- 1. Modernization of Stores Depot at Carriage Repair
Workshop,Lower Parel, Western Railway through Implementation
ofIntelligent WarehousingwithAutomated Storage & Retrieval
System (ASRS)
2. The inconvenient Truth
- Warehousing did not get its due importance on the Indian
Railways because;
- Materials management was always considered an ancillary
activity.
- When ever a new Locomotive sheds or a carriage workshop was
planned, provision for the warehousing was never given a
thought.
- It was always believed that once the workshop a locomotive shed
comes up, warehousing for the material shall take care of
itself.
- In the name of a warehouse, a ramshackle godown or an old steam
shed or an abandoned building wasprovided in the name of a stores
depot.
- This continues even today.
3. Recent Examples on WR
- New Electric Locomotive workshop at Dhaboi with an area
of>2.5 LakhSq.mhas a provision of only15 m X 100 m for the
materials management including warehousing.
- New CoachPOH workshop at BVP with an approximate area of 3 lakh
sq. mhas a provision for 15mX 100 m for the warehousing
purpose.
- New Mahim Scrap Depot in WR has a provision of13000 sq.m
consisting of 20 bins of 15m * 12 m each.
- Why is all this happening and what is the solution ?
4.
- Is Materials Management department required in the railways
?
- If the answer is yes, Why the above scenario ?
- Lack of will and vision in the departmental officers.
- We want to be Goody Goody.
- Don't want to raise inconvenient questions.
5.
- Warehousing as well as the supply chain management still
pertains to the era of Stone Age.
- Result: Archaic Procurement Rules.
- Spoilage and rusting of costly material
- Block storage on the ground floor
- Inundation of material during flooding, leaking roofs etc.
- Presently Modernization means getting a forklift or a Truck
from the Sr.DEE in a locomotive shed or Dy.CME in a workshop .
6. Modernization of Carriage Stores Depot at Carriage Repair
Workshop, Lower Parel, Western Railway
- CarriageStores Depot at Lower Parel is the biggest Stores Depot
on Western Railway.
- Annual material issues value of Rs. 600 Million.
- Accounts forapproximately 25 % of the annual issues on Western
Railway.
- Caters toCarriage Workshop &Divisional Consignees
(29).
- It stocks around 1200 stock items out of which 167 are safety,
257 are vital, 38 passenger amenity items .
- LHB Coachis a new technology with many items being imported and
limited indigenous vendors
7. Coach Holding of Parel Workshop TYPE ICF ICF-SHATABDI LHB
Holding 3000 60 110 8. 9. Major activity at Parel Workshop 36 62
LHB 15 5 0 1531 ICF POH 07-08 (estimate) 2006-07 Type Activity
Refurbishment of toilets, changingthe main door LHB Refurbishment
of toilets, Laying of Stainless Steel Inlay, changing LP Sheet,
Limpet Sheet ICF RSP 10. DivisionalFeeding points of Parel Stores
Depot Division Carriage Repair Depots BCT BCT, BDTS, BL, ST BRC
ANND ADI ADI, KKF, NBVJ, GIM RJT RJT, OKA, HXP RTM RTM, IND,BVP
BVP,VRL,PBR 11. Feeding Points Stores DepotLowerParel Carriage
Repair Workshop WR Divisions CWS-ADI-BG (165) CWS-ADI-MG(150)
CWS-RTM-P (54) CWS-BCT (56) CWS-BDTS(121) CWS-TRS-BAMY(5) CWS-BL
(114) CWS-ST (128) CWS-BRCP (20) CWS-ANND (73) CWS-SBI-MG(2)
CWS-BVJ (122) CWS-GIM (125) CWS-IND (163) CWS-MHW (24) CWS-UJN (13)
CWS-COR (13) CWS-BVC (117) CWS-PBR (123) Mumbai Baroda Ratlam
Ahmedabad Bhavnagar Rajkot CWS-RJT (115) 12. Annual issues &
closing Balance YEAR ISSUES( in 10 Million) BALANCE ( in 10
Million) TOR ( %) 2004-05 42.33 10.22 24.14 2005-06 46.01 10.11
21.97 2006-07 58.71 10.97 19.34 13. Annual usage value of various
category of stores 14. Category of items at Parel depot 15.
