भारत सरकार
Government of India
रेल मंत्रालय
MINISTRY OF RAILWAYS
TECHNICAL SPECIFICATION
FOR
STATIONARY FLASH BUTT WELDING PLANT
AND
CONNECTED MACHINES & ACCESSORIES
(NO. IRS-T-49-2019)
अनुसंधान, अिभकप एवंमानक संगठन, लखनऊ -11
Research, Designs and Standards Organisation, Lucknow-11
i
INDEX
CLAUSE
NO.
SUBJECT PAGE
NO.
0 General 1
1 Description/Scope of work 2
2 Automatic Flash Butt Welding Machine 2
3 Programmable Logic Control (PLC) 7
4 Computer based Weld Data Recording and Monitoring Equipment 7
5 Smoke Trapping Device/ Fume Extraction Equipment 9
6 Automatic Cooling Device 9
7 Post Weld Heat Treatment 9
8 Stand by Diesel Generator 10
9 Automatic Rail End Brushing Machine 10
10 Weld Grinding Machine 11
11 Rail Straightening Machine (Pre and Post Weld) 11
12 Maintenance Spares 12
13 Consumable Stores 13
14 Installation of Plant 13
15 Training of Staff 13
16 Layout 14
17 Instruction Manuals 14
18 Inspection of the Equipments/ Welding Plant 14
19 Additional Information 15
20 Equipment Environment 15
21 Warranty Clause 16
22 Annual Maintenance Contract (AMC) 16
ANNEXURE
Annexure
No.
Description Page
No.
I INSPECTION CERTIFICATE 17
ii
CORRECTION SLIPS
S.No. Correction
Slip No.
Date of
Issue
Subject Clause No(s)
affected
Remarks
1
Technical Specification for Stationary Flash Butt Welding Plant and
connected machines & accessories
0.0 General:
0.1 Stationary Flash Butt Welding Plants working in Indian Railways are of old vintage.
These plants are to be replaced with plants of state of art technology prevailing at
present. The old plant may have to be continued in service as per discretion of
Railway administration. It is intended that suitable layout keeping available
infrastructure viz. Rail handling system, Rail loading and unloading system etc. in
view is decided by the supplier of plant.
The capability of plants and equipments will have to physically demonstrate for
prevalent rail sections on Indian Railways. For Rail sections and UTS, which is not
in use at present, theoretical calculations shall be furnished to demonstrate the
capabilities.
0.2 This technical specification has been drafted to reflect the performance and quality
requirements of the Stationary Flash Butt Welding Plants. Bidders are requested to
carefully study the specification and ensure that their equipment fully complies with
these specifications. Thereafter, if a bidder feels that his equipment can
substantially meet the performance and quality requirements laid down herein but
does not fully satisfy a particular item of this specification, he shall mention the
deviations, if any, in the statement of deviation from the specifications, giving the
details how the functional requirements of this specification are going to be met
with.
0.3 The bidder shall specify the model of Flash Butt Welding Unit and related
equipments offered and furnish a detailed Technical Description of the same.
System/sub-systems and working mechanisms of the machine shall be described
in the “Technical Description” in detail along with the sketches to show the manner
in which the requirements of the specifications are accomplished by the offered
model of flash butt welding machine.
0.4 The tenderer shall furnish video showing the working of each machine in real time
under field conditions on compact disc/USB stick/any other means. In case, the
tenderer intends to offer the improved version of Automatic Flash Butt Welding
machine for welding of rails, for which video is not available, he can submit the
video of his existing working plant with description of changes proposed and a walk
through 3-D simulation model of proposed plant. Photographs of the machines
offered and technical literature shall also be enclosed with the offer. The
photographs shall also show close-ups of various working assemblies/systems of
the full Plant.
0.5 All machines including flash butt welding machine should be well synchronized,
durable, easy to maintain and of robust design. Machines should be able to cope
up the forces coming during the operation.
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The tenderer shall be either manufacturer of the Automatic Flash Butt Welding
Plant for welding of Rails or accredited agent of manufacturer. It shall be clearly
specified whether other equipments are manufactured for tenderer or are bought
out item. In case of bought out item, the model name and name of manufacturer
shall be clearly indicated.
1.0 Description/Scope of Work:
1.1 Flash Butt Welding Plant normally consisting of following machines/
equipments/components:
(i) Automatic Flash Butt Welding Unit (hereinafter called FBW machine) with
(a) Automatic stripping/ trimming unit.
