modified. alloy with high abrasion with
release facilities for maintenance and before replacement. Warranty of relatively good conductivity
Suitable welding electrodes should be provided for the rail electrodes equal to and water cooled with quick
sections as per IRS/T-12 to be welded. Arrangement should welding machine is release facilities for
be provided to blow off scale and flash from the electrodes. not justified. maintenance and replacement.
Electrodes supplied with machine shall be the part of Metallurgical composition of
welding machine and will have the same warranty as SCR- copper alloy of electrodes to
specified for the welding machine. The codal life of the Accepted as be specified to take care of
Page 15 of 49 
 be welded. electrodes in terms of number of welds should not be less provision is replacement of electrodes in
Arrangement should than 25000. The number of spare electrodes supplied with elaborated further. case manufacturers do not
be provided to blow the machine shall be two sets. The electrode holders shall support servicing of FBW unit
off scale and flash have a provision for vertical adjustment to compensate the after certain period. Suitable
from the electrodes. wear up to 25 mm. welding electrodes should be
Electrodes supplied The equipment to cool the water circulated in Electrode provided for the rail sections
with machine shall be should be included with the machine. upto 68 Kg/m to be welded.
the part of welding 2.Comments of SCR Arrangement should be
machine and will Electrodes provided to blow off scale and
have the same These are to be of copper alloy, water cooled with quick flash from the electrodes.
warranty as specified release facilities for maintenance before replacement. Electrodes supplied with
for the welding Metallurgical composition of copper alloy of electrodes to be M/s Schlatter – machine shall be the part of
machine. The codal specified to take care of replacement of electrodes in case Comments are welding machine.
life of the electrodes manufacturers do not support servicing of FBW unit after Informative only. The codal life of the electrodes
in terms of number of certain period. Suitable welding electrodes should be in terms of number of welds
welds should not be provided for the rail sections to be welded. Arrangement SR - should not be less than 25000.
less than 25000. The should be provided to blow off scale and flash from the Considered and The number of spare
number of spare electrodes. Electrodes supplied with machine shall be the incorporated. electrodes supplied with the
electrodes supplied part of welding machine and will have the same warranty as machine shall be two sets. The
with the machine specified for the welding machine. The codal life of the electrode holders shall have a
shall be two sets. electrodes in terms of number of welds should not be less M/s NENCKI – provision for vertical
The electrode holders than 25000. The number of spare electrodes supplied with No comments. adjustment to compensate the
shall have a provision the machine shall be two sets. The electrode holders shall wear up to 25 mm.
for vertical have a provision for vertical adjustment to compensate the The equipment to cool the
adjustment to wear up to 25 mm. water circulated in Electrode
compensate the wear 3.Comments of M/s Schlatter - should be included with the
up to 25 mm. Fulfilled. Schlatter GAAS80 electrodes have much longer machine.
life span than your requirement as they are not directly
involved in the clamping of the rails. However, as a rule, our
electrodes meet the required service life when used under
optimum conditions. The actual service life can also be
shorter if the pre-cleaning of the electrode contact surfaces
and / or the daily maintenance and care of the machines
are not carried out correctly.
The main advantage of Schlatter FBW machine is that the
electrodes are independent of the clamping unit, hence the
life expectancy is much higher.
4.Comments of SR -
Existing Para shall be revised as below.
These are to be of copper alloy with high abrasion with
relatively good conductivity and water cooled with quick
Page 16 of 49 
 
 release facilities for maintenance before replacement.
5. Comments of M/s NENCKI, Switzerland –
Not applicable for Nencki Machines. Part of Flash Butt
Welding manufacturer.

16. 2.8 Breaking & Inching 1.Comments of M/s Schlatter – M/s Schlatter – 2.8 Breaking & Inching
Mechanism: The welding machine has an emergency stop system to Comments are Mechanism:
The welding machine avoid damage to the machine or the operators. At the Informative only. The welding machine should
should be provided control panel, at the switch cabinet and at the ends of the be provided with an
with an independent M/s NENCKI – independent breaking and
machine, the corresponding shutters are open and
breaking and inching No comments. inching mechanism on each
mechanism on each accessible. side so as to permit the
side so as to permit 2. Comments of M/s NENCKI, Switzerland – welding operator to correct
the welding operator Not applicable for Nencki Machines. Part of Flash Butt position of the rails without any
to correct position of Welding manufacturer. impact.
the rails without any
impact.

17. 2.9 Rail Alignment & 1.Comments of NER - NER - 2.9 Rail Alignment & Twist
Twist Correction: 2.10 Rail Alignment & Twist Correction: Provision is Correction:
Flash Butt Welding Flash Butt Welding Machine should be equipped with elaborated further, Flash Butt Welding Machine
Machine should be automatic rail ends alignment facility. Rail alignment (lateral hence accepted. should be equipped with
equipped with and vertical) and de-twist facility should be incorporated in automatic rail ends alignment
automatic rail ends the fixed and moving heads of the machine for execution of facility. Rail alignment (lateral
alignment facility. the weld in perfect geometric alignment fully automatically and vertical) and de-twist
Rail alignment (lateral over a length of 1 m. There should be no need of any facility should be incorporated
and vertical) and de- manual adjustment while welding the new rails. Arrangement in the fixed and moving heads
twist facility should be through sensors which reads and records maximum of the machine for execution of
incorporated in the mismatch in alignment between Gauge faces should be the weld in perfect geometric
fixed and moving provided. Automatic selection of Gauge face should be alignment fully automatically
heads of the machine possible. The aligning force and de twisting force shall be over a length of 1 m. There
for execution of the sufficient for maximum rail section to be welded. Visual should be no need of any
weld in perfect indication should be available for correct alignment. manual adjustment while
geometric alignment Automatic rail alignment setup should be capable to perform welding the new rails.
fully automatically alignment as per stipulations of Manual for Flash Butt Arrangement through sensors
over a length of 1 m. Welding of Rails-2012. which reads and records
There should be There should be provision of manual adjustment in case maximum mismatch in
provision of manual cross section of two rail ends being welded have major alignment between Gauge
adjustment in case mismatch for welding of released rails. faces should be provided.
cross section of two Adequate lighting arrangement should be available inside Automatic selection of Gauge
rail ends being the machine to enable visual check of alignment and face should be possible. The
welded have major matching of rail ends aligning force and detwisting
Page 17 of 49 
 
 mismatch. Visual 2.Comments of SCR - force shall be sufficient for
indication should be Rail Alignment & Twist Correction: maximum rail section to be
available for correct Flash Butt Welding Machine should be equipped with SCR – welded. Visual display should
alignment. Automatic automatic rail ends alignment facility. Rail alignment (lateral Modified and be available for correct
rail alignment setup and vertical) and de-twist facility should be incorporated in corrected. Rail alignment. Automatic rail
should be capable to the fixed and moving heads of the machine for execution of section already alignment setup should be
perform alignment as the weld in perfect geometric alignment fully automatically considered in para capable to perform alignment
per stipulations of over a length of 1 m. There should be provision of manual 2.0 as per stipulations of Manual
Manual for Flash Butt adjustment in case cross section of two rail ends being for Flash Butt Welding of Rails-
Welding of Rails- welded have major mismatch. Visual display indication 2012.
2012. Adequate should be available for correct alignment. Automatic rail There should be provision of
lighting arrangement alignment setup should be capable to perform alignment as manual adjustment in case
should be available per stipulations of Manual for Flash Butt Welding of Rails- cross section of two rail ends
inside the machine to 2012. Adequate lighting arrangement should be available being welded have major
enable visual check inside the machine to enable visual check of alignment and mismatch for welding of
of alignment and matching of rail ends. (The guides of rail aligning device released rails.
matching of rail ends. should be suitable for 52/60kg rail sections). Adequate lighting arrangement
3.Comments of M/s Schlatter – M/s Schlatter – should be available inside the
Fulfilled - A description and some picture of the alignment Comments are machine to enable visual
and clamping system which meets the requirements Informative only. check of alignment and
described is an integral part of the machine. And are matching of rail ends.
included in the attached presentation. M/s NENCKI –
4. Comments of M/s NENCKI, Switzerland – No comments.
Not applicable for Nencki Machines. Part of Flash Butt
Welding manufacturer.

18. 2.10 Automatic Stripping 1.Comments of NER - NER - 2.10 Automatic Stripping
Unit: 2.11 Automatic Stripping Unit: Provision is Unit:
The welding unit The welding unit should have a trimming arrangement as an elaborated further, The welding unit should have
should have a integral part of the unit so that it can trim the excess upset hence accepted. a trimming arrangement as an
trimming immediately after welding. The weld should be in integral part of the unit so that
arrangement as an compression during trimming and removal of excess upset. it can trim the excess upset
integral part of the The action of stripping should be controlled completely by immediately after welding.
unit so that it can trim the welder automatic sequence panel. The trimmer should The action of stripping should
the excess upset have the capability to trim excess hot upset metal all round be controlled completely by
immediately after the rail section in such a way that minimum grinding is the welder automatic
welding. The weld required to achieve final finished profile at weld as SCR – sequence panel. The trimmer
should be in prescribed in Flash Butt Welding Manual. The maximum Specifications of should have the capability to
compression during thickness of trimmed surface shall be in accordance with trimming trim excess hot upset metal all
trimming and removal provisions of item (v) of Part ‘A’ & ‘B’ of Annexure-IV of dies/cutting edges round the rail section in such a
of excess upset. The Flash Butt Welding Manual-2012. etc. have covered way that minimum grinding is

Page 18 of 49 
 
 trimmer should have Suitable trimming dies should be provided for the rail under required to achieve final
the capability to trim sections to be welded. Sufficient force shall be available for “Maintenance finished profile at weld as
excess hot upset stripper for upset removal from any rail section/ Metallurgy Spare” in clause prescribed in Flash Butt
metal all round the which the machine is capable of welding. 12. Welding Manual. The
rail section in such a There should be a well designed weld chips collection trolley maximum thickness of
way that minimum which shall be capable to dispose the burn chips away from trimmed surface shall be in
grinding is required to trench of Main Welding Machine. accordance with provisions of
achieve final finished 2.Comments of SCR - item (v) of Part ‘A’ & ‘B’ of
profile at weld as Automatic Stripping Unit: Annexure-IV of Flash Butt
prescribed in Flash The welding unit should have a trimming arrangement as an Welding Manual-2012.
Butt Welding Manual. integral part of the unit so that it can trim the excess upset Suitable trimming dies should
The maximum immediately after welding. The weld should be in be provided for the rail
thickness of trimmed compression during trimming and removal of excess upset. sections to be welded.
surface shall be in The trimmer should have the capability to trim excess hot Sufficient force shall be
accordance with upset metal all round the rail section in such a way that available for stripper for upset
provisions of item (v) minimum grinding is required to achieve final finished profile removal from any rail section/
of Part ‘A’ & ‘B’ of at weld as prescribed in Flash Butt Welding Manual. The Metallurgy which the machine
Annexure-IV of Flash maximum thickness of trimmed surface shall be in is capable of welding.
Butt Welding Manual- accordance with provisions of item (v) of Part ‘A’ & ‘B’ of There should be a well
2012. Annexure-IV of Flash Butt Welding Manual-2012. designed weld chips collection
Suitable trimming 5 sets of Suitable trimming dies should be provided for the trolley which shall be capable
dies should be rail sections to be welded. Metallurgical specifications of to dispose the burn chips away
provided for the rail trimming dyes/cutting edges and specification of welding from trench of Main Welding
sections to be electrodes for reconditioning to be specified. There should Machine.
welded. There should be a well designed weld chips collection trolley which shall
be a well designed be capable to dispose the burn chips away from trench of
weld chips collection M/s Schlatter –
Main Welding Machine.
trolley which shall be Comments are
3.Comments of M/s Schlatter –
capable to dispose Informative only.
the burn chips away Fulfilled - A description and some picture of the automatic
from trench of Main stripping system which meets the requirements described is SR –
Welding Machine. an integral part of the machine. Picture and drawings are The welding unit
included in the attached presentation. should have a
4.Comments of SR – trimming
Additional Para to be included as below. arrangement as an
The stripping unit should be of movable design against the integral part of the
rails clamped in position. unit so that it can
5. Comments of M/s NENCKI, Switzerland – trim the excess
Not applicable for Nencki Machines. Part of Flash Butt upset immediately
Welding manufacturer. after welding. This
provision covers
the movable design
Page 19 of 49 
 
 of stripping unit
M/s NENCKI –
No comments.

