R.D.S.

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GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

TECHNICAL SPECIFICATION FOR SELF-STEERING Co-Co BOGIES OF 4000/4500 HP BROAD GAUGE (1676 mm) DIESEL ELECTRIC LOCOMOTIVES

SPECIFICATION NO. MP- 0.4900.15 (Revision 04) September 2011

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LUCKNOW - 226 011

Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives

TECHNICAL SPECIFICATION FOR SELF-STEERING Co-Co BOGIES OF 4000/4500 HP BROAD GAUGE (1676 mm) DIESEL ELECTRIC LOCOMOTIVES
1. 1.1 INTRODUCTION To cater for rapid growth in freight traffic, it has become necessary that freight locomotives are equipped with bogie, which has longer wheel life, longer period between two-wheel turnings and lesser track forces. To ensure high levels of performance, availability and operational reliability of locomotives, Indian Railways is seeking supply of track friendly self-steering bogie for diesel electric locomotives with a cutting edge technology along with complete Transfer of Technology for their design, development and manufacturing. This specification is for design development, supply and Transfer of Technology of Self-steering CoCo bogies of Broad Gauge (1676 mm) WDG4 EMD design freight diesel electric locomotives. The bogie design will be primarily applied on WDG4 locomotive (GT46MAC locomotive). The WDG4 locomotives are equipped with two bogies with three axles, two-stage suspension and axle hung nose suspended traction motor with single shoe type brake rigging arrangement and a rigid axle guidance. DEFINITIONS 'Tenderer' means the firm/ company submitting the offer for the supply of self-steering Co-Co bogies for 4000/4500 HP Broad Gauge (1676 mm) freight diesel electric locomotives conforming to this specification. 'Purchaser' means the President of Republic of India. 'RDSO' means Research Designs and Standards Organisation, Ministry of Railways, Manak Nagar, Lucknow-226011, India. 'Inspecting Officer' means person, firm, or department nominated by the purchaser to inspect the locomotive bogie on his behalf or the representative of the Inspecting Officer so nominated. 'DLW' means Diesel Locomotive Works, Varanasi - 221004 or their successors. 'Contractor' means any firm or company with whom the order for supply of self-steering Co-Co bogies for 4000/4500 HP Broad Gauge (1676 mm) freight diesel electric locomotives conforming to this specification has been placed or is intended to be placed. 'Sub-supplier'/ 'Sub-Vendor' means any person, firm or company from whom the contractor may obtain any material, sub-assemblies or assemblies used for the manufacture of locomotive selfsteering bogies. The Bogie Kit implies assembled self-steering bogie. It, however, excludes the wheel & axle sets with gear wheel, traction motors with TM pinion, suspension tube assembly including bearing housings, end fittings, suspension bearings and fasteners. The Component Kit implies all the components of complete self-steering bogie. It, however, excludes the wheel & axle sets with bull gear, traction motors, suspension tubes including suspension bearings and other components marked X in column E of Table 1. 'Braking effort' means net retarding force at the rail level. GT46MAC locomotive means WDG4 locomotives presently operating on Indian Railways. IRS means Indian Railway Standard. ToT means Transfer of Technology. UIC means Union Internationale Des Chemins De Fer (International Union of Railways). AAR means Association of American Rail Roads. The time frame specified in this specification is indicative and given with reference to date of contract (D date). However the contractor may indicate their time frame as practicable in its offer. IR means Indian Railways.
Specification No. 0.4900.15 (Rev.04) of September 2011 Page No. 1

1.2 1.3

2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17

Motive Power Directorate (VDG), RDSO, Lucknow

Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives

3.

ENVIRONMENTAL & TRACK CONDITIONS The track parameters and environment details given here are indicative only and for easy appreciation of operating conditions. The prospective bidder is responsible and is expected to have read and understood all relevant parameters for functionality & effective supply of self-steering bogies.

3.1

Climatic and Environmental Conditions Parameter Requirement Under Sun In Shade Ambient temp. Humidity Altitude : 70 C : 50 C : 47 C : 60 % :160 m Maximum temperature (Atmospheric) Humidity Reference site conditions Rainfall

3.1.1 3.1.2 3.1.3

100% saturation during rainy season.

3.1.4

Very heavy in certain areas. The bogie shall be designed to permit locomotive running at 10 km/h in a flood water level of 102 mm above rail level. Extremely dusty and desert terrains in certain areas. The bogie shall be designed to permit locomotive operation in coastal areas in humid and salt laden atmosphere.

3.1.5 3.1.6 3.2

Atmosphere during hot weather Coastal area

Track Parameters Parameters Requirements Broad Gauge (BG) 1676 mm (nominal). The track is to a standard of: 60 kg, 90 UTS rails on pre-stressed concrete sleepers, 1660 per km sleeper density, 300 mm depth of ballast cushion below the sleepers Or 52 kg, 90 UTS rails on pre-stressed concrete sleepers, 1540 per km sleeper density, 250 mm depth of ballast cushion below the sleepers

3.2.1 3.2.2

Gauge Track Structure

3.2.3

Sharpest curve & turn 174 m radius. out to be negotiated The locomotive shall also be checked for passage in both directions over standard BG 1 in 8 turnouts. Vogels layout or its internationally accepted equivalent for negotiability, throw over at headstock and coupler movement with details of clearances shall be prepared and supplied by the contractor. Maximum Super Elevation : 185 mm Maximum Cant Deficiency : 100 mm Schedule of Dimensions Indian Railways 'Schedule of Dimensions for Broad Gauge (1676 mm), 2004.