(b)Programmable Logic Control (PLC)
(c) Weld data recorder
(d) Smoke trapping device
(e) Automatic cooling device
(ii) Equipment for post weld heat treatment
(iii) Standby Diesel generator
(iv) Rail end brushing/ cleaning machine
(v) Fully automatic weld profile grinding machine
(vi) Rail straightening machine
(a) Pre-straightening machine
(b) Post weld straightening machine
(vii) Automatic punching machine capable for punching weld identification
number as per Para 9 of the Manual for Flash Butt Welding of Rails-Revised
2012.
All above plant and equipments shall be capable of welding/ handling rails of
section upto 68kg/m with ultimate tensile strength upto 130 kg/mm2.
1.2 This specification broadly covers the Working Mechanism & Functional
Requirements. The scope of work under this specification also covers installation
of the plant, Training of the staff, Layout, Foundation of the machines, Instruction
manuals, Inspection, Additional information, Equipment Environment, Warranty,
Annual Maintenance Contract (AMC)etc.
2.0 Automatic Flash Butt Welding Machine:
2.1 Weldability and range of application :
The FBW Machine should be designed for welding rails up to 68 Kg/m having
ultimate tensile strength up to 130 Kg/mm².
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The plant shall be capable to weld new rails/ released but serviceable rails of
various sections and metallurgies specified in Indian Railway’s Standard
Specification for Flat Bottom Rails(IRS-T-12-2009) with up to date Addendum and
Corrigendum slips (hereinafter called Specification of Rails) viz. 52/60/68Kg/m of
grades 880(C-Mn, Cu-Mo, Ni-Cr-Cu, Niobium, Vanadium), 1080(HH, Cr). Plant
would also be capable of welding of 60/68 Kg/m rails having mechanical &
chemical properties of R350HT of BS EN 13674-1:2011+A1:2017.
The machine should have facility for traversing by at least 500mm to facilitate
central positioning of the ends of long welded rails.
2.2 Machine Body:
The Machine body should be preferably of a frame type construction capable of
taking clamping and upset force to their axes of action. The machine frame should
have large openings in front of the welder to facilitate quick removal and
replacement of welder dies and clamps and to provide maximum visibility for
operation and maintenance. The machine frame assembly should be sturdy, all
welded steel fabrication suitably braced and stiffened at points of stresses to
minimize deflection and thermally stress relieved. The machine frame top should
have a single continuous beam structure to minimize welded joints, so that
deflection/ distortion/ cracks may be avoided. The weld zone should be fully
covered with spatter guards to trap the flash and a fume extractor to be provided to
exhaust this chamber. Guides should be provided at entry, and within the machine,
to enable free passage for rails during entry and transport. The welding standard
followed for manufacturing of machine should conform to latest Indian Standard or
equivalent International Standard. The manufacturer should specify the standard
followed and certify that it meets the welding standard.
2.3 Production Capacity:
The hourly output in terms of number of welded joints should not be less than 20
for 60 kg 90UTS, 13m rails including insertion of rails, clamping and aligning rail
ends, matching rail ends through power adjustment, welding cycle, stripping of
upset, unclamping and resetting of machine. The plant should be capable of
welding 260m long rail panels by continuous welding of 13/26/65m rail lengths.
The time in seconds for various operations per joint like positioning of welding
machine, clamping and aligning the rail ends, matching rail ends through powered
adjustments, welding cycle, placing stripper in position, stripping of upset metal,
unclamping and resetting of machine etc. shall be indicated.
Total rail usage per weld should be within 30mm.
2.4 Quality of Weld:
The welded joint produced by the machine should meet the various test standards
and geometrical tolerances specified in the Manual for Flash Butt Welding of Rails-
Revised -2012 with up to date Addendum and Corrigendum slips (hereinafter
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called FBW Manual). The machine offered shall be capable of producing
consistently and fully automatically weld to meet these stipulations.
The machine should be controlled by a PLC of latest version of a reputed
manufacturer which monitors all the vital parameters of the process such as
Voltage, Current, Displacement, Pressure, Time intervals, Velocity and Duration of
flashing etc. The parameters are also recorded and displayed on a Weld Data
Recorder as required. The PLC should also have a self diagnostic arrangement. If
the rail weld does not meet the preset values, suitable error indication shall be
shown whether the weld joint is “Good” or “Bad” and the operation should stop
automatically.
The software deciding the acceptance of welds based on different weld parameters
should be tailor made. Bandwidth for different rail sections and chemistry should
be specific and narrow one.