19. 2.11 Hydraulic Power 1.Comments of NER NER – 2.11 Hydraulic Power Pack:
Pack 2.12 Hydraulic Power Pack: Accepted. It is The machine shall have a
The machine shall The machine shall have a Hydraulic power pack consisting required to avoid Hydraulic power packs
have a Hydraulic of suitable units for the servo valve system and other damage of valve consisting of suitable units for
power pack requirements of the welding machine. The servo system system due to the servo valve system and
consisting of suitable should be sensitive to contamination, isolated and vibration. other requirements of the
units for the servo maintained with greater care. The unit should include oil welding machine.
valve system and reservoir, oil cooler, motor pump assemblies, associated The servo system should be
other requirements of filters, gauges, sensors, pressure relief valves, etc. for sensitive to contamination,
the welding machine. protection and long life of the hydraulic system. The isolated and maintained with
The servo system equipment should be capable of operation at an ambient SCR – greater care. The unit should
should be sensitive to temperature up to 550 C. On board system for filtration and Accepted as include oil reservoir, oil cooler,
contamination, monitoring the quality of hydraulic oil in hydraulic circuit provisions are motor pump assemblies,
isolated and should be provided. The gauge should clearly indicate that elaborated to make associated filters, gauges,
maintained with the hydraulic oil is contaminated beyond the permissible clearer. sensors, pressure relief
greater care. The unit limits and requires immediate replacement. valves, etc. for protection and
should include oil The manifolds of valve system should preferably be placed long life of the hydraulic
reservoir, oil cooler, and fixed outside the machine frame to avoid damage due to system. The equipment should
motor pump constant vibration and should be placed at convenient be capable of operation at an
assemblies, height. The hydraulic parts should be of renowned brand ambient temperature up to 550
associated filters, and its spare parts and service facilities should be available C. On board system for
gauges, sensors, in India. filtration and monitoring the
pressure relief 2.Comments of SCR M/s Schlatter – quality of hydraulic oil in
valves, etc. for Following line may be added after last line: Comments are hydraulic circuit should be
protection and long A separate filtering unit to be provided for hydraulic oil used Informative only. provided. The gauge should
life of the hydraulic in circuits before it enters hydraulic oil cooling system. clearly indicate that the
system. The 3.Comments of M/s Schlatter – hydraulic oil is contaminated
equipment should be Fulfilled - A description and picture of the hydraulic power beyond the permissible limits
capable of operation pack which meets the requirements described as an and requires immediate
at an ambient integral part of the machine. Picture are included in the replacement.
temperature up to attached presentation. The Hydraulic oil used shall be
550C. Onboard Note - Schlatter uses Bosch Rexroth, Germany make of commercially available
system for filtration hydraulic unit which is the best in the world. The service specification.
and monitoring the and parts are easily available through their local subsidiary The manifolds of valve system
quality of hydraulic oil worldwide and in particular India. should preferably be placed
in hydraulic circuit 4.Comments of SR - and fixed outside the machine
should be provided. Existing Para shall be revised as below. frame to avoid damage due to
The gauge should The machine shall have two separate Hydraulic power constant vibration and should
Page 20 of 49 
 
 clearly indicate that packs consisting of suitable units for the servo valve system be placed at convenient
the hydraulic oil is and other requirements of the welding machine. The servo height. The hydraulic parts
contaminated beyond system should be sensitive to contamination, isolated and should be of renowned brand
the permissible limits maintained with greater care. The unit should include oil and its spare parts and service
and requires reservoir, oil cooler, motor pump assemblies, associated SR - facilities should be available in
immediate filters, gauges, sensors, pressure relief valves, etc. for Instead of two India.
replacement. protection and long life of the hydraulic system. The suitable units, it A separate filtering unit to be
equipment should be capable of operation at an ambient may be any provided for hydraulic oil used
temperature up to 550C. Onboard system for filtration and number, hence not in circuits before it enters
monitoring the quality of hydraulic oil in hydraulic circuit considered. hydraulic oil cooling system.
should be provided. The gauge should clearly indicate that Second para
the hydraulic oil is contaminated beyond the permissible considered and
limits and requires immediate replacement. added.
The Hydraulic Oil used shall be of commercially available
specification. M/s NENCKI –
5. Comments of M/s NENCKI, Switzerland – No comments.
Not applicable for Nencki Machines. Part of Flash Butt
Welding manufacturer.

20. 2.12 Electrical power 1.Comments of NER - NER – 2.12 Electrical power Pack:
Pack 2.13 Electrical power Pack: Accepted as The Electrical equipments
The welding process The Electrical equipments should be fully tropicalized. The provisions are should be fully tropicalized.
will be based on equipment should suit connection to 400/440 volts 3 phase elaborated to make The equipment should suit
Direct Current for a 50 cycle (HZ) supply. The machine shall be capable of clearer. connection to 400/440 volts 3
uniform and fast heat adjusting/withstanding to a voltage fluctuation up to +10% phase 50 cycle (HZ) supply.
accumulation in the while in operation. A voltage stabilizer of 440 volt shall be The machine shall be capable
work piece. The three provided in mains supply of main welding machine to of adjusting/withstanding to a
phase mains minimize the voltage fluctuation and provide appropriate voltage fluctuation up to +10%
connection shall have voltage to mains of electrical power pack. while in operation. A voltage
a uniform power load The welding process will be based on Direct Current for a stabilizer of 440 volt shall be
possible and has a uniform and fast heat accumulation in the work piece. The provided in mains supply of
power factor better three phase mains connection shall have a uniform power main welding machine to
than 0.85. load possible and has a power factor better than 0.85. minimize the voltage
The secondary circuits of the transformers should be cooled fluctuation and provide
to prevent over-heating. A wide range of secondary voltages appropriate voltage to mains of
should be available to allow for the correct heating electrical power pack.
conditions to be selected for individual rail sizes. The welding process will be
The energy consumption per weld in KWH should be based on Direct Current for a
indicated for different rail sections. uniform and fast heat
2.Comments of SCR accumulation in the work
Following line may be added after last line: SCR – piece. The three phase mains
The manufacturer needs to stipulate the specifications of the Accepted and connection shall have a
Page 21 of 49 
 
 transformers required for functioning of FBW plant. modified. uniform power load possible
3.Comments of M/s Schlatter – and has a power factor better
Fulfilled - A detailed description and some picture and M/s Schlatter – than 0.85.
drawing are included in the attached presentation. Comments are The secondary circuits of the
4. Comments of M/s NENCKI, Switzerland – Informative only. transformers should be cooled
Not applicable for Nencki Machines. Part of Flash Butt to prevent over-heating. A
Welding manufacturer. wide range of secondary
M/s NENCKI – voltages should be available to
No comments allow for the correct heating
conditions to be selected for
individual rail sizes.
The energy consumption per
weld in KWH should be
indicated for different rail
sections.
The manufacturer needs to
stipulate the specifications of
the transformers required for
functioning of FBW plant.
21. 2.13 Centralised 1.Comments of M/s Schlatter – M/s Schlatter – 2.13 Centralised Lubrication
Lubrication - Fulfilled. No comments. -
Automatic Lubrication 2. Comments of M/s NENCKI, Switzerland – Automatic Lubrication is to be
to be provided for the Not applicable for Nencki Machines. Part of Flash Butt M/s NENCKI – provided for the machine. The
machine. The Welding manufacturer. No comments frequency of lubrication shall
frequency of be programmable.
lubrication shall be
programmable.

22. 2.14 Cooling System: 1.Comments of NER - NER – 2.14 Cooling System of
The cooling system 2.15 Cooling System of Machine: Accepted as Machine:
shall be efficient and The cooling system shall be efficient and designed for provisions are The cooling system shall be
designed for maximum ambient temperature of 55°C. Supplier may note elaborated to make efficient and designed for
maximum ambient that the Machine shall be working under extreme dusty clearer. maximum ambient
temperature of 55°C. conditions and the cooling mechanism should be temperature of 55°C. Supplier
Supplier may note maintainable under these conditions for all prime movers. may note that the Machine
that the Machine Adequate heat transfer arrangement for the hydraulic shall be working under
shall be working system shall be designed and provided so that under extreme dusty conditions and
under extreme dusty extreme heat conditions, the temperature of system oil does the cooling mechanism should
conditions and the not go beyond limit recommended by Oil Company. M/s Schlatter – be maintainable under these
cooling mechanism The installation of requisite device/system for temperature No comments. conditions for all prime
should be control of machine/ welding electrodes will be part of this movers. Adequate heat

Page 22 of 49 
 
 maintainable under item. transfer arrangement for the
these conditions for 2.Comments of M/s Schlatter – hydraulic system shall be
all prime movers. Fulfilled. designed and provided so that
Adequate heat under extreme heat conditions,
transfer arrangement the temperature of system oil
for the hydraulic does not go beyond limit
system shall be recommended by Oil
designed and Company.
provided so that The installation of requisite
under extreme heat device/system for temperature
conditions, the control of machine/ welding
temperature of electrodes will be part of this
system oil does not item.
go beyond limit
recommended by Oil
Company.