3.2.4

Motive Power Directorate (VDG), RDSO, Lucknow

Specification No. 0.4900.15 (Rev.04) of September 2011

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Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives

Parameters 3.2.5 Overall dimensions

Requirements Moving The offered design of self-steering bogie with new wheels when interfaced with WDG4 locomotive carbody in empty condition shall be within the dimensions shown in IR MMD EDO/T 2202.

3.2.6

Clearance above the The offered self-steering bogie shall be so designed that when Rail level interfaced with WDG4 locomotive carbody, no component shall infringe minimum clearance of 97mm above rail level with the locomotive fully loaded and wheels in fully worn condition to a diameter of 1016 mm.

3.3

Permissible Track Tolerances Permissible Track Tolerances B.G. Main Lines (Other than C&M 1 Vol. 1) < 15 mm < 2.78 mm / meter < 6 mm < 5 mm B.G. High Speed Route (C&M 1 Vol. 1) <10 mm <2.08 mm / meter < 3 mm < 5 mm

3.3.1 3.3.2 3.3.3 3.3.4 3.3.5

Unevenness (3.6 m base) Twist (3.6 m base) Gauge Variation Alignment (Versine on 7.2 m Chord) Gauge Widening On curves of 350m radius On curves of < 350m radius

- 5mm to + 3mm Up to + 10mm

4. FIELD PERFORMANCE AND DESIGN REQUIREMENTS OF SELF-STEERING BOGIE 4.1 Stability and Riding Quality Requirements Parameter 4.1.1 4.1.2 4.1.3 Maximum Lateral Force Derailment Co-efficient Requirements 4.5 tonnes (at a speed of 115 Kmph) <1 peaks

Lateral & Vertical Acceleration in the 0.35 g (0.3g preferable) driving cab and over the pivots in the loco Remark: Number of acceleration car body exceeding 0.2g to be kept to a minimum. Ride Index in the driving cab at floor level Angle of Attack (A.O.A.) 3.75

4.1.4 4.1.5

As optimized by the contractor,details of which should be brought out in the technical proposal as well as other appropriate stages.

The procedure for testing the above mentioned parameters shall be generally as per RDSO Report no. MT-288, April 2001, a copy of which may be obtained from RDSO.
Motive Power Directorate (VDG), RDSO, Lucknow Specification No. 0.4900.15 (Rev.04) of September 2011 Page No. 3

Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives

4.2

Field Performance Requirements Parameter Requirements When self-steering bogie with fully worn wheels of 1016 mm diameter is put under GT46MAC car body, the bogie shall be suitable on straight tangent track for: Operating Speed : 105 km/h (Maximum) Test Speed : 115 km/h Weight The offered design of self-steering bogie and allied components with the steering arrangement should not exceed the weight of existing HTSC bogie of WDG4 locomotive without wheel axle and motor assembly. Load A WDG4 locomotive equipped with the self-steering bogies shall be capable of providing the same or better starting and continuous adhesion on straight tangent track as obtained with the HTSC bogie for the GT46MAC. The starting adhesion of WDG4 locomotive on straight tangent track is 0.42. The tractive effort Vs speed characteristic of WDG4 locomotive for straight tangent track is enclosed. On curved track, WDG4 locomotive equipped with the self-steering bogies shall be capable of providing the adhesion higher than the value obtained with HTSC bogies on the existing WDG4 locomotives and the offer should indicate the extent of improvement in the adhesion value. The contractor may give details of quantification and clarify with a detailed note. The self-steering bogie offered shall be capable of negotiating curve of radius 100 m by itself, and not necessarily when coupled with WDG4 locomotives. The maximum un-sprung mass per axle shall preferably be limited to 4 tonnes. The dynamic augment shall not exceed 30% at maximum permissible speed.

4.2.1

Speed Potential

4.2.2

4.2.3

Adhesion Capability

4.2.4

Curve Negotiability

4.2.5

Un-sprung mass

4.2.6

Dynamic Augmentation

4.3

Qualifying Requirements The tenderer shall essentially provide satisfactory evidence acceptable to the purchaser as follows:

4.3.1 That they design, manufacture and supply service-proven self-steering locomotive bogies and have at least 20 locomotive sets in satisfactory service. (A declaration indicating the number of such locomotives fitted with radial bogies supplied by the tenderer along with owning rail roads shall be provided by the tenderer.) 4.3.2 They are in a position to transfer the complete technology for the design and manufacture of the complete offered self-steering bogie.
Motive Power Directorate (VDG), RDSO, Lucknow Specification No. 0.4900.15 (Rev.04) of September 2011 Page No. 4

Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives

4.3.3 A complete technical proposal (in the technical bid) clearly bringing out specific features and benefits of its offer, conceptual details of bogies offered, duly meeting the specification etc should be submitted by the tenderer. 5. ACTION PLAN FOR ADAPTION OF SELF-STEERING TECHNOLOGY It is planned to adapt the complete technology of self-steering bogies as under: 5.1 The scope of bogie kits (Column D) involves supply, assembly, oscillation trials & steady state curving test as well as field performance evaluation and TOT for 10 complete self-steering functional bogies along with one such bogie frame for endurance testing. The Contractor shall also supply 40 sets component kits (as per Column E of the table given below) . The sourcing of 40 component kits whether indigenous / imported is also given in the column F of the table. Table 1 A. Items B. C. D. First 10 Prototype bogies E. 11th to 50th bogies F. Common / Uncommon Items Vis--vis WDG4 HTSC non selfsteering bogie (Tentative) Bogie frame assembly Uncommon with brackets, bolts, liners & miscellaneous hardware 11th to 50th bogies Component Contractor to supply Items to be Component Kits, necessarily (Contractor to excluding items marked X indigenized(sourced supply Bogie from India) marked Kits, excluding items marked X) X * X# To be procured by (06 +01 bogie (Balance 44 nos. to be IR (Indigenous frame) procured by IR through source(s) to be indigenous sources) developed by the contractor)

5.2

5.2.1

5.2.2

Self-steering mechanism components

and

Uncommon

5.2.3

Traction Motor with Common Suspension tube & allied components, suspension bearing & pinion Wheel, axle & gearwheel Common

5.2.4 5.2.5

Bearing adopter Uncommon Assembly with bearings (End and middle axle) with components & hardware Lateral thrust pad -do-

Motive Power Directorate (VDG), RDSO, Lucknow

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Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives

Traction rod application: Traction rod assembly with Traction rod machined, rubber bushing & miscellaneous hardware 5.2.7 Nose link application: Nose link assembly with Nose link machined, rubber bushing & miscellaneous hardware 5.2.8 Primary helical coil springs 5.2.9 Secondary rubber springs 5.2.10 Primary vertical damper Secondary yaw/ lateral damper 5.2.11 Centre pivot assembly 5.2.6 Car body link assembly Miscellaneous hardware of carbody linkage assembly rigging 5.2.12 Brake arrangement with brake cylinders and miscellaneous hardware & components 5.2.13 Pneumatic pipe line and fittings for brake system, including Parking brake arrangement 5.2.14 Rubber parts of Sanding arrangement (Sander guide assembly with Sander hose) Other items & miscellaneous hardware of Sanding arrangement 5.2.15 Any other relevant bogie items not covered above

Uncommon

Preferably to be kept common

Uncommon Uncommon Uncommon Uncommon Preferably to be kept common -do-doUncommon

X
(These 40 nos. to be procured by IR through indigenous sources)

X X X X X X

Uncommon

X
(These 40 nos. to be procured by IR through indigenous sources)

Preferably to be kept common Preferably to be kept common

(These 40 nos. to be procured by IR through indigenous sources)

(These 40 nos. to be procured by IR through indigenous sources)

Motive Power Directorate (VDG), RDSO, Lucknow

Specification No. 0.4900.15 (Rev.04) of September 2011

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Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives

5.3.1

bogie frames are for the self-steering bogie assembly and the seventh bogie frame is spare for endurance testing. 5.3.2 # Rest 44 bogie frames shall be procured by Indian Railways from indigenous sources with technical assistance from the contractor including development of tooling, jigs and fixtures. The cost of which is not to be quoted by the supplier. 5.3.3 Development of at least one indigenous source by the contractor in line with column F of the above table is a must for items to be sourced indigenously. For other components, the contractor may decide to supply through import or through indigenous source. The drawing, specification and test certificates for all such components shall be provided by the contractor to IR. 5.3.4 The tenderer shall also offer per unit price for rubber or rubber bonded components, special fasteners like Huck bolts, helical springs, dampers & special bearings etc. such that IR may order such components in sets of ten loco sets for 51st self-steering bogie onwards. 5.3.5 All indigenous components shall be subjected to fresh inspection involving type testing, design validation and field trials for the first set of components, except as mentioned in Para 8.2 to 8.5. 5.3.6 For this tender requirements, the tenderer must select at least one appropriate Indian partner for indigenous manufacture of all fabricated components , identified in column F of Table 1, given that the Indian partner should have an established record of manufacturing bogie frames and components. 5.3.7 In case, the offer is made by this Indian partner, the evidence in respect of design, manufacture and supply of service-proven self-steering locomotive bogies and the capability to transfer complete technology, as mentioned above, shall be provided on behalf of the overseas manufacturer. 6. 6.1 DESIGN REQUIREMENTS OF SELF-STEERING BOGIE Bogie Construction Self-steering bogie shall be with a weld fabricated bogie frame for the Indian Railways GT46MAC (WDG4) locomotive. The contractor shall ensure fitment of self-steering bogie in WDG4 locomotives as follows: 6.1.2 Any modifications required for successful adaptation of offered self-steering bogie under WDG4 underframe including changes like re-location of TM air duct openings and secondary rubber spring seats etc should be clearly brought out by the contractor along with feasibility and methodology to achieve it. The contractor shall identify & indicate these design changes in existing WDG4 underframe. Preparation of engineering drawings for underframe & its manufacture shall be the responsibility of IR. 6.1.3 The existing location of centre pivots on WDG4 locos shall not be changed. Similarly, the length of the self-steering bogie shall not be more than that of the existing WDG4 HTSC non self-steering bogie to avoid infringements with MMD and other locomotive assemblies. In case these conditions are not met, the tenderer shall bring out the reasons for the same in their offer. The car body centre pivot link design of WDG4 locomotives shall, in any case, be retained. 6.1.4 The self-steering bogie shall be so designed that when interfaced with the WDG4 carbody, it shall fit within the MMD envelope as mentioned in Para 3.2.5. 6.1.5 Reduction of axle spacing, if required to improve the negotiability & weight, shall be done without infringing the component accessibility requirements for maintenance.
Motive Power Directorate (VDG), RDSO, Lucknow Specification No. 0.4900.15 (Rev.04) of September 2011 Page No. 7