Modernization of Carriage Repairs Depot at Carriage Repair
Workshop
- Stores depots on the Indian Railways are housed in a
dilapidated structures released from the old steam loco sheds or
abandoned carriage depots.
- Hence the structural strength as well as mechanizationis almost
nil in the old stores depots.
- In the estimate for new workshops or Diesel/Electric Loco
Sheds, few godowns are provided in the name of stores depot without
M&P & material handlingequipment.
- The entire gamut of activities in the workshops have been
mechanized with the inclusion of new technology.
- The material storage , handling and transportation in a stores
depots needs to be modernized so that instead of just acting as a
warehouse , the storesbecome a part of the supply chain management
and the production process.
- Presently, they work more as godowns rather than modern
warehouses.
16. Present Status 17. 18. 19. What does modernization involve
?
- Pragmatic mix of IW-ASRS, Drive in Pallet System, Selective
Pallet System, conveyor systems etc.
- Structurally strong building with adequate free height for
vertical storage.
- Adequate material handling equipments and transportation
facilities such as platform trucks, forklifts , LMV, HMV .
- RDBMS based IT application for purchase & Inventory
management with adequate Hardware resources.
20. Works Program May 2009 Railway Board > 50 Million
June-July 09 Railway Board > Rs. 20 Million but < Rs 50
Million Pink Book June-July 09 Railway Board >Rs. 3 Million but
< Rs. 20MillionFeb 2009 GM < Rs. 3 Million LAW BOOK
Commencing Yaer Sanctioning Authority Value of Works Plan Head 42
21. Machinery &Plants Program May 2008 Railway Board >Rs. 10
Million Sept/Oct 08 Railway Board > Rs. 1 Million but < Rs 10
Million Pink Book Sept/Oct 08 Railway Board Any Vehicles Sept/Oct
08 GM < Rs. 1 Million LAW BOOK Commencing Year Sanctioning
Authority Value of Works Plan Head 41 22. Process Involved in
creation of Infrastructure Facility1
- .Preparation of detailed Proposal by the field unit suo moto or
based on instruction of some senior officer
- Concurrence by associate finance
- Administrative approval of HOD
- Sanction ofAGM/GMup to 30 lakhs for normal items and up to 50
lakhs for safety works
- Concurrence of Railway Board finance for works > 30
Lakhs
23.
- Approval of Concerned Member I.e Member Mechanical for
Machinery & Plants as well as RSP and Member Engineering for
Works Program.
- Proposals above 5 crorers requires the approval of Minister for
Railways.
- Proposals above 50 crorers usually require the approval of
Cabinet.
24.
- Receipt of Sanction from Railway Board
- Approval of funds for the proposal
- Preparation of detailed estimate for the proposal
- Procurement of item or execution of work.
25. Works Program
- Railway Board fixes the financial limits for various plan
heads.
- Field units send vetted proposals to Hq.
- Zonal HQ coordinates the proposals .
- Major works costing > 5 crorers are submitted to Railway
Board in advance for scrutiny and clearance
- Works program is submitted 18 months in advancein respect of
works chargeable to CAP, DRF, DF, OLWR, CF under demand No. 16
26.
- PWP is initiated by field units in June/July and submitted for
net year in September.
- Railway Board takes a final decision after discussion with the
GM
- Parliament finally approves the same under various heads such
as assets, acquitions, construction, replacement .
- These are financed from CAP, CF, DRF,DF,OLWR
27. Summary of WP
- Identify requirement, detail, scope, worksite sketch,
feasibility, manpower reduction, new technology
- Acceptance by B.O and preparation of abstract estimate
inclusive of sub estimate pertaining to different departments.
- Obtain administrative approval of DRM/HOD.
- Get finance concurrence and sent it to CME/Planning.
- HQlist proposals in 3 categories.
- A. > 5 crorers, b. 30 lakhs to 5 crorers, c. < 30
lakhs
- The grouped proposals are put up to the concerned HOD &
PHOD
- Administrative approval of CME in consultation with other
H.O.D
- All the three lists put up to CE-Planning
28.