23. 3.0 Programmable 1.Comments of NER - NER – 3.0 Programmable Logic

Logic Control (PLC) 2.16 Programmable Logic Control (PLC) No change, only Control (PLC):
Flash Butt welding of Flash Butt welding of rails involves accurate and paragraph has Flash Butt Welding of rails
rails involves dependable control of current of the order of 70,000 Amps. been changed. involves accurate and
accurate and PLC, AD/DA conversions, sensor-actuator links etc. enables dependable control of current
dependable control of accurate performance. The tenderer should specify the of the order of 70,000 Amps.
current of the order of details of PLC incorporating with the machine. PLC, AD/DA conversions,
70,000 Amps. PLC, 2.Comments of M/s Schlatter – sensor-actuator links etc.
AD/DA conversions, Pls refer point 1.1 (ii) above. M/s Schlatter – enables accurate
sensor-actuator links 3.Comments of SR – No comments. performance. The bidder
etc. enables accurate Additional Para to be included as below. should specify the details of
performance. The The PLC Software listing shall be issued in the form of a SR – PLC incorporating with the
tenderer should Ladder Diagram along with the Operating Manual. Considered and machine.
specify the details of modified. The PLC Software listing shall
PLC incorporating 4. Comments of M/s NENCKI, Switzerland – be issued in the form of a
with the machine. Not applicable for Nencki Machines. Part of Flash Butt M/s NENCKI – Ladder Diagram along with the
Welding manufacturer. No comments Operating Manual.

24. 4.0 Weld Data 1.Comments of NER NER – 4.0 Computer based Weld
Recorder: 3.0 Computer based Weld Data Recording and Accepted as Data Recording and
Monitoring Equipment: provisions are Monitoring Equipment:
Automatic elaborated to make
microprocessors weld This equipment should be capable of being wired/ clearer. This equipment should be
control recorder connected directly to the rail welding machine and give an capable of being wired/

Page 23 of 49 
 
 should be provided to immediate read out which in comparison with pre-fed master . connected directly to the rail
record data data should automatically identify any inconsistency in welding machine and give an
pertaining to each welding machine operation. immediate read out which in
weld such as Automatic microprocessors weld control recorder should be comparison with pre-fed
temperature, voltage, provided to record data pertaining to each weld such as master data should
current, upset temperature, voltage, current, upset pressure and total automatically identify any
pressure and total welding time. It should be of the digital print out type in inconsistency in welding
welding time. It which the various values are printed in one colour (say blue) machine operation.
should be of the when they are within limits. Otherwise these are printed in Automatic microprocessors
digital print out type other colour (say red). For every red print there should be a weld control recorder should
in which the various small audible beep. The weld data recorder must be capable be provided to record data
values are printed in for online monitoring of weld sequence and quality of weld pertaining to each weld such
one colour (say blue) joints. The recording system should be a computer based as temperature, voltage,
when they are within data acquisition system specifically designed to record current, upset pressure and
limits. Otherwise entire weld process in detail for complete weld process total welding time. It should be
these are printed in analysis. The data logger will have a minimum capacity to of the digital print out type in
other colour (say store one lakh welds data for retrieval and study. which the various values are
red). For every red The hardware consists of a single processing unit, a printed in one colour (say blue)
print there should be processor unit (PC type) with hard memory, disk drive a when they are within limits.
a small audible beep. touch screen video display unit and Keyboard. The second Otherwise these are printed in
The weld data remote monitoring unit will consist of a basic computer with other colour (say red). For
recorder must be laser/ink jet printer. every red print there should be
capable for online The weld parameters sensed and operated upon by the a small audible beep. The
monitoring of weld machine control are to be communicated to the recorder weld data recorder must be
sequence and quality through a suitable communication port. All these signals are capable for online monitoring
of weld joints. The to be recorded in coded form in the memory in the recorder of weld sequence and quality
recording system for further retrieval, if desired. of weld joints. The recording
should be a computer Parameters to be recorded for each weld: system should be a computer
based data  Date & time of welding based data acquisition system
acquisition system  Joint serial number specifically designed to record
specifically designed  Section of the rail entire weld process in detail
to record entire weld  Pre weld alignment for complete weld process
process in detail for  Welding current in Amps (2 channels) analysis. The data logger will
complete weld  Line voltage in Volts have a minimum capacity to
process analysis. The  Welding voltage in Volts (2 channels) store one lakh welds data for
data logger will have retrieval and study.
 Clamping pressure Kg/cm2
a minimum capacity In order to minimize
 Butting pressure Kg/cm2
to store one lakh intervention to alter
welds data for  Number of Pre-Heats standardized input
retrieval and study.  Pre Heat time On - Off in sec. parameters, the software
The hardware  Burn off time in sec. should have the facility of
consists of a single  Flashing time in sec. password protection for
Page 24 of 49 
 
 processing unit, a  Total stroke in mm. modification of these
processor unit (PC  Butting stroke in mm. parameters.
type) with hard  Total time in sec. The hardware consists of a
memory, disk drive a  Upset length i.e. rail consumed per weld (mm) single processing unit, a
touch screen video  Heat soak back duration processor unit (PC type) with
display unit and  Post heat delay hard memory, disk drive a
Keyboard. The touch screen video display unit
 Post Heat ON Time
second remote and Keyboard. The second
 Post Heat OFF Time
monitoring unit will remote monitoring unit will
 Number of post Heats
consist of a basic consist of a basic computer
The system offered should be capable of building upto limit
computer with with laser/ink jet printer.
of 99 sets of parameters.
laser/ink jet printer. The weld parameters sensed
The supplier shall describe the elements employed in the
The weld parameters and operated upon by the
system with the details of the manufacturer. It should be
sensed and operated machine control are to be
ensured that consumable spares and repair facilities of the
upon by the machine communicated to the recorder
system are available in India.
control are to be through a suitable
It should be possible to locate the system in a separate
communicated to the communication port. All these
room situated upto 40 meters away from the welding
recorder through a signals are to be recorded in
machine.
suitable coded form in the memory in
The system shall be compatible with other machines
communication port. the recorder for further
supplied with plant for automatic feeding and maintaining
All these signals are retrieval, if desired.
the data base of complete weld from Pre-straightening to
to be recorded in Parameters to be recorded for
final finishing phase.
coded form in the each weld:
2.Comments of SCR -
memory in the  Date & time of welding
Weld Data Recorder:
recorder for further  Joint serial number
Automatic microprocessors weld control recorder should be
retrieval, if desired.
provided to record data pertaining to each weld such as  Section of the rail
Parameters to be
temperature, voltage, current, upset pressure and total  Pre weld alignment
recorded in each  Welding current in Amps
welding time. It should be of the digital print out type in
weld: (2 channels)
which the various values are printed in one colour (say blue)
 Date & time of  Line voltage in Volts
when they are within limits. Otherwise these are printed in
welding  Welding voltage in Volts (2
other colour (say red). For every red print there should be a
 Joint Sr. No. channels)
small audible beep. The weld data recorder must be capable
 Section of the rail for online monitoring of weld sequence and quality of weld SCR –
 Clamping pressure Kg/cm2
 Welding current joints. The recording system should be a computer based Accepted as
 Butting pressure Kg/cm2
in Amps (2 channels) data acquisition system specifically designed to record prevents data from
vandalism.  Number of Pre-Heats
 Line voltage in entire weld process in detail for complete weld process  Pre Heat time On - Off in
Volts analysis. The data logger will have a minimum capacity to sec.
 Welding voltage store one lakh welds data for retrieval and study. In order to  Burn off time in sec.
in Volts (2 channels) minimize intervention to alter standardized input parameters,  Flashing time in sec.
 Clamping the software should have the facility of password protection  Total stroke in mm.
pressure Kg/cm2 for modification of these parameters.  Butting stroke in mm.
Page 25 of 49 
 
  Butting pressure No change in other Para  Total time in sec.
Kg/cm2 3. Comments of NR- Upset length i.e. rail
 Number of Pre- Butting force and total time of weld should also be recorded consumed per weld (mm)
Heats as in mobile plant.  Heat soak back duration
 Pre Heat time On 4. Comments of M/s Schlatter –  Post heat delay
- Off in sec. Fulfilled - Schlatter WeldAnalyzer- System based on a  Post Heat ON Time
 Burn off time in Windows operated PC integral Part of scope of supply with  Post Heat OFF Time
sec. detailed description and some picture are included in the  Number of post Heats
 Flashing time in attached presentation.
 Duration of Butting
sec. 5.Comments of SR –
 Slippage of Rail (Yes or
 Total stroke in “Weld Data Recorder” – This title should be as “weld Data
No)
digital display and weld recorder”.
mm.
The machine should have to display the parameters for  Weld Analysis (GOOD or
 Butting stroke in BAD)
mm. every weld in a lively manner and printing as and when
required. Copying to other PC/System also shall be feasible The system offered should be
 Total time in sec. capable of building upto 99
even during welding process. NR –
 Upset length i.e.
Existing Para-2 shall be corrected as below. Butting pressure sets of parameters.
rail consumed per
The hardware shall consist of a Signal Conditioning Unit and total time of
weld (mm)
and a Data Logger unit (PC type) with hard memory, weld already The supplier shall describe the
external USB disk drive port, a Touch screen video mentioned in elements employed in the
The supplier shall system with the details of the
display unit and keyboard. The second remote monitoring specification.
describe the manufacturer. It should be
unit will consist of a basic computer with laser/inkjet printer.
elements employed ensured that consumable
Following additional points to be included under M/s Schlatter –
in the system with the spares and repair facilities of
Parameters to be recorder for each weld : Comments are
details of the the system are available in
 Duration of Butting Informative only.
manufacturer. India.
 Slippage of Rail (Yes or No)
It should be possible to locate
 Weld Analysis (GOOD or BAD) SR –
the system in a separate room
6. Comments of M/s NENCKI, Switzerland – Conidered and situated upto 40 meters away
modified. from the welding machine.
Not applicable for Nencki Machines. Part of Flash Butt The system shall be
Welding manufacturer. compatible with other
M/s NENCKI –
No comments. machines supplied with plant
for automatic feeding and
maintaining the data base of
complete weld from Pre-
straightening to final finishing
phase.

