Disclaimer

These specifications are tentative. They may require changes according to consignee’s
requirement. Consignees are therefore requested to modify these specifications
accordingly before processes for procurement.
 Table of contents Sections IV, V, VI (Bid documents Part II)

Section IV: Main Features and Description of Tender Requirements Page No.

Important Features of the tender

1 Instructions to Tenderers for filling Technical Bid 3
2 Description 4-5
3 Quantity and consignee 6
4 Scope of supply 6-8
5 Evaluation criteria 8
6 Other items to be quoted 9
7 Delivery Schedule Chart 9-11
Section V -- Technical Specification
Abbreviations 12

Clause 1. Basic Design features 13-25

Clause 2. General Electrical Specification 26-28

Clause 3. General Characteristics 28-32

Clause 4. Technical Literature 32-33

Clause 5. Spares 33

Clause 6. Consumables 33

Clause 7. Special Features 33

Clause 8. Deviations 33

Clause 9. Inspection & Testing at Manufacturer’s Works 33-34

Clause 10. Training 34

Clause 11. Foundation & Related drawings 34-36

Clause 12. Installation, Commissioning & Proving Test 36-38

Clause 13. Service facility in India & Technical Support 38

Clause 14. Bought Out Items 38-39

Clause 15. Colour 40

Clause 16. Warranty Obligation 40-41

Clause 17. Annual Maintenance Contract 41-43

Section-VI Annexures to Technical Specification

Annexure-A Format to be filled up by Bidder for submitting the Technical Bid 44-52

Annexure-B Format for Indemnity Bond to be filled up by Bidder and submitted with the Bid 53

Annexure-C Format for Joint Receipt Inspection Note 54

Page 1 of 72
Annexure-D Format for Joint Commissioning Note 55

Annexure-E Performance Appraisal Form (Appraisal on Completion of Warranty Period) 56

Annexure-F List of Components to be loaded on the machine 57-58

Annexure-G Format for Consignee’s Certificate for Quarterly Work Done under AMC 59

Annexure-H Format for Technical Suitability Assessment of New Firms 60-66

Annexure-I Format for Quality Assurance Plan 67

Annexure-J Proving Test Certificate (PTC) for Commissioning / Prove Out of Machine 68-69

Annexure-K Technical Specification of EOT Crane (05 Ton) 70-71

Annexure-A1 Certificate of Performance. 72

Page 2 of 72
 Section- IV
IMPORTANT FEATURES OF THE TENDER
1. INSTRUCTIONS TO TENDERERS FOR FILLING TECHNICAL BID
1.1 Unless otherwise stated, latest alterations/ revisions of specifications/ standards/
drawings shall be applicable. In respect of safety standards and environmental
standards relevant to the machine, the machine manufacturers shall ensure compliance
with International (CE/ISO/DIN/JIS)/National standards (IS) (wherever applicable).
1.2 Tenderers should offer and quote for all the specified concomitant accessories, as these
are considered essential for commissioning and utilization of the machine. Even if
bidder does not recommend the purchase of any of these accessories, the price must
be quoted for comparison purposes and their recommendation/suggestion to be
indicated in the offer. Tenderers should also quote for optional accessories, spares and
consumable spares as asked in the specifications.
1.3 In case, any item is required in sets, please specify nos. /pieces per set. This is essential
for proper technical evaluation of the offer. Offers received without this may be
considered as incomplete and liable to be rejected.
1.4 The bidder should quote only for the specified make of sub-assemblies and equipment
wherever specified. Makes of sub-systems other than the specified ones will normally
not be acceptable. In case, some other make is quoted, specific reasons for the same
including its features/advantages over specified makes must be brought out in the offer.
1.5 In case there is a contradiction in any information provided (some parametric values
given in the specification and those given in the brochure or some other document
enclosed by the tenderer), unless specifically mentioned in the deviation cum
confirmation statement under Annexure A of Section VI, the values as given in the
specification shall be taken as confirmed by the tenderer and offer evaluated
accordingly.
1.6 Bidder or his authorized agent, in their own interest, should visit the consignees listed
in clause 3 Section-IV with prior appointment with Controlling Officer of the consignee
and acquaint themselves with existing process of manufacturing/remanufacturing, site
conditions, availability of material handling facilities etc.
1.7 The Purchaser may accept internationally accepted alternative specifications
which ensure equal or higher quality than the specifications mentioned in the Technical
Specification. However, the decision of the Purchaser in this regard shall be final. A
copy of the alternative specifications offered should be sent along with the offer. The
Tenderer should also furnish “Statement of Deviations” from tender specifications (as
per Annexure A, Section-VI) along with the offer.
1.8 The bidder who has not been placed with any order through COFMOW for the tendered
machine (any capacity) shall be considered as New Vendor. Whenever, technically &
commercially responsive bid is received from a New Vendor, a technical team from
COFMOW shall carry out the Capability Assessment of the premises of the bidder to
assess their capability to design and manufacture the tendered machine as per
COFMOW Specifications. Based on the report of Capability Assessment the bidder will
be considered as Suitable/ Unsuitable for placement of any order through
COFMOW. The bidder shall submit the information on Annexure-H of Section-VI in the
original offer.

Page 3 of 72
2. Description: Broad Gauge CNC Surface Wheel Lathe as per Specification No.
COFMOW/CNC-SWL/BG/2021 (with AMC) Rev.0
2.1 The machine shall have following capability:
2.1.1 Re-profiling of wheel sets as per drawings mentioned in Annexures - F, having work
hardened spots of upto 450 BHN. The tensile strength of the wheel material under
normal conditions may be upto 125 Kg/mm 2.
2.1.2 Simultaneous machining of both the wheels within the specified accuracy as per
clause 2.2.1.vi below.
2.1.3 Machining inner and outer faces of wheels.
2.1.4 Undertaking cuts of depth upto 8mm, i.e. a reduction of 16mm on the diameter, without
undue vibrations. It shall be free from chattering and vibrations while one or both
wheels of a wheelset are being re-profiled.
2.1.5 For wheel sets which do not permit loading by machine jack or in the event of jack
being out of order, it shall be possible to load the wheel sets using shop overhead
crane.
2.1.6 The machine should meet the requirements specified in clause 2.2 below of these
specifications.
2.1.7 The offered system shall be capable of handling wheelsets, which are likely to have a
fair amount of dust, grease, grime, etc. on them.
2.2 Leading parameters (Schedule-1):
(Note: No deviation is permitted in major parameters. The bidder should indicate
the actual parameters offered.)
2.2.1 Major parameters:
S No Parameter Values
i) Track Gauge 1676 mm
ii) Capacity of lifting mechanism 2500 Kg (minimum)
iii) Cutting Speed (continuously variable) 25 - 80 m/min
iv) Feed rate(continuously variable) 0.1 to 4.0 mm/rev
v) Rapid traverse of tool slide 3000 mm/min
vi) Accuracy
a) Difference in tread diameter of two Less than 0.3 mm on the same
wheels Axle.
b) Inaccuracies in machined profile Less than 0.2 mm when checked
with a Standard Profile Gauge.
c) Surface finish after machining 20 microns Ra or better.
d) Runout on tread diameter shall not 0.3 mm
exceed
vii) Job Parameters
a) Wheel diameter 723 mm - 1250 mm
b) Axle length 1850 - 2750 mm
c) Tyre/Wheel width 125 -145 mm
viii) Method of wheel set clamping & 4 jaw axial clamping grippers
driving
2.2.2 Other Parameters
i) Power supply As per clause 2.13.1 of Section-V

Page 4 of 72
2.3 Performance Standards
The machine shall confirm to IS: 210 for Grey iron castings, IS: 1030 for Carbon steel
castings, IS: 2062 or equivalent International standards for machine frame and other
associated structure such as table.

2.4 Productivity(Cycle Time):

2.4.1 The bidder shall offer per wheel-set floor to floor cycle time for all the activities
including following:
a. Machine start up,
b. Initial orientation and programming,
c. Control panel operation,
d. Wheel set handling from turn table to machine,
e. Loading of wheel set on machine
f. Pre-machining measurement of wheel set for all the items as specified in clause
no. 1.2.7.2.
g. Profile Machining,
h. Post- machining measurement of wheel disc diameter,
i. Unloading of machined wheel set,
j. Wheel set handling from machine to turn table.

Using single operator, the total floor to floor cycle time for one-wheel set should not
exceed 16 minutes. The machine productivity with claimed cycle time shall be proved
for removal of 8mm material radially. This material removal rate shall be possible for
wheel tread diameter of at least 900mm or above. The exact sequence of operation
including multiple cuts, if any, along with the breakup of the timings of various activities
shall be explained in the offer. The claimed productivity shall be achieved with the
accuracies indicated in Schedule-1

2.4.2 The bidder shall also furnish speed-feed-power (curve/ nomograms) for machining of
wheel sets of tread diameter ranging from 750 to 1250mm for depth of cuts varying
upto 8mm radially, for material strength upto 125 Kg. /mm 2.

2.5 Prove out at firm’s premises

2.5.1 A performance test shall be carried out at the manufacturer’s works to check the
machine with respect to the purpose and capability requirements as per Clause 2.1 to
the satisfaction of the appointed Inspecting Agency. This performance test shall be
done on 5 wheel sets, out of which 3 have to be machined in continuation, which will
be made available on a returnable basis by Indian Railways against Bank Guarantee
by firm for an amount to be indicated by the consignee.
The supplier shall make all arrangement for transporting the wheel sets to their works
and back alongwith the machine. In case, the wheel sets are not available with the
consignee, supplier may take similar wheel sets from the nearby Railway locations/
Units on returnable basis against a Bank Guarantee of the value of the wheel sets.

2.6 Prove out at consignee’s works:

2.6.1 The machine performance shall be demonstrated for the claimed cycle time as per
clause 2.4.1 above on 50 nos. of wheel sets.

Page 5 of 72
3. QUANTITY & CONSIGNEE :

S. Consignee/ Key No. Quantity

No. Consignee Code
1. SSE/C&W/SGT/SWR (023103) 221304 01
2. CWM/JUWS/NWR (094055) 221150 01
3. SSE/C&W/KJGY/NR (A-3389) 218379 01
4. SSE/C&W/Sambalpur/ECoR (043024) 221246 01
5. SSE/C&W/NTSK/NFR (045111) 221190 01
6. Dy.CME(G)/ER/KPA (093075) 221280 01
4. Scope of Supply:
4.1 The scope of supply shall include design, manufacture, supply, installation, testing,
commissioning and proving of machine on turnkey basis. It includes all the
concomitant accessories/ equipments as detailed in the specification and other
concomitant accessories/ equipment, which the manufacturer considers essential to
make the machine fully operational, when installed and commissioned. It shall also
include installation and commissioning of related equipment, training of personnel in
operation and maintenance of machine and supply of technical documentation.

4.2 CONCOMITANT ACCESSORIES:

Applicable for all consignee

4.2.1 The machine should be accompanied with the following
concomitant accessories:
4.2.1.1 Tool holders and tool inserts to cover all 5n
operations specified in Clause 1(List of tool ho
with part numbers be furnished in the bid).(Ref. 10
Cl. 1.2.13 of Sec. V) ins
typ

4.2.1.2 Checking gauges for all wheel profiles one

mentioned in the drawings as per Annexures -
F
4.2.1.3 Maintenance tools one
(List of tools be furnished in the bid).
4.2.1.4 60-degree and 90-degree centers for barrels two
4.2.1.5 Electrical cables for connecting control cabinet 10m
to machine terminal box
4.2.1.6 First fill of oils and (Qu
lubricants. eac
be
the
4.2.1.7 Automatic conveyor chip disposal
system (Ref. Cl. 1.2.9 of Sec. V)
4.2.1.8 Electrostatic oil filtration
equipment (Ref. Cl. 1.2.12 of
Sec. V)
4.2.1.9 Wheel set handling system
Track length and foundation = 10 mtrs.
(Ref.Cl.1.2.14)
4.2.1.10 Automatic turn-table (Ref. Cl. 1.2.15)

Page 6 of 72
 4.2.1.11 Compatible voltage stabilizer (Ref. Cl. 2.13.2
of Sec. V)
4.2.1.12 Compatible ultra-isolation transformer (Ref. Cl.
2.13.3 of Sec. V)

4.2.1.13 Brake disc machining arrangement for

LHB Wheels(Ref. Cl.1.2.19 of Sec. V)
4.2.1.14 Chip Crusher (Ref. Cl. 1.2.20 of Sec. V)

Applicable for Schedule-II consignee only

4.2.2 Concomitant works
4.2.2.1 The scope of supply shall also include the following
concomitant works. The cost of these works shall be quoted
separately and the cost shall also be included for the purpose
of commercial evaluation.
4.2.2.1.1 Construction of covered shed for housing Surface Wheel Lathe
(Ref. Cl. 1.2.21 of section V)
4.2.2.2 Linkage of track (Ref. Cl. 1.2.22 of section V)
4.2.2.2.1 Inside shed (for shed size Ref. cl.1.2.21.3 of A
section V)
4.2.2.2.2 Outside shed (ref. Cl.1.2.22.2 of section V). 5
Bidder shall furnish the rate in respect of track
linkage per meter of length basis.
4.2.2.3 Power supply connection (Ref. Cl. 1.2.23 of 5
section V) Bidder shall furnish the rate in
respect of per meter of length basis.
4.2.2.4 Provision of Toilets with urinal facility Size
3x2 m2 along with Septic Tanks of Suitable
Capacity.
4.2.3 Tower PC (Ref. Cl. 1.2.24 of section V)
4.2.4 DG Set (Ref. Cl. 1.2.25 of section V)
4.2.5 EOT Crane, Capacity:5T (Ref. Cl. 1.2.26 of
section V)
4.2.6 Any other accessory/ equipment, which the manufacturer
considers essential to make the machine fully operational, when
installed and commissioned connected to power source and give
the specified output/productivity.
4.3 Optional Accessories:
Following optional accessories shall be quoted by the tenderer. Cost of optional
accessories shall be quoted separately and shall not be included in the basic price of
the machine. Cost of optional accessories will not be taken for commercial evaluation
of the firms.
4.3.1 Wheel Cleaning System:
A wheel cleaning system of suitable design should be provided for cleaning of dust,
grease, grime etc. from the wheel before machining. Wheel cleaning system should
be installed before the turn table so that cleaned wheel can be supplied to the machine
through turn table / wheel handling system. The system should consist of suitable

Page 7 of 72
 arrangement for wheel loading, movement and unloading. Complete details of the
system, consumables etc. should be furnished in the bid.
4.3.2 Chip Compactor:
A Heavy duty chip compactor shall be considered for compacting the chips generated
from CNC Surface Wheel Lathe to final bale size of approximately 8” X 8” X 10” to
12”.
4.3.3 ELEVATED PLATFORM WITH WHEEL SET LIFTING AND LOWERING DEVICE:
4.3.3.1 The machines shall be installed at elevated foundation to avoid water logging in wheel
shop. Top of the roll in and roll out rails of the machines shall be at a height of
approximately 1150 mm from the shop floor level.
Hence, lifting device shall be required for lifting the wheel set from shop floor rails to
roll in rails at a height of 1150 mm and lowering device shall be required for lowering
the wheel set from roll out rails at a height of 1150 mm back to shop floor rails. Length
of elevated platform shall be approximately 10 meters. Lifting and lowering devices
shall be capable of handling Broad Gauge wheel sets of parameters mentioned in
Schedule-I.
Necessary rails of appropriate size and quantity for laying on the elevated platform
shall be provided by the consignee
4.3.4 Firm should also quote charges for modification in software for any other profile, not
specified in the tender, on each profile basis for future requirement, due to
amendment in wheel profile drawings at later stage.
4.3.5 Any other accessory which can improve the productivity, performance, reliability,
efficiency, or enhance the capability of the machine as a whole or part thereof, should
be quoted as Optional Accessory.
5. EVALUATION CRITERIA
Total value of the offer will be calculated based on
i. The cost of the basic machine.
ii. Cost of the concomitant accessories according to tender specifications.
iii. Cost of any other accessory which in the opinion of supplier is essentially
required for making the machine fully functional.
iv. Cost of foundation of the machine.
v. Cost of installation & commissioning etc
vi. Cost of Preventive Maintenance during 1st & 2nd year of Warranty Period.
vii. Cost of comprehensive AMC for five years after the warranty as per clause
17.
viii. Duties and taxes as quoted by the bidder, insurance and freight.
ix. Cost of concomitant works according to tender specifications.

6. OTHER ITEMS TO BE QUOTED:

The following items will need to be quoted additionally though will not be part of
commercial evaluation:
i. Optional Accessories with break-up of individual items as specified in clause
4.3 of section IV.
ii. Consumables/Spares as per clause 6 of section V with breakup of individual
items as applicable.

Page 8 of 72
7. DELIVERY SCHEDULE CHART:
In the event of acceptance of the offer, the machine(s) shall be supplied as per the following
Milestone Chart:
Name of machine -Broad Gauge CNC Surface Wheel Lathe.
Specification No. - COFMOW/ CNC-SWL/BG/2021 (with AMC) Rev.0
SN. Activity Activity Outer Limit of Outer Limit of
Code Time Schedule Time Schedule
expected by expected by
COFMOW for COFMOW for
Schedule-I Schedule-II
Consignee Consignee
1. Issue of LOA D1 -

2. Submission of PBG by Successful Bidder D2 D1 + 30 days

3. Issue of AT / Contract D3 D2 + 30 days

By COFMOW (after verification of PBG)

4. Opening of LC by COFMOW (for foreign D4 D3 + 30 days

suppliers)

5 Submission of GA drawings and requisition D5 D3 + 45 days

for the trial component (s) (if applicable) to
consignee by Successful Bidder/Supplier
along with information on power and other
utilities required for machine.
6. Approval of GA drawings by consignee (to be D6 D5 + 45 days
governed by clause 11.2 of Section-V) and
confirmation of availability of components to be
proved out at manufacturer premises and value
of BG required for providing prove out
components. Commented [SS1]: As per clause 2.5.1 of section IV,
7. Confirmation of availability of clear site by D7 By D6 (i.e. at the time of Indemnity Bond is permitted.
consignee approval of GA drg.)
7.1 Construction of covered shed, linkage of D 7.1 NA D7 + 210
track, inside shed, outside shed, power days
supply connection, provision of toilets with
urinal facility along with septic tanks by
supplier (As applicable for Schedule-II
Consignee)
8 Completion of foundation D8 D7 + 150 D7.1 + 150
days or latest days or latest
by D10 by D10

Page 9 of 72
9 Submission of BG/Indemnity Bond and D9 D6 + 60 days D6
collection of components from consignee
by the supplier for prove out of machine at
manufacturer’s works.
10 Supply/ Delivery of machine (for foreign D10 For First For
suppliers on FOB basis) Machine: Ma
D4 + 180
days Or D4
D6 + 180 day
Days D7
(whichever is Day
later) (wh
Indigenous late
portion of Ind
supply (if por
any) sup
D6 + 180 any
days D7
Or receipt of day
machine at rece
site ma
whichever is site
later. wh
late
Thereafter
subsequent The
machines: sub
@ Two ma
machines @
per month ma
per
Supply/ Delivery of machine (for indigenous D10 For First For
suppliers) machine: ma
D6 + 120 D7
days day
Thereafter The
subsequent sub
machines: ma
@ Two @
machines ma
per month per
11 Power connection for the machine and other D11 D10 + 7 days D10
on site requirements to be provided by
railways

Page 10 of 72
 12 Railway to give call to supplier for the D12 D10 + 7 days D10
commissioning of
Machine.
13 Installation, commissioning and proving out D13 D11 + 180 D11
of machine by supplier. days day
D12 + 180 D12
days day
(whichever is (wh
later) late
14. Issue of PTC by consignee D14 D13 + 30 D13
days
15 Warranty by supplier D15 D13 + 2 D13
years yea
16 CAMC D16 D15 + 5 D15
years yea

Payment terms for Concomitant Works (Covered Shed, Linkage of Track, Inside Shed, Outside Shed,
Power Supply Connection, Provision of Toilets with urinal facility along with septic tanks):
[Applicable for Schedule-II Consignee only]
i. 80% Payment of the cost of all taken together (Covered Shed, Linkage of Track, Inside
Shed, Outside Shed, Power Supply Connection, Provision of Toilets with urinal facility along
with septic tanks), will be made on the issue of completion certificate by the consignee and
receipt of machine at site.
ii. 20% Payment of the cost will be made upon issue of PTC for Surface Wheel Lathe Machine.