- Works programme meeting chaired by G.M and attended by all phod
for prioritizing and finalsing.
- Separate meetings for works above 5 crorers and others.
- Proposals approved by GM are putup to finance for
concurrence.
- After finance concurrence, all proposals are handed over to
CE-P for inclusion in PWP of the Railway for onward submission to
Railway Board.
- Works Programme meeting is held in Railway Board attended by
GMto finalise the works.
- Railway Board conveys the approval of works through the pink
Book
29.
- Works above Rs 50 Lakhs are itemised.
- Works less than Rs 50 Lakhs are given as lumpsum.
- At the Railway Level, works > Rs 50 Laks and having a major
portion of civil work are executed by CAO-C
- works > Rs 50 Laks and having a major portion of mechanical
l work are to be executed by person nominated by CME
- Works costing < Rs 50 Laks are executed by the division
30. Estimated cost of the project
- Sanctioned in M&P Program for the year 2007-08 under plan
head 41.
- Drive in Pallet & Selective Pallet System.
- Platform Trucks & Others.
Rs. 115 Million Rs. 10 Million 31. Preliminary Work
involved-1
- Find out the weight of individualitem to be kept in the
ASRS
- Find out the dimensions of each item.
- Find out the weight and dimension of items traditionally being
received in the existing packaging conditions.
- Work out the number of pallets required.
- Work out the No of aisle, height and width.
32. Preliminary Work involved-2
- Select the area for the ASRS.
- If Greenfield project, decide the type of building to be
constructed.
- For old workshops , land is a constrain.
- Think of demolishing the existing structure.
- New storage area during the construction activity to be
planned.
- Workshop shall normally be reluctant to provide new area during
the interim construction period.
- Fight for new Space during construction period.
33.
- Involve civil consultants for new or modification to existing
building.
- Try to get the soil test report for an existing nearby areaor
hire a consultant for the same.
- Vetting by associate finance.
34.
- Approvalof Mech, Civil, Electrical ,Stores H.O.D.
- HQ finance vetting and approval of GM.
- Inclusion in PWP of the Railway for submission to Railway
Board.
- ConvinceAM(PU),EDME(W), EDF(X), EDF(S), DME(P-II), DF(s)
35. Detailed Estimate
- Get civil estimate from the PEB vendors as well as the civil
engineering department and convert the sane into civil sub
estimate.
- Get estimate of ASRSfrom ASRS vendors and convert that into
mechanical Sub estimate.
- Get electrical estimate from ASRS vendor & convert the same
into electrical sub estimate.
- Approval of sub estimates from respective H.O.D.
36.
- Decision regarding Turn Key implementation.
- Project to be dealt by Materials Management department only
including the civil and other works.
- Prepare single tender document .
- Decide qualifying criterion.
- Decide payment conditions separately for civil and ASRS
work.
- The payment terms must be conducive to the vendors so that
working capital is not blocked and contractors are not in
distress.