2.5 Clamping Units:
The clamping unit should be capable of applying a load suitable for different
section of rails i.e. upto 68 Kg/m. Multiple clamps to be provided for holding the
rails to prevent slippage during butting operation and to prevent abnormal
indentation of the rails. The bidder should specify the details of clamping cylinders
and ratio of clamping and forging force.
2.6 Forging Unit:
Forging unit should be of air/oil intensified type capable of applying forging force
suitable for welding rails up to 68 Kg/m. The rams of forging unit shall be so placed
so as to ensure equal distribution of the forging load across the interfaces. The
control includes a servo system, which should be controlled by the PLC for fine
control on the velocity of flashing. The forging action, which has to be as fast as
possible, should be accomplished with the help of a gas charged accumulator. The
accumulator system must be connected to filled/charged Nitrogen cylinder with
required pressure gauge and other necessary fixture. If any deficiency of nitrogen
gas is observed in accumulator, then it must be easily recouped by nitrogen
cylinder. The unit should be capable of delivering suitable force for welding 68
Kg/m rails with UTS of 130Kg/mm2.
In view of the heavy force involved, certain interlocks should be incorporated in the
system. The weld initiation should not be done without clamping. Similarly, the
machine should not retract after welding unless de-clamped. This is to avoid
application of tensile force on the still plastic joint inadvertently after welding.
2.7 Welding Electrodes:
These are to be of copper alloy with high abrasion with relatively good conductivity
and water cooled with quick release facilities for maintenance and replacement.
Metallurgical composition of copper alloy electrodes to be specified to take care of
replacement of electrodes in case manufacturers do not support servicing of FBW
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unit after certain period. Suitable welding electrodes should be provided for the rail
sections upto 68 Kg/m to be welded. Arrangement should be provided to blow off
scale and flash from the electrodes. Electrodes supplied with machine shall be the
part of welding machine.
The codal life of the electrodes in terms of number of welds should not be less than
25000. The number of spare electrodes supplied with the machine shall be two
sets. The electrode holders shall have a provision for vertical adjustment to
compensate the wear up to 25 mm.
The equipment to cool the water circulated in electrode should be included with the
machine.
2.8 Breaking & Inching Mechanism:
The welding machine should be provided with an independent breaking and
inching mechanism on each side so as to permit the welding operator to correct
position of the rails without any impact.
2.9 Rail Alignment & Twist Correction:
Flash Butt Welding Machine should be equipped with automatic rail ends
alignment facility. Rail alignment (lateral and vertical) and de-twist facility should be
incorporated in the fixed and moving heads of the machine for execution of the
weld in perfect geometric alignment fully automatically over a length of 1 m. There
should be no need of any manual adjustment while welding the new rails.
Arrangement through sensors which reads and records maximum mismatch in
alignment between gauge faces should be provided. Automatic selection of gauge
face should be possible.The aligning force and detwisting force shall be sufficient
for maximum rail section to be welded. Visual display should be available for
correct alignment. Automatic rail alignment setup should be capable to perform
alignment as per stipulations of Manual for Flash Butt Welding of Rails-2012.
There should be provision of manual adjustment in case cross section of two rail
ends being welded have major mismatch for welding of released rails.
Adequate lighting arrangement should be available inside the machine to enable
visual check of alignment and matching of rail ends.
2.10 Automatic Stripping Unit:
The welding unit should have a trimming arrangement as an integral part of the
unit so that it can trim the excess upset immediately after welding. The action of
stripping should be controlled completely by the welder automatic sequence panel.
The trimmer should have the capability to trim excess hot upset metal all round the
rail section in such a way that minimum grinding is required to achieve final
finished profile at weld as prescribed in FBW Manual. The maximum thickness of
trimmed surface shall be in accordance with provisions of item (v) of Part ‘A’ & ‘B’
of Annexure-IV of FBW Manual.
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Suitable trimming dies should be provided for the rail sections to be welded.
Sufficient force shall be available for stripper for upset removal from any rail
section/ Metallurgy which the machine is capable of welding.
There should be a well designed weld chips collection trolley which shall be
capable to dispose the burn chips away from trench of welding machine.
2.11 Hydraulic Power Pack:
The machine shall have a Hydraulic power packs consisting of suitable units for
the servo valve system and other requirements of the welding machine.