Notwithstanding the delivery period indicated elsewhere in the tender document, the delivery indicated
in this schedule shall be taken as overriding and final.

Page 11 of 72
 Section-V
TECHNICAL SPECIFICATION

ABBREVIATIONS
A-1,A-2, A-3, A-4 Standard paper sizes
AC Alternating Current
AMC Annual Maintenance Contract
AT Acceptance of Tender
BG Bank Guarantee
PCME Principal Chief Mechanical Engineer
CME/PCM Chief Mechanical Engineer/Post Contract Management
CNC Computer Numeric Control
COFMOW Central Organisation for Modernisation of Workshops
PCMM Principal Chief Material Manager
Db Decibel
DC Direct Current
FA&CAO Financial Advisor & Chief Accounts Officer
GA (Drawing) General Arrangement (Drawing)
HRC Hardness Rockwell ‘C’ Scale (value)
Hz Hertz
IEC-Pub International Electro technical Commission - Publication
JCN Joint Commissioning Note
JRI Joint Receipt Inspection
kW Kilo Watt
LC Letter of Credit
LD Liquidated Damages
LOA Letter of Acceptance
NC Numeric Control
NIT Notice Inviting Tenders
PBG Performance Bank Guarantee
PDF Portable Document Format
PLC Programmable Logic Controller
PTC Proving Test Certificate
PU Production Unit (Any of the six Railway Production Units e.g. RCF,
ICF etc.)
RDSO Research Design & Standards Organisation
SS Solid state, stainless steel
WBG Warranty Bank Guarantee

Page 12 of 72
 Specification No.- COFMOW/ CNC-SWL/BG/2021 (with AMC) Rev.0

1. BASIC DESIGN FEATURES:

1.1 Safety features:
The design shall ensure complete safety of the operator and the machine at all times.
Suitable interlocks against faulty operational sequence, sudden power failure,
fluctuation in supply voltage beyond permissible range and malfunctions in the
hydraulic system shall be provided. Protective guards wherever necessary shall be
provided. Details of the safety features provided in the machine shall be furnished in
the bid.
1.2 SPECIFIC CHARACTERISTICS
1.2.1 MACHINE BED
1.2.1.1 The machine bed shall be of cast iron grade FG-260 of IS: 210 or better and of rigid
structure to ensure vibration free operation. Constructional details and material
specification of the bed should be furnished in the offer. The bed shall have hardened
and ground wear resistant liners for long life. Telescopic covers shall be provided on
the guide-ways to protect them from chips, dust etc. In addition to these, scrapers
shall be used to prevent entry of dust, chips, etc. Details of the complete system shall
be furnished in the offer.
1.2.1.2 Adequate openings shall be provided in the machine bed to allow chips to drop freely
into the chip conveyor. Conveyor belt length shall be such that the chips are taken to
a distance of about 5-10m from the machine as per approved GAD.
1.2.1.3 The machine bed shall be provided with levelling elements for initial and subsequent
alignment.
1.2.2 HEAD STOCK
1.2.2.1 The machine will be provided with two nos. of head stocks of cast iron grade FG: 260
of IS: 210 and of rigid structure. The headstocks should be individually powered each
traversable on hardened guide-ways on each side of the bed to enable obstruction
free roll-in & roll-out operation of wheel-sets. Both head stocks shall move through
individual electric motors connected to sturdy lead screws to ensure fail safe self-
locking property. Automatic locking shall be provided when gauge length distance is
reached. Arrangement provided for longitudinal movement and power locking of the
head stocks shall be explained in the bid.
1.2.2.2 It shall be possible to pre-set the travel of the headstocks according to the length of
axles from CNC controls using the metallic linear measuring system. Arrangement
provided shall be explained in the bid.
1.2.2.3 The head stock drives shall have minimum number of gears. Material specification,
actual hardness and surface finish of gears including the rim gear shall be indicated in
the bid. In case of any alternate arrangement proposed, the advantages of the
same shall be explained along with the details.
1.2.2.4 The main spindle shall be precision machined incorporating adjustable, double row,
high precision, antifriction bearings for its mounting. The axial thrust shall be
absorbed by preloaded antifriction thrust bearings. The material specification of the
spindle and its mounting design shall be explained in the bid.
1.2.2.5 To enable unobstructed loading of wheel-sets with axle boxes, the two face plates
must always stop at the same pre-determined angular position so that the driving
dogs do not obstruct the wheel loading zone. In case the face plates stop at different

Page 13 of 72
 angular positions due to any malfunctioning, it shall not be possible to start the main
drive unless the face plates are synchronized in the same angular position.
Arrangement provided shall be explained in the bid.
1.2.2.6 Even if the Brake disc machining arrangement is not opted, machine should allow
handling of wheel sets equipped with Disc Brakes for machining operations.
1.2.3 WHEEL SET CLAMPING AND HOLDING
1.2.3.1 Each faceplate driven by main spindle shall be provided with a self-centering 4 jaw
hydraulically operated axial clamping device for clamping the wheels on outside rim
face. Clamping pressure shall be adjustable by CNC controls. Main spindle shall be
forged carbon steel. The clamping device shall have adequate radially infinitely
adjustable arrangement for accommodating wheelsets of varying diameters as per
clause 2.2.1 (vii) of Schedule-1. The clamping device shall be capable of quick
adjustment so that minimum setting time is required for machining different types of
wheelsets. The hardened and ground guide-ways shall be incorporated on the face
plate for the radial movement of clamping devices. Details of the system shall be
furnished in the offer.
1.2.3.2 The clamping arrangement shall have replaceable jaws which shall cater to all wheels
shown in drawings mentioned in Annexure - F. Details of the system shall be
furnished in the offer.
1.2.3.3 Radial movement of axial clamping elements shall be powered and synchronized.
The hydraulic clamping device shall ensure uniform clamping pressure the wheel set
in order to avoid any deformation of the wheel while being clamped. Clamping force
shall be adjustable. Gauges shall be provided at suitable locations to indicate the
clamping pressure. Details of the system shall be furnished in the offer.
1.2.3.4 The clamping and driving arrangement shall ensure that the axle centers and
headstock rotation center coincide. For this, the headstock shall carry hydraulically
operated barrels with removable centers of 90 o and 60o, having automatic locking
arrangement. It shall be possible to pre-set the centering force. The barrels will be
controlled via hydraulic cylinders capable of generating a centering force of 5 to 35
KN. Pressure indicators shall be provided for indicating centering forces. Details of
the system along with arrangement for wear compensation between spindle and the
barrel shall be provided and explained in the bid.
1.2.3.5 The oil supply for the movement of the barrels and the jaws shall be through an oil
distributor which will not have any seals so that breakdowns due to seal failures do
not occur. Details of the system offered shall be furnished in the bid.
1.2.3.6 Detailed calculations for clamping force shall be furnished in the bid.
1.2.4 WHEEL SET LIFTING, CENTERING AND LOWERING
1.2.4.1 The machine cycle shall provide for automatic raising, centering and lowering of
wheel-sets by means of a centrally positioned wheel set lifting jack just below spindle
center line. Details of the system shall be furnished in the bid.
1.2.4.2 Failure of the hydraulic system must not lead to dropping down of the wheel-set.
1.2.4.3 A manual push button over-ride arrangement for stopping the raised wheel-set at any
position shall be provided.
1.2.4.4 A wheel-set ejection system shall be provided to roll out the wheel-set after re-
profiling.

1.2.5 MAIN DRIVE

Page 14 of 72
1.2.5.1 The main drive for rotating the wheel set shall be through AC motor with step-less
speed control over the range of speed specified in Schedule-1. Details of the drive
shall be furnished in the bid.
1.2.5.2 Each face plate shall be driven by a separate motor. Both face plate motors shall be
synchronized to ensure minimal variation in the rotary speeds of the two face plates.
The maximum variation in the speeds of the two motors shall be indicated in the offer.
The design should take into account the heat build-up resulting from this variation in
rotational speeds. Long shafts shall not be used for transmission of drive power.
Arrangement for synchronization of the two-face plate drives along with details of the
drive motors used shall be explained in the bid.
1.2.6 CNC CONTROL
1.2.6.1 The CNC control system should be of latest version of FANUC FS 0i F with Alpha i/
Beta i AC Servo motors or latest version of Sinumerik 828D of Siemens make. AC
Servomotors, PLC’s and AC drive control systems etc. should be of the same make as
that of CNC control system.
1.2.6.2 The CNC and electrical control equipment cabinet for the machine should be provided
with air conditioning equipment consisting of filter, fan, de-humidifier and temperature
control. The air conditioning system should be equipped with environment friendly
refrigerant.
The offered CNC Control System shall have the following features:
1 It should have provision of 15” TFT/LCD latest coloured screen and Alfa-numeric
keyboard with soft keys.
2 Adequate memory capacity should be available with SSD/ PCMCIA Card / Flash
Card for storage of part program, tool offset and other off sets Commented [SS2]: CNC system is specified at clause
3 Facility for program and tool data transfer through RS 232/ Ethernet port/ USB Port 1.2.6.1 of section V. Standard available features of
these system will remain applicable.
should be available. Program running from external source through RS 232/ Ethernet
port / USB Port should also be available. Commented [SS3]: CNC system is specified at clause
4 Loading and unloading of program through Ethernet port/PCMCIA Card/ flash 1.2.6.1 of section V. Standard available features of
these system will remain applicable.
disk/Pen drive should be possible.
5 Data protection key (password protection) shall be provided. It shall prevent the
program offset parameters, data etc. from being registered, modified or deleted
erroneously. All the passwords shall be given to consignee during commissioning of the
machine. Bidders will certify that there is no such password in the machine, which has
not been given to the consignee and the consignee has to approach the
manufacturer for rectification later on/ at regular interval.
6 The offered CNC control system should have the provision of displaying the menu &
other contents in English language.
7 Facility should be available for tool retraction in case of emergency or power failure.
Supplier should ensure necessary back up power availability for this purpose. The firm
should provide UPS of adequate for this purpose. Details of UPS like make, Ampere-
hour rating of battery, backup rating in minutes etc.
8 In case of interruption and subsequent restoration of power supply to the machine,
it should be possible to resume operation from the point at which it was interrupted or
at the starting point of running or previous block. Commented [SS4]: Due to sudden loading of cutting tool
9 It should be possible to add, delete or modify program blocks. An access password exactly at the point of interruption and to avoid line
formation on wheel profile, it is necessary to restart the
should be provided to prevent tempering with program edit. cut behind the point of interruption.

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10 Back ground editing facility should be available such that when machine is executing
a CNC program in Auto mode, the operator should be able to enter new program or
carry out editing of the other program .
11 Teach in mode should be available.
12 It should be possible to directly program CNC system from machine console.
13 Mirror imaging feature should be available for machining operation.
14 Inch/Metric program should be available for dimension input.
15 Linear and circular interpolation programming should be possible.
16 The control panel should have provision for manual over ride for speed from 50 to
120% and feeds from 0-120% of the program value.
17 Absolute/Incremental input - Program data may be in either absolute or
incremental from selectable by G code.
18 Feed rate programming - Feed rate should be programmable in direct millimetres
per minute (MMPM) or inches per minute (IPM). Feed rate should also be
programmable in mm per revolution (MMPR) or inches per revolution (IPR) selectable
by G codes.
19 Dwell - Programmable up to 99.9 seconds using G-code.
20 The control should be able to give error messages with diagnostic level up to PLC in
case of malfunctioning of the system. The controller should also maintain a record of the
error messages with date and time that are registered by the machine.
21 Pitch error compensation through software should be accepted by the control. Any
other feature present in the CNC control should be explained in detail.
22 PLC integrated with CNC control should be provided.
23 Spindle control - CSS orientation.
24 All necessary back up data and program like NC, PLC, HMI and DP data/parameters,
fixed cycles and part programs, PLC program should be made available on PEN
DRIVE of 16 GB capacity and ghost program should be made available on spare hard
disk drive as fitted on the CNC Control. Commented [SS5]: CNC systems 828D and FANUC FS
25 Execution and PLC programs should be in F-EPROM so that power failure should 0i F specified at clause 1.2.6.1 do not have the hard
disc for improved reliability and reduced
not affect system execution and PLC program. maintenance requirements. All the back-up data as per
26 Ladder diagram/STL diagram with cross-reference listing of the PLC program should this clause is managed through the PEN Drive of 16 GB
during maintenance and restoration of CNC
be displayed provided for ease in maintenance purpose. In case, this cannot be System.
provided, the alternate documents/ means should be given to assist maintenance
staff for troubleshooting.
27 Fanuc/ Siemens unit of the country which supplies CNC system should enter in to
repair & Service contract with Fanuc/ Siemens India for attending the defects.
Documents must be enclosed in the offer.
28 There should be provision of password protection for operator name, component
number and data log registration in CNC system, using PMC (programmable
machining controller). This provision should be developed by machine tool builders.
29 Machine safety: CNC must have Unexpected Torque detection feature to avoid both
static and dynamic accidents on machine. CNC should also have facility to records
the position values, alarm details etc during the accident and can be used for the
investigating the reason for the accident.
30 CNC should have separate screen/window for Setup guidance screen. Work piece
coordinate system can be set by touching the tool to the work piece.
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 31 CNC manufacturer must give support for spare parts and repairs for minimum 15
years. Commented [SS6]: As per clause 16.1 below,
32 On board PLC editing with password protection should be possible. machine is required to be designed for service life of
15 years. Similarly, codal life of Surface wheel lathe is
33 Industry 4.0 Features 15 years as per Railway board.
33.1 REMOTE PERFOMANCE MONITORING
CNC system should be able to monitor parameters of CNC and other machine
components. CNC parameters and data like axis and drive data etc. and data of
machine from the sensors/probes additionally installed for monitoring health of
machine as enumerated in clause 40.3/1.1 to 40.3/1.14 etc.
After loading the wheel set on the machine, pre inspection shall be carried out. Wear
data and diameter of individual wheel of the wheel set as measured should be
recorded in Excel format with respect to the wheel set identification number and real
time clock of CNC system of the Machine. Similarly, after completing the wheel
profiling operation, diameter of individual wheel of the wheel set shall be measured
and recorded. Similarly, machined wheel profile type shall also be recorded. Both
these records shall be stored in Excel format with respect to the wheel set
identification number and real time clock of CNC system of Machine. Via high-speed
internet connection through Ethernet (LAN) cabled connection or 3G / 4G wireless
internet connection, this wheel set pre and post inspection data shall be remotely
accessible to authorized representatives of COFMOW and consignee and emailed
to designate email ids at the pre-determined time frequency. Necessary hardware
and software shall be supplied by machine manufacturer. However, high speed
internet connection as detailed above has to be arranged by consignee.
33.2 REMOTE DIAGNOSTICS
Using remote diagnosis feature CNC controls of the machine shall be connected to
remote computer located at manufacturer’s service centre using the high-speed
internet connection. This high-speed internet connection can be established using
Ethernet (LAN) cabled connection or 3G / 4G wireless plug and play telephony
(dongle) or router connected to CNC controls. Necessary hardware and software
required for this remote diagnosis shall be provided by machine manufacturer,
however, high-speed internet connection as detailed above needs shall be arranged
by consignee. Remote computer of manufacturer shall also be connected to high
speed internet connection using above methods. Remote computer and its internet
connectivity shall be managed by the machine manufacturer. Suitable software like
‘Team Viewer / eWON’ shall be used for the communication between CNC controls
and the remote computer. On activation of this software secured connection shall be
established with remote computer. Remote computer shall be able to access all the
CNC and PLC data including the PLC ladder. CNC parameters and data like axis
and drive data shall be accessed and modified from the remote computer. Status of
inputs and outputs for PLC shall be accessed and faults if any shall be identified.
Software related issues shall be corrected and hardware related issues like faulty
limit switches, faulty proximity switches etc. shall be advised to site engineer or
technician for correction over phone. Complete CNC screens shall be visible on the
remote Computer. Software shall be corrected in situ or corrected software shall be
uploaded from the remote computer. This shall enable quick and specialised services
employing experts from the manufacturers headquarter for the quick resolution of
software and hardware related issues on the machines.

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 33.3 Predictive Maintenance
1. CNC controls of machine shall be equipped with predictive maintenance
software to generate and log the alarms on machine controls as well as on
manufacturer’s server / cloud. These alarms shall be directly Communicated
to two email ids assigned by consignee and one or two email ids of supplier.
CNC controls shall be equipped with necessary software and hardware for
connecting to internet. Consignee shall provide continuous High-speed
internet connection using Ethernet (LAN) cabled connection or 3G / 4G
wireless plug and play telephony (dongle). Caution alarm will be generated
sufficiently in advance before final failure alarm. Machine shall continue to
work during caution alarm, which shall be repeated every eight hours till the
time corrective action is taken or till the time failure alarm is generated.
Caution and failure alarms must be provided for the following minimum
conditions:
1.1 Hydraulic and lubrication oil low level.
1.2 Hydraulic oil high temperature.
1.3 Hydraulic and lubrication oil filter clogging.
1.4 Condition of hydraulic pump by monitoring its leakage rate.
1.5 Spindle drive motor current.
1.6 CNC Axes motor current.
1.7 Calibration of the machine.
1.8 Vibrations on tool slides.
1.9 Monitoring the working of electrostatic filtration unit.
1.10 Monitoring the working of hydraulic oil chiller unit.
1.11 Spindle rotation speed both side will be monitored.
1.12 Gripper and centre sleeve pressure will be continuously monitored.
1.13 Battery of CNC system.
1.14 Battery of UPS for CNC system.
1.15 Temperature inside the control panel will be continuously monitored.
2. In addition to above, an instantaneous email shall be provided in case of an
emergency alarms, like hitting of CNC axes hard limit switches, headstock over
travel limit switches etc.
3. Separate CNC screen/window to measure individual and cumulative energy
consumption of each servo and spindle motor should be available to know
regeneration energy and power saving.
4. CNC must give information about the failure of FANs, Servo Motors & Drives
with dedicated screens to check online health of FANs, Servo Motors & Drives.
5. CNC should have facility to measure the life of the consumables in the separate
screen like filters, batteries etc. and alarm should be displayed once the life is
over.
Note: Bidder should submit details of hardware and software incorporated to meet
these predictive maintenance requirements in their offer.
1.2.7 MEASURING SYSTEM
1.2.7.1 Probe type measurement system shall be incorporated in the machine for pre and
post machining measurement of wheel set. It should be suitably integrated with the
CNC system of the machine. Suitable arrangement for protection of the probes shall
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 be made. The bidder shall furnish constructional details of the measuring system
indicating the following details:
a. No. and types of measuring probes.
b. Make and model no. of measuring system/probes.
c. Working principle of the measuring system to be explained with schematic
diagram.
1.2.7.2 The measuring system shall be capable of taking the following measurements:
i. Tread diameter at defined location (63.5mm from wheel face).
ii. Wheel gauge at minimum 3 points.
iii. Flange thickness at minimum 3 points.
iv. Flange height at minimum 3 points.
v. Radial run out at tread diameter.
vi. Inside face run out.
vii. Tread profile.
1.2.8 CUTTING DEPTH DETERMINATION AND TREAD PROFILE MACHINING
1.2.8.1 Two separate CNC controlled tool posts shall be provided for simultaneous
machining of both wheels on a wheel-set. Slides of tool post shall be made from cast
iron minimum grade FG-260 as per IS 210.
1.2.8.2 Tool posts shall be designed in such a way that even for turning small diameter
wheels, there is no excessive tool overhang and the cutting forces are directed
through the main body of the tool post. Accuracies as per clause 2.2.1.vi of section
IV shall be achieved while cutting work hardened flat spots present on wheel tread.
A profile of the tool post indicating the direction of cutting forces shall be furnished in
the bid. Maximum permissible value of cutting force which the machine can withstand
shall be indicated in the bid.
1.2.8.3 The tool post guides shall be provided with hardened and ground replaceable steel
liners for high wear resistance. The guide-ways shall be covered with telescopic
covers for protection against swarf, dust etc.
1.2.8.4 Each tool post shall have facility of longitudinal and cross movement through pre-
loaded ball screw nut. The drive shall be through AC servo motor and reduction gear
arrangement. Simultaneous operation and interpolation of these two movements
shall also be possible. The feed of the right hand side and the left hand side tools
must be synchronized to ensure similar profiles within the permissible values.
Details of the system shall be furnished in the bid.
1.2.8.5 Machining of the inner face of wheel tread without the need for tool changing shall
be possible.
1.2.8.6 The CNC system should ensure automatic positioning of the tools during machining
cycle.
1.2.8.7 The CNC system shall automatically control the feed required at various sections of
the profile.
1.2.8.8 Machine should be equipped with automatic tool retraction system to ensure that
tools are automatically withdrawn in case of power failure. Bidder should indicate the
details of arrangement provided in the machine.
1.2.8.9 The machine shall be provided with a CNC based system to determine minimum
metal removal necessary to achieve the required profile. The system shall be
capable of comparing the wear level on complete wheel tread and flanges of both

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 wheels of the wheel-set for deciding the precise diameter along with minimal metal
removal required for turning.
The system should recommend the most economic cut to restore the profile to
achieve higher wheel life. However, the operator should have the option to modify
the CNC suggested most economical cut.
1.2.8.10 CNC system should include software capable of turning any wheel profiles of various
flange thickness as given in the wheel profiles in drawings at Annexure-F. Software
should be user friendly and adequate training should be given to the nominated staff
to generate part programme of new profile.
1.2.8.11 The required diameter shall be indicated on the screen for the operator to take
corrective action, if required. Based on this decision, the CNC system shall calculate
the distribution of cuts in order to process the re-profiling in single/multiple cuts.
1.2.8.12 In case the operator defines the target diameter, the system shall do a feasibility
check of all cutting parameters before accepting the execution command, in order to
avoid a situation of collision of the tool post with the job. Suitable safeguard should
be provided in the system.
1.2.8.13 Suitable display system to indicate the tread diameter of both wheels of the wheel-
set before and after machining shall be provided. Arrangement provided shall be
explained in the bid.
1.2.8.14 One calibration wheel set shall be machined out of the wheel sets taken from the
consignee and supplied along with the machine with necessary certificate to check
the accuracy of machine as per recommended frequency. Method of calibration, time
taken in calibration and the recommended frequency for calibration of equipment
shall be explained in the bid.
1.2.8.15 A Laser Printer Cum Scanner A-4 size compatible with the system for the purpose of
printing of data/analysis/comparisons etc. shall be included in the scope of supply.