37. Other storage & retrieval systems Storage carousel
Push-back rack Shelves/bins/drawers Flow-through rack Mezzanine
Stacking frame Drive-in rack Split case order picking system
Cantilever rack Selective pallet rack Automatic storage/retrieval
systems (AS/RS Unit load AS/RS MiniloadAS/RS Man-on-board AS/RS
Sliding rack Block stacking (no equipment) 38. 1.Block Stacking(No
Equipment)
- Bulk storage using block stacking can result in the minimum
cost of storage since cube utilization is high and no storage
medium is required, but material accessibility is low since only
the top of the front stack is accessible and loads at bottom of a
stack must not require support
- Storage racks are used when support and/or material
accessibility is required
39. Selective Pallet Rack
- Pallets are supported between load-supporting beams
- Special attachments and decking can be used to make the racks
capable of supporting other types of unit loads besides pallets
(e.g., coils, drums, skids)
- Standard single-deep storage using a counterbalanced lift
truck
- Narrow-Aisle storage using a narrow-aisle lift truck
- Deep-Reach greater than single-deep storage (typically
double-deep storage
40. Drive-Through Rack
- Loads are supported by rails attached to the upright beams
- Lift trucks are driven between the uprights beams
- Requires similar-width loads
- Open at both ends, allowing access from both ends (FIFO)
41. .Drive-In Rack
- Same as drive-through rack, except closed at one end, allowing
entry from only one end (LIFO)
42. Flow-Through Rack
- Loads are supported on an incline to enable gravity-based
movement of the loads within the rack (via, e.g., a gravity roller
conveyor)
- Loaded at the higher end and unloaded at the lower end
(FIFO)
43. Push-Back Rack
- Same as flow-through rack, except loaded and unloaded at the
lower end and closed at the higher end (LIFO)
44. Sliding Rack
- Only one mobile aisle is used to access several rows of
racks
- Location of the aisle is changed by sliding the rows of racks
along guide rails in the floor
- Typically found in library stacks
45. Cantilever Rack
- Loads are supported by cantilever "arms"
- Used to store long loads (e.g., bar stock, pipes, lumber)
- Similar to pallet racks, except the front upright beams and the
front supporting beams are eliminated
46. Shelves/Bins/Drawers 47. Storage Carousel
- Carousel consists of a set of vertically or horizontally
revolving storage baskets or bins
- Materials (and the storage medium) move to the operator,
"part-to-man," for end-of-aisle picking
- Each level of the carousel can rotate independently in a
clockwise or counter-clockwise direction
- Control ranges from manually activated push buttons to
automated computer controlled systems
- Provides an alternative to typical "man-to-part" AS/RS, where
the S/R machine moves to the part
48. Automatic Storage/Retrieval Systems (AS/RS)
- Consists of an integrated computer-controlled system that
combines the storage medium, transport mechanism, and controls with
various levels of automation for fast and accurate random storage
of products and materials
- Storage/retrieval (S/R) machine in an AS/RS operates in narrow
aisle, serving rack slots on both sides of aisle; can travel in
horizontal (along the aisle) and vertical (up and down a rack)
directions at same time
- Advantages: fewer material handlers, better material control
(including security), and more efficient use of storage space
- Disadvantages: high capital Investment.
49. Unit Load AS/RS
- Used to store/retrieve loads that are palletized or unitized
and weigh over 500 lbs.
- Stacking heights up to 130 ft. high, with most ranging from 60
to 85 ft. high; 5 to 6 ft. wide aisles; single- or double-deep
storage racks
50. Miniload AS/RS
- Used to store/retrieve small parts and tools that can be stored
in a storage bin or drawer
- End-of-aisle order picking and replenishment
- Stacking heights range from 12 to 20 ft.; bin capacities range
from 200 to 750 lbs.
- Termed a "microload AS/RS" when used in assembly, kitting, and
testing operations to deliver small containers of parts to
individual workstations, where workstations are typically located
on the sides of a pair of racks and the S/R machine operates
between the racks to move containers to openings in the racks
(storage lanes) located next to each station
51. Man-On-Board AS/RS
- Used for in-aisle picking; operator picks from shelves, bins,
or drawers within the storage structure
- Manual or automatic control
- S/R machine is similar to an order picker or turret truck and
can sometimes operate as an industrial truck when outside an aisle,
except the S/R is guided along a rail when operating in an
aisle
52.
- Working Capacity: 1500 Kg. loads at 100% duty cycle
- End-of-Aisle Run-out Required: 15 ft.
- Height Requirements: 12 ft. to 100 ft.
- S/R Machine Length: 15 ft.
- Aisle Width: 80" Pallet to Pallet
- Horizontal Speed: 700 FPM
General Specifications of IW-ASRS 53. General Specifications of
IW-ASRS
- Construction: Modular component design. All parts designed for
100% duty cycle. Welded steel frame. Single mast tube, strut
braced. Structural steel base.
- Drive and Idler Wheels: Flanged forged alloy steel. Case
Hardened to 55 Rockwell C. Reground for concentricity. Heavy-duty
pillow block bearing support.
- Fork Extractor Mechanism:
- Construction: Precession fabricated steel
- Load Support: Industrial Standard Forks
- Extractor Drive: Patented ball screw and rotator with variable
frequency drives, industrial gear reducers, and brake.