* The 10 bogie kits under column D shall be supplied with only 7 bogie frames wherein 6

Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives

6.1.6 Suitable arrangement should be provided to lock the self-steering mechanism whenever required. 6.2 Bogie Dimensions The offered design of self-steering bogie with new wheels when interfaced with existing WDG4 locomotive carbody in empty condition shall be within the dimensions shown in IR MMD mentioned in Para 3.2.5. The OGA drawing of the existing HTSC bogie is enclosed. 6.3 Wheel/ Axle/ Gears/ Traction Motor Assembly and Un-sprung Mass The wheel/axle/gear/traction motor assembly shall be the same as that for the GT46MAC (HTSC non self-steering) bogie. This assumes use of the EMD / Siemens 1TB 2525-OTA-02 as well as 1TB 2622-OTA-02 AC traction motor. The un-sprung mass shall not exceed that of the HTSC bogie on the GT46MAC locomotive. Layout drawings for the bogie assembly with aforesaid AC traction motor is enclosed. Mono block wheels of solid one-piece multi wear type made of heavy-duty steel confirming to EMD drawing no. 40077314 & axle to EMD drawing no. 40076350 shall be used. The wheel roller bearing used shall conform to EMD drawing no. 40077969. 6.4 Bogie Frame Design: The weld fabricated self-steering bogie frame shall be designed for an axle load of 22.5 metric tonnes. Although the contractor may recommend different axle and bearing for 22.5 T axle load application, for current supply, axles and bearings shall be the same as that of GT 46 MAC, as mentioned in clause 6.3. It shall preferably consist mainly of straight box sections designed to integrate the necessary steering components. The bogie frame shall be of a robust, high quality and cost-effective design suited for ease of manufacture. It must be optimized for the manufacturing techniques of weldments to achieve a high life expectancy and reliability. The contractor shall, however, be required to work out a 25 tonne variation of the design also for IR to employ the same in future; it being understood that this requirement is for the structural design of the frame and suspension and does not imply that the other equipment like traction motors would be suited for the higher tractive effort associated with 25 tonne application. An additional bogie weight allowance of 1000 kg per bogie for the structural enhancement of bogie frame, steering beams, traction rods and bearing adapters shall be permitted. It is also understood that both primary and secondary springs, vertical dampers, brake units, and possible other components may need replacement if the bogie design is upgraded from 22.5t axle load to 25.0t axle load application. The requirement of 25.0t variation of the design is an optional item. Contractor may quote separately for this requirement duly giving details of time schedule needed as well as complete price and a complete broad outline of this item. Material: The major structural material for the bogie frame shall be ASTM A572 Grade 50 or equivalent, with minimum yield strength of 345 MPa or 50,000 psi. Special purpose low hydrogen welding processes will be utilized. No pre-heat shall be required for plate sizes up to 1.5 inclusive. For plate thickness of more than 1.5, low carbon steel, not requiring pre-heat or post-heat, shall be considered. If required by the contractor, Indian Railways shall provide a list of readily available structural steel plate sizes in India for the bogie structural steel. 6.5 Steering Components The bogie self-steering mechanism including various steering components should be suitably designed to: 6.5.1 Meet the intended speed potential with WDG4 locomotive carbody. 6.5.2 Must be robust and reliable to operate on IR track standard. 6.5.3 Ensure component accessibility requirement during maintenance.
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Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives

6.6

Brake Rigging All wheels shall be provided with single composition brake shoe acting on the wheel tread. The gross braking ratio shall be the same as for the WDG4 HTSC non self-steering bogie operating on Indian Railways. The system shall include a suitable device for taking up slack etc. Detailed calculations for the brake power along with brake rigging diagram shall be provided by the contractor. Adequate safety straps below the moving components of brake rigging (or any other alternative arrangement) shall be provided to prevent fouling with track in the event of failure of any component.

6.7

Parking Brake Electrically or pneumatically operated parking brake shall be provided so that no manually powered operation is required to apply and release the parking brake. Locomotive with self-steering bogies shall have equivalent or higher parking brake holding capability than that of existing WDG4 locomotives. Bogie Suspension With the fabricated bogie frame consisting of box sections, the primary helical coil springs and the secondary rubber springs should be suitably accommodated such that the loco does not infringe the prescribed IR MMD when the bogie is interfaced with the WDG4 locomotive carbody. Sanders The bogies shall have 4 inboard and out board sand nozzles and hardware that are compatible with the sanding equipment on the WDG4 car body. Pneumatic sanding shall be provided for both bogies and it shall be effective in either direction of travel. Sand pipe nozzles shall be located at a distance of 30mm from rail level and the height of the nozzles shall be adjustable to cater for the wheel wear.