The servo system should be sensitive to contamination, isolated and maintained
with greater care. The unit should include oil reservoir, oil cooler, motor pump
assemblies, associated filters, gauges, sensors, pressure relief valves, etc. for
protection and long life of the hydraulic system. The equipment should be capable
of operation at an ambient temperature up to 550 C. On board system for filtration
and monitoring the quality of hydraulic oil in hydraulic circuit should be provided.
The gauge should clearly indicate that the hydraulic oil is contaminated beyond the
permissible limits and requires immediate replacement.
The Hydraulic oil used shall be of commercially available specification.
The manifolds of valve system should preferably be placed and fixed outside the
machine frame to avoid damage due to constant vibration and should be placed at
convenient height. The hydraulic parts should be of renowned brand and its spare
parts and service facilities should be available in India.
A separate filtering unit to be provided for hydraulic oil used in circuits before it
enters hydraulic oil cooling system.
2.12 Electrical power Pack:
The Electrical equipments should be fully tropicalized. The equipment should suit
connection to 400/440 volts 3 phase 50 cycle (HZ) supply. The machine shall be
capable of adjusting/withstanding to a voltage fluctuation up to +10% while in
operation. A voltage stabilizer of 440 volt shall be provided in mains supply of
welding machine to minimize the voltage fluctuation and provide appropriate
voltage to mains of electrical power pack.
The welding process will be based on Direct Current for a uniform and fast heat
accumulation in the work piece. The three phase mains connection shall have a
uniform power load possible and has a power factor better than 0.85.
The secondary circuits of the transformers should be cooled to prevent overheating.
A wide range of secondary voltages should be available to allow for the
correct heating conditions to be selected for individual rail sizes.
The energy consumption per weld in KWH should be indicated for different rail
sections.
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The manufacturer needs to stipulate the specifications of the transformers required
for functioning of FBW plant.
2.13 Centralized Lubrication:
Automatic Lubrication is to be provided for the machine. The frequency of
lubrication shall be programmable.
2.14 Cooling System of Machine:
The cooling system shall be efficient and designed for maximum ambient
temperature of 55°C. Supplier may note that the machine shall be working under
extreme dusty conditions and the cooling mechanism should be maintainable
under these conditions for all prime movers. Adequate heat transfer arrangement
for the hydraulic system shall be designed and provided so that under extreme
heat conditions, the temperature of system oil does not go beyond limit
recommended by Oil Company.
The installation of requisite device/system for temperature control of machine/
welding electrodes will be part of this item.
3.0 Programmable Logic Control (PLC):
Flash Butt Welding of rails involves accurate and dependable control of current of
the order of 70,000 Amps. PLC, AD/DA conversions, sensor-actuator links etc.
enables accurate performance. The bidder should specify the details of PLC
incorporating with the machine.
The PLC Software listing shall be issued in the form of a Ladder Diagram along
with the Operating Manual.
4.0 Computer based Weld Data Recording and Monitoring Equipment:
This equipment should be capable of being wired/ connected directly to the FBW
machine and give an immediate read out which in comparison with pre-fed master
data should automatically identify any inconsistency in welding machine operation.
Automatic microprocessors weld control recorder should be provided to record
data pertaining to each weld such as voltage, current, upset pressure and total
welding time and temperature of cooling water and servo oil. It should be of the
digital print out type in which the various values are printed in one colour (say blue)
when they are within limits. Otherwise these are printed in other colour (say red).
For every red print there should be a small audible beep. The weld data recorder
must be capable for online monitoring of weld sequence and quality of weld joints.
The recording system should be a computer based data acquisition system
specifically designed to record entire weld process in detail for complete weld
process analysis. The data logger will have a minimum capacity to store one lakh
welds data for retrieval and study.
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In order to minimize intervention to alter standardized input parameters, the
software should have the facility of password protection for modification of these
parameters.
The hardware consists of a single processing unit, a processor unit (PC type) with
hard memory, disk drive, a touch screen video display unit and Keyboard. The
second remote monitoring unit will consist of a basic computer with laser/ink jet
printer.
The weld parameters sensed and operated upon by the machine control are to be
communicated to the recorder through a suitable communication port. All these
signals are to be recorded in coded form in the memory in the recorder for further
retrieval, if desired.
Parameters to be recorded for each weld:
Date & time of welding
Joint serial number
Section and UTS of the rail
Pre weld alignment
Welding current (Primary, amps)
Line voltage in Volts
Primary voltage (Volts)
Clamping pressure Kg/cm2
Butting pressure Kg/cm2
Number of Pre-Heats
Pre Heat time On - Off in sec.