54. Crane Rail with V-H Drives
- Floor mounted , Rail mounted .
- Vertical & Horizontal Drives:
- High performance sine-coded, pulse width modulated AC vector
motor drives which generates an adjustable voltage/ frequency three
phase output for complete speed control.
- Automatic stall prevention and voltage boost prevents nuisance
tripping during load or line side transient conditions.
- The drives will not induce any voltage or distortion back into
the utility line and maintains a displacement power factor of not
less than 0.98 throughout its speed range.
55. Communication & Controls
- Electrical Components : IEEE code compliance throughout. IEEE
rated enclosure, sensors, and wiring. Panel-mounted diagnostic
indicator lights. Panel-mounted maintenance controls.
- Logistics and Positioning : Onboard programmable controller A-B
SLC-500 communication by infrared modem. Steel code bar, optical
address readers. Fine positioning, motor-mounted resolvers with
1/16'' accuracy or 1 deg. Accurate positioning on start-up.
56. Rack & Pallets
- Front and rear aisle-obstruction detectors. Onboard and
off-board emergency stops. Load and centering sensors and
interlocks.
- Virtually any post and beam (conventional) existing or new
racks capable of safely bearing the pallet loads (pushback and flow
rack). Continuity of vertical shelf distance from floor not
required. Common depth dimension recommended, but differing depths
can often be accommodated. Racks must be attached to the floor but
no shimming is needed except with extreme floor conditions.
- Any two or four way pallet capable of being used.
57. Loading/ Unloading Area RAIL RAIL RAIL 58. Vertical crane of
IW-ASRS 59. Drive-in-Pallet System 1 2 3 60. Why use IW-ASRS at
Parel Depot
- Parel workshop has one of the smallestfootprint to Coach POH
ratio.
- Located in the heart ofMetropolitan city-Mumbai with costly
land where lateral expansion is not a n option.
- POH target of ICF, LHB increasing.
- Area can be released for workshop modernization & expansion
activities only by releasing the dead space being occupied by
multifarious stores godowns.
- This is where IW-ASRS comes into play.
- IW-ASRSutilizes vertical storage capacity leading to efficient
storage & retrieval
61. Proposed site at Lower Parel
- Central ward of Parel Depot
- 50% area with mezzanine floor
- Max. free height available 6 m.
- Free height available in mezzanine area is 3 m.
62. Constrains
- IW-ASRS requires a Greenfield area with free height of15to 20
m
- CoarseRubble masonry wall .
- Roof truss supported on 100 year old Cast Iron columns of 6m
height.
- Flooringis uneven with a limited bearing capacity.
- Annual flooding of ground floor during monsoon.
- IW-ASRS requires a free height of minimum 15-20 m .
- Average load per 1.2m*1m pallet is one ton . Each pallet column
can go up to 15 bays .
- Hence bearing capacity of the flooring should be 12 MT per 1.2
sq.m
63. Solution
- Break Mezzanine floor with area of 25m*45m to obtain free
height.
- New foundation for the columns.
- New Columns of 20m height.
- New hardonite flooring with leveled ground for movement of
sophisticated machinery
- Raise wall height byusing prefab light weight material
- Uselight weight roofing material having energy saving
features
64. Activities involved in ASRS
- Civil Engineering work of site preparation
- Leveled flooring with adequate bearing capacity
- Adequate free height for 15-20 m for vertical storage &
movement of vertical crane.
65. ! 66. Modus Operandi of execution
- Prepare detailed sub estimate of electrical, civil &
mechanical portion .
- Obtain sanction of respective HOD.
- Prepare material schedules for purchase components .
- Prepare tender schedule for works portion.
- Obtain dispensation from COFMOW.
- Float only one works tender to take care of mechanical, civil
as well as electrical work to be carried out by a single agency on
a turn key basis.
- Have provision for operation for 2 years by the contracting
agency along with training to be followed by fiveyears
comprehensive AMC.
67. PLAN, ELEVATION & SECTION OFPAREL STORES DEPOT 68. FRONT
VIEW OF IW-ASRS AT PAREL STORES DEPOT 69. TOP VIEW OF PAREL STORES
DEPOT WITH IW-ASRS 70. PALLET & SECTION AT C 71. What and where
is the central ward ?