6.8

6.9

6.10 Wheel Set Trolley To handle the eventuality of axle getting locked on line, a suitable working procedure to lift (suspend the affected axle on bogie frame) the locked axle should be specified by the contractor. In case this is not feasible, the contractor shall assist IR in developing drawings for a wheel set trolley (towing equipment) of appropriate design with instruction manual for safely towing the locomotive to the maintenance shed. It should be lightweight and reliable design easy to carry to the site and convenient to assemble. 6.11 The tenderer should bring out in the technical proposal, any other relevant technical requirements other than those mentioned above, which are essential for successful operation of these bogies. 7. 7.1 METHODOLOGY OF DESIGN DEVELOPMENT The methodology used for design development shall provide for active involvement of IR personnel, mainly from RDSO & DLW, broadly as per the activities and milestones as follows: Though RDSO would prefer the time schedule indicated, however contractor may quote its best possible offer. Activity by the Contractor Activity of IR Personnel Remarks Completion By (Weeks) D + 32

7.1.1

Preparation of concept layout in line with the specification.

Motive Power Directorate (VDG), RDSO, Lucknow

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Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives

7.1.2

Dynamic simulations with new as well as worn wheel profiles based on the said concept layout using a Multibody dynamics simulation software.

7.1.3

Two IR personnel to be involved in the process of simulations such that they can run simulations on ADAMS / Rail dynamics simulation package or equivalent at the contractors premises. Concept design review with IR techno-managerial team and experts team of the contractor, and approval of the concept by IR. Activity by the Contractor Activity of IR Personnel

Conceptual layout and simulation results shall be delivered to IR.

Remarks

Completion By (Weeks)

7.1.4

Preparation of Engineering drawings.

7.1.5

FEA of bogie frame and major components.

Four IR personnel to be involved in the process of solid modeling on Unigraphics and drafting at contractors premises. Two IR personnel to be associated in the process of FEA for insight into the methodology used by the contractor at contractors premises.

The solid model shall be delivered to IR. FEA results shall be delivered to IR.

D + 60

7.1.6 7.1.7 7.1.8

Finalization of Engineering design. Detailed design review with IR techno-managerial team at contractors premises and approval of the design. Review of the drawings from Four IR personnel to be associated manufacturability standpoint in in the process at contractors association with the suppliers of premises. major components Development of static and fatigue Two IR personnel to be associated (dynamic) structural test during the development of test procedures, load levels and cycling procedure at contractors premises. sequences and association with IR during actual testing. D + 65

7.1.9

D + 72

7.1.10 Release of final solid model of the Preparation of final 2-D drawings A set of final solid bogie assembly with all components work based on the said model shall model shall be based on the results of all previous be done at RDSO. delivered to IR. studies and fatigue testing. 7.2 Based on the above model, the working man days of IR personnel who shall be deputed to work at the R&D/Design centre of the contractor during design and drafting vehicle dynamics modeling and simulation and FEA etc., as mentioned in para 7.1 above, shall be indicated by the contractor activity-wise, given that this shall not be less than 150 man days and that the to and fro fare and living expenses of all such IR staff shall be borne by Indian Railways. This is over and above the training man days mentioned in clause 10. In addition to the above exercise of association during design, two specific higher level detailed design review meetings shall be held between representatives of Indian Railways and the contractor to ensure suitability of design and smooth progress of ToT. These meetings shall be held in the manufacturer's premises.

7.3

Motive Power Directorate (VDG), RDSO, Lucknow

Specification No. 0.4900.15 (Rev.04) of September 2011

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Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives

7.4

Besides, the contractor shall also undertake the following activities and furnish the relevant calculations / computerized analysis results showing the extent of improvements in various parameters as follows vis--vis WDG4 HTSC non self-steering bogie: 7.4.1 Angle of Attack (AoA) of the leading axles on curves. 7.4.2 Lateral forces at axle box level. 7.4.3 Rail / wheel wear. 7.4.4 Flange wear index on curves. 7.4.5 L/V ratio (derailment co-efficient). TYPE TESTS, DESIGN VALIDATION AND FIELD TRIALS The above exercise shall constitute the following stages: Stage Responsibility Inspection Agency Stage inspection of fabrication at manufacturers premises Static load test of bogie frame at manufacturers premises Fatigue testing of bogie frame Contractor IR

8. 8.1

Remarks -

Completion By (Weeks) D + 95

8.1.1

8.1.2 8.1.3

Contractor Contractor + RDSO

IR IR

Actual fatigue testing shall be done at RDSO on the spare bogie frame. On completion of testing, the said bogie frame shall be scrapped. Strain gauging to be done under the supervision of RDSO as per the stipulations of IR. Supply of items for strain gauging shall be ensured by the contractor. -

D + 100 The contractor may quote their alternatives so as to meet the end objective in proper time frame. D + 104

8.1.4

8.1.5

Final Inspection of bogie frames and components at manufacturers premises Final Assembly Inspection at DLW Road Run Trial at DLW Oscillation Trials (See Clause 8.3 also)