1.2.9 AUTOMATIC CONVEYOR CHIP DISPOSAL SYSTEM

1.2.9.1 The machine shall be equipped with a conveyor type chip disposal system for
removal of chips generated during machining. It shall be of sufficient capacity to
handle the throughput likely to be encountered during machining, involving maximum
material removal rate permissible on the machine. It shall be designed with suitable
safety features to ensure operation in the adverse conditions envisaged on such a
machine taking into account any eventuality like overload, conveyor jam, etc. The
length of the conveyor shall be such that the chips are taken to a distance of about
5-10m from the machine as per approved GAD. 2 nos. chip trolleys / bins shall also
be supplied with chip conveyor. This is to ensure that the area and the vicinity of the
machine is kept clean even under full utilization. The details of the system offered
along with its operation methodology shall be explained in the bid.

1.2.10 LUBRICATION SYSTEM

1.2.10.1 An automatic adjustable, centralized lubrication system for ensuring delivery of

metered quantity of lubricant at regular intervals to all areas requiring lubrication shall
be provided. Grease lubrication system shall be used for the tool slide and headstock
guide ways. The lubrication system shall be explained in the bid with a lubrication

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 diagram. Arrangement provided to ensure safety of the machine in case of failure of
lubrication shall be explained in the bid.
1.2.10.2 Suitable filters shall be provided in the lubrication circuit of close loop lubrication for
rotating parts. Capacity of the lubricating oil tank shall be sufficient for at least 100
hours of continuous operation. Slots for pouring and removing lubricating oil and
replacing filters shall be easily accessible.
1.2.10.3 A filter cleaning chart shall be displayed on a metal plate at a conspicuous location
on the machine indicating periodicity and procedure of cleaning/replacement of
filters.
1.2.10.4 Lubricating oils suitable for use on the machine shall be available in India. The
successful bidder shall be required to indicate equivalent brands of oils indigenously
available.
1.2.11 HYDRAULIC SYSTEM
1.2.11.1 The hydraulic system shall be equipped with the following:
i. Oil tank reservoir.
ii. Electric motor-driven pump unit.
iii. Pressure gauges or pressure check points at all locations where pressure
has to be set or monitored.
iv. Safety valves where pressure limits are set.
v. Equipment for checking temperature of hydraulic oil in the circuit.
vi. Filters of suitable size for full capacity of pressurized oil placed in between
the circuit and the pump.
vii. Electrical clogging indicator to indicate clogged filters. Details of the
clogging indicator shall be furnished in the bid.
viii. Oil level indicator.
1.2.11.2 The sump aggregate shall have the following:
i. Dust proof cover single slot for entry of air. An air filter of suitable size shall be
provided.
ii. Oil level sight gauges to indicate minimum and maximum levels of oil in
sump.
iii. Filters of suitable size shall be provided for filtration of hydraulic oil. Type,
make, model no. and location of filters shall be indicated in the bid.
iv. A drain plug at the lowest portion of the tank. It shall be possible to drain out
complete oil from the tank without disconnecting any pipes or other fittings.
1.2.11.3 Arrangement to detect rise in temperature of oil beyond the safe working levels shall
be provided. Arrangement shall be provided to stop all functions of the machine in
case this temperature is exceeded. The arrangement provided along with this
temperature limit shall be explained in the bid.
1.2.11.4 Chiller type heat exchanger of adequate capacity shall be provided for effective
cooling of hydraulic oil. It should ensure that hydraulic oil temperature does not
exceed 50°C under local ambient conditions. Heat load calculations and the details
of system should be furnished. Adequate margin shall be available to ensure trouble
free performance.
1.2.11.5 Hydraulic oils used in the machine shall be available in India. Exact brand and names
of equivalent brands shall be indicated in the bid.

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1.2.11.6 All hydraulic supply hoses for head stock function are to be guided in cable guiding
chains in order to ensure prevention against damage.
1.2.12 ELECTROSTATIC OIL FILTRATION EQUIPMENT
In addition to regular filters (incorporated in the hydraulic system) suitable for filtering
particles of size 10 micron and above, an Electrostatic oil filtration equipment with
provision of moisture absorption shall also be provided. It will draw oil from tank and
return it after passing through filtration media. Suspended particles of size more than
0.01 micron present in hydraulic oil, shall be removed from oil through the
Electrostatic oil filtration equipment. Details of equipment shall be furnished in the
offer.
1.2.13 TOOLING
The bidder shall furnish full details of the tooling including part list numbers.
Approximate tool life in terms of number of cutting passes per cutting edge for a depth
of cut of 8mm for wheel diameters of 900 mm, at the cutting parameters used for
productivity requirements shall be indicated in the bid. A full list of tool holders and
inserts indicating quantity and rate of each item shall be furnished in the bid.
1.2.14 WHEELSET HANDLING SYSTEM
A wheel-set handling system complete with track rail and all requisite accessories
shall be supplied with the machine. It shall be totally independent of existing overhead
cranes. Wheel-sets received for machining from the turntable shall be loaded onto
the machine by this system. It should be able to handle wheelsets at the frequency
required to meet the stipulated productivity output of the machine. The lifting capacity
of the system shall be at least 2500 Kg. Details of the arrangement including a
schematic drawing shall be furnished in the bid
1.2.15 AUTOMATIC TURN-TABLE
Turntable shall be offered along with the machine. It shall be located ahead of the
wheel handling system and machined wheel-sets shall be received on the turntable,
which after rotation through 90 degrees shall eject out the wheel-set to the stacking
line for machined wheels. Similarly, after receiving wheels from the feeding line, it
shall rotate through 90 degrees and then roll out the wheel-sets onto the machine.
The rotation and roll out motion shall be powered and push button controlled. The
full sequence of operation shall be explained in the bid. Details of the arrangement
alongwith a schematic drawing shall also be furnished in the bid.
1.2.16 MACHINE CYCLE
The bidder shall explain the machine cycle step by step for loading, measurements,
machining and unloading of wheel-set indicating each stage where operator’s
intervention is required. The cycle shall include all machine-setting operations which
need to be carried out. Complete operation of the machine should be possible by a
single operator.
1.2.17 CONTROLS
1.2.17.1 The machine shall be provided with a centralized ergonomically designed control
panel. The control panel shall be user friendly with ergonomically located switches,
buttons and selector handles, etc. to ensure that the operator is not unduly stressed
during operation of the machine. Layout of the control panel shall be furnished in the
offer along with the display screen size. The control console should also be located
next to the machine at convenient height & location for ease of operation from the
normal machine operating position.

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1.2.17.2 A load meter shall be provided to indicate the load on the machine.
1.2.17.3 All electric cables for power supply and control of head stock functions shall be
guided in cable guiding chains in order to ensure prevention against damage.
1.2.18 ELECTRICALS

1.2.18.1 The main drive motors should be protected to IP55 to IS4691. Each main drive panel
will be installed with a special dust filter. This will correspond to protection class IP42
1.2.18.2 All motors shall be of the heavy-duty type equipped with sealed ball bearings and
overload protection. Enclosures will be of either steel or cast iron. Overload
protection is provided for motors to permit operation within their rating under all
design load conditions.
1.2.18.3 Insulation is class F and temperature rating of the motors will not exceed that
permitted by class B insulation.
1.2.18.4 Each individual motor power circuit is provided with Motor Protection Circuit Breakers
for protection against short circuit, overload and on load single phasing.
1.2.19 Brake disc machining arrangement

The arrangement shall be capable of machining the brake discs fitted on the axles of
wheel sets (equipped with brake discs). The arrangement shall consist of an
additional ram provided on the basic tool post of the machine. This ram with tool
holder shall be kept in retracted position during wheel turning operations. The ram
shall be extended out only when brake disc turning operation is required to be
performed. 5 nos. of tool holders and 50 nos. of inserts shall be supplied with the
machine for this purpose (if Brake disc machining arrangement is opted). Details of
arrangement shall be furnished in the offer.
1.2.20 Chip Crusher
Chip crusher shall be provided to crush the chips generated during wheel machining
operation. The chip crusher shall be mounted below the machine before chip
conveyor with suitable hoppers and shall be capable of handling the volume of chips
generated during the machining operation. It shall be box type of steel casing with
number of high grade steel blades running at slow speed. Suitable safety measures
shall be incorporated to handle blocking situation. Details of arrangement chip
crusher arrangement and safety measures shall be furnished in the offer.
1.2.21 Covered shed for housing Surface Wheel Lathe: [Applicable for the
Schedule-II Consignees only]
1.2.21.1 A cover shed for housing the complete Surface Wheel Lathe is to be constructed
on turnkey basis including detailed design engineering, excavation and
construction work on the piece of land provided by the consignee.
1.2.21.2 The bidder will have to get detailed design approved by the Govt. approved
agency/structural engineer. The structural design shall take into account various
site conditions including wind pressure.
1.2.21.3 The size of shed will be 35M long and 15M wide. The roof of the shed will be
sloping from the centre towards both the side walls. Height of the roof at the
centre and on the side wall will be about 9 meters and 8 meters respectively.

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1.2.21.4 The roof of the shed is to be with trusses and covered with pre-coated sheets of
minimum 0.5 mm TCT. Adequate no. of transparent sheets shall be provided in
the roof for providing natural light in the shed.
1.2.21.5 Heavy duty RCC flooring excluding the pit area is to be provided in the shed. The
flooring shall be industrial grade flooring of at least 100mm depth PCC and
200mm depth of RCC.
1.2.21.6 Adequately spaced columns shall be provided on the side of the shed. These
columns should be of RCC/PEB construction. Brick masonry wall shall be
provided on all 4 sides (excluding the gate/shutter area on the two sides) of the
shed upto a height of 3 meters with provision of metallic windows. Above the
height of 3 meter to the edge of roof the side wall will be covered with pre-coated
sheets of minimum 0.5 mm TCT mounted on mild steel structure.
1.2.21.7 All civil engineering works connected with construction of the shed is in the scope
of the bidder.
1.2.21.8 Necessary illumination in the shed shall be provided. The average illumination of 150
lux shall be maintained in the shed. Necessary electrical wiring with switches for the
lamps/fixtures shall be provided.
1.2.21.9 One room for Surface Wheel Lathe staff:

i) One room of size 4-meter length X 3-meter width and 3-meter height is also
in the scope of work of shed required for operating and maintenance
personnel. This room will be constructed within the shed in one of the corner.
ii) Side wall shall be constructed by brick masonry with adequate column and
RCC slab on the roof.
iii) The room shall have provision of doors with lock.
iv) Electrical wiring with switches for two lights, one ceiling fan and two 5 ampere
sockets are to be provided in the room.
v) Adequate no. of glass windows with metallic frames shall be provided in the
side walls for natural light and ventilation.
1.2.21.10 The shed will be provided with manually operated mechanized rolling shutter on
two sides (entry and exit side of the shed). The sizes of the rolling shutter should
be sufficient for passing in and out of the locomotives. Firm to mention the size
of the shutters in the offer.
The sizes of shed and room mentioned above may change. Hence the firm
Note: should quote the total cost as per clause and also quote per sq. ft. cost for shed
and room separately.
1.2.22 Linkage of Track: [Applicable for the Schedule-II Consignees only]
1.2.22.1 The scope of work will also include laying and grouting the rails in the flooring
from the edge of the machine pit to the edge of shed for the movement of
locomotive/coach/wagon. Further laying of rails to connect with the existing lines
in the shed / workshop (excluding points turnouts and crossings) shall also be
done by supplier only using ballast and sleepers.
1.2.22.2 The bidder shall quote for per meter length of the laying of the track inside the
shed area and outside the shed area (from the edge of the shed to the point of
linking of the existing track in the shed/workshop) separately. The total track
length will depend on the actual site conditions. Necessary rails, sleepers, ,

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 elastic clips, ballast, murrum etc. and other fittings required for the same will be
supplied by the Railways.
1.2.22.3 In case the rail/tracks on either side of shed already exist, it will be the sole
responsibility of the bidder/supplier to ensure that machine rail level matches with
shed rail level. In case the supplier is not able to match the machine rail level, he will
undertake to lay fresh rail/track on either side of the shed matching with machine rail
level at his own cost to the satisfaction of the consignee. Type of rail/track to be laid by
the bidder will be similar to the existing track.

1.2.23 Power supply connection: [Applicable for the Schedule-II Consignee only]

1.2.23.1 The bidder shall also provide the electrical connection from the transformer in the
shed/workshop to the shed of the Surface Wheel Lathe for operation of the machine
and lighting in the shed. The electrical cables will be laid underground with suitable
single brick protection on three sides. The provision of transformer and enhancement of
the load (if required), is in the scope of consignee. The cable shall be armoured cable
of three and half core of minimum 240 sq. mm diameter to IS: 694 latest or equivalent
international standard to withstand the total load of the shed and machine. Firm should
give details of the cable, IS and make in the offer.
1.2.23.2 The cost of laying of cable (including material cost) shall be quoted on per meter
basis. The total length will depend on actual site conditions.
1.2.23.3 All the necessary electrical equipments like distribution board and control panel etc.
to be provided by the bidder.

1.2.24 A Tower PC with CPU along-with UPS and a suitable Laser Printer cum scanner is
to be offered as optional accessory. The specification for PC shall be Intel i5 or higher
Processor, Speed minimum 2.6 GHz, Screen size: 18.5 minimum, Inbuilt Wi-Fi &
Bluetooth hardware inside CPU for connecting to other network, Minimum 6 nos. of
USB ports of 3.0 in CPU, 1000 VA UPS.
Commented [SS7]: Due to continuous developments
processors are continuously upgraded.
1.2.25 DG Set [Applicable for the Schedule-II Consignee only]:

The supplier shall supply 200 KVA DG Set with AMF panel as per electricity load of
Surface Wheel Lathe Shed, Room & Machine. DG set shall be located outside of the
building and shall be supported on RCC pedestal. D.G set should switch ON and
OFF automatically (with AMF Panel) in case of power failure / resumption. All related
control systems and connectivity shall be part of scope of supply of DG set. Suitable
devises for protection from voltage fluctuation, surges, overloading etc. shall be
provided and furnished in the bid. Complete technical details of the DG set indicating
model no., make, capacity, major parameters etc. shall be furnished in the bid.
The set should be mounted on anti-vibration pads and enclosed in an acoustic
canopy with necessary insulation and natural ventilation.

1.2.26 EOT Crane 05 Ton [Applicable for the Schedule-II Consignee only].
The Technical specification is attached as Annexure-K.

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 2 GENERAL ELECTRIC SPECIFICATION
2.1 The provision of this General Specification shall apply, where ever relevant.
2.2 All equipments and material shall comply with appropriate Indian Standards (latest),
International Standards or National Standards of the country of origin provided the
latter are equivalent to or better than the former. The tenderer shall indicate the
Standards applicable. The following standards are applicable in particular.
(Corresponding International Standards like ASA, NEMA, BSS, DIN etc. may also be
quoted).
IS : 325-1979 (latest) - Three phase induction motors
(corresponding to IEC pub-34-1) (Latest).
IS : 1248 (Latest) - Direct acting indicating analogue electrical
measuring instruments and their
accessories (corresponding to IEC Pub-
51) (Latest).
IS : 1231-1974 (Latest) - Dimensions of three phase induction motors
(corresponding to IEC Pub-72-1) (Latest).
IS : 1271-1985 (Latest) - Classification of insulation material for
electrical machinery & apparatus in relation
to their thermal stability in service
(corresponding to IEC-Pub-85) (Latest).
IS : 6875 (Latest) - Push Buttons and related control switches
corresponding to IEC Pub/73) (Latest).
IS : 375-1963 (Latest) - Marking and arrangement of switch gear,
bus bars, main connection & auxiliary
wiring.
IS : 996-1979 (Latest) Single phase small AC and
universal electrical motors.
IS : 1356 (Latest) Electrical equipment of machine tools.
IS : 2516 (Latest) Circuit breakers (corresponding to
IEC Pub-56) (Latest)
2.3 Unless specified in the main specification, the AC motors and starters shall be of the
following type. Tenderer is, however, free to give alternative proposal along with
justification, if in his view alternative proposal in warranted by site conditions.
TYPE OF MOTOR TYPE OF STARTER
2.3.1 Any type of AC motor starting current Direct on line.
of which does not exceed 75 amps.
2.3.2 AC squirrel cage, introduction motors, Star delta or Auto transformer type.
starting current of which is above 75
amps. if started direct on line.
2.3.3 AC slipring type motor Resistance type air/fan Cooled
2.3.4 AC synchronous or Suitable maker’s standard.
synchronous induction motor.
2.3.5 DC motor Resistance type/Thyristor type.
2.4 The control gear for AC/DC motors shall incorporate the following protection devices
as concomitant accessories
2.4.1 No Voltage Protection - No voltage protection shall be provided so that machine will
not start up again by itself when, following an interruption the supply is restored.
2.4.2 Short Circuit Protection - To protect against short circuits due to insulation failure of
faulty connections HRC fuses/MPCB’s shall be provided for each motor. The rating of
the fuse shall be such as to take care of the over current due to motor starting

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2.4.3 Over Load Protection - To prevent motors from overloading, overload protection
shall be provided separately for each motor. Three phase motors shall be protected by
overload tripping devices on each phase
2.4.4 Single Phasing Protection- On load single phasing protection shall be provided
using MPCB as detailed above
2.5 Control equipment shall be mounted in separate drip proof enclosures. Control
enclosures and compartments are to be so designed as to give adequate protection
against ingress of dust, oil, coolant or chips. All control devices like contractors etc.
shall be front mounted on a rigidly fabricated metal panel for ease of operation. All
other electrics shall be installed that they are readily accessible when the doors and
covers are opened. Hinged covers shall be interlocked with the machine tool control
to prevent operation of the machine when cover is open
2.6 The motor shall be totally enclosed with or without fan cooled frame. Screen protected
drip proof type motor may be provided if it is mounted inside protective enclosures
2.7 The electrical equipments shall comply with the requirement of Indian Electricity Act
and Rules (latest)
2.8 All instruments shall be of the Industrial Grade “A” (IS-1248) switch board type the
range of the instrument shall be such that the maximum load expected in the circuit
shall produce a deflection of 60% to 80% of the full scale
2.9 The supplier shall furnish 3 sets of complete electrical and electronic wiring diagrams
in full details to enable the maintenance staff to locate faults in the circuits, 3 sets of
part catalogues, maintenance manuals operating instructions with details of coils and
windings, used in the equipment to facilitate repairs and maintenance should also be
supplied
2.10 For main motor class minimum “F” Class insulation shall be provided. If any other
class of insulation is proposed, detailed justification for providing different class of
insulation shall be given
2.11 Motors shall be designed to withstand frequent starts, stops and reversals as
demanded in the operation of the machine
2.12 Two earthing terminals shall be provided on all electric motors including the control
gear.
2.13 POWER SUPPLY
2.13.1 The machine shall be suitable for operation on 415 volts 3 phase 50 cycles AC 3 wire
or 4 wire system with neutral solidity earthed. The supply voltage may very up to +10%
-20%. The frequency may vary up to + 3%. However, full rated power of the motor
shall be available at the lower voltage. Firm should confirm satisfactory performance
of the machine at incoming power supply in the range 415V+10%-20% and 50HZ+3%
frequency or should provide voltage stabilizer as specified against clause 2.13.2
below of required capacity.
2.13.2 The voltage stabilizer, if required, shall conform to :
i. Input Voltage - 320 to 460 volts 3 phase 4 wire supply.
ii. Output Voltage - 415 volts
iii. Regulation - + 1% from No load to Full load
iv. Rate of correction - 20 volts per second per phase
v. Wave from distortion - NIL