25. 5.0 Smoke Trapping 1.Comments of NER - NER – 5.0 Smoke Trapping Device/
Device- 4.0 Smoke Trapping Device/ Fume Extraction Accepted as Fume Extraction Equipment:
All smoke and spark Equipment: provisions are
Page 26 of 49 
 
 material shall be
trapped by device
and deposited in the
receptacle.
Fumes and dust must
be sucked out from
the welding chamber
and passes through a
cyclone separator
and exhausted to the
atmosphere though a
chimney of suitable
height. The
particulate matter
must be collected in a
bin at the bottom of
the separator. It
must ensure that
there is no discomfort
to operator due to
welding fumes and
dust.
The cyclone
separator should be
mounted outside the
shed which houses
the flash butt welder.
Only the suction
ducting should be
brought in and
connected through
suitable flexible
ducting to permit the
machine traverse for
rail panel positioning.
The motor control
should be mounted
inside the shed for
easy access to the
rail flash butt welding
operator. The fume
extractor should be
elaborated to make All smoke and spark material
All smoke and spark material shall be trapped by device and clearer. shall be trapped by device and
deposited in the receptacle. deposited in the receptacle.
Fumes and dust must be sucked out from the welding Fumes and dust must be
chamber and passes through a cyclone separator and sucked out from the welding
exhausted to the atmosphere though a chimney of suitable chamber and passes through
height. The particulate matter must be collected in a bin at a cyclone separator and
the bottom of the separator. The bin shall have adequate exhausted to the atmosphere
capacity for at least day’s production to avoid frequent though a chimney of suitable
removal. It must ensure that there is no discomfort to height. The particulate matter
operator due to welding fumes and dust and operator is fully must be collected in a bin at
protected from the spatter. the bottom of the separator.
The cyclone separator should be mounted outside the shed The bin shall have adequate
which houses the flash butt welder. Only the suction ducting capacity for atleast day’s
should be brought in and connected through suitable flexible production to avoid frequent
ducting to permit the machine traverse for rail panel removal. It must ensure that
positioning. there is no discomfort to
The motor control should be mounted inside the shed for operator due to welding fumes
easy access to the rail flash butt welding operator. The fume and dust and operator is fully
extractor should be interlocked with the Flash butt welder to protected from the spatter.
ensure that it is in operation before welding commences. The cyclone separator should
be mounted outside the shed
2.Comments of M/s Schlatter - which houses the flash butt
Part of the scope of delivery is a smoke extraction hood to welder. Only the suction
which an exhaust system can then be connected. Exhaust ducting should be brought in
system is part of the scope of delivery of project by Maco and connected through
Corporation. suitable flexible ducting to
3. Comments of M/s NENCKI, Switzerland – M/s Schlatter – permit the machine traverse
Not applicable for Nencki Machines. Part of Flash Butt No change for rail panel positioning.
Welding manufacturer. referred. The motor control should be
mounted inside the shed for
M/s NENCKI – easy access to the rail flash
No comments. butt welding operator. The
fume extractor should be
interlocked with the Flash butt
welder to ensure that it is in
operation before welding
commences.
Page 27 of 49 
 interlocked with the
Flash butt welder to
ensure that it is in
operation before
welding commences.

26. 6.0 Automatic Cooling 1.Comments of NER - NER – 6.0 Automatic Cooling
Device: 2.17 Automatic Cooling Device: Accepted as Device:
Adequate cooling Adequate cooling arrangements (Air/liquid) for cooling of provisions are Adequate cooling
arrangements welded rails to normal temperature should be provided. The elaborated to make arrangements (Air/liquid) for
(Air/liquid) for cooling cooling arrangement for all rail sections and rail steel should clearer. cooling of welded rails to
of welded rails to be quick enough so as not to reduce the capacity of plant M/s Schlatter – normal temperature should be
normal temperature i.e. 20 joints per hour. The arrangement shall be specified System should be provided. The cooling
should be provided. by tenderer. automatic. arrangement for all rail
M/s NENCKI – sections and rail steel should
2.Comments of M/s Schlatter - Provisions are as be quick enough so as not to
Air cooling device type Voest Alpine and associated per RDSO’s reduce the capacity of plant
compressor is supplied as a separate part and must be used Manual for Flash i.e. 20 joints per hour. The
/ operated manually. Butt Welding of arrangement shall be specified
3. Comments of M/s NENCKI, Switzerland – Rails, Revised by the bidder.
Welds must cool down to a certain temperature naturally, 2012. Air/water
see RDSO handbook. If cool down is forced, microstructural cooling can be
changes in the rail may apply. done when
temperature 3500C
as per provisions of
the Manual for
Flash Butt Welding
of Rails-2012.

27. 7.0 Post Weld heat 1.Comments of NER - NER - 7.0 Post Weld heat
treatment: 2.18 Post Weld heat treatment: Accepted as treatment:
Equipment should Equipment should provide for post heat treatment facilities provisions are Alloy steel rails and heat
provide for post heat with necessary control features. This device among other elaborated to make treated/head hardened rails
treatment facilities thing shall enable the post heating sequence being set to clearer. need post weld heat treatment
with necessary pre-determine temperature and cooling time with a selector to ensure variation in hardness
control features. This switch to bring in the automatic post heat cycle whenever within acceptable limits in heat
device among other required. In case of welding of 1080 grade chromium rails affected zone. Suitable
thing shall enable the and 1080 grade Head Hardened rails, controlled cooling and equipment should be provided
post heating fast cooling (quenching) shall be required respectively to for post heat treatment
sequence being set maintain the properties of parent rail in heat affected zone. facilities with necessary control
to pre-determine The facility should preferably be in-built with the welding features. This device among
temperature and machine. other thing shall enable the
Page 28 of 49 
 
 cooling time with a The facilities, if proposed to be provided separately on the post heating sequence being
selector switch to welding line at the adjustable distance from the machine, set to pre-determine
bring in the automatic should have proper interlock with main welding machine to temperature and cooling time
post heat cycle be incorporated in welding cycle. The up-gradation should with a selector switch to bring
whenever required. In be possible by adding new component or the system should M/s Mechelonic- in the automatic post heat
case of welding of be compatible for up-gradation. Considered and cycle whenever required. The
1080 grade provision has made facility should preferably be in-
chromium rails and 2.Comments of M/s Mechelonic- optional. built with the welding machine.
1080 grade Head Built in post heat facility will increase cycle time. The facilities, if proposed to be
Hardened rails, M/s Schlatter - provided separately on the
controlled cooling 3.Comments of M/s Schlatter - considered and welding line at the adjustable
and fast cooling The FBW GAAS80 is not equipped with an integrated after provision has made distance from the machine,
(quenching) shall be heat treatment module for forced cooling of head hardened optional. should have proper interlock
required respectively rails. We supply a separate cooling unit type VoestAlpine with main welding machine to
to maintain the M/s NENCKI – be incorporated in welding
with an electric compressor for installation near the welding
properties of parent Suitable cycle.
rail in heat affected machine. equipments may be
zone. These facilities 4. Comments of M/s NENCKI, Switzerland – provided.
should be either in Post weld heat treatment: described in RDSO Handbook,
built with the machine Annex. I, Para 5.4 (Page 22), here described features are
or provided not necessary, production time will be much higher,
separately on the recommended distances available in handbook. The
welding line at the solution described in RDSO Handbook, Annex. I, Para 5.4
adjustable distance (Page 22) is a very practical and simple solution and is more
from the machine. than sufficient to get good results.
The up-gradation Post weld air quenching treatment: described in RDSO
should be possible by Handbook, Annex. II, Para 5.4 (Page 23).
adding new
component or the
system should be
compatible for up-
gradation.

28. 8.0 Specification for 1.Comments of NER - NER - 8.0 Stand by Diesel
Stand by Generator- 5. Specification for Stand by Diesel Generator: Accepted as Generator:
A suitable diesel provisions are
operated generating A suitable diesel operated generating set with adequate elaborated to make 8.1 A suitable diesel operated
set with adequate capacity to feed welding transformer, compressor, electric clearer. generating set with adequate
capacity to feed hoists, Goliath crane and motorized line etc. to be supplied capacity to feed welding
welding transformer, with the welding plant as standby for welding operation. The transformer, compressor,
compressor, electric basis for deciding capacity should be clearly brought out in electric hoists, Goliath crane
hoists, Goliath crane the offer. and motorized line etc. to be
Page 29 of 49 
 
 and motorized The generator shall be powered by indigenous diesel engine supplied with the welding plant
conveyer line etc. to and shall have proven record of service in tropical as standby for welding
be supplied with the conditions. The detailed technical literature and operation. The basis for
welding plant as specifications along with manufacturer’s literature should deciding capacity should be
standby for welding accompany the offer. clearly brought out in the offer.
operation. 2. Comments of NR- NR-
The generator shall be
All the machines including generators should be sound proof Modified provision
powered by indigenous diesel
(sound level should be within the limit) incorporated as
engine and shall have proven
3. Comments of M/s Schlatter – clause 20.3
record of service in tropical
Noted. Part of scope of supply of Maco Corporation. Pls conditions. The detailed
refer technical specification sheet attached. M/s Schlatter –
technical literature and
4. Comments of SR- Comments are
specifications along with
Existing Para shall be corrected as below. Informative only.
manufacturer’s literature
Backup power supply shall be provided with Two Diesel should accompany the offer.
operated Gensets. SR- A suitable
One Genset with adequate capacity shall feed the Welding diesel operated 8.2 The engine should have
Machine including Control Panel, Weld Data Recorder, generating set with Electronic Control Module
Hydraulic Power Packs, Chiller Unit, Stripping Unit, Brushing adequate capacity (ECM) or similar arrangement
Device, Smoke Trapping Device which are essential for the will fulfil the for taking out operating
Welding process. requirement. parameters on real time basis
The second GenSet with suitable capacity shall feed the such as RPM, load,
flow line machinery such as Conveyors, Hoist, Air M/s NENCKI – temperature, pressure and
Compressors, Grinding Machines, Rail Straightening No comments. diagnostic data as well as trip
Machine, Testing equipments, etc. and historical data. These
5. Comments of M/s NENCKI, Switzerland – TMM Dte – data should be displayed and
Not applicable for Nencki Machines. Part of Flash Butt Accepted and stored on a centralized
Welding manufacturer. modified computer and monitoring
accordingly. system. It should also be
6. Comments of TMM Dte – possible to transfer these data
8.1 A suitable diesel operated generating set with adequate on USB device through the
capacity to feed welding transformer, compressor, electric centralized computer based
hoists, Goliath crane and motorized line etc. to be supplied control.
with the welding plant as standby for welding operation. The 8.3 In order to adhere to
basis for deciding capacity should be clearly brought out in pollution Control norms, the
the offer. The generator shall be powered by indigenous diesel engine should be
diesel engine and shall have proven record of service in electronically controlled
tropical conditions. The detailed technical literature and emmissionized engine with
specifications along with manufacturer’s literature should minimum compliance of tier 2
accompany the offer. stage.
8.2 The engine should have Electronic Control Module 8.4 The engine should be
(ECM) or similar arrangement for taking out operating enclosed in a weather
Page 30 of 49 
 