- The location of ASRS shall be the central ward.
- Central ward measures 60m X 45 m ETE.
- On the north end of CW is CR2 Shop.
- On the Southof CW is macadam road.
- On the east of CW is fitting shop
- On the south of CW is rail line
72. Layout of C ward Dy.CMM-PLChamber CA/TA toDy.CMM lift AMM,
Ledger Section & computer cell NF Ward DMS Returned stores&
platform Survey Plot &Loading platform 73. LAYOUTFOR THE
PROPOSED ASRS AT THE CENTRAL WARD 74. Installation of IW-ASRS
- Transport the material to the prepared ASRS site.
- Provide Bill of Material along with WTC.
- Get Payment for 80% of material cost.
- Cranes, Transfer Car, Pallets etc.
- Integrated with Warehouse Management System
- Integrate with Depot Module of MMIS
75. Existing Plan of Roof forCentral Ward Existing Elevation of
Roof forCentral Ward Dy.CMM-PLChamber CA/TA toDy.CMM lift AMM,
Ledger Section & computer cell NF Ward DMS Returned stores&
platform Survey Plot &Loading platform 76. Future elevation of
Roof forCentral Ward Dy.CMM-PLChamber CA/TA toDy.CMM lift AMM,
Ledger Section & computer cell NF Ward DMS Returned stores&
platform Survey Plot &Loading platform 77. Layout of C ward
Dy.CMM-PLChamber CA/TA toDy.CMM lift AMM, Ledger Section &
computer cell NF Ward DMS Returned stores& platform Survey Plot
&Loading platform 78. CIVIL CONSTRUCTION
- Remove the roof asbestos sheets.
- Transport to BMC dumping ground.
- Provide additional colums to take the load of columns to be
removed at 4,1 to 4,6.
- Dismantle truss and purlins.
- Weigh them and transport to W. R Scrap Yard at Mahim.
- Dismantle west end wall of CW.
- Transport the debris to BMC Dumping Ground.
- Dismantle the Ledger and computer center
- Transport the debris to BMC DG.
79. Civil Work (Cont.)
- Dismantle the south end wall of CW.
- Transport the debris to BMC DG.
- Provide roof for the non-dismantled area.
- Transport them to WR Scrap Yard at Mahim.
80. Civil Work (Cont.)
- Prepare the ASRS working area.
- Constructsuperstructure to house ASRS
81. S/ASRS/LPL/2008/01DATED 07.07.2008openingON 12.11.2008 AT
11.00 HRSSCOPE: Design , fabrication, supply, commissioning and
testing of automated storage and retrieval system at carriage
repair stores depot, lower Parel, MumbaiEMD:7.70 Lakhs. Expected
time of completion:12 TO 15 Months from the date of issue ofsigning
of contract Tender Details 82. Major work involved
- Dismantling of exiting central ward buildingand
construction
- Provisioning of ASRS with crane, racks, pallets, electrical
controls etc.
83. CIVIL WORK INVOLVES Demolishing /dismantling of existing
structure/building and segregation of dismantled debris along with
their transportation to nominated Scrap Yards .Construction of
concrete platform of approximate height 1 Mtr For supporting entire
ASRS structure.Erection of pre-engineered modular
steelstructure/building for housing the ASRS .Provision of High
Rise Racking System with minimum 3840 racking Locations 84.
Provision of cage and plain pallets for keeping material. Provision
of High rise Fully Automated, Computer Controlled, Stacker Crane
and Transfer Car system along with necessary Aisle
Equipment0.Provision of comprehensive Warehouse Management
System.Provision of Electricals, screened partition and fire
protection system for complete ASRS system. CIVIL WORK . CONT. 85.
Two bid system
- Part Ifor Civil Engineering Work
- Part- II forMechanical and Electrical Work
- In prescribed format as given in Annexure B of tender
Document
86. PAYMENT TERMS
- Mechanical and Electrical Work :
- 50 per cent on proof of inspection and dispatch of documents .