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 vi. Efficiency - Not less than 97%
vii. Winding and class - Copper wire wound with “B” class of
insulation of insulation or better

2.13.3 In case of machines equipped with NC, SS, CNC, Thyristor controlled devices and
other sophisticated electronic gadgets including microprocessors etc. which
are susceptible to power line spikes and surges, a suitable voltage stabilizer and ultra-
isolation transformer to cover for the entire electrical load of the machine shall be
offered as a concomitant accessory. conforming to Specification for voltage stabilizer
as mentioned in clause 2.13.2 above and isolation transformer to the parameters
mentioned below.
i. Transformer ratio - 1:1
ii. Winding - Copper wire wound with “F” class
insulation or better
iii. Protection - To arrest spikes and surges to the order of
3 KV for 200-400 micro seconds duration
iv. Common Mode - 120 dB
Rejection Ratio
v. Isolation - Capacitance 005 Pf: resistance greater
than 1000 Mega Ohms
2.13.4 Voltage stabilizer shall be equipped with a protective relay to trip the AC power supply
to the machine instantaneously with audio and visual indication to the operator.
Settings of the protective relay for low and high voltage shall be 320 volts and 460
volts respectively.
2.14 ATMOSPHERIC CONDITIONS
2.14.1 The ambient temperature at the site at which the machine will be installed may vary
from -4ºC to +50ºC over the year. The relative humidity may be as high as 98%. The
atmosphere is expected to be dusty. The machines offered shall be suitably
tropicalised to work under these atmospheric conditions without any adverse effect on
their performance.
2.15 The temperature rise shall not reach such a value that there is a risk of injury to any
insulating material or adjacent parts.
2.16 The drive shall be capable of operating at any one of the speed required independent
of the load in accordance with the requirements of the machine.
2.17 Information/data shall be furnished as per the format of submission of technical bid
Annexure-A.
3 GENERAL CHARACTERISTIC
3.1 RIGIDITY AND STABILITY
3.1.1 The machine shall be robust, rigid and of sturdy construction. It shall be designed to
meet heavy duty demands of various operations on the machine under normal
Workshop environment for such machines. It shall be free for vibrations even when
working at full capacity.
3.1.2 All machine castings shall be made of close grained high grade cast iron like
Mechanite or equivalent materials meeting IS-210 Standards to ensure durability and
rigidity. The casting shall be thermal stress relieved to ensure stability and continued
accuracy.
3.1.3 All machine fabrications of critical load bearing assemblies like beds, columns etc.
shall be adequately strengthened and stress relieved.
3.1.4 Change in ambient temperature shall not affect the performance of the machine.
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3.1.5 There shall be no change in the performance of the machine either on switching on the
machine or after continuous running.
3.1.6 There shall be no resonant vibrations throughout the working range of the machine at all
load levels.
3.2 SAFETY CONTROLS
3.2.1 The machine shall incorporate safety devices to provide protection to the operator and
machine against all possible operational and machinery failures.
3.2.2 Suitable interlock shall be provided to prevent machine operations in the event of:
3.2.2.1 Faulty sequence of operation.
3.2.2.2 Fluctuation in supply voltage.
3.2.2.3 Resumption of power supply after power failure.
3.2.2.4 Non-positioning of safety guards.
3.2.2.5 Failure of hydraulic system (where applicable)
3.2.2.6 Failure of lubricating system (In case of automatic including drop in pressure lubrication)
3.2.3 A fault or damage in the control circuit or interruption re-establishment after an interruption
of fluctuation in whatever manner in the power supply to the machinery must not lead to
dangerous situations in particular.
3.2.3.1 The machinery must not start unexpectedly.
3.2.3.2 The machinery must not be prevented from stopping if command has already been given.
3.2.3.3 No moving part of the machinery or piece held by the machinery shall fall or be ejected.
3.2.3.4 The protection devices must remain effective.
3.2.4. The machine shall be fitted with an emergency stop device to enable actual or impending
danger to be averted. This device must be:-
3.2.4.1 Conveniently located.
3.2.4.2 Clearly identifiable.
3.2.4.3 Stop the machine as quickly as possible without causing additional hazards.
3.2.4.4 The emergency stop must remain engaged. It should be possible to disengage it only by
appropriate operation. Disengaging the control must not restart the machinery but only
permit restarting.
3.2.5 Safety features shall also include.
3.2.5.1 Safety device against overload for all mechanical and electric items to the extent possible.
3.2.5.2 Safety stops against over-running of slides.
3.2.6 Guard and protection devices shall protect exposed persons against risks related to
moving transmission parts (such as pulleys, belts, gears, rack and pinion, shafts etc.) and
moving parts directly involved in the process to the extent possible. This shall meet the
following requirements:-
3.2.6.1 Be of robust construction .
3.2.6.2 Not give rise to any additional risk .
3.2.6.3 Not be easy to by-pass or render non-operational.
3.2.6.4 Be located at an adequate distance from danger zone.
3.2.6.5 Cause minimum obstruction to the view of the production process.
3.2.6.6 Rigidly connected and not prone to rattling.
3.2.6.7 Enable essential work to be carried out without the guard or protection device having to
be dismantled.

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3.2.7 A load meter shall be provided to indicate the load on the machine. The meter shall
have a suitable mark to indicate the maximum load the machine can take. Full details
of the above and other safety features indicating how each one functions must be
explained in the offer.
3.3 OPERATIONAL CONTROLS
3.3.1 The operation of the machine shall be by push buttons or soft keys or selector
switches.
3.3.2 The control devices shall be:
3.3.2.1 Clearly visible and identifiable.
3.3.2.2 Ergonomically positioned for safe operation without hesitating or loss of time, and
without ambiguity.
3.4 LIGHTING
3.4.1 Integral lighting suitable for the operations concerned where its lack is likely to cause
a risk despite ambient lighting of normal intensity shall be provided.
3.4.2 The manufacturer must ensure that there is no area of shadow likely to cause
nuisance, that there is no irritating dazzle and that there are no dangerous
stroboscopic effects due to lighting provided by the manufacturer.
3.4.3 Integral parts requiring frequent inspection and adjustment and maintenance areas
must be provided with appropriate lighting.
3.4.4 The machine lighting should be of low voltage so as to prevent any hazard to the
operator.
3.5 MACHINE MAINTAINABILITY
3.5.1 The machine shall be so designed as to require minimum possible maintenance and
to give trouble free service.
3.5.2 All assemblies/parts of the machine shall be easily accessible for maintenance.
3.5.3 The machine shall not require major dis-assembly for checking and replacement of a
particular part, especially for parts requiring periodical check-up and replacement.
3.5.4 The manufacturer must provide means of access e.g. stairs, ladders, cat walks etc. to
allow access safety to all areas used for production, adjustments and maintenance
operations.
3.6 WEAR COMPENSATION ADJUSTMENT
3.6.1 The original built in accuracy of the machine shall be capable of being maintained
conveniently and economically by suitable adjustments for taking up wear on slides,
bearings and load screws. The system of adjustments incorporated shall be explained
in the offer.
3.7 COOLANT SYSTEM (WHERE APPLICABLE)
3.7.1 Suitable coolant system with pump, motor, tank, filter etc. shall be provided. The
coolant pump shall be as per IS:2161-1962. The filter shall be of reusable type and
indigenously available. If reusable filter cannot be offered the filter cartridge shall be
readily available in India. Source of supply shall be indicated. Adequate no. of filters
for 2 years working on double shift basis shall be offered as spare. Details of the
coolant system shall be indicated in the offer.
3.7.2 The supply of coolant shall be in ample volume. Provision to re-circulate the coolant
shall be available. A chip and coolant tray shall be provided. The volume of coolant
flow shall be indicated. It shall be adjustable.

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3.7.3 An enclosure shall be provided to prevent the coolant from splashing outside the
machining zone. Details of enclosure shall be provided. Specific requirements of
coolant system for grinding machines etc. shall be clearly indicated.
3.8 LUBRICATION SYSTEM (WHERE APPLICABLE)
3.8.1 The machine shall be provided with an automatic lubricating system for ensuring
delivery of adequate quantity of lubricant to areas requiring continuous lubrication.
Suitable arrangements must be provided for indication of failure of the lubricating
system.
3.8.2 The system shall be provided with interlock to prevent machine operating/starting in
the event of the failure lubrication system.
3.8.3 Reusable filters capable of filtering chips, dust particles etc. shall be provided. Indicators
for showing clogged condition of filters shall be available. The filters shall be indigenously
available. If reusable filter cannot be offered the filter cartridge shall be readily available in
India. Source of supply shall be indicated. Adequate no. of filters for 2 years working on
double shift basis shall be offered as spare.
3.8.4 Lubrication and filter cleaning chart shall be displayed on a metal plate at a
conspicuous location on the machine indicating :-
a) Specific location of points on the machine to be oiled lubricated/greased.
b) Periodicity of lubrication of these points.
c) Filter to be cleaned.
d) Periodicity of cleaning filters.
e) Periodicity of replenishing lubricating oil for the centralized system.
f) Any other similar relevant information
3.8.5 Points where manual lubrication is needed shall be separately indicated. Frequency
of lubrication shall be also clearly mentioned.
3.8.6 Lubricating oils used in the machine shall be available in India. Successful tenderer
will be required to indicate brand names of approved oils manufactured by various
Indian Oil Companies
3.8.7 First fill of lubricating oils used in the machine shall be provided with the machine.
Details of lubricating system provided shall be indicated.
3.9 PNEUMATIC SYSTEM (WHERE APPLICABLE)
3.9.1 The compressed air supply will be provided by the customer at the machine within
pressure range of 4.5-7.5 kg/cm2 and a moisture content or 1000 ppm. The pneumatic
system of the machine should be designed accordingly. An alarm shall be provided
for low air pressure.
3.9.2 Suitable filter/moisture trap shall be provided by the contractor in the system of pneumatic
air intake. The filter shall be reusable type and indigenously available. If reusable filter
cannot be offered, the filter cartridge shall be easily available in India. Source of supply
shall be indicated. Adequate no. of filters for 2 years working on double shift basis shall
be offered as spare.
3.9.3 Air pressure regulator, if necessary, shall be provided by the tenderer.
3.9.4 The make of pneumatic control equipment shall be of reputed make. The makes shall
be indicated.
3.10. HYDRAULIC SYSTEM (WHERE APPLICABLE)
3.10.1 Hydraulic circuit must be equipped with the following safety and inspection
equipments:
(a) Pressure gauges at all places, where pressure has to be set up or inspected.
(b) Safety valves for hydraulic circuit if relief valve does not fulfill this function.
(c) Equipment for checking of temperature in the circuit or in the pump wherever necessary.
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 (d) Arrangement to show if the filters (including those in the pump set) are choked and need
cleaning. The filters shall be of reusable type and indigenously available. If reusable filter
cannot be offered, the filter cartridge shall be readily available in India. Source of supply
shall be indicated. Adequate no. of filters for 2 years working on double shift basis shall
be offered as spare.
(e) Alarm for low oil level.
3.10.2 The sump aggregate shall have the following:
(a) Oil level sight gauges or any other equipment showing the minimum and maximum oil
levels in sump.
(b) A drain plug at the lowest portion of the tank.
(c) It shall be possible to drain the oil from the tank without disconnecting any pipes or other
fittings.
3.10.3 The temperature of oil in hydraulic circuits shall not exceed 60 degrees C in any case.
Suitable arrangement shall be incorporated to ensure that the oil is not overheated
under local weather conditions at continuous normal working of the machine.
3.10.4 Facilities for bleeding of air in case of air lock shall be provided.
3.10.5 The hydraulic reservoir, pump and allied equipment shall be suitably segregated from
the machine in order to remove major source of heat.
3.10.6 Hydraulic oils used on the machine shall be available in India. Successful tenderer will
be required to indicate brand names of approved oils supplied by various Indian Oil
Companies.
3.10.7 First fill of hydraulic oils used on the machine shall be provided with the machine.
4.0 TECHNICAL LITERATURE:
4.1 One copy of the printed illustrative catalogue showing features of the machine and its
elements must be enclosed with each copy of the bid.
4.2 The technical literature shall be provided for the complete machine, including imported
and indigenously purchased components / sub- assemblies. The successful tenderer
will have to furnish 4 (four) copies each of the following manuals directly to the
consignee along with the machine. Out of these 04 sets, the bidder shall be required
to submit one set of all documents in best available condition one month prior to the
training for the machine. One set of technical literature should cover the following
details:
i. Operational & Maintenance manual of the machine.
ii. Operational & Maintenance manual of the servo controlled voltage stabilizer.
iii. Operational & Maintenance manual of the ultra-isolation transformer.
iv. Instruction & Maintenance manual for Hydraulic Oil Cooling Unit.
v. User manual for Tool changer system (if provided).
vi. Technical & Maintenance manual for Hydraulic System.
vii. Technical & Maintenance manual for Lubrication System.
viii. Operator Guide for CNC Control System (if provided in soft copy).
ix. Programming Guide for CNC Control System (if provided in soft copy).
x. Diagnostic & Trouble shooting Guide for CNC Control System ((if provided in
soft copy).
xi. Start-up Guide for CNC Control System (if provided in soft copy).
xii. Machine Software listing (if provided in soft copy).
xiii. Soft and hard copies of PLC Program in ladder form with cross reference listing
and PLC project file in soft copy.
xiv. Drawings of tooling & fixtures, hard copies in A-2 size as well as soft copy in
PDF format.
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 xv. Wiring diagram, in which length of wires must be mentioned, hard copies in A-
4 size as well as soft copy in PDF format in soft copy.
xvi. Mechanical drawings (spindle assembly, table assembly, column assembly),
hard copies in A-2/3 size as well as soft copy in PDF format.
xvii. Spare part manual including part lists no., hard copies in A-4 size as well as in
PDF format.
xviii. Lay out drawings in A-2 size, which clearly shows the position of all type of
electrical components in machine.
Note: 1. All manual and literature should be in English/Hindi.
2.In addition, a hard copy of technical literatures of the items in clause 4.2(viii, ix,
x, xi ,xii. xiii) shall also be provided in digital form to the consignees as an effective
aid to their working.
5.0 SPARES
5.1 Since the machine will be under comprehensive preventive maintenance during
warranty period of two (02) years and under AMC for five (05) years after the warranty
period, it is the sole responsibility of bidders to stock such spares as required for
smoother execution of PMC during warranty and AMC in order to achieve response
time in compliance to machine availability as per stipulated requirements.
6.0 CONSUMABLES:
6.1 The list of consumable spares shall be furnished and quoted along with their unit rate.
6.2 Consumables shall be supplied along with the machine or as per agreed time table, if
ordered.
7.0 SPECIAL FEATURES:
7.1 Special features incorporated in the machine, if any, shall be indicated separately in
the bid clearly indicating the advantages.
8.0 DEVATIONS:
8.1 The tenderer shall certify that the offered machine fully meets the specification.
Various design features incorporated in the machine to fulfill different technical
performance requirements shall be fully explained in the offer. However, minor
deviations from these specifications which do not affect or in any way interfere with
the stipulated performance standards or would result in improved safety/ reliability or
would reduce recurring maintenance/operating cost of the machine, can be
considered for acceptance. The tenderer in such eventuality shall clearly indicate the
details of these deviations and their implications as per the following format:
8.2 All Deviations shall be clearly indicated in the deviation statement as per the format
of submission of technical bid Annexure-A.
9.0 INSPECTION AND TESTING AT MANUFACTURER’S WORKS:
9.1 The machine shall be inspected and tested during different stages of its manufacture
starting from raw material till the completion of machine, by the purchaser or his
authorized representative at the supplier’s or his sub-supplier’s works. The Quality
Assurance Programme as per Annexure-I shall be submitted along with the bid. The
bidder must submit the exhaustive QAP incorporating the tests as given in Annexure-
I along with other tests /stage inspection as followed by them.
9.2 A load and functional test like no load test and maximum Horse Power test must be
carried out at the manufacturer’s works. Rigidity of the machine shall be demonstrated
to the satisfaction of appointed inspector or inspecting agency.

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9.3 Manufacturers must have suitable facilities at their works for carrying out various
performance tests on the sub-assembly/assembly/machine. The tenderer shall clearly
confirm that all facilities exist and shall be made available to the inspecting authority.
9.4 A Sample Inspection Chart for inspecting the equipment shall be supplied along with the
bid. The inspection chart should indicate all the tests that are carried out during the
machine manufacture and also the tests to be offered to inspecting agency. The standard to
which this inspection chart conforms should be clearly indicated. Against each test,
acceptable limit/ range of values shall be indicated.
9.5 The complete machine along with concomitant accessories as per clause 4.2.1 of
Section IV shall be inspected at manufacturer’s premises as per approved GA
drawing. Inspecting authority shall not carry out the final inspection in case GA
Drawing is not approved by the consignee.
10.0 TRAINING:
10.1 Free training by the firm shall be imparted in operation and maintenance of the machine.
The training to be imparted shall cover operation, troubleshooting and repair of all
mechanical, hydraulic, electrical & electronics equipments (CNC Control & AC Drives) and
CNC/PLC part programming. This training shall be provided to 4 per consignee nominated
by the consignee, for a period of 2 weeks free of cost at the manufacturer’s premises. One
weeks training will also be provided to one person free of cost from COFMOW in design
and construction of the machine. All charges pertaining to travel, boarding and lodging
shall be borne by Indian Railways.
10.2 Subsequently, technical experts from the manufacturer will fully and adequately
provide training to operators and maintenance staff nominated by the consignee at
the time of commissioning of the machine.
10.3 The supplier will be responsible for co-coordinating with the consignee the travel plans
of trainees to ensure that the training is imparted on the machine at its assembly and
testing stage. The bidder shall also submit training schedule along with the offer.
Note: All training should be imparted in English/Hindi only.
11.0 FOUNDATION & RELATED DRAWINGS
11.1 SUBMISSION OF GA, FOUNDATION & RELATED DRAWINGS FOR APPROVAL:
11.1.1 For each machine, the supplier shall first submit 04 copies of GA drawings with complete
layout of machine elements like bed, hydraulic tank, coolant tank, electrical panel, Servo
Controlled Voltage Stabilizer etc. and other related diagrams (Mechanical, Hydraulic,
Electrical & Electronics) along with machine weight, overall dimensions, electrical load
with length of 3 phase, 415 V AC electric power cable for approval as per time schedule
specified in Section-IV to each consignee for approval and to enable the consignee for
making necessary arrangements for Installation & Commissioning of Machine on receipt.
After getting approval from consignee, the supplier shall supply directly to each consignee
6 copies of approved GA foundation drawings and related diagrams for each machine
within 04 weeks from the date of approval of GA drawing for information only in line with
applicable IS Specifications (Latest) or relevant international standards
11.2 APPROVAL OF GA DRAWING : To be governed by Time Schedule in clause 7 of
section-IV and following stipulations.
11.2.1 General Arrangement Drawings will be sent by the ‘Contractor’ to the Consignee as per
Time Schedule annexed in LOA/AT. Consignee will download the copy of AT from
COFMOW website and take necessary action for approval of GA drawings. The
‘Contractor’ should ensure that drawings sent to consignee are complete in all respects
as specified in technical specification. The GA drawings shall be approved by the