 parameters on real time basis such as RPM, load, protective, sound and dust
temperature, pressure and diagnostic data as well as trip resistant enclosure to minimize
and historical data. These data should be displayed and engine noise and to prevent
stored on a centralized computer and monitoring system. It oozing out of oil spills etc. from
should also be possible to transfer these data on USB engine area to the adjacent
device through the centralized computer based control. components like alternator,
hoses, electrical cables fittings
8.3 In order to adhere to pollution Control norms, the diesel
as a protection against fire. All
engine should be electronically controlled emmissionized
doors on the enclosure shall
engine with minimum compliance of tier 2 stage.
be strategically located in
8.4 The engine should be enclosed in a weather protective, areas as to allow ease of
sound and dust resistant enclosure to minimize engine noise maintenance of the engine and
and to prevent oozing out of oil spills etc. from engine area allow good access to and
to the adjacent components like alternator, hoses, electrical visibility of instruments,
cables fittings as a protection against fire. All doors on the controls, engine gauges, etc.
enclosure shall be strategically located in areas as to allow Sufficient louvers shall be
ease of maintenance of the engine and allow good access provided to allow the total
to and visibility of instruments, controls, engine gauges, etc. engine cooling air
sufficient louvers shall be provided to allow the total engine requirements used in this
cooling air requirements used in this application. application.
29. 9.0 Rail End Brushing 1.Comments of NER - NER – 9.0 Automatic Rail End
9.1 Machine: 6.0 Automatic Rail End Brushing Machine: Accepted as Brushing Machine:
Brushing Machine for 6.1 Brushing Machine shall be so designed that it will provisions are 9.1 Brushing Machine
cleaning of rail end automatically clean the specified area of rail along with dust elaborated to make shall be so designed that it will
along with dust evacuation before welding in order to establish uniform clearer. automatically clean the
evacuation before contact on running surface. The machine shall be capable to specified area of rail along with
welding in order to remove the scale rust and other grit from the rails using steel dust evacuation before
establish uniform wire brushes. The brushing process should ensure optimal NR – welding in order to establish
contact on running contact resistance between the rails and the welding Accepted and uniform contact on running
surface. The machine electrodes. The operation shall meet the provisions of the incorporated as surface. The machine shall be
shall be capable to Manual for flash butt welding of rails issued by RDSO. clause 9.6. capable to remove the scale,
remove the scale rust 2.Comments of NR - rust and other grit from the
and other grit from Suction and dust collection system should also be available rails using steel wire brushes.
the rails using steel in machine. The brushing process should
wire brushes. The 3. Comments of M/s Schlatter – ensure optimal contact
brushing process Noted. Part of scope of supply of Maco Corporation as resistance between the rails
should ensure bought out in case of Turnkey execution of FBWP. Pls refer and the welding electrodes.
optimal contact technical specification sheet attached. M/s Schlatter – The operation shall meet the
resistance between Comments are provisions of the Manual for
4. Comments of M/s NENCKI, Switzerland –
the rails and the Informative only. flash butt welding of rails
Noted. Draft specifications are enclosed herewith for your
welding electrodes. issued by RDSO.
reference.
Page 31 of 49 
 
 The operation shall
meet the provisions
of the Manual for
flash butt welding of
rails issued by
RDSO.

30. 9.2 Clamping Unit : No comments --- 9.2 Clamping Unit :

Clamping units to be Clamping units shall be
provided for centering provided for centering of the
of the rails while rails while brushing. The
brushing. The system system preferably to be
preferably to be hydraulically operated for the
hydraulically movements of the brushing
operated for the units and electric motors for
movements of the continuous control torque for
brushing units and the brushing, thus ensuring
electric motors for efficient cleaning of the rails.
continuous control
torque for the
brushing, thus
ensuring efficient
cleaning of the rails.
31. 9.3 The area to be 1.Comments of SR - SR – 9.3 The area to be
cleaned: The rails Additional Para to be included as below. Electrode contact cleaned: The rails end faces
end faces and the Provision for cleaning web portion of rail shall be provided if locations of rails and the adjoining surface of
adjoining surface of the welding electrodes are designed for camping on the web has been the rail profile to a width of
the rail profile to a portion of the rails. mentioned. about 25mm all round and
width of about 25mm electrode contact locations of
M/s NENCKI –
all round and 2. Comments of M/s NENCKI, Switzerland – rails.
Cleaning of
electrode contact Noted. Our machine cleans the top, bottom and butt of the
adjoining surfaces
locations. rail. The cleaning of the web is not necessary. is required as per
provisions of FBW
Manual-2012

32. 9.4 Operation: 1.Comments of NER - NER – 9.4 Operation: The

6.4 Operation: The operation should be automatic and Accepted as operation should be automatic
The operation should
sensors are to be provided to detect rail ends and position provisions are and sensors are to be
be automatic and
them inside the machine. Once rail end is positioned, the elaborated to make provided to detect rail ends
sensors are to be
Page 32 of 49 
 
 provided to detect rail brushing cycle to be executed by the per-programmed logic clearer. and position them inside the
ends and position control sequence. The cleaning shall be accomplished machine. Once rail end is
them inside the within the weld cycle time of 120 sec. so that productivity of positioned, the brushing cycle
machine. Once rail plant is not adversely affected. to be executed by the pre-
end is positioned, the programmed logic control
brushing cycle to be sequence. The cleaning shall
executed by the per- be accomplished within the
programmed logic weld cycle time, so that
control sequence. productivity of plant is not
adversely affected.
33. 9.5 Safety: No comments --- 9.5 Safety:
The machine will be The machine will be
equipped with all equipped with all safety
safety features features commensurate with
commensurate with good engineering practice and
good engineering industrial standards as
practice and expected. The machine should
industrial standards disable and indicate in case of
as expected. The system failure. Fail safe
machine should interlocks should be provided
disable and indicate to prevent faulty
in case of system operation. The supplier should
failure. Fail safe indicate the safety features
interlocks should be provided in the machine.
provided to prevent
9.6 Suction and dust
faulty operation. The
collection system should also
supplier should
be available in machine.
indicate the safety
features provided in
the machine.

34. 10 Weld Grinding 1.Comments of NER - NER – 10.0 Weld Grinding Machine:
Machine- 7.0 Weld Grinding Machine: Accepted as The machine should be
The machine should The machine should be capable of running on 440V 3 phase provisions are capable of running on 440V 3
be designed as to AC Electrical supply and shall be so designed as to elaborated to make phase AC Electrical supply.
complete the grinding complete the grinding operation on all sides of the rail in two clearer. The machine shall be so
operation on all sides minutes. The machine should have powered movement on designed as to complete the
of the rail in two its own wheels for positioning and use large high speed grinding operation on all sides
minutes. The grinding wheels on each for top, bottom and two gauge of the rail in not more than 5
machine should have faces. The grinding operation shall be automatic. The weld minutes.
Page 33 of 49 
 
 powered movement finish tolerance as specified in the “Manual for flash butt In order to maximize the
on its own wheels welding of rails” issued by RDSO should be achieved after output of the welding plant as
and use large high grinding. Wheel dressing arrangement should be built in the a whole, more than one
speed grinding machine. automatic grinding machine
wheels on each for It shall be ensured that indigenously available grinding may be planned in the same
top, bottom and two stones can be used on this machine. welding line or an alternative
gauge faces. Wheel line, as per layout of the plant.
dressing 2. Comments of NR – NR – The machine should have
arrangement must be Machine should have PLC control, dust collection system, Accepted and powered movement on its own
designed to run on Internal digital measuring and recording system. incorporated. wheels for positioning and use
440V AC 3 phase. M/s Mechelonic – large high speed grinding
3.Comments of M/s Mechelonic Not accepted as wheels each for top, bottom
Semi-automatic profile grinding machine with manual automatic grinding and two gauge faces. The
grinding support is preferred as a automatic machine will operation is more grinding operation shall be
take too long time for grinding, reducing production.3. reliable. automatic. The weld finish
M/s Schlatter – tolerance as specified in the
4. Comments of M/s Schlatter – Accepted and “Manual for flash butt welding
Noted. Part of scope of supply of Maco Corporation as provisions made for of rails” issued by RDSO
bought out in case of Turnkey execution of FBWP. Pls refer one or two grinding should be achieved after
technical specification sheet attached. machines, so that grinding.
production may not It shall be ensured that
Firm has also mentioned at Para 2.3 that grinding operation
hamper. indigenously available grinding
takes approx. 5 - 6 minutes and thus determines the hourly stones can be used on this
output of a long rail welding plant. M/s NENCKI – machine.
5. Comments of M/s NENCKI, Switzerland – Accepted and Machine should have PLC
Not possible in 2 minutes provisions made for control, dust collection system,
No Machine in the world is able to grind the rail profile in 2 one or two grinding Internal digital measuring and
mins. machines, so that recording system.
Cycle time of the Nencki Grinding Machine is approx. 5 production may not
minutes (if tolerances of the rail and weld are met). Our hamper.
machine grinds the top and both sides of the Railhead. The
dressing of the grinding wheel is not necessary.

35. 11 Specification for 1.Comments of NER - NER - 11.0 Rail Straightening

Rail Straightening 8.0 Specification for Rail Straightening Machine (Pre Accepted except Machine (Pre and Post
Machine (Pre and and Post Weld): rails section 78 Weld):
Post Weld) Kg/m as provisions 11.1 The Pre Straightening
The post 8.1 The Pre Straightening machine is required to correct are elaborated to machine is required to correct
straightening rail end of rails to be welded and this machines shall be make clearer. rail end of rails to be welded
machine should be stationary with suitable inching movement for placement of and this machine shall be
capable of re-moving rails in the press. The Post Straightening machine is stationary with suitable inching
the bad alignment in required to correct the weld alignment and this machine movement for placement of
Page 34 of 49 
 
 the welded flash butt should be self propelled to adjust itself to correct weld rails in the press. The Post
joints and should suit location without affecting the welding line. Both the Straightening machine is
various rail sections machines should be capable of correcting both vertical and required to correct the weld
i.e. 52Kg, 60Kg & 68 lateral alignment for all the rail sections to be welded i.e. alignment and this machine
Kg. The machine rails upto 78 kg/m. should be self propelled to
should provide 8.2 The post straightening machine should be capable adjust itself to correct weld
alignment correction of re-moving the bad alignment in the welded flash butt location without affecting the
in vertical and lateral joints and should suit various rail sections i.e. 52Kg, 60Kg & welding line. Both the
direction and should 68 Kg. The machine should provide alignment correction in machines should be capable
have powered vertical and lateral direction and should have powered of correcting both vertical and
travelling travelling arrangement for adjusting to different lengths of lateral alignment for all the rail
arrangement for rails being welded. The machine should also have sections to be welded i.e. rails
adjusting to different misalignment measuring device and also visual indicator to upto 68 kg/m.
lengths of rails being point out the location and extent of misalignment. The 11.2 The post straightening
welded. The machine alignment correction supports should be moveable so as to machine should be capable of
should also have handle short and long kinks. re-moving the bad alignment in
misalignment 8.3 The pre-straightening press should be provided as a the welded flash butt joints and
measuring device stationary press, where as the post-straightening press should suit various rail
and also visual should be a mobile press. The press should be self sections. The machine should
indicator to point out propelled for positioning on the rail to be straightened. A provide alignment correction in
the location and straightness measuring device should be provided to vertical and lateral direction
extent of measure and record the straightness of the rail at the joint. and should have powered
misalignment. The 8.4 The frame of presses must be of robust design. travelling arrangement for
alignment correction Adequate stiffeners and gusseting is to be provided for adjusting to different lengths of
supports should be structural strength. All welded structures must be suitably rails being welded. The
moveable so as to stress relieved by heat treatment. The horizontal and vertical machine should have
handle short and long cylinders should not be integral with the main machine body misalignment measuring
kinks. to facilitate maintenance of the cylinders as modular units. device and also visual
The pre-straightening 8.5 The laser measurement system should measure the indicator to point out the
press should be straightness of the welded joint, and display it in a graphical location and extent of
provided as a form and stores the data in the tabular form. The laser misalignment. The alignment
stationary press, measurement device must measure the head of the rail on correction supports should be
where as the post- the three surfaces, namely; Top Side, Front gauge face and moveable so as to handle
straightening press Rear gauge face. short and long kinks.
should be a mobile The measurement should be done with the help of laser 11.3 The pre-straightening
press. The press displacement sensor and the final straightness data should press should be provided as a
should be self- be stored in memory for later retrieval and analysis. If the stationary press. A
propelled for rail is within the acceptable tolerance band the operation is straightness measuring device
positioning on the rail complete or else the operator will have to repeat the cycle till should be provided to measure
to be straightened. A the required straightness is achieved. and record the straightness of
straightness 8.6 The Rail Straightening Machines should have a the rail.
measuring device control system with PLC, key board and other required 11.4 The frame of presses
Page 35 of 49 
 