Contractor

IR

DLW under supervision of contractor IR IR

IR

8.1.6 8.1.7

IR RDSO

8.1.8

Steady State Curving

IR

RDSO

The contractor shall depute their design and ToT team during the assembly of the prototype bogies at DLW. In association with the contractor. In association with the contractor, who shall provide a minimum of six instrumented bearing adapters for fitment in the leading bogie of the locomotive. The detailed drawings of adapters shall also be given by the contractor to IR for use in future. In association with the

D + 116

D + 128

Motive Power Directorate (VDG), RDSO, Lucknow

Specification No. 0.4900.15 (Rev.04) of September 2011

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Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives

Test (See Clause 8.4 also) 8.1.9 Performance Rating Trials IR IR RDSO IR

contractor, who shall provide the details of the instrumentation and test method. In association with the contractor D + 136

8.1.10 Service Trial and Evaluation (See Clause 8.5 also) 8.2

Three prototype locomotives shall be initially assembled by DLW and therefore the contractor shall supply first six prototype bogie kits initially including one spare bogie frame for fatigue testing (i.e. a total of seven bogie frames) by D + 108 weeks. The first prototype locomotive fitted with self-steering bogies shall be subjected to the oscillation trials by IR to ascertain the operational performance, capability and safety; the contractor shall, however, associate and actively assist IR during the trials. The locomotive fitted with the selfsteering bogie shall fulfill the prescribed stability and riding quality criteria. The prototype locomotive shall be subjected to trials on track maintained to main line as well as C&M1 Volume 1 standards at test speeds up to 115 Km/h (10% above operating speed), in four configurations viz., instrumented bogie leading and trailing with new and condemning wheel profile. The trial procedure shall be as per RDSO report no. MT-288, April 2001. The following criteria will be adopted for clearing the stock for regular operations: 8.3.1 The lateral/ transverse forces lasting more than 2 meters shall not exceed 4.5 tonnes, when measured at the wheel axle box level. 8.3.2 Evaluation shall also be done in terms of ride index which shall not be greater than 3.75. 8.3.3 A derailment coefficient should be worked out in the form of ratio between the lateral force (Hy) and the wheel load (Q) acting continuously over a period of 1/20th second and the value of Hy/Q shall not exceed 1. 8.3.4 The value of acceleration recorded as near as possible to the bogie pivot in the driving cab, shall be limited to 0.3g both in vertical and lateral mode. A peak value upto 0.35g may be permitted, if the records do not indicate a resonant tendency in the region of the peak value. 8.3.5 A general indication of stable running characteristic of the locomotives as evidenced by the movement of the bogie on straight and curved track and by the acceleration reading and instantaneous wheel load variation/ spring deflections.

8.3

8.4

The first prototype locomotive shall also be used for Steady State Curving test. The contractor shall provide the method of measurement of desired parameters as well as the method of calculation of AOA (Angle of attack) on leading bogie from the test data. The contactor shall also provide the list and details of equipments required for the measurement of AOA, along with the price list. The other two prototype locomotives fitted with the self-steering bogie shall be evaluated during field operation under actual load conditions for a minimum of three months, mainly to evaluate the superiority or equivalence of maintainability, accessibility, reliability and availability of the selfsteering bogies vis--vis the conventional WDG4 bogies. This evaluation is also intended to prove not only reliability of the operational performance under different conditions of track, load, operating conditions, etc. but also assess the maintainability, accessibility of components and such other aspects which have been envisaged in this specification.

8.5

Motive Power Directorate (VDG), RDSO, Lucknow

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8.6

Mutually agreed modifications found necessary as a result of the tests/ trials shall be incorporated by the contractor at his own cost in the locomotives in a manner approved by the purchaser. Drawings incorporating the modifications found necessary, as a result of tests and trials, shall be submitted by the contractor to RDSO and DLW.

8.7

After successful oscillation and field trials, duly certified by RDSO, the contractor shall be given clearance to supply the balance 04 bogie kits (excluding bogie frames and components marked X in Table-1 Column D) and 40 component kits. Any specific field trial requirement for indigenous kit shall be mutually decided by IR and the contractor. The supply of balance 04 bogie kits shall be completed by D + 140 weeks and 40 component kits by D + 158 weeks. All supplies shall be subjected to pre-inspection by RDSO/ authorized representatives before their dispatch.