Burn off time in sec.
Flashing time in sec.
Total stroke in mm.
Butting stroke in mm.
Total time in sec.
Upset length i.e. rail consumed per weld (mm)
Heat soak back duration
Post heat delay
Post Heat ON Time
Post Heat OFF Time
Number of post Heats
Duration of Butting
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Slippage of Rail (Yes or No)
Weld Analysis (GOOD or BAD)
The system offered should be capable of building upto 99 sets of parameters.
The supplier shall describe the elements employed in the system with the details of
the manufacturer. It should be ensured that consumable spares and repair facilities
of the system are available in India.
It should be possible to locate the system in a separate room situated upto 40
meters away from the welding machine.
The system shall be compatible with other machines supplied with plant for
automatic feeding and maintaining the data base of complete weld from Prestraightening
to final finishing phase.
5.0 Smoke Trapping Device/ Fume Extraction Equipment:
All smoke and spark material shall be trapped by device and deposited in the
receptacle.
Fumes and dust must be sucked out from the welding chamber and passes
through a cyclone separator and exhausted to the atmosphere though a chimney
of suitable height. The particulate matter must be collected in a bin at the bottom of
the separator. The bin shall have adequate capacity for atleast day’s production to
avoid frequent removal. It must ensure that there is no discomfort to operator due
to welding fumes and dust and operator is fully protected from the spatter.
The cyclone separator should be mounted outside the shed which houses the flash
butt welder. Only the suction ducting should be brought in and connected through
suitable flexible ducting to permit the machine traverse for rail panel positioning.
The motor control should be mounted inside the shed for easy access to the flash
butt welding operator. The fume extractor should be interlocked with the Flash butt
welder to ensure that it is in operation before welding commences.
6.0 Automatic Cooling Device:
Adequate cooling arrangements (Air/water/liquid) for cooling of welded rails to
normal temperature should be provided at such suitable distance from the welding
machine where temperature of the weld is not more than 3500 C. The cooling
arrangement for all rail sections and rail steel should be quick enough so as not to
reduce the capacity of plant i.e. 20 joints per hour. The arrangement shall be
specified by the bidder.
7.0 Post Weld Heat Treatment:
Alloy steel rails and heat treated/head hardened rails need post weld heat
treatment to ensure variation in hardness within acceptable limits in heat affected
zone. Suitable equipment should be provided for post heat treatment facilities with
necessary control features. This device among other thing shall enable the post
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heating sequence being set to pre-determine temperature and cooling time with a
selector switch to bring in the automatic post heat cycle whenever required. The
facility should preferably be in-built with the welding machine.
The facilities, if proposed to be provided separately on the welding line at the
adjustable distance from the machine, should have proper interlock with main
welding machine to be incorporated in welding cycle.
8.0 Stand by Diesel Generator:
8.1 A suitable diesel operated generating set with adequate capacity to feed welding
transformer, compressor, electric hoists, Goliath crane and motorized line etc. to
be supplied with the welding plant as standby for welding operation. The basis for
deciding capacity should be clearly brought out in the offer.
The generator shall be powered by indigenous diesel engine and shall have
proven record of service in tropical conditions.The detailed technical literature and
specifications along with manufacturer’s literature should accompany the offer.
8.2 The engine should have Electronic Control Module (ECM) or similar arrangement
for taking out operating parameters on real time basis such as RPM, load,
temperature, pressure and diagnostic data as well as trip and historical data.
These data should be displayed and stored on a centralized computer and
monitoring system. It should also be possible to transfer these data on USB
device through the centralized computer based control.
8.3 In order to adhere to pollution control norms, the diesel engine should be
electronically controlled emmissionized engine with minimum compliance of tier 2
stage.
8.4 The engine should be enclosed in a weather protective, sound and dust resistant
enclosure to minimize engine noise and to prevent oozing out of oil spills etc. from
engine area to the adjacent components like alternator, hoses, electrical cables,
fittings as a protection against fire. All doors on the enclosure shall be strategically
located in areas as to allow ease of maintenance of the engine and allow good
access to and visibility of instruments, controls, engine gauges, etc. Sufficient
louvers shall be provided to allow the total engine cooling air requirements used in
this application.
9.0 Automatic Rail End Brushing Machine:
9.1 Brushing Machine shall be so designed that it will automatically clean the specified
area of railalong with dust evacuation before welding in order to establish uniform
contact on running surface. The machine shall be capable to remove the scale,
rust and other grit from the rails using steel wire brushes. The brushing process
should ensure optimal contact resistance between the rails and the welding
electrodes. The operation shall meet the provisions of the Manual for flash butt
welding of rails-2012 issued by RDSO.