 should be provided to devices. It should also have software to visualize the must be of robust design.
measure and record straightness of the rails, force supplied on the rails, the Adequate stiffeners and
the straightness of deformation process induced by straightening force and gusseting is to be provided for
the rail at the joint. shall be displayed on the screen. The final alignment structural strength. All welded
The frame must be of achieved shall automatically get recorded and stored for structures must be suitably
robust design. further analysis. This should be compatible with weld data stress relieved by heat
Adequate stiffeners recorder so that the data of press is fed to recorder for treatment. The horizontal and
and gusseting is to comprehensive record. vertical cylinders should not be
be provided for 8.7 The design shall be such that manual verification of integral with the main machine
structural strength. All alignment is easily possible and area is well illuminated. The body to facilitate maintenance
welded structures control panel should have provision for emergency stop for of the cylinders as modular
must be suitably emergency and interlock to stop machine if deflection units.
stress relieved by beyond pre-specified limit is exceeded to prevent breakage 11.5 The laser
heat treatment. of rail. measurement system should
The horizontal and 2.Comments of SCR - measure the straightness of
vertical cylinders No change in Para 1 & 2 the welded joint, and display it
should not be integral The horizontal and vertical cylinders should not be integral in a graphical form and data
with the main with the main machine body to facilitate maintenance of the should be stored in the tabular
machine body to cylinders as modular units. The laser measurement system form. The laser measurement
facilitate maintenance device must measure the head
should measure the straightness of the welded joint, and
of the cylinders as SCR – of the rail on the three
modular units. The displays it in a graphical form and stores the data should be Accepted and surfaces, namely; Top Side,
laser measurement stored in the tabular form. The laser measurement device modified. Front gauge face and Rear
system should must measure the head of the rail on the three surfaces, gauge face.
measures the namely; Top Side, Front gauge face and Rear gauge face. The measurement should be
straightness of the No change in next Para done with the help of laser
welded joint, and displacement sensor and the
displays it in a 3.Comments of NR – final straightness data should
graphical form and Machine should have digital measurement system. be stored in memory for later
stores the data in the retrieval and analysis. If the
tabular form. The 4. Comments of M/s Schlatter – rail is within the acceptable
laser measurement Noted. Part of scope of supply of Maco Corporation as tolerance band the operation is
device must measure bought out in case of Turnkey execution of FBWP. Pls refer complete or else the operator
the head of the rail on technical specification sheet attached. will have to repeat the cycle till
the three surfaces, NR – the required straightness is
namely; Top Side, 5.Comments of SR – Already achieved.
Front gauge face and Additional Para to be included as below. incorporated. 11.6 The Rail Straightening
Rear gauge face. Adequate spare dies for various rail sections such as 52kg / Machines should have a
The measurement 60kg / 68kg shall be provided. M/s Schlatter – control system with PLC, key
should be done with In addition to various rail sections, various steel grades shall Comments are board and other required
the help of laser also be mentioned to include in 70 UTS, 90 UTS and 110 Informative only. devices. It should also have
displacement sensor UTS and this should be included in under the Para 2.1 itself. software to visualize the
Page 36 of 49 
 
 and the final 6. Comments of M/s NENCKI, Switzerland – straightness of the rails, force
straightness data Post straightening: ok SR – supplied on the rails, the
should be stored in Note: Suitable dies for deformation process induced
memory for later Offset/steps between two welded rails cannot be aligned. different rail by straightening force and
retrieval and analysis. Pre-straightening: A separate/additional machine will be sections to be shall be displayed on the
If the rail is within the necessary for pre-straightening the rail ends. It is not a part welded are screen. The final alignment
acceptable tolerance of the Nencki Straightening Machine. included in clause achieved shall automatically
band the operation is 2.11. get recorded and stored for
complete or else the Rail sections and further analysis. This should
operator will have to grades to be be compatible with weld data
repeat the cycle till welded are recorder so that the data of
the required mentioned at press is fed to recorder for
straightness is clause 2.1. comprehensive record.
achieved. 11.7 The design shall be
The Rail M/s NENCKI – such that manual verification
Straightening Requirement of two of alignment is easily possible
Machines should separate machines and area is well illuminated.
have a control (Pre and Post The control panel should have
system with PLC, key Straightening) is provision for emergency stop
board and other mentioned. for emergency and interlock to
required devices. It stop machine if deflection
should also have beyond pre-specified limit is
software to visualize exceeded to prevent breakage
the straightness of of rail.
the rails, force
supplied on the rails,
the deformation
process induced by
straightening force
shall be displayed on
the screen.
36. 12 Maintenance 1.Comments of NER- NER – 12.0 Maintenance spares:
spares- 10.0 Maintenance spares: Accepted as 12.1 The tenderers are
The tenderers are 10.1 The tenderers are required to furnish a detailed list provisions are required to furnish a detailed
required to furnish a of essential spare parts along with detailed drawings and elaborated to make list of essential spare parts
detailed list of specifications required for operation of entire plant for a more clear. along with detailed drawings
essential spare parts period of two years. These spares should be included with and
along with detailed the price of each equipment. specifications/metallurgical
drawings and 10.2 It should be necessary for the tenderer to indicate specifications required for
specifications as to which of the parts listed can be procured indigenously operation of entire plant for a
required for operation and identifying the remaining items which are required to be period of two years. These
of entire plant for a necessarily imported. spares should be included with
Page 37 of 49 
 
 period of two years. 10.3 The tenderer should provide the itemized list of the price of each equipment.
These spares should spare parts giving full particulars of the parts indicating part 12.2 It should be necessary
be including with the number, description, name of manufacturer, unit price, for the tenderer to indicate as
price of each recommended quantity etc. The sketches/ drawings NR – to which of the parts listed can
equipment. wherever required unit price of all such items should also be These have been be procured indigenously and
furnished. covered under item identifying the remaining items
It should be of AMC. which are required to be
necessary for the 2. Comments of NR – necessarily imported.
tenderer to indicate There should be provision of sufficient quantity of spare 12.3 The tenderer should
as to which of the parts of various machines so as to maintain the machines provide the itemized list of
parts listed can be for minimum 3 years after warranty period. List of spare M/s Schlatter – spare parts giving full
procured parts with machine manual alongwith their stipulated life, the No comments. particulars of the parts
indigenously name of manufacturer etc. should be provided. indicating part number,
identifying the 3. Comments of M/s Schlatter – M/s NENCKI – description, name of
remaining items Noted. Will be part of tender documents. No comments. manufacturer, unit price,
which are required to 3. Comments of M/s NENCKI, Switzerland – recommended quantity etc.
be necessarily A detailed spare part list is part of the offer. The sketches/ drawings
imported. wherever required should also
be furnished.
The tenderer should
give full particulars of
the parts, part
number, name of
manufacturer etc.
The unit price of all
such items should
also be furnished.

37. 13 Consumable 1.Comments of NER - NER - 13.0 Consumable Stores:

Stores- 11.0 Consumable Stores: Accepted and
The tenderer should modified. The tenderer should furnish
furnish detailed The tenderer should furnish detailed specification of all detailed specification of all
specification of all consumable stores except fuel required for the operation of consumable stores except fuel
consumable stores the equipment offered including stripping unit, grinding required for the operation of
except fuel required machines and weld recorder together with the average the equipment offered
for the operation of expected consumption rate for one single 08 hours shift per including stripping unit,
the equipment day, clearly indentifying whether all such items are grinding machines and weld
offered including indigenously available or whether any item is required to be recorder together with the
stripping unit and imported on continuing counting basis. The unit price and average expected
weld recorder quantity of all such items should be quoted. The consumable consumption rate for one
together with the stores except fuel for a period of two years should be single 08 hours shift per day,
average expected included in the quotation for the welding plant. clearly indentifying whether all
Page 38 of 49 
 
 consumption rate for 2.Comments of SCR- such items are indigenously
one single 08 hours Consumable Stores- SCR- available or whether any item
shift per day, clearly The tenderer should furnish detailed specification of all Accepted and is required to be imported on
indentifying whether consumable stores except fuel required for the operation of modified. continuing basis. The unit
all such items are price and quantity of all such
the equipment offered including stripping unit and weld
indigenously items should be quoted. The
available or whether recorder together with the average expected consumption consumable stores except fuel
any item is required rate for one single 08 hours shift per day, clearly indentifying for a period of two years
to be imported on whether all such items are indigenously available or whether should be included in the
counting basis. The any item is required to be imported on counting basis. The tendered offer for the welding
price of all such items plant.
should be quoted. price of all such items should be quoted. The consumable
The consumable stores except fuel for a period of two years should be
stores except fuel for included in the tendered offer quotation for the welding
a period of two years plant.
should be included in
the quotation for the 3. Comments of M/s Schlatter –
welding plant. Noted. Will be part of tender documents
4. Comments of M/s NENCKI, Switzerland –A detailed list M/s Schlatter –
of the consumables is part of the offer. No Comments.