8.8 8.9

8.10 Complete bogie assembly for first 05 loco sets shall be done at DLW under the supervision and guidance of the contractor. 8.11 Fatigue testing shall be done concurrently with oscillation trials and field evaluations. 9. 9.1 SCOPE FOR TRANSFER OF TECHNOLOGY As mentioned in Clause 7, the contractor shall ensure involving IR, mainly RDSO and DLW, actively in design of self-steering bogies so that it greatly complements the TOT activity as such. In addition to the transfer of know-how already covered under the Clause 7, the contractor shall undertake to transfer complete technical know-how (the offer should bring out clearly how same shall be transferred including form/ format and mode) for design, manufacture and maintenance of self-steering bogie including: 9.1.1 Design calculations and use of computer aided design packages utilized for development of design of bogies described in this specification comprising entire UG model of the radial bogie designed for IR, the vehicle model for simulation through ADAMS Rail or equivalent, the dynamic simulation report, FEA report of bogie frame, steering beams, bearing adapters, and other components. 9.1.2 The contractor shall supply a complete set of drawings for tools, jigs and fixtures to be used for assembly of self-steering bogies and extend their technical support and assistance for indigenous manufacture and development of indigenous source(s) as laid down in para 5.3.3 and 5.3.6. 9.1.3 Detailed key and manufacturing drawings, type and routine test details, batch analysis and QAP (Quality Assurance Plan) of the bogie assembly and its components, including stage & final inspection and testing, with special stress on bogie assembly facilities and plant layout. The drawings shall include dimensions, tolerances, surface finish and material specification of all equipment/components. 9.1.4 Manufacturing process sheets including detailed comments on special techniques for welding, forging or casting, heat treatment, assembly etc, wherever applicable. 9.1.5 Detailed specifications for special machines and plants, including details of jigs, fixtures and special tools required for manufacture, inspection and testing of the bogie assembly and its component etc. 9.1.6 Test and inspection plan for raw materials used in manufacture of bogie assembly and its components. 9.1.7 Detailed maintenance instructions for the bogie assembly, to be tailor-made to coincide with the schedules of maintenance in vogue for WDG4 locomotives
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9.1.8 Other technical clarifications and supplementary instructions as may be required for successful manufacture of bogies. 9.2 9.3 The contractor shall depute their adequate & qualified staff to DLW during assembly of the first 10 bogie kits. The contractor shall ensure continuous transfer of updated design and manufacturing technology during the period of collaboration, which shall be 4 years, or till completion of the entire scope of supply, whichever is later. After this period, all the design and manufacturing documents & deliverables shall be the property of IR without any let or hindrance for use in India. Besides, for all the drawings of self-steering bogie designed for IR, the contractor will continue to provide all updating information for aforesaid period for all drawings which have been revised. Indian Railway will have the full right to get the bogies of this design and its components covered by the TOT, manufactured in its own units or that of its vendors in India, for use in India, during the period of collaboration agreement or after the end of this period. The technology transfer shall get under way immediately after the agreement is signed. Successful completion of the ToT shall require that a series of ToT meetings to be held at the premises of the manufacturer as well as at DLW & RDSO, over and above the design review meetings mentioned earlier. TRAINING Contractor shall arrange to train Indian Railways personnel in his premises or premises of his subsuppliers in design, manufacture, quality control, inspection, inventory control, cost benefit analysis & maintenance of self-steering bogies. In addition, for maintenance and repair practices, the contractor shall arrange for training of Indian Railway personnel with some of the user railroads. A total of 300 working man-days shall be provided for IR personnel who shall be deputed for training in batches of not less than six persons. The contractor shall allot a minimum of 50 man-days of their personnel exclusively for this activity The training shall include the following (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) FEA of bogie frame, self steering components, bearing adopters, traction rods and other bogie components, Fatigue analysis, yield analysis load case analysis and formulation Vehicle dynamic analysis and simulation Review of related Technical Specifications, concept design review, UG modelling reviews, ,Product requirements review, Detail Design review , Production information review Study of bogie manufacturing & assembling practices including study- visit(s) to factory(ies) manufacturing self steering bogies Repair and maintenance practices of self steering bogies Welding Techniques Development of fixtures for bogie frame Inspection and testing practices for bogie Production informations, Spares and inventories required for self steering bogies.

9.4 9.5

10.

For the purpose of training, to and fro fare and living expenses of IR personnel shall be borne by Indian Railways. The training imparted shall be adequate to develop design capability and to ensure full technology transfer. Tenderer should bring out the scope and depth of training plan envisaged.
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11.

WARRANTY, SPARE PARTS AND SERVICE MANUALS

11.1 The self-steering bogie as a whole, as well as equipment, systems and sub-systems shall have warranty for satisfactory performance for a period of 3 years from date of commissioning. All aspects of workmanship and design shall be covered by this warranty. Only wearing parts, which require recurring replacement shall be excluded. A list of such parts should be furnished by contractor in his technical offer. This warranty shall include: 11.1.1 Replacement of defective components, free of cost C.I.F. India by the contractor. 11.1.2 The contractor shall provide free of cost assistance in replacement of defective components/ assembly. 11.1.3 Any specialized tools etc not available with Indian Railways shall be supplied/ loaned free of cost by the contractor. 11.2 The contractor shall indicate, in an itemized list, life expectations of components subject to wear under Indian ambient conditions. 11.3 The contractor shall make recommendation suggesting scale of spares and necessary tools, jigs and fixtures required for maintenance of 50 such bogies for a period of 06 years at the time of submitting the final design for approval to the Railway. Price proposal for these shall also be submitted along with this recommendation by the contractor. The contractor shall ensure continuous availability of spares and other equipments at these prices for maintenance of self steering bogies. 11.4 The contractor shall furnish Instruction Manuals for operation and maintenance of bogies and its components, trouble shooting instructions, Spare Parts Catalogue and other technical information as may be required for maintenance of bogies in India. These manuals / instructions shall be supplied in electronic copy to RDSO, Lucknow and DLW, Varanasi. 12. DELIVERABLES AND SCOPE OF SUPPLY