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 consignee and given back to the contractor, under advice to COFMOW, as per the Time
Schedule in the LOA/AT.
11.2.2 Delays in submission of drawings by Contractor will be added to the delay in supply
of machine in case submission of GA drawing is delayed beyond stipulated time as
per time schedule and LD will be levied as per bid document Part-I. Thus the number
of days’ delay in submission of GA drawing plus the number of days’ delay in supply
of machine, for the purpose of calculations of LD as per clause 1002 of section II of
bid document Part-I. However, if the contractor supplies the machine before original
delivery period as per AT the number of days by which machine has been supplied
earlier than original delivery period that many days will be subtracted from the delay
in submission of GA drawings and LD will be levied accordingly. Delays in approval
of the drawings by consignee will not be on account of Contractor, except as detailed
below.
11.2.3 In case Consignee finds some deficiencies in the Drawings and returns the same for
rectification to the ‘Contractor’, the contractor must return the rectified drawings within
30 days from the date of issue of letter by Consignee. This period will not be counted
towards LD calculation. The consignee shall ensure that all deficiencies in the
Drawings shall be pointed for clarifications to the firm together at one time only instead
of piecemeal multiple reference.
11.2.4 A repeat back reference(s) by Consignee to Contractor pointing out further
defects/deficiencies in the Drawings, will be considered a delay on account of the
contractor, except for special circumstances like change in location, review of
arrangement etc. Thus, Contractors must take utmost care in ensuring completeness
as per requirements of the Consignee.
11.2.5 Where GA Drawing cannot be approved by consignee due to clear site not being
available etc., the Consignee must inform Contractor and COFMOW, explaining the
exact delay. However, initiative must be taken by Contractor to obtain such a
certificate from Consignee. Contractor must bring any difficulty/dispute to the notice
of COFMOW immediately.
11.2.6 In their own interest, contractor must maintain a log of events in this respect with clear
dates and regularly inform consignee and COFMOW to avoid wrong levy of LD.
Consignees must cooperate with Contractors by providing all assistance, including
clear information about any expected delays in site availability, promptly and in writing.
11.2.7 If an order has been placed on the firm, the firm will have to advise the consignee well
in advance regarding requirement of road permit and assistance required from the
consignee, if any, so that delay on this account is avoided. Firm should also visit the
site before dispatch of machine to assess the condition of path to be used for
movement of trailer.
11.3 DISPATCH OF THE MACHINE FROM MANUFACTURER WORKS:
11.3.1 The supplier should normally dispatch the machine only after the foundation is ready
for installation and commissioning of the machine on arrival.
11.3.2 In case of delay on part of consignee in providing the clear site for construction of
foundation or any other facility as specified in the contract to the supplier, the supplier
will report the matter to COFMOW and consignee. In case of delay in readiness of site
on part of consignee, COFMOW shall take up the matter with concerned Railway/ PU,
and advise supplier accordingly.
11.3.3 In case proving of component at manufacturer works, the supplier should request for
the same as soon as possible after receiving contract keeping allowance of transit
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 time etc. and approximately 60 days for consignee to handover the parts after receipt
of the request accompanied by appropriate and valid bid guarantee. In the event of
consignee certifying the non-availability of prove out components, such components
will be deemed to be proved out at manufacturer works. However the firm will prove
out these components at consignee subject to the availability
12.0 INSTALLATION, COMMISSIONING AND PROVING TESTS: (ON TURNKEY
BASIS)
12.1 Joint Check - The contractor or his agent would be required to carry out a joint check
at consignee’s end, along with the consignee, before unpacking is done, to avoid
subsequent complaints regarding short shipment/transit damages. It is necessary that
this joint receipt inspection be done immediately on receipt of the machine by
consignee & bidder’s representative to avoid commissioning delays due to
shortages/transit damages. After receipt of the machine as above a Joint Receipt
Inspection note (JRI) as per Annexure-C of Section-VI shall be prepared by the
consignee and the firms representative indicating the tentative time schedule for
various activities of installation and commissioning. For Indian manufacturers, JRI
note shall accompany the bill for 80% payment.
12.2 RESPONSIBILITIES OF CONSIGNEE AND BIDDER
12.2.1 The consignee shall be responsible for-
i. Provision of a clear covered (except where shed is in the scope of contract)
site for construction of foundation as per the schedule to ensure its
readiness before arrival of machine at site.
ii. In case where construction of shed is also in the scope of contractor the
consignee shall ensure site is encroachment and encumbrance free.
iii. Electricity, water and compressed air for installation and commissioning of
machine shall be provided free of cost within one week of arrival of
machine at site.
iv. Wherever a road mobile crane has to be arranged by the supplier for
material handling, a clear approach for it up to the site has to be provided.
v. Clear covered space for storage of material/equipment required for
working/ construction of foundation and installation of the machine etc.
vi. The consignee shall arrange the raw material for prove out at their end
within 15 days of the dry run of the machine (installation, power connection,
auxiliary connection like air, water connection) failing which such
components will be deemed to have been proved out. The components
supplied by the consignee in time will be required to be proved out as per
time schedule chart.
vii. The inspection of foundation, structures etc. and installation of the machine
shall be done by authorized representative of the consignee.
12.2.2 The bidder shall be responsible for-
i. Design & Construction of foundation, flooring of sufficient thickness, civil
works (in line with scope of supply) suiting local soil conditions at the site
in compliance with clause 3700 (3701 to 3704) of Bid Document Part-I ii.
Advise consignee in time regarding schedule for requirement of clear site
for construction of foundation and other infrastructure, resources &
facilities required

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 iii. Construction of foundation as well as flooring (if required) of sufficient
thickness suiting local soil conditions, for machine shall be completed by
the bidder at the site provided by the consignee before receipt of the
machine at their premises
iv. Provision of all tools and equipment, technical and unskilled manpower,
material handling accessories/ equipment and material for installation and
commissioning.
v. Unloading of the machine on receipt (both imported and indigenous
machine) and its movement to the site of installation including provision of
road mobile crane.
vi. The bidder should ensure the proper earthing for the machine and its
peripherals/accessories.
vii. The bidder shall be responsible for meeting all the criteria set by State
Pollution Control Board and Central Pollution Control Board, wherever
applicable, with respect to air, water, noise, land etc. The bidder shall be
responsible for obtaining clearance/certificate for
installation/commissioning /operation of the machine/system supplied.
The consignee will provide the administrative help for establishment of
communication with the Pollution Control Board.
12.3 Consignee will provide only 415 V+10%-20%, 3 phase 50 Hz+3% AC supply at a
single point (mains). All types of cables, connections, circuit breakers etc. required for
connecting power supply point to different parts of the machine/control cabinets, shall
be the responsibility of the bidder. Requirement of grounding/earthing with required
material shall also be incorporated by the bidder during construction of foundation.
Electrical work like laying of power/electrical cables & earthing wires from mains to
machine control panel (upto 20 meters) as well as within the machine, with supply of
all materials shall also be carried out by the supplier.
12.4 The supplier shall demonstrate machine performance and prove out the claimed
capability for successful commissioning at the consignee’s works as per clause 2.4 of
Section-IV. The M&P shall be deemed to be “commissioned” at consignee premises
on the date when it is tested and meets with the specified capabilities/functions
according to the technical specifications. In addition to above, in case of tooled-up
M&P, the M&P shall be deemed to be “Commissioned” at consignee premises on the
date when “prove out” components specified as per the relevant clause of technical
specification have been successfully proved out meeting the productivity requirements
of Technical specification. The consignee shall arrange the raw material for prove out
at their end within X days of dry run of the machine (installation, power connection,
auxiliary connections like air, water etc.) failing which such components will be
deemed proved out. The components supplied by consignee in time will be required
to be proved out within Y days thereafter. Any delay in providing the “raw material or
any other input” for proving out shall not be logged on supplier’s account.
A Joint Commissioning Note (JCN) to this effect shall be made as per the format at
Annexure-D of Section-VI. After issue of JCN the performance shall be watched for a
period of one month, after which the PTC shall be issued. The issue of PTC cannot
be delayed by more than 60 days from the issue of JCN. If some minor breakdowns
are noticed after the issue of JCN, these shall be attended as per warranty obligations
and suitable extension of the warranty period, under intimation to COFMOW. If no
intimation is given to COFMOW and the PTC is not issued till the expiry of 60 days
from the issue of JCN, then the issue will be discussed in a meeting between

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 CME/PCM and the consignee. Based on this, decision to issue PTC will be taken by
CME/PCM, the concerned technical officer and PCME

12.5 If an assembly/sub-assembly requires to be taken back to the manufacturer’s

premises for repair/replacement either before commissioning or during warranty, the
manufacturer or his agent would be required to submit BG of suitable amount. In case
the entire machine has to be taken back, a Bank Guarantee for the cost of the machine
would have to be submitted. The bank guarantee should be of adequate value so as to
cover the cost of the assembly/sub-assembly/paid up cost of the machine
13.0 SERVICE FACILITY IN INDIA AND TECHNICAL SUPPORT
13.1 The tenderer will clearly spell out in the offer the facilities available with him or his agent
for providing adequate after-sales service in India during warranty period in the appropriate
section of Annexure ‘A’ of Bid Document Part-II. The complete details such as organization for
after sales service, availability of technically competent engineers and warehousing
facilities for spares should be clearly indicated. Bidders not offering complete
servicing/repair facilities in India to ensure quick response to maintenance/ servicing calls are
not likely to be considered.
13.2 After the warranty period and AMC period, if any, the manufacturer or his agent shall
agree to provide service supports for trouble shooting and obtaining spare parts. The
manufacturer shall be obliged to provide spare parts required by the Purchasers for a
period of 12 years from the date of delivery of the machine at the ultimate destination to
safeguard against obsolescence.
13.3 Tenderer who are OEM, shall undertake to supply spare parts for a period of expected
life of machine. Other tenderers shall submit undertaking from OEM for supply of
spare parts for a period of expected life of the machine.
13.4 During warranty period, the supplier or his authorized agent shall attend for break
down as soon as possible, but in no case later than 72 hours of receipt of intimation of
the breakdown.
14.0 BOUGHT OUT ITEMS:
14.1 The bidder shall furnish along with the offer a list of all critical items/ sub-assemblies
which are bought out by the bidder and proposed to be used, along with the
manufacturer’s name, brand model etc. The successful bidder may be required to
produce invoices to ensure genuineness of such products / verification by the
Inspecting agency.
14.2 The bidder should clearly indicate that in case of components/sub-assemblies taken from
reputed companies such as Vickers, Rexroth, RITTAL, THK, and Shenburger etc., the
parent company has already entered into contract with their Indian units/affiliates for
undertakings repairs/after sales service during warranty and post warranty.
S. No Sub Assembly Accepted Make
1. CNC & Drive SIEMENS/FANUC/Heidenhain/ Mitsubishi/HMT NUM
Controller
2. Hydraulic pumps Rexroth/Vickers/Yuken/Atos/Parker / Hydac/ Hawe
and valves
3. Feed back devices Heidenhain/ Fagor/ Siemens/ Fanuc/ Mitsubishi/
Kubler/ Hengtler/ Honer/ Ballerf/Sony
4. Ball screws THK/INA/Tsubaki/Rexroth/Steinmeyerstar/ Gamfior / Commented [SS8]: As per Underfloor Wheel lathe AT OP
Schenburger/Shuton/ Korta / Hiwin / Star/NTN 608540.
5. Air conditioner for RITTAL/Warner Finley/Kelvin / M&G- Cooling System /
Control cabinet Advance / Sunbeam / Walia/ Tropicool
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 6. Spindle Bearings FAG/SKF/Timken/NTN/KOYO / RKB/ LIBE/ ZKL/ INA/
IKO/ EVOLMEC
7. Lubrication System Cenlub/Dropco/Vogel/ Rexroth/ Bijur Delimon/
Centraline/ Jaguar/SKF LINCOLN
8. Electrical Control RITTAL/ Siemens or of other reputed make with IP55
Cabinet Protection level
9. Servo Controlled Servomax/Consul/ Aplab/ Golden/ Powerguard
Voltage Stabilizer
10. Ultra Isolation Servomax/Consul/ Aplab/ Golden/ Powerguard
Transformer
11. Electromagnetic Vortex /GhatgePatil
clutch
12. A.C. Motors NGEF/BBL/ABB/KEC/Crompton/ Siemens/ Allen
Bradley/ NORD/ Hindustan Motors/ Bonfiglioli/Rossi
13. Brake motors Siemens/KEC/Crompton/NGEF/BBL/ Hindustan
Motors
14. Proximity Switch Elap/Schneider/Omron/Scanner
15. Contactors Siemens/BCH/ABB/Schneider/L&T
16. Limit switches BCH/Siemens/L&T/Teknic/Euchener/Honeywell, USA
17. Push button Teknic/Siemens/ Schneider/BCH / ESBEE
18. ‘O’ Rings & rubber Merlin/Parker/Busak/Hunger/Merkel/Soloseal/
seals Walkersolo/ Halite/Seal Mart/Aston/PRP
19. Pneumatic Control Festo/Shavo Norgen/Shradder Scovil/Electro
Equipment Pneumatics/ Parker/ SMC Pneumatics/ Pneumax/
Dunker/ Scovil/ IMI Norgen
20. Control gears L&T/Siemens/BCH/ABB/Schneider / C&S
21. Cable/wire Siemens/Indramat/ Hubershnuer/ Finolex/Havells/
POLYCAB/ LAPP/ Roliflex/ RR Cable
22. Gear reducer Elecon/Greaves/Shanthi/ZF/New Allenbury/
Bongfilivali / ROSSI/NORD/ PREMIUM/ GIRAD/ Apex/
Siemens/ Rototech/ Kavistu/ Cyclo
23. AC Drive Fanuc/Siemens/ABB/Allen Bradley /Schneider / L&T/
MITSUBISHI
24. AC servo motor Fanuc/Siemens/ABB/Allen Bradley /Schneider
25. PLC Siemens/Fanuc/ Mitsubhishi/ Messung/Hitachi/ABB/
Allenbradley/ Schneider / L&T
26. Air circuit breaker Siemens/L&T /ABB
27. Connectors Harting/Kontact/L&T/Omron / Indoelectric/ Phoenix/
Connect well
28. Hydraulic seamless Parker/Maharashtra seamless/Indian seamless/
tubes Sainest /Gandhi spl. Tubes
29. MCCB Schneider/ABB/Siemens/L&T
30. Cutting tools Sandvik/ Kennametal - Widia/ Iscar/ Taegu-Tec/ Iscar/
Ceratizit
31. Drills and Taps Addison/Zenith(IT)/Universal
Note:
1. In case any other reputed make is offered, satisfactory justification for the same
will have to be given in the offer.
2. The bidder should explicitly mention “Not applicable”, against the items, indicated
above; whichever is not applicable in the offered machine.
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15.0 COLOUR:
The machine and its accessories shall be painted in Apple Green Colour No.281 to
IS: 5-1978, (if any specific colour code standardized by BIS is available, the same be
given). The machine can also be painted in equivalent RAL/DIN/other International
Standards. If there is a standard color scheme of the manufacturer, the same can also
be considered and may be specified.
16.0 WARRANTY OBLIGATION -The following conditions regarding Maintenance and
reliability shall also apply:-
16.1 The machine shall be designed for a life of 15 years with regular maintenance and all
the structural members of the machine and the foundation shall be guaranteed for 15
years against cracks breakages and etc. during the course of normal operations.
Tenderer would submit suitable undertaking.
16.2 Foreign suppliers who do not have registered office / maintenance facilities in India
may authorize an Indian agent, who shall be responsible for maintenance and break
down support. In such case, Indian agent should have experience of maintaining at
least 5 CNC machines during past 5 years preceding the tender opening date. The
tenderer should submit documentary evidence towards the experience of the Indian
agent, along with the offer.
16.3 In addition to warranty obligations prescribed under clause 3400 and 3500 of the Bid
Document Pt.-I, the warranty period would also cover comprehensive preventive
maintenance, which will be inclusive of all spares, material and labour cost. All
maintenance consumables like lubricants and grease except hydraulic oil / machine
coolants shall form part of the scope of the preventive maintenance during the
warranty. The cost of preventive maintenance to be carried out during warranty period
should be quoted separately.
16.4 The payment of preventive maintenance schedule carried out during warranty period
shall be made by COFMOW annually at the end of each year after completion of the
work and issue of certificate by the consignee as per annexure-E of section-VI.
16.5 The machine shall at all times give contractual out-put and accuracy. Any deficiency
or break down for a total of 02 hr. or more for a day would be treated as failure for the
day, for the purpose of extending warranty period in terms of clause 3405 of Bid
Documents Part-I.
16.6 The tenderer shall ensure that in case a failure is reported by a consignee qualified
service engineers shall visit the site within two days from the date of complaint on
calendar day’s basis. The period of three days (excluding date of complaint) after the
failure reported shall be treated as grace period, which will not count towards
breakdown time for up to one failure per month and a maximum of 3 failures per
quarter. In case the number of failure exceeds one failure per month or three during
any quarter of warranty, grace period of only 1 day will be permissible for such
additional failure. Complaints shall be lodged by consignee by fax phone, e-mail or
per bearer at address given by the tenderer.
16.7 The details of preventive maintenance to be provided during warranty period shall be
indicated by the tenderer giving details of type of preventive schedule, periodicity on
items to be checked, items to be replaced and expected plant down time. Preventive
maintenance schedules shall be conducted on weekends as far as possible or any
other day through mutual agreement with consignees. Released parts against
replacement may be handed over to contractor. Total breakdown hours shall be
calculated after discounting grace period and preventive maintenance period.

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16.8 Maximum permissible down time till it is restored back to the contractual output and
accuracy levels, in any quarter of the year during the warranty period, shall be 150 hrs. in
case the total breakdown period in any one of year during warranty period, exceeds 500
hrs., the consignee shall inform the same to COFMOW To ensure this a record of
breakdown (duly signed by shop in-charge) in hours on quarterly basis should be
maintained by the consignee and joint report with the contractor shall be made for each
breakdown attention. At the end of first and second year of warranty, these details of
breakdown hours during warranty period should be advised to COFMOW as per
performance appraisal report given in Annexure - E of section -VI. The firm will then
request COFMOW for release of WBG annexing the performance appraisal report as per
Annexure-E of Section-VI and the breakdown details mentioned above.
Penalty will be levied on the bidder for breakdown period on working days basis
(excluding holidays) after discounting for the grace period. Penalty will be calculated
as percentage of annual preventive maintenance charges and will be deducted from
the respective annual payments as under:
Breakdown period Applicable penalty
Up to 150 hours in each quarter Nil
and not exceeding 500 hours
annually
Exceeding 150 hours - up to 5 % of annual preventive maintenance
200 hours in any quarter and charges
not exceeding 500 hours
annually
Exceeding 500 hours - up to 750 10% of annual preventive maintenance
hours annually charges
Exceeding 750 hours - up to 1000 25% of annual preventive maintenance
hours annually charges
Exceeding 1000 hours annually 50% of annual preventive maintenance
charges and Encashment of Warranty Bank
Guarantee besides other action like noting
adverse performance of the bidder and/or
agent for future tenders and their offer in the
subsequent tenders will not be considered
for placement of any order.
17.0 ANNUAL MAINTENANCE CONTRACT
17.1 Tenderers are required to quote for a comprehensive Annual Maintenance Contract
for the machine supplied against this specification for a period of five years on yearly
basis giving the rates for each year i.e. first year, second year. So on., which will be
inclusive of all spares, material and labour costs. The duties and taxes as applicable
should be indicated separately. Released parts against replacement shall be handed
over to contractor. All consumables spare and materials shall form a part of the
scope of comprehensive AMC except as follows.
a. Diesel/Fuel, oils, greases or coolant.
b. Major machines elements/structural members which are under guarantee for a
period specified in clause 16.1 as stipulated in ‘warranty obligations’ requirement
17.2 AMC shall be operated, managed and paid by the consignees indicated under clause
3 of Section IV. The consignee shall indicate the bill payment authority & custodian
of the AMC BG. No further agreement is required for operating AMC at consignee
end.