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Suction and dust collection system shall be available in machine. It should be
provided with a powerful dust exhausting system.
9.2 Clamping Unit : Clamping units shall be provided for centering of the rails while
brushing. The system preferably to be hydraulically operated for the movements of
the brushing units and electric motors for continuous control torque for the
brushing, thus ensuring efficient cleaning of the rails.
9.3 The area to be cleaned: The rails end faces and the adjoining surface of the rail
profile to a width of about 25mm all round and electrode contact locations of rails.
9.4 Operation: The operation should be automatic and sensors are to be provided to
detect rail ends and position them inside the machine. Once rail end is positioned,
the brushing cycle to be executed by the pre-programmed logic control sequence.
The cleaning shall be accomplished within the weld cycle time, so that productivity
of plant is not adversely affected.
9.5 Safety: The machine will be equipped with all safety features commensurate with
good engineering practice and industrial standards as expected. The machine
should disable and indicate in case of system failure. Fail safe interlocks should
be provided to prevent faulty operation. The supplier should indicate the safety
features provided in the machine.
10.0 Weld Grinding Machine:
The machine should be capable of running on 440V 3 phase AC Electrical supply.
The machine shall be so designed as to complete the grinding operation on all
sides of the rail in not more than 5 minutes.
In order to maximize the output of the welding plant as a whole, more than one
automatic grinding machine may be planned in the same welding line or an
alternative line, as per layout of the plant.
The machine should have powered movement on its own wheels for positioning
and use large high speed grinding wheels. The grinding operation shall be
automatic. The weld finish tolerance on rail profile as specified in the FBW Manual
should be achieved after grinding.
It shall be ensured that indigenously available grinding stones can be used on this
machine.
Machine should have PLC control, dust exhausting system, internal laser
measuring and recording system.
11.0 Rail Straightening Machine (Pre and Post Weld):
11.1 The Pre Straightening machine is required to correct rail end of rails to be welded
and this machine shall be stationary with suitable inching movement for placement
of rails in the press. The Post Straightening machine is required to correct the weld
alignment and this machine should be self propelled to adjust itself to correct weld
location without affecting the welding line. Both the machines should be capable of
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correcting both vertical and lateral alignment for all the rail sections to be welded
i.e. rails upto 68 kg/m.
11.2 The post straightening machine should be capable of removing the bad alignment
in the welded flash butt joints and should suit various rail sections. The machine
should provide alignment correction in vertical and lateral direction and should
have powered travelling arrangement for adjusting to different lengths of rails being
welded. The machine should have misalignment measuring device and also visual
indicator to point out the location and extent of misalignment. The alignment
correction supports should be moveable so as to handle short and long kinks.
11.3 The pre-straightening press should be provided as a stationary press. A
straightness measuring device should be provided to measure and record the
straightness of the rail.
11.4 The frame of presses must be of robust design. Adequate stiffeners and gusseting
is to be provided for structural strength. All welded structures must be suitably
stress relieved by heat treatment. The horizontal and vertical cylinders should not
be integral with the main machine body to facilitate maintenance of the cylinders as
modular units.
11.5 The laser measurement system should measure the straightness of the welded
joint and display it in a graphical form and data should be stored in the tabular
form. The laser measurement device must measure the head of the rail on the
three surfaces, namely; top side, front gauge face and rear gauge face.
The measurement should be done with the help of laser displacement sensor and
the final straightness data should be stored in memory for later retrieval and
analysis. If the rail is within the acceptable tolerance band the operation is
complete or else the operator will have to repeat the cycle till the required
straightness is achieved.
11.6 The Rail Straightening Machines should have a control system with PLC, key
board and other required devices. It should also have software to visualize the
straightness of the rails, force supplied on the rails, the deformation process
induced by straightening force and shall be displayed on the screen. The final
alignment achieved shall automatically get recorded and stored for further analysis.
This should be compatible with weld data recorder so that the data of press is fed
to recorder for comprehensive record.
11.7 The design shall be such that the manual verification of alignment is easily
possible and area is well illuminated. The control panel should have provision for
emergency stop for emergency and interlock to stop machine if deflection beyond
pre-specified limit is exceeded to prevent breakage of rail.