M/s NENCKI –
No comments.
38. 14 14.0 Installation of 1.Comments of NER - NER – 14.0 Installation of plant:
plant- 9.0 Installation of plant: Accepted as 14.1 The installation of the
14.1 The installation 9.1 The installation of the plant should be undertaken by provisions are plant should be undertaken by
of the plant should be the suppliers of the plant or their agents in India, who elaborated to make the suppliers of the plant or
undertaken by the should commission the same. The services of firm’s clearer. their agents in India, who
suppliers of the plant Engineers should be made available to install and operate should commission the same.
or their agents in the same for at least two months. Railway staff will also be The services of firm’s
India, who should trained by the supplier of the plant for 02 months in regular Engineers should be made
commission the operation of the plant, as part of the contract. available to install and
same. The services 9.2 The installation includes the making foundation for operate the same for at least
of firm Engineer machines as per requirement and design finalized by two months. Railway staff will
should be made supplier, supply and providing all the Installation materials also be trained by the supplier
available to install like bolts and nuts, brackets etc complete in all respect. of the plant for 02 months in
and operate the should be provided in adequate quantities, quoting unit price regular operation of the plant,
same for at least two and quantity recommended. Special tools required for as part of the contract.
months. Railway staff installation/maintenance shall provided by the tenderer. 14.2 The installation
will also be trained by 2. Comments of M/s Schlatter – includes the making
the supplier of the Noted. The above scope of work is under Maco Corporation foundation for machines as per
plant for 02 months in M/s Schlatter – requirement and design
Page 39 of 49 
 
 regular operation of (India) Private Ltd. Comments are finalized by supplier, supply
the plant, as part of 3. Comments of M/s NENCKI, Switzerland – Informative only. and providing all the
the contract. 14.1 Noted Installation materials like bolts
14.2 Installation Installation will be done by Nencki service engineers from M/s NENCKI – and nuts, brackets etc
materials like bolts India and/or Switzerland. Comments are complete in all respect.
and nuts, brackets Training: For each Nencki-Machines (Brushing, Grinding, Informative only. Special tools required for
should be provided in Straightening, testing) there will not more than 1 to 2 weeks installation/maintenance shall
adequate quantities, per machine of training necessary. provided by the tenderer.
quoting unit price and 14.2 Noted
quantity Installation materials like bolts, nuts and brackets are part
recommended. of the scope of supply.
Special tools required
for installation/
maintenance shall
provided by the
tenderer.

39. 15 15.0 Training of 1.Comments of NER NER - 15.0 Training of staff:

staff- 12.0 Training of staff: Accepted as 15.1 One copy of complete
15.1 Two persons 12.1 Two persons from the Railway will be trained, as provisions are technical literature of
from the Railway will part of this contract (including transportation from India and elaborated to make machines/tools/equipments
be trained, as part of back, boarding, lodging etc.) for a period of one month each clearer. including installation, operation
this contract in Manufacturerer’s country or any other country where and service
(including similar machines are working. The cost of training includes manuals/instructions and
transportation from lodging, boarding, air passage etc. and training material to complete electrical &
India and back, be provided. hydraulic, trouble shooting
boarding, lodging 12.2 In addition to above, the operating staff will be charts, component drawings/
etc.) for a period of trained for day to day operation and maintenance during the description and other relevant
one month each in two months period the plant is under operation of the technical details as a
country where similar supplier and thereafter for another period of 4 months. reference documents in soft &
machines are 12.3 The audio visual material like films, video tapes, hard copies in English
working. slides etc. will also be made available by the suppliers which language.
15.2The audio visual may facilitate general training of the staff. NR – .
material like films, 2. Comments of NR – Two person training 15.2 In addition to above,
video tapes, slides Three persons from the railway should be trained for period for a month will the operating staff will be
etc. will also be made of one month at two countries 15 days each to learn best of suffice the purpose. trained for day to day
available by the the practices. operation and maintenance
suppliers which may 3. Comments of M/s Schlatter – M/s Schlatter – during the two months period
facilitate general Noted. Will be fulfilled. No Comments. the plant is under operation of
training of the staff. 4. Comments of M/s NENCKI, Switzerland – the supplier and thereafter for
15.1 Training from Indian person of one month at a similar M/s NENCKI- another period of 4 months.
factory is unusual and not necessary Advance training is 15.3 The audio visual
Page 40 of 49 
 
 Same machines are operated in India, training on such required. material like films, video tapes,
plants shall be organised and borne by Indian Railway itself. slides etc. will also be made
From made experience, it is not necessary to hold such available by the suppliers
training in advance, since operators will be trained on the which may facilitate general
machines delivered. training of the staff.
15.2 If available.

40. 16 16.0 Layout- 1.Comments of NER- NER- 16.0 Layout:

The tenderer should 13.0 Layout: Accepted as 16.1 The tenderer should
furnish the overall 13.1 The tenderer should furnish the overall layout of their provisions are furnish the overall layout of
layout of their plant plant together with sketches or drawing pertaining to the elaborated to make their plant together with
together with same to appreciate the inter-se position of various units and clearer. sketches or drawing pertaining
sketches or drawing infra-structural requirements to be provided by the Railways. to the same to appreciate the
pertaining to the The location of the plant vis-à-vis essential accessories is to inter-se- position of various
same to appreciate be furnished in the form of block diagram. units and infrastructural
the inter-se position 13.2 The proposed layout shall consider the existing requirements to be provided
of various units and facilities available in the existing Plants. It is desirable that by the Railways. The location
infra-structural tenderer visits the plant to have details of existing layout of the plant vis-à-vis essential
requirements to be themselves. The overall dimensions of the layout Length, accessories is to be furnished
provided by the Breath, Height and structure/shed required for in the form of block diagram.
Railways. The accommodating the equipment, specification of essential 16.2 The proposed layout shall
location of the plant elements etc. should be indicated. consider the existing facilities
vis-à-vis essential 2. Comments of M/s Schlatter –Noted. Will be part of the available in the existing Plants.
accessories is to be tender documents. M/s Schlatter – It is desirable that tenderer
furnished in the form No Comments visits the plant to have details
of block diagram. 3. Comments of M/s NENCKI, Switzerland – of existing layout themselves.
Noted M/s NENCKI – The overall dimensions of the
Plant layout to be furnished by general contractor, machine Comments are layout including Length,
supplier to furnish machine layouts/ General Arrangement Informative only. Breath, Height and
Drawings. structure/shed required for
accommodating the
equipment, specification of
essential elements etc. should
be indicated.
41. 17 Instruction 1.Comments of NER - NER – 17.0 Instruction Manuals:
Manuals- 14.0 Instruction Manuals: Accepted and All manuals (installation,
All manuals All manuals (installation, operation and service) shall be in modified. operation and service) shall be
(installation, English. Detailed installation documents complete with in English. Detailed installation
operation and typical layout, special tools and accessories etc. should be documents complete with
service) shall be in supplied in six sets, well in time to enable coordination with typical layout, list of special
English. Detailed order to installation activities. Equipment description tools and accessories etc.

Page 41 of 49 
 
 installation including installation, testing, schematic wiring, physical should be supplied in six sets,
documents complete location, drawings, etc. shall be supplied. well in time to enable
with typical layout 2.Comments of SCR coordination with order to
special tools and Instruction Manuals- installation activities.
accessories etc. All manuals (installation, operation and service) shall be in Equipment description
should be supplied in English. Detailed installation documents complete with SCR – including installation, testing,
six sets, well in time typical layout, list of special tools and accessories etc. Change of wording schematic wiring, physical
to enable should be supplied in six sets, well in time to enable does not change location, drawings, etc. shall
coordination with coordination for with order to installation activity. Equipment any meaning. be supplied.
order to installation description including installation, testing, schematic wiring,
activity. Equipment physical location, drawings, etc. shall be supplied.
description including 3. Comments of M/s Schlatter –
installation, testing, Noted. Will be fulfilled.
schematic wiring,
physical location, 4. Comments of M/s NENCKI, Switzerland – Noted.
drawings, etc. shall M/s Schlatter –
be supplied. No Comments
42. 18.0 Inspection of the 1.Comments of NER - NER- 18.0 Inspection of the
18.1 Welding Plant 15.0 Inspection of the Equipments of Welding Plant Accepted and Equipments/ Welding Plant
All the equipment will modified.
be tested before 2.Comments of SCR – 18.1 All the equipment will be
dispatch by the 18.1 All the equipment will be tested before dispatch by the SCR – tested before dispatch by the
technical inspection technical inspection officers of Indian Embassy or Inspection team technical inspection officers of
officers of Indian authorized representative of Indian Railways. In view of may be decided at Indian Embassy or authorized
Embassy or specialization of FBW machine, it is desirable that officials later stage, this representative of Indian
authorized from RDSO (Metallurgical & chemical and Track directorate) may not be part of Railways. While inspecting the
representative of and Zonal Railways shall comprise of members of technical specification. machine before dispatch from
Indian Railways. inspection team. While inspecting the machine before the supplier’s premises, the
While inspecting the dispatch from the supplier’s premises, the inspecting officer inspecting officer shall verify
machine before shall verify the conformity of the machine with respect to the conformity of the machine
dispatch from the individual specification as above. The machine’s with respect to individual
supplier’s premises, conformity/non-conformity issue in respect to each item shall specification as above. The
the inspecting officer be jointly recorded before issue of the inspection certificate machine’s conformity/non-
shall verify the and approval for dispatch of the machine as per Annexure –I conformity issue in respect to
conformity of the enclosed. each item shall be jointly
machine with respect 3. Comments of M/s Schlatter – recorded before issue of the
to individual Noted. Will be fulfilled. inspection certificate and
specification as 4.Comments of SR – M/s Schlatter – approval for dispatch of the
above. The Additional Para to be included as below. No Comments machine as per Annexure –I
machine’s During the inspection, conformity tests shall be carried out enclosed.
conformity/non- as per Manual for Flash Butt Welding of Rails-Revised-2012 SR –
conformity issue in “The inspecting
Page 42 of 49 
 
 respect to each item and amended upto date out of 3 joints each with minimum officer shall verify
shall be jointly cross section of 60kg rails subjected to Transverse Load the conformity of
recorded before issue Test and Macro Examination. the machine with
of the inspection respect to
5. Comments of M/s NENCKI, Switzerland –
certificate and individual
approval for dispatch All machines will be tested at our premises. specification as
of the machine as per FAT in our factory. above” is already
Annexure –I mentioned in this
enclosed. clause.