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17.3 AMC is a part of scope of supply, in case of concomitant requirement and included
in commercial evaluation criteria vide clause 5 of Section-IV. The detailed terms and
conditions of AMC shall be as given in following clauses:
17.3.1 The duration of AMC shall be 5 years from the date of expiry of warranty. Rates for
AMC shall be quoted by the tenderer on yearly basis, which will remain applicable
during the duration of AMC and not subject to any variation except any statutory
changes in taxes and duties as compared to quoted rates
17.3.2 The tenderer must provide AMC services at the consignee location without any
precondition. The AMC should include complete responsibility for the bought out sub-
assemblies and components like CNC system, diesel engine, AC unit etc
17.3.3 The details of preventive maintenance services including cleaning of machine to be
provided under AMC shall be provided by the tenderer in the following format.
S. TYPE OF PERIODICITY ITEMS TO ITEMS OF EXPECTED
No. PREVENTIVE BE REPLACEMENT PLANT DOWN TIME
SCHEDULE CHECKED
17.3.4 Preventive maintenance shall preferably be conducted on weekends through mutual
agreement with the consignee. Each preventive maintenance schedule normally
shall not exceed one day. The total shutdown time for preventive maintenance
should be kept as low as possible but not more than 60 hours/month (averaged over
the quarter) including time for cleaning, weekly, fortnightly, monthly, quarterly
schedules etc. The preventive maintenance regime offered must be aimed at
achieving minimum 90% uptime of the plant excluding the plant down time for
preventive maintenance schedules
17.3.5 The tenderer shall ensure that in case a failure is reported by a consignee, qualified
service engineers visit the site within 3 days from the date of complaint on calendar
days’ basis. This period of 3 days (excluding date of complaint) after the failure report
shall be treated as grace period, which will not count towards plant down time for
upto one failure per quarter and a maximum of 4 failures per annum. Incase, the
number of failures exceed one during any quarter or four during any year of AMC,
grace period of only 2 days will be permissible for such additional failures.
Complaints shall be lodged by consignee by fax, email or per bearer at address given
by the tenderer. The responsibility to keep the failure reporting address details
current will rest with the tenderer
17.3.6 In case preventive maintenance is carried out along with breakdown maintenance
schedule; preventive maintenance time will be deducted from breakdown time of the
plant
17.3.7 Penalty Clause: Penalty shall be levied on the tenderer for maintaining plant up time
below the limit of 90% calculated on working days basis, after discounting for grace
period and preventive maintenance period. Penalty shall be calculated as %age of
quarterly payment and will be deducted from the respective quarterly payments.
Penalty calculation will be done over quarterly payment period:
S.No Availability Slab Applicable Penalty
1 90% to 80% 0.5% for every 1% (or part thereof) reduction in
availability of plant below 90%.
2 Below 80% 1% for every 1% (or part thereof) reduction in
availability of plant below 80%.
17.3.8 A Bank Guarantee equal to 1/4 of annual value (highest of the annual values if the
rates offered for various years are different) of AMC subject to a minimum value of
1.25% of the quoted cost of machine including concomitant accessory (in case the

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 annual AMC rate quoted is less than 5% of the cost of machine), will be submitted
by the tenderer to the consignee 90 days before the expiry of warranty. AMC will
have the validity of 5 years 6 months. The bidder can submit multiple BG for lesser
duration to cover the period of 5 year 6 months ensuring the uninterrupted validity of
the AMC BG for 5 year 6 months. The confirmation for the submission of this BG
shall be submitted to COFMOW for release of WBG. The AMC BG will be returned
on completion of AMC period. In case, the tenderer fails to provide AMC services
successfully, the AMC BG will be forfeited. This will be in addition to penalty as per
clause 17.3.7 above. This provision would not be applicable where the advance
payment is made.
17.3.9 Plant up time of less than 60% for two consecutive quarters will constitute complete
failure of tenderer to provide the AMC services successfully and will result in
forfeiture of AMC BG, besides other action like noting adverse performance of the
bidder and/or agent for future tenders and their offer in the subsequent tenders will
not be considered for placement of any order. This will be in addition to penalty
clause 17.3.7 above for the period of actual performance
17.3.10 As per clause 5.1.1 of bid document Part-II section V, where AMC is part of
evaluation of offer, it is the sole responsibility of bidders to stock all spares and
materials as required for smoother execution of AMC in order to achieve response
time in compliance to machine availability as per stipulated requirements
17.3.10.1 In all cases of plant failure except as mentioned in clause 17.3.10.2, any other spare
part or material necessary to restore the plant to proper working order will be
arranged by the tenderer as a part of AMC
17.3.10.2 In case of damage to the machine on account of any external factor, viz., floods,
earthquake, fire, arson or sabotage, entire cost of spare parts and material
necessary for repair of the plant shall be borne by the railways. However, the
tenderer shall provide services of their engineers free of cost as a part of AMC to
restore the plant to working order.
17.3.10.3 In case of damage to the plant as mentioned in para 17.3.10.2, any spare parts and
material necessary to restore the plant to proper working order shall be arranged by
the tenderer and charged on actual basis duly certified by authorized railway official
in the next quarterly bills. The rates charged for such spare parts shall be based
upon the spare part rate list provided by tenderer in compliance of clause 5.2 or any
other valid document. The tenderer shall furnish documents to support the rates
charged for spares used for repair under para 17.3.11(a)
17.3.11 Normally quarterly payment (@ 1/4th of the annual quoted rates) under AMC will be
made to the tenderer within 30 days from the end of that quarter subject to
submission of the following documents by the tenderer to the paying authority
assigned by the consignee:
a. Consignee’s certificate for work done as per Annexure-G of Section-VI with
calculation of down time and penalty applicable.
b. A certificate by consignee that no spare part is due with the tenderer as per
clause 17.3.10 above.
c. Bills submitted by the tenderer & accepted by consignee.
d. Attested photocopy of the AMC BG
17.3.12 The AMC contract can be terminated in following ways: Consignee may terminate
the AMC in the event of failure of tenderer to provide AMC services of the AMC
agreement in addition to encashing of AMC BG as per clause 17.3.8.
17.3.13 Other general conditions shall be governed by Bid Document Part-I (Section-I, II and
III) as applicable to respective COFMOW A/T.

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 SECTION VI

ANNEXURE-A

FORMAT FOR SUBMISSION OF TECHNICAL BID

1. a) We, M/s.------------ offer our --------- machine, model no. ------- as per the description given in
Schedule of Requirements.

b) We state that, except for the following, for which clause wise brief description and justification for
deviation has been indicated, our machine fully complies with all the clauses as given in technical specification
Section-V.

c) We also confirm all the schedules given in the Delivery Schedule at para 7 of Section-IV.

S.No. Clause/Item Brief description of Justification for deviation

Deviation

Note1: In case there is a contradiction in any information provided (some parametric values given in
the specification and those given in the brochure or some other document enclosed by the
tenderer), unless specifically mentioned in the deviation cum confirmation statement under
Annexure A of Section VI, the values as given in the specification shall be taken as confirmed
by the tenderer and offer evaluated accordingly.
Note2: In case tenderer offers internationally accepted alternative specifications as per clause 1.7,
complete details of alternative specification, apart from filling above deviation statement, may
be enclosed

2. We further certify that we are meeting the reference clause as;

(A) We are the regular manufacturer of this type of machine.

(B) We have made the following past supplies of similar machines as per clause A(2) & A(3) of
special conditions during last 10 years:-

S. Name of the Purchaser’s Purchase/ Supply Quantity Date of Date of CNC Surface
No. Purchaser Phone, Email Order number and Supplied Supply Installation and/ Wheel Lathe
with Address Address, Name of date (along with a (with proof (@) or for a Railway
the contact copy of the PO) of supply) @ Commissioning Application
person @ (Yes/No)

@ (along with copies of relevant documents to establish linkages of documents/ entities as detailed in clause 5 of Qualifying
Requirements).

(C) We are submitting following performance certificate from past users as per clause A (4) of
Special Conditions: -

S. Name of Purchase/ Supply Order Quantity Date of Date of Date of issue Performan
No. the number and date (along Supplied Supply Installation and/ of as
Purchaser with a copy of the PO) (It or Performance Annexure
with should be the one(s) Commissioning Certificate A1
Address which are enlisted at
clause 2 B above )

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3. We are having following facilities available with us or our agent for providing adequate aftersales
service in India during warranty period. Complete details of after sales service, availability of
technically competent engineers and warehousing facilities for spares is indicated below:
• After sales service centers;
• Availability of technically competent engineers;
• Warehousing facilities for spares:

4. We have quoted for the following optional accessories as indicated under clause 4.3 of
section IV

S No. Description of the optional Quantity Rate Indigenous Shelf Li

accessory (in Nos.) Months)

5. We have quoted for following recommended perishable and non-perishable spares required
for normal maintenance to cover complete range of mechanical, hydraulic and electrical
equipments including controls on double shift working basis:
Perishable Spares:
S No. Description of the Part Quantity Rate Shelf Life (in Months)
spares number (In Nos) (In Rs.)

Non-perishable spares:
S.No. Description of the spares Part number Quantity Rate (In R
(In Nos.)

6. *We hereby confirm that we are the OEM and undertake to supply spare parts for a period of
expected life of machine.
OR
*We hereby confirm that we are not the OEM, but are submitting undertaking from OEM for
supply of spare parts for a period of expected life of the machine to provide maintenance spares
(as and when ordered) after the expiry of the Warranty/AMC for 5 years (life of machine - 15yrs)
including the maintenance spares required for the bought out sub-assemblies and parts.
(*Strike out whichever is not applicable)
7. We have quoted consumables required as per clause 6.1 of Section V of Bid Document Pt-II, in
the format give below
Sr No. Description of the consumable Qty Unit Rate
spares

8. It is certified that we are having suitable facilities at our works for carrying out various
performance tests on the sub-assembly/assembly/machine and these shall be made
available to the inspecting authority.

Page 45 of 72
9. BOUGHT OUT ITEMS: We hereby furnish a list of all critical items/ sub-assemblies which
are bought out by us and proposed to be used, along with the manufacturer’s name, brand
model etc.
Sr No. Description Item no.1 Item no. 2 I
1. Brief description of item
2. Model no.
3. Make
4. Quantity/machine
5. Manufacturer’s name and complete
address
6. Whether imported or indigenous
7. Country of origin

10. The details of Preventive Maintenance during warranty and comprehensive Annual
Maintenance Contract as per clause 16.7 & clause 17 of Section-V respectively. The
Preventive Maintenance during warranty and comprehensive Annual Maintenance Contract
is in the scope of this tender. Details of preventive maintenance services including cleaning
of machine to be provided under PMC during warranty and AMC as per clause 16.3 is given
in the following format.
S.No Type of Periodicity Items to Items of Expected plant
preventive Be checked Replacement Down time
schedule

11. We further submit the following information about the offered machine as per the
technical specification section VI and Important Features of the tender section IV.
We understand that any omission of any of the below mentioned information will
render our offer incomplete to that extent.

S.N. Information required As per Value

Clause No. /Write up/
Brochure
1.
2.2 Leading parameters
2.2.1 Major parameters:
(Note: No deviation in major parameter shall be accepted. )
Clause no. Item Description As specified Value/ Write up/ Brochure
of Section- (As offered)
IV
i) Track Gauge 1676 mm
ii) Capacity of lifting 2500Kg (minimum)
mechanism
iii) Cutting Speed 25 - 80 m/min
(continuously
variable)
iv) Feed rate 0.1 to 4.0 mm/rev
(continuously
variable)

Page 46 of 72
 v) Rapid traverse of tool 3000mm/min
slide
vi) Accuracy
a) Difference in tread Less than 0.3 mm
diameter of two on the same Axle.
wheels
b) Inaccuracies in Less than 0.2mm
machined profile when checked with
a Standard Profile
Gauge.
c) Surface finish after 20 microns Ra or
machining better.
d) Runout on tread 0.3 mm
diameter shall not
exceed
vii) Job Parameters
a) Wheel diameter 723mm - 1250mm
b) Axle length 1850 - 2750mm
c) Tyre/Wheel width 125 -145mm
viii) Method of wheel set 4 jaw axial clamping
clamping & driving grippers
2.2.2 Other parameters
Clause no. Item Description As specified Value/ Write Justification
of Section- up/ Brochure for deviation
IV (As offered) offered (if any)
i) Power supply As per clause 2.13.1
of Section-V
2. Technical Details/Particulars of Motors, Control Gears,
Voltage Stabilizer & Isolation Transformer
2.1 A.C. Motors and Control Gears
AC MOTOR
• Manufacturer’s Name
• Type of enclosure
• Type of duty (Ref. IS: 325) (Latest)
• Rating-Continuous/intermittent
• Output (KW/BHP)
• AC voltage across phases, number of
phases & frequency.
• Speed in RPM
• Class of insulation
• Normal full load current
• Starting current
• Maximum current at the time of change over
from lower speed to higher speed
• Type of motor-Squirrel cage/slipring (wound
rotor)
• Temperature rise of windings and other
parts allowed above an ambient temperature
of 50 degree C.
Page 47 of 72
 • Frame size of motor
• End use of motor
CONTROL GEARS
• Manufacturer’s Name
• Type of control gear (Direct on line/Star
Delta/Auto-transformer etc.)
• Rating of starting gear in KW & amps.
• Short circuit protection (y/n)
• No volt trip (y/n)
• Overload trip (y/n)
• Delayed action current sensitive single
phasing preventor (y/n)
• Standard specifications to which the motor
• control gear and its ancillary offered conform
to

2.2 D.C. Motors and Control Gears

DC MOTOR
• Manufacturer’s Name
• Type of enclosure
• Type of duty (Ref. IS: 4722) (Latest)
• Rating-Continuous/intermittent
• Output (KW/BHP)
• DC voltage across phases, number of phases
& frequency
• Method of excitation whether shunt, series,
compound or separately excited, if separately
excited state excitation voltage.
• Speed in RPM
• Class of insulation
• Normal full load current in amps.
• Starting current
• Temperature rise of windings and other parts
allowed above an ambient temperature of 50
degree C.
• Frame size of motor
• End use of motor
CONTROL GEARS
• Manufacturer’s Name
• Type of control gear (Direct on
line/Resistance type/Thyristor type)
• Rating of starting gear in KW & amps.
• Short circuit protection (Y/N)
• No volt trip (y/n)
• Overload trip (y/n)
• Standard specifications to which the motor
control gear and its ancillary offered conform
to
• Standard specification to which control gear
conforms to

Page 48 of 72
 2.3 Voltage Stabiliser& Ultra Isolation Transformer

VOLTAGE STABILISER
• Manufacturer’s Name
• Type of voltage stabilizer:
a) DC servo motor type
b) AC servo motor type
c) Solid state
• Rated capacity in KVA
• Nos. of phases & frequency
• Type of input supply unbalanced
• Input voltage
• Output voltage
• Rate of correction
• Class of insulation & winding (only copper
wound is acceptable)
• Type of control circuitry
• Class of duty
• Type of cooling
• Indicating instruments and their ranges
• Safety features
ULTRA ISOLATION TRANSFORMER
• Manufacturer’s Name
• Rated capacity
• Ratio of input/output voltage
• Class of insulation
• Arrangement for suppression of power line
surges, spikes, transients and noises
• Type for cooling.
3 The exact sequence of operation including multiple cuts, if 2.4.1 of Sect. IV
any, along with the breakup of the timings of various
activities shall be explained in the offer.
4 Speed-feed-power (curve/ nomograms) for machining of 2.4.2 of Sect. IV
wheel sets of tread diameter ranging from 750 to 1250mm
for depth of cuts varying upto 8mm radially, for material
strength upto 125 Kg. /mm 2.

5 Maintenance tools 4.2.1.3 of Sect.

(List of tools be furnished in the bid). IV
6 First fill of oils and lubricants. (Quantity of each item shall be 4.2.1.6 of
indicated in the bid). Sect. IV

7 Complete details of wheel cleaning system, consumables 4.3.1 of Sect.

etc. IV

8 Details of the safety features provided in the 1.1 of sect. V

machine.
9 Constructional details and material specification of the bed. 1.2.1.1 of sect.
Details of the complete system of telescopic covers,
scrappers to prevent entry of dust etc.
10 Arrangement provided for longitudinal movement and power 1.2.2.1 of sect. V
locking of the head stocks.
Page 49 of 72
11 Arrangement provided to preset the travel of the 1.2.2.2 of
headstocks according to the length of axles from CNC sect. V
controls using the metallic linear measuring system shall
be explained.
12 Material specification, actual hardness and surface finish 1.2.2.3 of sect.
of gears including the rim gear shall be indicated in the bid. V
In case of any alternate arrangement proposed, the
advantages of the same shall be explained along with the
details.
13 The material specification of the spindle and its mounting 1.2.2.4 of
design shall be explained. sect. V

14 Arrangement provided for synchronization of face plates in 1.2.2.5 of

the same angular position shall be explained. sect. V

15 Details of the system as asked in the clause shall be 1.2.3.1 of

furnished. sect. V
16 Details of the system as asked in the clause shall be 1.2.3.2 of
furnished. sect. V
17 Details of the system as asked in the clause shall be 1.2.3.3 of
furnished. sect. V
18 Details of the system along with arrangement for wear 1.2.3.4 of
compensation between spindle and the barrel shall be sect. V
provided and explained.

19 Details of the oil distributor system as asked in the clause 1.2.3.5 of

shall be furnished. sect. V

20 Detailed calculations for clamping force shall be furnished. 1.2.3.6 of

sect. V
21 Details of the wheel set lifting, centering and lowering 1.2.4.1 of
system as asked in the clause shall be furnished. sect. V
22 Details of the drive as asked in the clause shall be 1.2.5.1 of
furnished. sect. V
23 The maximum variation in the speeds of the two motors 1.2.5.2 of
shall be indicated. Arrangement for synchronization of the sect. V
two-face plate drives along with details of the drive motors
used shall be explained.
24 Details of UPS like make, Ampere hour rating of battery , 1.2.6.2 (7) of
back-up rating in minutes etc sect. V
25 Details of hardware and software incorporated to meet 1.2.6.2.33.3
predictive maintenance requirements to be explained. of Sect. V
26 Constructional details of the Probe Type Measuring 1.2.7.1 of
System indicating the following details: sect. V
a. No. and types of measuring probes.
b. Make and model no. of measuring system/probes.
c. Working principle of the measuring system to be
explained with schematic diagram.
27 Profile of the tool post indicating the direction of cutting 1.2.8.2 of
forces shall be furnished. Maximum permissible value of sect. V
cutting force which the machine can withstand shall be
indicated.

Page 50 of 72
28 Details of the system as asked in the clause shall be 1.2.8.4 of
furnished. sect. V

29 Details of arrangement provided in the machine as asked 1.2.8.8 of

in the clause shall be furnished. sect. V
30 Method of calibration, time taken in calibration and the 1.2.8.14 of
recommended frequency for calibration of equipment shall sect. V
be explained.

31 Details of the conveyor type chip disposal system offered 1.2.9.1 of

along with its operation methodology shall be explained. sect. V

32 Lubrication system shall be explained with a lubrication 1.2.10.1 of

diagram. Arrangement provided to ensure safety of the sect. V
machine in case of failure of lubrication shall be explained.

33 Details of the clogging indicator shall be furnished. 1.2.11.1 (vii)

of sect. V
34 Type, make, model no. and location of filters shall be 1.2.11.2.(iii)
indicated. of sect. V
35 The arrangement provided alongwith this temperature limit 1.2.11.3 of
shall be explained. sect. V
35 Heat load calculations and the details of system should be 1.2.11.4 of
furnished. sect. V
36 Exact brand and names of Hydraulic oils equivalent brands 1.2.11.5 of
shall be indicated. sect. V
37 Details of Electrostatic oil filtration equipment shall be 1.2.12 of sect.
furnished. V

38 Full details of the tooling including part list numbers shall 1.2.13 of
be furnished. Approximate tool life in terms of number of sect. V
cutting passes per cutting edge for a depth of cut of 8mm
for wheel diameters of 900 mm, at the cutting parameters
used for productivity requirements shall be indicated. A full
list of tool holders and inserts indicating quantity and rate
of each item shall also be furnished.

39 Details of the wheel-set handling system including a 1.2.14 of

schematic drawing shall be furnished. sect. V

40 The full sequence of operation shall be explained and 1.2.15 of

details of the arrangement as asked in the clause alongwith sect. V
a schematic drawing shall also be furnished.