12.0 Maintenance Spares:
12.1 The tenderers are required to furnish a detailed list of essential spare parts along
with detailed drawings and specifications/metallurgical specifications required for
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operation of entire plant for a period of two years. These spares should be included
with the price of each equipment.
12.2 It should be necessary for the tenderer to indicate as to which of the parts listed
can be procured indigenously and identifying the remaining items which are
required to be necessarily imported.
12.3 The tenderer should provide the itemized list of spare parts giving full particulars of
the parts indicating part number, description, name of manufacturer, unit price,
recommended quantity etc. The sketches/ drawings wherever required should also
be furnished.
13.0 Consumable Stores:
The tenderer should furnish detailed specification of all consumable stores except
fuel required for the smooth running and operation of all the machinery & plants
offered under the contract, clearly indentifying whether all such items are
indigenously available or any item is required to be imported on continuing basis.
The unit price and quantity of all such items should be quoted. The consumable
stores except fuel for a period of two years should be included in the tendered offer
for the welding plant.
14.0 Installation of Plant:
14.1 The installation of the plant should be undertaken by the manufacturers of the plant
or their agents in India, who should commission the same. The services of firm’s
engineers should be made available to install and operate the same for at least two
months. Railway staff will also be trained by the supplier of the plant for 02 months
in regular operation of the plant, as part of the contract.
14.2 The installation includes the making foundation for machines as per requirement
and design finalized by manufacturer or his authorized agent in India, supply and
providing all the installation materials like bolts and nuts, brackets etc complete in
all respect. Special tools required for installation/maintenance shall be provided by
the tenderer.
15.0 Training of Staff:
15.1 Two persons from the Railway will be trained, as part of this contract for a period of
one month each in manufacturer’s country or any other country where similar
machines are working. The cost of training includes lodging, boarding, air fare etc.
and training material shall be borne by the tenderer.
15.2 In addition to above, the operating staff will be trained for day to day operation and
maintenance during the two months period the plant is under operation of the
supplier.
15.3 The audio visual material like films, videos, slides etc. will also be made available
by the suppliers which may facilitate general training of the staff.
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16.0 Layout:
16.1 The tenderer should furnish the overall layout of their proposed plant together with
sketches or drawing pertaining to the same to appreciate the inter-se- position of
various units and infrastructural requirements to be provided by the Railways. The
location of the plant vis-à-vis essential accessories is to be furnished in the form of
block diagram.
16.2 The proposed layout shall consider the existing facilities available in the existing
plants. It is desirable that tenderer visits the plant to have details of existing layout
themselves. The overall dimensions of the layout including length, breath, height
and structure/shed required for accommodating the equipment, specification of
essential elements etc. should be indicated.
17.0 Instruction Manuals:
All manuals (installation, operation and service) shall be supplied in English.
Detailed installation documents complete with typical layout, list of special tools
and accessories etc. should be supplied in six sets, well in time to enable
coordination with order to installation activities. Equipment description including
installation, testing, schematic wiring, physical location, drawings, etc. shall be
supplied.
18.0 Inspection of the Equipments/ Welding Plant:
18.1 All the equipment will be tested before dispatch by the technical inspection officers
of Indian Embassy or authorized representative of Indian Railways. While
inspecting the machine before dispatch from the supplier’s premises, the
inspecting officer shall verify the conformity of the machine with respect to
individual specification as above. The machine’s conformity/non-conformity issue
in respect to each item shall be jointly recorded before issue of the inspection
certificate and approval for dispatch of the machine as per Annexure –I enclosed.
18.2 The following documents shall be provided to the Inspecting Officer at least 4
weeks in advance of the date of inspection.
i) One copy of complete technical literature of machines/tools/equipments
including installation, operation and service manuals/instructions and
complete electrical & hydraulic, trouble shooting charts, component drawings/
description and other relevant technical details as a reference documents in
soft & hard copies in English language.
ii) Clause by clause comments of the manufacturer to be sent to Inspecting
Officer (IO) in advance for his review. Comments should state manufacturer’s
conformity of compliance of each of the requirement stated in each clause,
elaborating where necessary the details/manner in which the requirement has
been complied. The proforma for the clause-wise comments is given below:
15
iii) Manufacturer’s Internal Quality Inspection Report of the machine.
iv) Manufacturer’s quality certificate and/or test reports for bought out
assemblies/sub-assemblies to be provided to IO, containing serial number
wherever applicable.
v) Draft Inspection Report to be prepared by the manufacturer, containing all
Annexure mentioned at clause 18.3
18.3 List of documents to be annexed in the draft Inspection Report should include:
i. Maker’s Test Certificate.
ii. Manufacturer’s Internal Quality Inspection Report
iii. Quality Certificates of Bought out assemblies/sub-assemblies
iv. List of spare parts to be dispatched along with the machine
v. List of tools to be dispatched along with the machine
vi. List of Manuals, Drawings, Spare Parts Catalogues, etc. to be dispatched
along with the machine, duly indicating the number of sets of each.