43. 18.2 The following 1. Comments of M/s Schlatter – M/s Schlatter – 18.2 The following documents
documents shall be Noted. Will be fulfilled. No Comments shall be provided to the
provided to the 2. Comments of M/s NENCKI, Switzerland – Inspecting Officer at least 4
Inspecting Officer at Noted. weeks in advance of the date
least 4 weeks in of inspection.
advance of the date i) One copy of complete
of inspection. technical literature of
i) One copy of machines/tools/equipment
complete technical s including installation,
literature of operation and service
machines/tools/equip manuals/instructions and
ments, in English complete electrical &
language, including hydraulic, trouble shooting
installation, operation charts, component
and service drawings/ description and
manuals/instructions other relevant technical
and complete details as a reference
electrical & hydraulic, documents in soft & hard
trouble shooting copies in English
charts, component language.
drawings/ description ii) Clause by clause
and other relevant comments of the
technical details as a manufacturer to be sent to
reference documents Inspecting Officer (IO) in
in soft & hard copies advance for his review.
for the inspecting Comments should state
officer. manufacturer’s conformity
ii) Clause by of compliance of each of
clause comments of the requirement stated in
the manufacturer to each clause, elaborating
be sent to Inspecting where necessary the
Officer (IO) in details/manner in which
Page 43 of 49 
 
 advance for his the requirement has been
review. Comments complied. The proforma
should state for the clause-wise
manufacturer’s comments is given below:
conformity of
compliance of each Commen Comments
of the requirement ts of of
stated in each clause, manufac Inspecting

Clause no.
elaborating where
turer Officer
necessary the

Clause
details/manner in
which the
requirement has
been complied. The
proforma for the
clause-wise
comments is given
below:
iii) Manufacturer’s Internal
Quality Inspection Report
of

of

of the machine.
iv) Manufacturer’s quality
Inspecting Officer

certificate and/or test

reports for bought out
manufacturer

assemblies/sub-
Comments

Comments
Clause no.

assemblies to be provided
Clause

to IO, containing serial

number wherever
applicable.
v) Draft Inspection Report to
be prepared by the
manufacturer, containing
all Annexure mentioned at
clause 18.3

iii) Manufacturer’
s Internal Quality
Inspection Report of
the machine.
iv) Manufacturer’
s quality certificate
and/or test reports for
Page 44 of 49 
 
 bought out
assemblies/sub-
assemblies to be
provided to IO,
containing serial
number wherever
applicable.
v) Draft
Inspection Report to
be prepared by the
manufacturer,
containing all
Annexure mentioned
at clause 18.3

44. 18.3 List of documents to 1. Comments of M/s Schlatter – M/s Schlatter – 18.3 List of documents to be
be annexed in the Noted. Will be part of tender documents No Comments annexed in the draft Inspection
draft Inspection 2. Comments of M/s NENCKI, Switzerland – Report should include:
Report should Noted i. Maker’s Test Certificate.
include: ii. Manufacturer’s Internal
i. Maker’s Test Quality Inspection Report
Certificate. iii. Quality Certificates of
ii. Manufacturer’s Bought out
Internal Quality assemblies/sub-
Inspection assemblies
Report iv. List of spare parts to be
iii. Quality dispatched along with the
Certificates of machine
Bought out v. List of tools to be
assemblies/sub- dispatched along with the
assemblies machine
iv. List of spare vi. List of Manuals, Drawings,
parts to be Spare Parts Catalogues,
dispatched etc. to be dispatched
along with the along with the machine,
machine duly indicating the number
v. List of tools to of sets of each.
be dispatched
along with the
machine
vi. List of Manuals,
Drawings,
Page 45 of 49 
 
 Spare Parts
Catalogues, etc.
to be
dispatched
along with the
machine, duly
indicating the
number of sets
of each.

45. 19 Additional 1. Comments of NR- NR – 19.0 Additional information

information – Any updation of plant with the upgradation of technology or Accepted and –
19.1 Names and as per requirement of railway in future upto 10 years which incorporated as 19.1 Names and address of
address of the is possible with minor alteration/addition etc should be new clause 19.4. the administration to which the
administration to acceptable to OEM through agency. Most of the upgradation equipment quoted has already
which the equipment would be based on changes/modification in software of been supplied by the tenderer
quoted has already control panels of machine(s) in this regard. should also be indicated.
been supplied by the 19.2 The supply of drawing will
tenderer should also 2. Comments of M/s Schlatter – M/s Schlatter – in no way absolve the tenderer
be indicated. Noted. Will be part of the tender documents. No Comments. of his responsibilities of
19.2 The supply of 3. Comments of M/s NENCKI, Switzerland – supplying the equipments
drawing will in no way 19.1 We suggest a specific eligibility/pre-qualification criteria strictly according to the
absolve the tenderer to be imposed in order to assure the past supply and specifications.
of his responsibilities performance of the machine. 19.3 Four copies of test and
of supplying the 19.2 Noted inspection certificates for each
equipments strictly 19.3 Noted equipment should be supplied
according to the along with the equipment.
specifications. 19.4 Any updation of plant with
19.3 Four copies of the upgradation of technology
test and inspection or as per requirement of
certificates for each railway in future upto 10 years
equipment should be which is possible with minor
supplied along with alteration/addition etc should
the equipment. be acceptable to OEM through
agency. Most of the
upgradation would be based
on changes/modification in
software of control panels of
machine(s) in this regard.
46. 20.0 Equipment --- ---- 20.0 Equipment
Environment- Environment-

Page 46 of 49 
 
47. 20.1 Equipment It shall be 1. Comments of M/s Schlatter – M/s Schlatter – 20.1 Equipment shall be
capable of Noted. Fulfilled. There are 3 active machines already Comments are capable of continuous
continuous operation running in India. informative only. operation during the varying
during the varying 2. Comments of M/s NENCKI, Switzerland – atmospheric and climatic
atmospheric and Noted conditions prevailing
climatic conditions throughout the year in India.
prevailing throughout The range of climatic
the year in India. The conditions is as follows: -
range of climatic a. Ambient temperature : -
conditions is as 100 to 550C
follows: - b. Altitude: : Sea level to
a. Ambient 1800 m above mean sea
temperature : - level
100 to 550C c. Humidity: : 40% to 100%
b. Altitude: : Sea d. Rail temperature : (-) 10°
level to 1800 m C to (+) 75° C
above mean sea
level
c. Humidity: : 40%
to 100%
d. Rail temperature
: (-) 10° C to (+)
75° C

48. 20.2 The entire equipment 1. Comments of M/s Schlatter – M/s Schlatter – 20.2 The entire equipment
should be thoroughly Noted. Fulfilled. No Comments. should be thoroughly
tropicalised for 2. Comments of M/s NENCKI, Switzerland – tropicalised for working in
working in Indian Noted Indian conditions.
conditions.
49. New ----- 2. Comments of NR against clause 8 NR- 20.3 All the machines
All the machines including generators should be sound proof Accepted as including generators should be
(sound level should be within the limit) modified in new sound proof.
3. Comments of NR as a new clause mentioned at Sl. clause 20.3. Various parameters regarding
No. 58 – sound and air pollution should
Various parameters regarding sound and air pollution should be provided by manufacturer
be provided by manufacturer with machine so that the same with machine so that the same
may be addressed rightly in case the plants are situated may be addressed rightly in
now at built up area. case the plants are situated at
built up area.
50. 21 Warranty Clause: 1. Comments of NER- NER – 21.0 Warranty Clause:
In addition to the 18.0 Warranty Clause: Accepted and In addition to the special
special conditions of In addition to the special conditions of contract dealing with modified. conditions of contract dealing
Page 47 of 49 
 
 contract dealing with warranty, the following will apply: with warranty, the following will
warranty, the Should any design modification be made in any part of the apply:
following will apply: equipment offered, the period of Warranty (24 months) Should any design
Should any design would commence from the date of the modified part is modification be made in any
modification be made commissioned in service for the purpose of that part and part of the equipment offered,
in any part of the those parts which may get damaged due to defects in the the period of Warranty (24
equipment offered, new replaced part, the cost of such modification should be months) would commence
the period of 24 borne by the supplier. from the date the modified part
months would 2. Comments of NR- is commissioned in service for
commence from the 21&22. Warranty Clause/extended warranty & annual NR – the purpose of that part and
date of the modified maintenance clause Warranty clause should have Two years warranty those parts which may get
part is commissioned provision of extended warranty upto 3 years after the period and five years AMC damaged due to defects in the
in service for the of 2 years original warranty with moderate charges. will suffice the new replaced part, the cost of
purpose of that part It may also be looked into for the provision of 5 years AMC purpose. such modification should be
and those parts (after 2+3years warranty & extended warranty) so that borne by the supplier.
which may get smooth working at plant after commissioning of new plant
damaged due to may be ensured with good quality of machines and there
defects in the new critical parts. This will also help to establish the trend of
replaced part, the maintenance required in machine at later stage. Proper
cost of such safeguard of extended warranty and AMC may be ensured
modification should through appropriate clause of penalty clause.
be borne by the 3. Comments of M/s Schlatter – M/s Schlatter –
supplier. Noted. Will be part of the tender documents. No Comments.
4. Comments of M/s NENCKI, Switzerland –
We can grant 24 months on exchanged/modified parts.

51. 22 Annual 1.Comments of NER NER – 22.0 Annual Maintenance

Maintenance 19.0 Annual Maintenance Contract (AMC): Accepted as Contract (AMC):
Contract (AMC): 19.1 The Plant and connected machines will be required provisions are
Tenderers are to be maintained for a period of Five (5) years after the elaborated to make 22.1 The Plant and
required compulsorily expiry of warranty period. clearer. connected machines will be
to quote for 19.2 For above, Tenderers are required compulsorily to required to be maintained for a
comprehensive quote for comprehensive annual maintenance contract per period of Five (5) years after
annual maintenance year for all machines and plants for a period of 5 years. The the expiry of warranty period.
contract per year for duration of AMC shall be of five years from the date of expiry
all machines and of the warranty. The AMC will be inclusive of preventive 22.2 For above, tenderers
plants for a period of maintenance services, day-to-day services, supply of all are required compulsorily to
5 years. The duration spares, maintenance material required and labour cost. All quote for comprehensive
of AMC shall be of consumables except fuel, lubricating oils, hydraulic oil, annual maintenance contract
five years from the toolings, drills and tapes shall form part of the scope of per year for all machines for a
date of expiry of the comprehensive AMC. period of 5 years. The duration
warranty. The AMC 2.Comments of M/s Mechelonic of AMC shall be of five years
Page 48 of 49 
 
 will be inclusive of It is suggested to train one Electrical and one Mechanical from the date of expiry of the
preventive person from the operation side, who will maintain the plant M/s Mechelonic – warranty. The AMC will be
maintenance on a day-to-day basis. We will provide daily maintenance Accepted. Day-to- inclusive of preventive
services, day-to-day schedule for this purpose. day services have maintenance services, supply
services, supply of all 3. Comments of M/s Schlatter – been removed from of all spares, maintenance
spares, maintenance Noted. Will be submitted with the tender documents. specification. material required and labour
material required and 4. Comments of M/s NENCKI, Switzerland – cost. All consumables except
labour cost. All Noted M/s Schlatter – fuel, lubricating oils, hydraulic
consumables except No Comments. oil, toolings, drills and tapes
fuel, lubricating oils, shall form part of the scope of
hydraulic oil, toolings, comprehensive AMC.
drills and tapes shall
form part of the
scope of
comprehensive AMC.

52. -- New clause Comments of SCR - SCR- 22.3 Technical audit for every
22.1 Technical audit for every 20000 joints by OEM during Accepted and new 20000 joints by OEM during
AMC period shall be part of AMC. clause 22.0 added. AMC period shall be part of
AMC.
53. -- New clause 1. Comments of NR- NR – ----
Various parameters regarding sound and air pollution should Accepted and
be provided by manufacturer with machine so that the same added in clause
may be addressed rightly in case the plants are situated 20.3
now at built up area.

Page 49 of 49