41 The bidder shall explain the machine cycle step by step for 1.2.16 of
loading, measurements, machining and unloading of sect. V
wheel- set indicating each stage where operator’s
intervention is required.
42 Layout of the control panel shall be furnished along with 1.2.17.1 of
the display screen size. sect. V
43 Kindly furnish the details of Brake Disc Machining 1.2.19 of
Arrangement. sect. V
44 Kindly furnish the details of Chip Crusher & indicate the 1.2.20 of
Safety measures. sect. V
Page 51 of 72
45 Kindly furnish the size of the shutters. 1.2.21.10 of
sect. V
46 Kindly furnish the details of the cable & its IS & make. 1.2.23.1 of
sect. V
47 Sample Inspection Chart for inspecting the equipment shall 9.4 of sect. V
be provided.
48 The Quality Assurance Programme as per Annexure-I 9.1 of sect. V
shall be submitted along with the bid.
49 Misc.
i Number of driver jaws per face
plate
ii Clamping force per jaw (infinitely variable)
i. Max. KN
ii. Min. KN
iii Centering force(infinitely variable)
i. Max. KN
ii. Min. KN
iv Maximum permissible weight on lifting device- Kg.
v Gross weight of the machine- Kg.
vi Overall dimensions
vii Maximum electrical power consumption under full
load
viii Main motor power
ix Hydraulic motor power
x Lubrication motor power
xi Hydraulic oil consumption per
shift
xii Lubrication oil consumption per shift
xiii Space requirement
xiv Machine weight

Signature of the
authorized representative of the
bidder with company stamp

Page 52 of 72
 ANNEXURE-B

FORMAT FOR INDEMNITY BOND

This deed of Indemnity executed by M/s. -------------------- hereinafter referred to as

Indemnifier’ which expression shall, unless repugnant to the context or meaning thereof,
include its successors, administrators, representative and assignees in favour of Central
Organisation for Modernisation of Workshops, Railway offices Complex, Tilak Bridge, New
Delhi - 110 002, India, hereinafter referred to as the ‘Indemnified’ which expression shall
unless repugnant to the context or meaning thereof, include its successors and assignees
witnesses as to.

Whereas the Indemnifier herein had participated in a global tender for the supply of ------
------------------ (machine name) which is opened on -------------- (date) on terms and
conditions set out interalia in the Tender Document.

And whereas, clause of the above mentioned tender document described that the
machine shall be designed for a life of 15 years with regular maintenance and all the
structural members of the machine should be guaranteed for 15 years against cracks,
breakages etc. during the course of normal operations from the date of commissioning
whichever is earlier of the stores supplied by the Indemnifier to the indemnified.

The indemnifier hereby irrevocably agrees to indemnify the indemnified that in the event
of the said machine not achieving the life guarantee, the indemnifier shall as may be
deemed necessary repair the defective machine at site, free of cost, within a reasonable
time specified by the indemnified or reimburse the pro-rata cost of the machine to the
extent a life not achieved as per the guarantee, or supply a spare stores for the defective
portion only free of cost at site.

Bidder’s authorized signatory

With seal

Station:
Date:
Witness:1.-----------------------
(Signature with Name, Designation & Address)

2. -------------------------
(Signature with Name, Designation & Address)

Page 53 of 72
 Annexure-C

JOINT RECEIPT INSPECTION NOTE

Note: With the issue of JRI, payment is released to the contractor, as per the terms of contract.
Consignee shall satisfy themselves that the conditions of contract are met before issue
of the JRI.
Date……………..
Sub: Receipt of consignment for machine……………………. Ref:
COFMOW Contract No………………….

1. Name of consignee/Railway
2. Machine name
3. Quantity
4. Name of supplier
5. Consignment of the machine received on
6. The foundation & associated works essential for “Safe Installation of Machine” are
ready (for turnkey contracts only) *
* If there are Delays on account of Consignee such as clear site is not given, then the condition 6 will not
be a valid ground for holding JRI.
It is certified that the consignment of the machine has been received complete and in good condition as
per specification shown in the contract.

Tentative plan for installation and commissioning of the machine is as under

1. Date of clear site provided

2. Contract Turnkey/Non-turnkey
3. Status of readiness of foundation:
3(a) Already constructed on
3(b) Under construction & likely date of its completion
3(c) Construction yet to be started from ……. and likely date of its
completion
4. Status of availability of electrical power, water and Available/Not-available
compressed air etc.
5. Number of components to be proved out on the machine
6. Likely date for start of erection/installation
7. Likely date for switch-on the machine
8. Likely date of completion of commissioning of the machine

Representative of firm Representative of consignee

Designation Designation
(Minimum Gazetted level)

Page 54 of 72
 ANNEXURE-D

JOINT COMMISSIONING NOTE

Date:………………
Sub: Commissioning of (name of machine)………………….

Ref: COFMOW AT No………………………….

1. Name of consignee/Railway

2. Machine name

3. Quantity

4. Name of supplier

5. Machine received on

6. All the parameters of the machine are found okay. The proving test on
the machine was conducted from ………… to ………….. and machine is
working satisfactorily.

7. Machine has finally been commissioned on……………….. . The

machine has been handed over for regular use and kept under one
month observation to watch its performance.

8. Following minor deficiencies (if any) found during joint observation trials
are to be attended/rectified by the firm during one month observation
and before issuing the PTC for the machine:

a.

b.

c.

Representative of firm Representative of consignee

Designation Designation
(Minimum Gazetted level)

Page 55 of 72
 ANNEXURE-E
PERFORMANCE APPRAISAL FORM

APPRAISAL ON COMPLETION OF _____YEAR of WARRANTY PERIOD

To, M/s. ……… Dated …………

1. COFMOW AT No.
2. Consignee/Railway
3. Name of supplier
4. Machine Name
5. Machine received on
6. Machine commissioned on
7. PTC issued on
8. Warranty period expired on
9. Performance during warranty period:
9(a) Total number of breakdowns
9(b) Total downtime in number of
days
10(a) Any warranty complaint pending Yes/No
on date
10(b) If yes, then the date and nature of
defect(s)

11. In case, of the machine with mandatory PMC during warranty period, following details
of breakdown hours for preceding eight quarters must also be furnished.

Quarter Period Breakdown hours

From -------To--------
1
to
8

Signature-------------------
Name------------------------
Designation:DY.CME/Sr.DME/Dy.CEE/Sr.DEE
Office Stamp
1. COS/COFMOW/Railway Offices Complex, TilakBridge, New Delhi-110 002
2. CME(PCM)/COFMOW/Railway Offices Complex, TilakBridge, New Delhi-110 002
3. FA&CAO/COFMOW
Note:
i.) This appraisal may please be sent immediately on completion of first and second year of
warranty period. If any extension of warranty period required, may please also be
mentioned with details.
ii) Sr.Scale Officer having independent charge is also authorised to sign.

Page 56 of 72
 ANNEXURE-F

LIST OF COMPONENTS TO BE LOADED ON THE MACHINE

(Common to all consignees)

S.NO. RDSO DRAWING NO. Loco/Wagon/Coach

1. SKDL-2561, alt-8 LOCO
2. SKVL-526 , alt-NIL LOCO
3. SKDL-4461 , alt-NIL LOCO
4. CSL-3040, alt-2 LOCO
5. SKETCH-92082 alt-1 COACH
6. WD-89060/S-2 WAGON
COFMOW DRAWING NO.
7. COFMOW/SWL/BG/2006 PARTICULARS OF C&W WHEEL SETS
sheet 1 of 5
8. COFMOW/SWL/BG/2006 PARTICULARS OF DIESEL & ELECTRIC LOCO
sheet 2 of 5 WHEEL SETS
9. COFMOW/SWL/BG/2006 C & W WHEEL CENTRE PROFILE
sheet 4 of 5
10. COFMOW/SWL/BG/2006 PARTICULARS OF DIESEL & ELECTRIC LOCO
sheet 5 of 5 WHEEL SETS
LHB Wheel Set

11 LHB wheel set 1. Worn wheel profile - RDSO sketch-91146 Alt-3

Wheel, Axle complete for 2. Intermediate worn wheel profile for coaching stock
FIAT type Bogies-LW RDSO sketch-92082 Alt-1
02001 a) Fig.6 (25mm thick flange profile)
b) Fig.7 (26mm thick flange profile)
c)Fig.8 (27mm thick flange profile)
d)Fig. 9(28mm thick flange profile)
3. Facing of brake disc to be performed as indicated in
the drawing.

For CWM/JUWS Consignee

S.NO. RDSO DRAWING NO. Loco/Wagon/Coach
1 WTAC3-0-2-301 COACH -WHEEL & AXLE COMPLETE 16.25 TON
2 40076742, 10662498 LOCO WDG-4 & WDP4
3 RDSO SKETCH-91146 ALT WORN WHEEL PROFILE
3
4 SKETCH-92082 alt-2 INTERMEDIATE WORN WHEEL PROFILE FOR
COACHING STOCK
5 SKDL-2561, alt-8 LOCO
6 SKVL-526 , alt-NIL LOCO

Page 57 of 72
 7 SKDL-4461 , alt-NIL LOCO
8 CSL-3040, alt-2 LOCO
9 WD-89060/S-2 WAGON
COFMOW DRAWING NO.
10 COFMOW/SWL/BG/2006 PARTICULARS OF C&W WHEEL SETS
sheet 1 of 5
11 COFMOW/SWL/BG/2006 PARTICULARS OF DIESEL & ELECTRIC LOCO WHEEL
sheet 2 of 5 SETS
12 COFMOW/SWL/BG/2006 C & W WHEEL CENTRE PROFILE
sheet 4 of 5
13 COFMOW/SWL/BG/2006 PARTICULARS OF DIESEL & ELECTRIC LOCO WHEEL
sheet 5 of 5 SETS
LHB Wheel Set
14 LHB wheel set 1. Worn wheel profile - RDSO sketch-91146 Alt-3
Wheel, Axle complete for 2. Intermediate worn wheel profile for coaching stock
FIAT type Bogies-LW RDSO sketch-92082 Alt-1
02001 a) Fig.6 (25mm thick flange profile)
b) Fig.7 (26mm thick flange profile)
c) Fig.8 (27mm thick flange profile)
d) Fig. 9(28mm thick flange profile)
3. Facing of brake disc to be performed as indicated in the
drawing.
15 SK-K-4004-1-1 alt 3 Solid forged wheels for motor &trailer coaches of DEMU
16 WI-4764 ALT 9 BCN Wheel finish
17 LW 02115 alt a Solid forged wheels (finish turned) for fiat type bogies of
LHB
18 LW 02103 Solid forged wheels rough turned

For KPA/ER Consignee

S.NO. DRAWING NO. Component Name Operations to be
carried out
1 D/WL-5060R Alt.2 Rough Wheel for BG Locomotive
(Rolled) (WAP4, WAG5, WAG7, etc.) i. Wheel
2 1209-01-111-003 Alt. 4 3-phase loco wheel disc (WAG9, Turning
WAP7, etc.)
3 w/wl-1660R Wheel Solid Forged ii. Inner Flange

4 K-4004 (for Forge disc) Solid Forged Wheel (Motor & Trailer iii. Distance
Coaches) Machining
5 RWF-w-111 (for Cast Cast Steel Wheel (Rough) for EMU
disc) Coaches
6 w/wl-4764/R BOX-N Wheel disc
7 WTAC3-0-2-301 Wheel & Axle Complete for direct
mounted Roller Bearing arrangement
8 MRB/M-0-2-004 Wheel & Axle Complete for Motor
Coach (BHEL)

Page 58 of 72
 Annexure-G

Consignee’s Certificate for Quarterly Work Done Under AMC

1. Name of Plant:
2. Consignee
3. COFMOW AT No.
4. Name of Contractor
5. Quarterly charges for AMC(Standard): Rs.______________
As per COFMOW AT no.______________dt.___________
6. Quarter for which bills are preferred:___________________
From:____________________To._______________________
7. No. of Breakdowns during the quarter:
8. Calculation of Penalty and Net AMC charges payable to Contractor for the quarter:
i. Total Plant Down Time (in days):
ii. Standard down days for preventive maintenance (in days/quarter):
iii. Total grace period for break down:
iv. Net down time for the plant [= (i)-{(ii)+(iii)}] :
v. 100% Availability for the quarter (in days) :
vi. Actual availability [= (v)-(iv)] :
Actual availability in %age [= {(vi) / (v)}x 100]:
vii. Calculation of penalty:
a. %age availability below 90% to 80%:
b. %age availability below 80%:
c. Penalty[={(vii a)x(5)x0.005 +(vii b)x(5)x0.01}]:
viii. Net amount payable as AMC charges to [=(5)-(vii c)]
It is certified that all spares borrowed by the contractor for the previous quarter have been returned
in good condition.

Signature of authorized representative of consignee

Page 59 of 72
 Annexure-H

CENTRAL ORGANISATION FOR MODERNISATION OF WORKSHOPS

(C O F M O W)
Report on Capability Assessment of New Vendors

M/s ………………………(Name of Vendor)…………………………

Machine/Product Class ……………………..

Contents:
Para - 1 : General Information
Para - 2 : General Information (Technical)
Para - 3 : Design Capability
Para - 4 : Manufacturing Process
Para - 5 : Quality Assurance
Para - 6 : After-Sales Service
Para - 7 : Past Performance
Para - 8 : Commercial Information
Para - 9 : Conclusions
Para - 10 : Recommendations

List of Annexures:

A : List of Managerial Staff

B : Plan of Works to be assessed
C : List of Machinery & Plant
D : List of Raw Materials in Stock
E : Q.A.P. of the Firm.
F : List of QC equipments, Measuring equipments and Gauges
G : List of Important Customers & Orders
H : List of pending orders
I : Performance of Machines supplied
J : Proof of Ownership
K : Factory License, NSIC/ SSI
L : Copy of Latest Electricity Bill
M : Certified copies of Balance Sheet and Profit & Loss accounts
N : Income Tax Clearance Certificate
Other Annexure (if any)
Report on Capability Assessment of New Vendors

Page 60 of 72
i) Name of Vendor …………….

ii) Purpose: ……… (Assessing officers should detail the purpose of assessment,
manufacturer, name of the machine and the tender number which necessitated
assessment or otherwise.)
iii) Scope: ……. (The scope should define scope of capability assessment carried out
detailing the machine/system or range of machines/systems.)

iv) Details of Stores/Items/Parts/components for which assessment is carried out.

(Indicate complete description. Vendor should submit a request to include more
similar items in the assessment if required)

v) Assessment done on …….

1.0 General Information

1.1. Background of vendor in Brief

1.1.2 Location

1.2 Postal Address

i. Head Office :

ii. Works/Factory (as per Factory License) :

1.3. Telephone No. (with STD code and Mobile)

i. Head Office :
ii. Works/Factory :
iii. Authorized Person who can be contacted telephonically:

1.4. E-mail IDs

i. Head Office :

ii. Works/Factory :

iii. Authorized Person :

1.5 Description of Factory/Works.

i. Total land area :

(in Sq. metres)

ii. Total covered area :

(in sq. metres)

iii. Different sub-units :

(with details of covered/
uncovered area, etc.)

iv. Special features, if any :

1.6. No. of personnel employed (category-wise).

Page 61 of 72
 i. Managerial :
(List to be attached as Annexure-A)

ii. Supervisory : Permanent _____ Temporary ____

iii. Skilled artisans : Permanent _____ Temporary ____

iv. Unskilled : Permanent _____ Temporary ____

1.7 Hours of working :

1.8 Is this first inspection for assessment?

If it is a re-inspection, details of earlier capability assessment(s) to be recorded and
attached.

2.0 General Information--Technical

2.1 Description of different departments in the Factory/Works and function of

each department.

2.1.1 The break-up of different work areas given below

Unit - I
Administrative Block :
Fabrication and assembly :
Machine Shop :
Store :
Laboratory :

Unit - II, Unit - III ……

Administrative Block :
Fabrication and assembly. :
Machine Shop :
Store :
Laboratory :

2.1.2 A plan of the works, as described above, to be attached (Annexure-B).

2.2 Detailed description of Machinery and Plant in each department Unit wise (make and year
of procurement/commissioning to be provided. For special type of equipment copy of
pamphlets/write ups to be furnished so as to supplement the description).
The list of machinery & plant available to be attached (Annexure-C).

2.2.1 It was observed that ............... (Comments of Assessing Officer(s), on machines and
infrastructure)
2.3 Plans for future expansion, if any……………..

2.4 Details of raw-materials held in stock (state whether imported/indigenous).

(list enclosed as Annexure-D)

2.5 Production Capacity.

i. Per month :
Page 62 of 72
 ii. Per year :

2.5.1 Whether Production capacity has been certified by external agencies? If yes, then
details/certificates to be attached.
(Comments of Assessing Officer(s))

2.6 Enumerate Type of Stores/Items, which the firm is capable of manufacturing.

(Comments of Assessing Officer(s))

3.0 Design Capability

3.1 Availability of Qualified Personnel.

(Comments of Assessing Officer(s))

3.2 Assessment of Expertise and Facilities.

(Comments of Assessing Officer(s))

4.0 Manufacturing Process

4.1 In-house Manufacturing Facilities for the item(s) being assessed.

(Comments of Assessing Officer(s))

4.2 Details of manufacturing process relevant to the items for which assessment is
carried out.
(Comments of Assessing Officer(s))
4.3 Important Items/processes Outsourced by the Vendors
(Comments of Assessing Officer(s))

4.4 What is the system of traceability of the components/sub-assemblies manufactured in-

house and outsourced.
(Assessment team to comment on the traceability records maintained by the vendor for
the range of machines manufactured, from the stage of drawings to dispatch of
material/machine.)

5.0 Quality Assurance

5.1 Does the factory have an established Quality Assurance Programme. If yes, please
enclose a copy of the write-up? If not, what plans are there if any for setting it up? (QAP
attached as Annexure-E)
(Comments of Assessing Officer(s))

5.2 Details of Quality Assurance Organisation.

Names of key personnel, their qualifications, designations and position in overall
management structure (Data in tabular form, explain with organisation chart, if
necessary).

5.2.1 The QC organisation is headed by Shri........, who is designated as............., with

responsibility for............... (Comments of Assessing Officer(s))

5.3 Enlist Quality Control Testing Facilities and Laboratory equipment available.
Page 63 of 72
 5.3.1 In-house facilities available for inspection and QC include the following:
i..........
ii.........
iii.........
(list enclosed as Annexure-F)

5.4 Availability of gauges

5.4.1 The following important items of gauging and other related equipment are
available: (Annexure F)

5.5 Calibration of Laboratory/test equipment/gauges, indicated in para 5.3 and 5.4

above:

i. How is the calibration done? :

ii. Frequency of calibration. :
iii. System to ensure that calibration of above equipments :
does not fall overdue.
iv. Action taken if such calibration has fallen overdue :

(Comments of Assessing Officer(s))

5.6 Source of procurement of raw-materials, important bought-outs, and steps taken to

ensure their quality.
(Comments of Assessing Officer(s))
5.7 Details of inspection/checks done on material during various stages of the above
manufacturing process.

(Comments of Assessing Officer(s))

5.8 Have acceptable values for the parameters inspected during above stage checks been
laid down? If yes, the action taken if value of the parameter inspected does
not meet the desired laid-down value.

(Comments of Assessing Officer(s))

5.9 System for documentation of the results of the above stage checks.

(Comments of Assessing Officer(s))

6.0 After-Sales Service

6.1 After-Sales Service Facilities Available at Works and Branch Offices.

6.2 What is the system of recording customer complaints and action taken their upon.
(Comments of Assessing Officer(s))

6.3 Assessment of Quality of Service Including Response times.

(Comments of Assessing Officer(s))

7.0 Past Performance

Page 64 of 72
 7.1 List of important customers of the firm (as relevant to the works for which
assessment being done)

This is attached at Annexure-G.

7.2 Details of important orders executed/supplies in the past.

Also included in Annexure-G................

7.3 Details of Pending orders in hand (Annexure-H)

7.4 Whether another unit/factory of the firm is already approved by COFMOW for
supply of stores/components.
(Comments of Assessing Officer(s))

7.5 Performance of machines manufactured and supplied in the past to different

consignees.
(Comments of Assessing Officer(s))
7.5.1 Machines at M/s. ……….. (Name of consignee)
7.5.2 Conclusions on performance (Attach performance certificates from at least 5 consignees
where machines are working for more than one year since commissioning as Annexure-I).
(Comments of Assessing Officer(s))
8.0 Commercial Information
8.1 Copies of following documents obtained and attached as Annexures.
i. Proof of Ownership. : Annexure-J.
ii. Factory License, NSIC/ SSI : Annexure-K.
iii. Latest Electricity Bill. : Annexure-L.
iv. CA/CS certified copies of Balance sheets and Profit & Loss accounts : Annexure-M

8.2 Whether the firm is registered under Indian Factories Act.

(Comments of Assessing Officer(s))

8.3 Whether the firm comes under the scope of Industries (Development &
Regulations) Act, 1951.
(Comments of Assessing Officer(s))

8.4 Income Tax Clearance Certificate Copy attached at Annexure-N.

9.0 Conclusions

(Comments of Assessing Officer(s))

10 Recommendations
(Should detail the findings in line with the scope of the assessment)

(Signatures of the Assessing Officer(s)

Name & Designation
Place:
Date:

Page 65 of 72
 ANNEXURE - A
LIST OF MANAGERIAL STAFF
AS ON------------------

S.No. Name Designation Qualification Working since

ANNEXURE -C
LIST OF MACHINERY AND PLANT

S.No. Description of Items Make Qty. Year of procurement

ANNEXURE - F
LIST OF QC EQUIPMENT, MEASURING EQUIPMENT AND GAUGES

S.No. Description Range Least Qty. Year of

count where procurement
applicable

ANNEXURE - G
LIST OF IMPORATANT CUSTOMER & ORDERS EXECUTED W.E.F.............(DATE)

S.No. Purchaser Description/ Delivery Date recd. Date REMARKS

Order No. value dt. Comm.