19.0 Additional Information:
19.1 Names and address of the administration to which the equipment quoted has
already been supplied by the tenderer should also be indicated.
19.2 The supply of drawing will in no way absolve the tenderer of his responsibilities of
supplying the equipments strictly according to the specifications.
19.3 Four copies of test and inspection certificates for each equipment should be
supplied along with the equipment.
19.4 Any updation of plant with the upgradation of technology or as per requirement of
railway in future upto 10 years which is possible with minor alteration/addition etc
should be acceptable to OEM through agency. Most of the upgradation would be
based on changes/modification in software of control panels of machine(s) in this
regard.
20.0 Equipment Environment:
20.1 Equipment shall be capable of continuous operation during the varying
atmospheric and climatic conditions prevailing throughout the year in India. The
range of climatic conditions is as follows: -
a. Ambient temperature : -100 to 550 C
b. Altitude: : Sea level to 1800 m above mean sea level
Clause no. Clause Comments of
manufacturer
Comments of Inspecting
Officer
16
c. Humidity: : 40% to 100%
d. Rail temperature : (-) 10° C to (+) 75° C
20.2 The entire equipment should be thoroughly tropicalised for working in Indian
conditions.
20.3 All the machines including generators should be environment friendly.
Various parameters regarding sound and air pollution should be provided by
manufacturer with machine so that the same may be addressed rightly in case the
plants are situated at built up area.
21.0 Warranty Clause:
In addition to the special conditions of contract dealing with warranty, the following
will apply:
Should any design modification be made in any part of the equipment offered, the
period of Warranty (24 months) would commence from the date the modified part
is commissioned in service for the purpose of that part and those parts which may
get damaged due to defects in the new replaced part, the cost of such modification
should be borne by the supplier.
22.0 Annual Maintenance Contract (AMC):
22.1 The Plant and connected machines will be required to be maintained for a period
of Five (5) years after the expiry of warranty period.
22.2 For above, tenderers are required compulsorily to quote for comprehensive annual
maintenance contract per year for all machines for a period of 5 years. The
duration of AMC shall be of five years from the date of expiry of the warranty. The
AMC will be inclusive of preventive maintenance services, supply of all spares,
maintenance material required and labour cost. All consumables except fuel,
lubricating oils, hydraulic oil, toolings, drills and tapes shall form part of the scope
of comprehensive AMC.
22.3 Technical audit for every 20000 joints by OEM or his authorized representative
during AMC period shall be part of AMC.
*******
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ANNEXURE –I
INSPECTION CERTIFECATE
Certificate of Inspection of………………………………………… (Model No.…………..) by
Inspecting Official and Approval for dispatch of Machine.
(Strike out whichever not applicable)
This is to certify that I have inspected the …………….……………. ………… bearing Sl. No.
…………………………..from (date)……………...to ……………..at
(place)……………………….for its conformity / non –conformity with respect to the laid down
Technical Specification on contract agreement
No.……………………..…………….dated………………..between the President of India through
…………………………………………………………. and M/s. (Name of
Contractor) ………………………………….…………
The detailed inspection note regarding its conformity / non conformity to the laid down
specification is enclosed along with Annexure ‘A”. It is observed that:
(Strike out whichever is not applicable)
• The ……………………………… ……..conforms to all the laid down Specifications.
• The …………………………………… conforms to all the laid downSpecifications except those
at Sl.No…………………………………………...
• The above deviations are minor / major affecting / not affecting the performance of the
equipment/machine in substantial way.
The following T & P, manuals, drawings are to be supplied along with the machine.
1……………………………….
2……………………………….
3……………………………….
Based on the above the ………………………………………………is certified/not certified to be
conforming to the specifications.
The ………………………………………………… is approved/ not approved for dispatch to
………………………………………......( consignee) Indian Railway.
SIGNATURE AND DATE
For M/s …………………. INSPECTING OFFICIAL
(NAME AND DESIGNAQTION)
……………………………. for and on Behalf of President of India
…………………………..