12.1 Supply & assembly of six bogies kits functionally working as per this specification. 12.2 One Self Steering radial bogie frame for endurance testing as per the prescribed scheme. 12.3 Oscillation Trials: Successful completion of oscillation trial in line shall be considered as one deliverable. 12.4 Satisfactory Field Trials as mentioned in clause 8.5. 12.5 Supply & assembly, trials and field performance of balance 4 bogies kits functionally working as per this specification. 12.6 Training as per relevant Para of this specification. 12.7 Complete Transfer of Technology as per this specification. 12.8 Forty (40) component kits as per Column E & F of Table 1 under Para 5. 12.9 Other Items as mentioned in this specification or as considered essential by the tenderer under various clauses. (Firm should bring out any other relevant deliverable essential for the completion of this self steering project). 12.10 Tenderer should quote for each of the above heads separately & clearly and in appropriate currencies, duly indicating all taxes & duties including withholding tax etc and any other charges applicable. If these are not mentioned, same will be considered as inclusive. 12.11 Tenderer should also indicate clearly, the total all inclusive cost. 13. DEVIATIONS & TECHNICAL CLARIFICATIONS Deviations to this specification, if any, shall be indicated clearly and the same shall be considered on merit. Any further technical clarifications required by the tenderer, can be obtained from Director
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Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives

General, (Motive Power) Research Designs and Standards Organisation, Manak Nagar, Lucknow226011 (India). 14. Special Clauses Design development and supply of bogie components as per the specification Transfer of Technology Training Activity 14.2.1 Completion of activities as per Para 7 of this specification followed by: Supply and assembly of six (06) bogie kits functionally working as per this specification. Supply of one self-steering bogie frame for endurance testing as per the prescribed scheme. 14.2.2 Successful completion of: i. Oscillation trials and Steady State Curving test of the first prototype locomotive fitted with self-steering bogies in India. ii. Evaluation of other two locomotives fitted with self-steering bogies during field operation under actual load conditions for a minimum of three months. Successful modifications found necessary as a result of the tests/ trials shall be incorporated by the contractor at his own cost in the locomotives in a manner approved by the purchaser. Drawings incorporating the modifications found necessary, as a result of tests and trials, including their submission by the contractor to RDSO and DLW. 14.2.3 Supply & assembly, trials and field performance (subsequent to successful oscillation and field trials of first six (06) bogie kits) of balance 04 bogie kits functionally working as per this specification (excluding bogie frames and components marked X in Table-1 Column D of this specification). Supply from 11th to 50th bogie kits to be made in lots of 04. 14.2.4 Successful completion of Transfer of Technology as per this specification. (a) Completion of activities under paras 7.1.1, 7.1.2 and 7.1.3 of this specification. (c)Completion of activities under paras 7.1.4, 7.1.5, 7.1.6 and 7.1.7 of this specification. (d) Completion of activities under paras 7.1.8, 7.1.9 and 7.1.10 of this specification. (e)Completion of activities as at para 7.4, final assembly inspection of the first loco set of prototype bogies
Motive Power Directorate (VDG), RDSO, Lucknow

14.1 The tenderer shall quote separately for the following item wise:

14.2 Payment Schedule Payment 50% of the contract value of supply of 6 bogie kits and one spare bogie frame

Balance payment for supplies of 6 bogie kits and one spare bogie frame

To be made in lots of 04 bogie kits each on pro-rata basis.

20% of TOT contract value against bank guarantee 25% of TOT contract value against bank guarantee 20% of TOT contract value against bank guarantee 20% of TOT contract value against bank guarantee
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(f) Completion of activities as at para 7.4, final assembly inspection of the first loco set of prototype bogies (g)Completion of all TOT works

10% of TOT contract value against bank guarantee Remaining payment of TOT contract value against bank guarantee The first instalment of 50% will be paid after 150 working man-days of training and the other instalment of 50% after completion of remaining training man-days. All balance payments (if any) of the contract on execution of the necessary Warranty bank guarantee

14.2.5 Successful completion of training as per this specification.

14.2.6 Expiry of Contract including completion of all supplies, ToT and training

On completion of each milestone/activity, party will submit invoice for material supplied and successful completion of activity to be certified by ED/MP/RDSO. All payments will be made through electronic means /irrevocable unconfirmed LC. 14.3 Payment shall be made after Stage wise Certification by RDSO on completion of each activity as above. 14.4 Tenderer shall be responsible for safe delivery (inclusive of loading, unloading and safety / protection and installation/ commissioning) of all consignments / physical deliverable and accordingly quote as up to Destination. 14.5 Delivery for all bogie and component kits shall be made to DLW, Varanasi, India and for the endurance test, bogie frame delivery shall be made to RDSO, Lucknow, India. 14.6 Firm should separately bring out the freight component for each such delivery. 14.7 Successful tenderer shall nominate a project monitoring group to ensure timely and satisfactory completion of all activities related to this project in a professional manner and to liaison with Motive Power Directorate of RDSO and DLW/ Varanasi. 14.8 For the products which are manufactured in India, the payment shall be done in Indian Rupees after successful delivery of materials to the consignee. For items manufactured outside India, payments will be made in the currency(ies) of the country(ies) where they are manufactured.

Motive Power Directorate (VDG), RDSO, Lucknow

Specification No. 0.4900.15 (Rev.04) of September 2011

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