ANNEXURE - H
LIST OF PENDING ORDERS AS ON------------(DATE)

S.No. Purchaser Order No. and date Value

Page 66 of 72
 ANNEXURE-I
QUALITY ASSURANCE PLAN
MACHINE DESCRIPTION

Category S. Component/ Sample Type Of Check Quality TYPE REMARKS

No. Process Size record OF
CHECK
Bought Out Steels 1 Chemical & TC & CHP
Raw Sample Mech. INV.
Material / Size
Bought Out Bearings 100% Visual Inv CHP
Components
Electric Motors 100% Review of TC TC & V
INV
Hydraulic 100% Review of TC TC & V
Pumps & INV
Elements
Rubber 100% Visual TC & V
Seals, O INV
Rings &
Seals
Controllers 100% Review of TC TC & V
INV
Ball Screw 100% Visual IIR V
Bought out Weld joints
sub
assemblies Load 100 % RT IR CHP
Bearings

Others 5% DPT IIR V

Hardness and 100% Hardness IIR V

In process
Inspection
stage
Heat 100% Review of Inv. IIR V
Treatment
Castings 100% Visual IIR V
Spindles 100% IIR V
surface finish Random Surface IIR V
of
components
Noise level 100 % Sound IIR CHP
Temperature 100 % Measurement IIR V
rise
Structures 100% Relevant IR CHP
Geometry ISO/DIN/IS/JIS
alignment, standard
Guideways

INV - Invoice TC - Test Certificate V - Verification CHP - Customer Hold Point

IIR - Internal Inspection Report IR - Inspection Report

Page 67 of 72
 Annexure-J

Proving Test Certificate (PTC) for Commissioning / Prove Out of Machine

(separate certificate to be issued for each machine)

NO. Dated
SPEED / REGD POST
M/s.

Sub: Proving TestCertificate of machines.

Ref: COFMOW Contract/AT No.____________ dt. _______.

1. this is to certify that the machine as detailed below has been received in good condition along with all the
concomitant/standard and special/optional accessories & spares in terms of above referred AT (subject to remarks in item
No.2) and the same has been installed and commissioned:

a) Description of the machine (s)_______________________________

b) Machine No.(s)___________________________________________
c) Quantity_________________________________________________
d) Bill of Lading No. ___________________dt.________________} (for imported
e) Name of the vessel____________________________________} contract
f) R/R No./L.R./Dispatch particulars______________________________
g) Name of the Consignee_____________________________________
h) Date of first submission of GA/foundation drawings (if applicable) _____
indicate delays in number of days: On Railways Account________________days
on Firm’s Account _________ days
Total _______days
i) Date of final approval of GA/foundation drawings (if applicable) _____
indicate delays in number of days: On Railways Account_______________days
on Firm’s Account _________ days
Total _______days
j) Date of receipt of the machine________________________________
k) Date of joint verification _____________________________________
l) For machines ordered on non-turnkey basis:
i)- Date of power supply provided for the machine by the
Railway____________
ii)- Date of call to the contractor after site/foundation/installation etc
is ready by the Railway________________________________
m) For machines ordered on turnkey basis:
i)- Date of intimation of readiness of site for starting foundation
work (if relevant in terms of contract) ______________________
ii)- Date of readiness of foundation by the contractor____________
iii)- Date of readiness of other infrastructure facilities like shed, track
linkage etc. by the Railway/contractor (delete whichever is not
applicable__________
iv)- Date of power supply provided for the machine by the
Railway_____________
v)- Indicate delays in number of days: On Rly. account _____ days
On Firm’s account _____ days
Total ______ days
n) Time allowed for commissioning after date of call as per L (ii) above or after date of readiness of site as per m(iii)
above (as relevant in terms of contract) number of days allowed__________________. o)
Date of commissioning of the machine_________________________.
Page 68 of 72
 Indicate delays in commissioning in number of days:
i)- On firm’s account due to reasons such as non-arrival of engineer,
problem in machine/toolings etc.
______(state reason) _______days during /Installationcommissioningprove out & .
ii)- On Railway’s account due to reasons such as non-provision of
Raw/Trial material, Crane, Staff, Measuring tools/gauges etc.
______(state reason) _______days during /Installationcommissioningprove out &
p) Whether delay in supply of the machine (if any), has caused any loss/inconvenience to the Railways (Yes/No)
___________________.
If yes, extent of loss in monetary terms: Rs. _____________ (Details to be enclosed if loss is quantifiable. However,
if loss is not quantifiable then indicate “Not Quantifiable” in the space provided.
2. Details of Accessories/Spares not yet supplied and recoveries to be made on that account.
S. No. Description Amount to be recovered
a)
b)
3. The proving test has been done to our entire satisfaction and the operators have been trained to operate the
machine as per provisions of the contract. If not, the amount to be recovered on this account: Rs. ______________. 4.
You have failed to fulfill the contractual obligations with regard to the following:
a) ____________________________
b) ____________________________
5. The amount of recovery on account of non-supply of accessories and spares is given under para - 2 & 3 above and
loss/damage on account of your failure to fulfil the contractual obligations as given in Para 4 above will be advised to
you by COFMOW. These shall be recovered from your bills/Performance Guarantee Bond in terms of Para 0705 of
General Conditions of contract. Bid Documents Part-I.
6. This issue of commissioning/PTC certificate proves only the technical acceptability and functioning of the machine
on the date of issue of the Certificate. This issue of PTC does not amount to waiver of any of the terms and conditions of
the contract or delay in supply of drawings, machine or commissioning thereof and it does not absolve the supplier of its
liability for any loss or damages suffered by the Railways due to same.

Signature __________(To be signed in all the pages)

Name ___________________________
Designation: JAG/ SG officer
Office Stamp
Copy by Speed/Regd. Post to:

1. PCMM/COFMOW, Railway Offices Complex, TilakBridge, New Delhi-110 002

2. PFA/ COFMOW, Railway Offices Complex, TilakBridge, New Delhi-110 002
3. PCME/ COFMOW, Railway Offices Complex, TilakBridge, New Delhi-110 002
4. CME/Plg. Of the Railway issuing certificate.

Signature _______________________
Name ___________________________
Designation: JAG/SG officer
Office Stamp

Note: Sr. Scale Officer having independent charge is also authorized to sign this certificate.

Page 69 of 72
 Annexure-K
EOT Crane (05 Ton) for CNC Surface Wheel Lathe Shed (for Schedule-II Consignee).
Specification No.- COFMOW/ CNC-SWL/BG/2021 (with AMC) Rev.0

1. Purpose -
Electrically Overhead Travelling single girder crane shall be used for handling of wheel sets and other related activities.

2. Scope of supply -
The Scope of supply shall include the following along with necessary fittings, fixtures and ancillaries.
(i) Bridge structure (single girder)
(ii) Track wheels for longitudinal and cross travel
(iii) Travelling mechanism for longitudinal and cross travel
(iv) Hoisting mechanism.
(v) Brake Mechanism separately for long travel, cross traverse and hoisting.
(vi) Trolley.
(vii) Service Platform.
(viii) Pendant for all the operations of crane.
(ix) Electrical motors, control gear and equipment.

3. DESIGN
3.1 The crane shall be designed, manufactured, erected and tested generally in accordance with the following
specifications:
i) IS: 3177-1999 (latest) - Indian Standard Code of Practice for electric overhead travelling cranes.
ii) IS: 807-1976 (or latest) - Indian Standard Code of Practice for design, manufacture, erection and testing
(structural portion) of cranes and hoists.
iii) IS: 800 -1984 (or latest) - Indian Standard code of practice for General Construction in steel.
iv) IS: 3938- 1983 (or latest)- Indian Standard Specification for Electric Wire Rope Hoists
3.2 The design of the crane structure as well as all the component parts of the crane mechanism shall conform to
class of duty III (Three) IS: 3177 - 1977 or latest & IS: 3938 or latest .
3.3 The cranes shall be supplied complete in all respects. Unfamiliarly with, or ignorance of, local conditions, will
not be accepted later as adequate reason for delays in commissioning by successful bidder.

4. PURPOSE FOR WHICH REQUIRED

4.1 Capability.
The Single Girder crane should be capable of:
i. Hoisting, i.e. lifting and lowering of all loads up to the maximum specified working and load at different specified
speeds
ii. Traveling and traversing at specified speeds in both loaded and unloaded conditions.
5. RIGIDITY CONTROL SAFETY

5.1 The crane should be rigid, robust and of sturdy construction

5.2 Crane controls should be suitably interlocked to prevent accidental movement of the crane.
5.3 Suitable limit switches for long, cross travel and Hoist should be provided to prevent over-travel.

5.4 Electrical interlocks should be so provided that the two operations of traversing and traveling can
be performed simultaneously, but while hoisting it is not possible to undertake either traversing or
traveling.
5.5 Suitable buffers should be provided to prevent over travel of the crane mechanism in both
longitudinal and cross traverse directions.
5.6 Suitable guards should be provided to prevent inadvertent contact with down shop leads.
5.7 Suitable isolation switches and stop buttons should be provided to isolate the electric supply for
maintenance, or in the event of an emergency.
5.8 Sheaves shall be provided with rigid guards to retain the wire ropes in the grooves.

Page 70 of 72
6. CONSTRUCTION DETAILS
6.1 Crane will consist of single girder carrying hoist with cross movement trolley and fixed on two end carriages.
End carriages shall run on the bridge rails installed on the shed gantries. The trolley wheels should be double
flanged with suitable bearing arrangement.
6.2 Standard plain shank type trapezoidal section hook should be used unless otherwise specified. The hook
should conform to the relevant Indian Standard Specifications IS: 15560 (latest).
6.3 Wire rope: The wire rope should confirm to IS: 2266-1977 or latest specification for steel wire ropes for general
engineering purpose.

6.4 Shrouded Bus Bar Conductor shall conform to the following:

i. The conductor system shall be finger safe to IP-21 with necessary supporting technical evidence of same
and the conductor and material shall be of suitable metal (Galvanised Iron upto 100 Amps & Copper above
100 Amps) insulated by a high impact gloss finish VR 935/2 PVC compound which shall have a step/groove
shrouded all along its length for effective moulding of the conductor system.
ii. The conductor shall be in minimum 4 m length to be jointed with moulded joint of the same material as the
conductor and these conductors shall be supported by way of a single piece moulding, four pole hanger with
single bolt fixing.
iii. The current collector arm should be aluminium die cast totally insulated and the connection cable shall be
fully enclosed and double insulated within the collector arm with a proven performance supported by
documentary evidence.

7. MAJOR PARAMETERS -

S. N. ITEM DETAILS
7.1 Type Single girder
7.2 Main Hoist 5T
7.3 Class of duty III (Three) IS: 3177 - 1977 or latest
7.4 Crane controls Pendant
7.5 Speeds
7.5.1 Main Hoist (min.) 3.15m/min
7.5.2 Long Travel (min.) 20 m/min
7.5.3 Cross Travel (min.) 10m/min
7.5.4 VVVF drive (step less speed for all motions) Required
7.6 Span ( centre to centre of gantry rail) 14 to 14.5 as per shed design.
7.7 Lift of Hook above floor level (MH) H1 (MH) = 5,000 mm (Tentative)
7.8 Drop of hook below floor (MH) H2 (MH) = 1000 mm (Tentative)
7.9 Type of Hook ‘C’ Type
7.10 Type of Down Shop Leads Shrouded Type
7.11 Length of Down Shop Leads required (cost to be 35 Meter
indicated on per Meter basis)
7.12 Crane has to work Indoor

8. OTHER REQUIREMENTS-

Lifting Tackle to suit Lifting of wheel set - One no.

Page 71 of 72
 Annexure-A1 (Certificate of Performance)
Important Note : i) The certificate shall not be older than one year from the original date of closing of tender.
The performance certificate issued after original date of closing of tender (in cases where tender closing date has
been extended) are also acceptable however the machine must have completed one year of satisfactory working
after date of commissioning as on original date of closing of tender.
ii) Performance certificate shall contain following information.

Letter Head of issuing authority

(See Important Note above) Date of issuance:

To Principal CAO/COFMOW, New Delhi

Or
TO WHOMSOEVER IT MAY CONCERN

SN Head Details
1 Name of the Supplier
2 Name of End User
3 Name of the machine/description of machine
4 Purchase/Supply Order Number
5 Date of Purchase/Supply Order
6 Date of Supply of machine(s)
7 Quantity supplied
8 Manufacturer’s Serial Number(s) of machine(s) or
Plant/system etc. number (or some mode to identify
the machine) (Optional)
9 Date of Commissioning (Give individual date for each
machine)
10 Performance of the machine Satisfactory/unsatisfactory
11 Any other information which user intends to append,
for example a) aspects bringing out similar nature of
machine, b) major/leading parameters of the machine

Name & Designation

Contact Number
Signature of the issuing authority
Email id
(Seal of the Organisation)

Page 72 of 72
 SPECIAL CONDITIONS OF TENDER NO. OP-609350 (Broad Gauge CNC Surface Wheel
Lathe)

The following conditions are applicable in addition to those contained in Bid Documents
Part I & Bid Documents Part II (technical specification/requirements). In case, any of
the conditions mentioned hereunder are contrary to those mentioned elsewhere,
conditions mentioned in this document (Special conditions of Tender) shall supersede
the corresponding conditions given in Bid Documents Part I & II.

A)Qualifying Requirement of Tenderers - Clause 0501 (e) of “Instructions to Tenderers”,

Bid Documents Part-I - Reference Clause for Broad Gauge CNC Surface Wheel Lathe

1. The tenderer shall provide satisfactory evidence, acceptable to the purchaser to

show that he is a regular machine tool manufacturer and has adequate plant and
manufacturing capacity and has a “Quality Assurance Program”. The
information as per Annexure-2 under bid document Pt-I may please be
furnished. The manufacturer shall have valid ISO 9001 certificate on the
original date of closing of tender and a copy of same should be submitted
along with the bid.

2. The bidder/manufacturer must have supplied at least 01 (one) number of

same/similar machines in last 10 years (to be reckoned from the original date of
closing of tender).

Statement of past supplies along with (i) purchaser’s name (ii) address, (iii) email
address (iv) phone/fax number of purchaser, (v) purchase order (PO) or supply
order number (vi) PO date (vii) along with the copies of purchase order(s) (POs),
(viii) quantity supplied (with proof of supply), (ix) date of supply and (x) their
commissioning date shall be submitted with the offer. Copies of POs/
commissioning/ performance certificates submitted shall also indicate the
parameters / specification of subject machine to prove same/ similarity aspect of
the machine as mentioned in Para 3 below; technical specifications of the
machine from the related document of the PO may be attached to supplement
the PO in regard to the respective parameters of similarity aspect of the
machine. Specifications attached shall have linkages to the PO.

3. For the purpose of similarity, similar machine required under clause 2 means:

3.1 For regular order:

01 number of “CNC Surface Wheel Lathe manufactured and supplied in last 10
years (to be reckoned from the original date of closing of tender) for a Railway
application. However, the track gauge and wheel diameter may vary”.

3.2 For developmental order:

Validity unknown
a.) 01 no. of CNC Under Floor Wheel Lathe or CNC Portal Wheel Lathe
Digitally signed by
RABINDRA KUMAR manufactured and supplied in last 10 years (to be reckoned from the original
PANDIT
Date: 2021.10.05
12:05:00 IST
Reason: IREPS-CRIS
Location: New Delhi
 date of closing of tender) for a Railway application. However, the track gauge
and wheel diameter may vary”. OR,

b) 03 nos. of “CNC Lathe Machine manufactured and supplied in last 10 years

(to be reckoned from the original date of closing of tender), each having a
minimum configuration in terms of following parameters (i) Swing diameter over
bed 1300 mm, (ii) Centre distance 3000 mm, (iii) Motor power 30 KW and (iv)
Bed width 1000 mm”.

4. The tenderer shall, in their offer, submit performance certificate of at least 1 no.
of such machine (which are counted for the purpose of clause 2 above) supplied
in the last 10 years and the machine covered by this certificate must have
worked satisfactorily for at least one year from the date of commissioning as on
the original date of closing of tender.

The certificate shall not be older than one year from the original date of closing of
tender. The performance certificate issued after original date of closing of tender
(In cases, where tender closing date has been extended) are also acceptable
however the machine must have completed one year of satisfactory working
after date of commissioning as on original date of closing of tender.

The performance certificate submitted by the tenderer shall have been issued by
the actual end user organization of the machine, with their clear signature and
address therein, in whose premises the machine is installed and commissioned.
Performance certificate should be as per Annexure-A1.

5. All necessary information/ documents required for establishing reference

requirement as per clauses A (2) to A (4) above shall be submitted by the bidder
along with original offer itself for establishing linkage of documents/entities such
as manufacturer/PO/Consignee/Supply/Installation/Commissioning/performance
certificate of the machine. No further clarification/ correspondence shall be
sought / entertained in this regard. In case no information or incomplete
information or illegible information is furnished by the bidder, their offer shall be
summarily rejected.

6. Non-compliance of flowing shall lead to summary rejection of the offer and no

correspondence in this regard will be entertained.
a) The productivity requirement, as specified in clause 2.4.1 of section IV of the
bid documents shall be clearly furnished.
b) There shall not be any deviation from the major parameters mentioned in
clause 2.2.1 of section IV of bid documents part II.

7. Developmental Order:

a) Only Indian machine tool manufacturers shall be considered for

developmental order. The quantity for developmental order, if any, shall not
be more than 01 number. The machine to be supplied against
developmental order shall include concomitant accessories. A bidder who
has not manufactured and supplied in last 10 years (to be reckoned from the
 original date of tender opening) CNC Surface Wheel Lathe against
COFMOW’s tenders shall only be eligible for quoting against the
developmental order.The bidder who has already been placed with or will be
placed with developmental order of CNC Surface Wheel Lathe, shall not be
considered in subsequent tenders for the same machine till the machine
ordered against developmental order is supplied, commissioned &
successfully proved out and completes one year of satisfactory working after
its commissioning. In addition, PTC in respect of the machine must have
been issued before the original date of opening of the subject tender.
(Please refer Annexure-J of Section VI of Bid Document Part-II.)
b) The bidder qualifying against development clauses shall be considered for
placement of developmental order provided they meet technical
requirements as given in technical specifications of tender and their offer is
competitive in price.

8. Payment Terms:
The payment terms for developmental order will be 80% after supply and
successful commissioning & prove out of machine at the consignee’s premises
and 20% after issue of PTC by consignee.

9. Attention of bidder is also invited to affidavit enclosed with corrigendum

No.17 to Bid Documents Part-I. Successful bidder shall be required to
submit the same before release of LOA.
 Annexure-A1 (Certificate of Performance)

Important Note: i) The certificate shall not be older than one year from the
original date of closing of tender.The performance certificate issued after
original date of closing of tender (in cases where tender closing date has been
extended) are also acceptable however the machine must have completed one
year of satisfactory working after date of commissioning as on original date of
closing of tender.

ii) Performance certificate shall contain following information.

Letter Head of issuing authority

(See Important Note above) Date of issuance:

To Principal CAO/COFMOW, New Delhi

Or

TO WHOMSOEVER IT MAY CONCERN

SN Head Details
1 Name of the Supplier
2 Name of End User
3 Name of the machine/description
of machine
4 Purchase/Supply Order Number
5 Date of Purchase/Supply Order
6 Date of Supply of machine(s)
7 Quantity supplied
8 Manufacturer’s Serial Number(s)
of machine(s) or Plant/system etc.
number (or some mode to identify
the machine) (Optional)
9 Date of Commissioning (Give
individual date for each machine)
10 Performance of the machine Satisfactory/u
11 Any other information which user
intends to append, for example a)
aspects bringing out similar nature
of machine, b) major/leading
parameters of the machine

Name & Designation

Contact Number

Signature of the issuing authority

Email id

(Seal of the Organisation)