For dispatches by Road, 50% payment will be made on receipt of
material duly pre-inspected and receipted at site by the consignee
in good condition
- ii) Balance 40 % payment shall be made after successful
installation &
- commissioning of the ASRS i.e. Cranes , Transfer cars ,racks,
pallets etc.
- iii) Balance 10 per cent payment within 90 days of
commissioning of the entire project on furnishing a Bank
Guarantee.If a Tenderer requests a variation in the payment terms
and if such variation is acceptable to the Purchaser, the same
would be evaluated at an interest rate of12 percent per annumfor
purposes of comparison with other tenders.
87. PAYMENT TERMS Payment will be made for the actual work done
at site on pro-rata basis. The tendered is free to submit its stage
payment schedule based on the activities involved such as
dismantling of building, removal of debris, construction of ASRS
platform, erection of columns, construction of roof etc.Advance
payment ofaccepted rate/structural steel of bars, HTS wires,
neoprene bearings, anchorages, sheathing etc. shall be made after
bringing to the site ofwork and on production of necessary purchase
voucher/Test certificates, an insurance policy covering losses due
to thefts & floods and against indemnity bond submitted by the
contractors and accepted by competent authority. This advance is
recoverable from running bills to the extant quantity of above
material are consumed up to the running bills stage. Sr.No Work
Payment to be made Remarks. (a) Supply of reinforced steel 70% (b)
Supply of material other than reinforced steel 60% (c) Fabrication
& Erection 90% (d) On commissioning 100% 88. EMD & SD EMD.
Deposit Receipt, Pay order,Demand Draft, Guarantee Bonds.
Performance Guarantee/Security Deposit To. Be depositedExcise Duty
& Modvat 89. Technical Specification 1 One Single Mast Stacker
Crane for 1000 mm (W) X 1200 mm (D) X 1200 mm (H) Pallets of one
ton capacity and capable of serving a height of 18 meters or
moreTransfer Car Racking SystemPlain Steel Pallets -:Qty 1920
Numbers of Four way entry Plain Steel pallets ofsize 1000 mm (W) X
1200 mm(D) X 1200 mm (H) Cage Steel Pallets :Qty. 1920 Numbers of
Four way entry four side wire mesh cage steel pallets of size 1000
mm (W) X 1200 mm(D) X 1200 mm Mechanical Aisle Equipments:Railway
railwith adjustable clamps for holding the rails inposition &
to ensure alignment. Top rail shall be mounted on the racking
system through clamps 90. Electrical Aisle Equipments:The
Electrical aisle equipment shall consist of Power rail (fully
enclosed Bus Bar), which is mounted on the racking system below the
first loading level with necessary protection as feature as per
Indian Electricity Act. Controls & Hardware All necessary
controls, PLC, Hardware etc. Software Warehouse Management System
and inverter control system OPERATION CYCLE Technical Specification
2 91.
- The Stacker Cranes should be linked to central computer control
through WMS
- Warehouse Management System(WMS)
- Inventory Control Software (ICS)
- Location Management Software Module (LMS
- Handling Control Software Module (HCS)
Automated Controls and Software 92. DESIGN STANDARDS 1 The
design of the AS/RS should conform to Indian and International
standards, ensuring that best of the System is supplied. Following
Indian and International Standards should be followed. IS 800 1984
General Construction on steel IS 801 1975 Code of practice for use
of cold formed light gauge steel structural members in general
building construction IS 10748 1984 Hot-rolled Steel Strip for
Welded Tubes and Pipes Specification IS 3655 1966 Recommended
practice for electroplating IS 101 1964 Methods of Sampling and
test for paints, varnishes and related Products 93. DESIGN
STANDARDS 2 IS 2074 1992 Ready Mixed Paint, Air Drying, Red Oxide
Zinc Chrome, Priming Specification IS 513 : Cold Rolled Low Carbon
Steel Sheets & Strips IS 325 : 3-Phase induction motor
specifications. IS 1363 : Hexagon Head Bolts, Screws and Nuts IS
2062 : 1999 Steel for General Structural Purposes Specification IS
4923 : 1997 Hollow Steel Sections for structural use IS 2266 :
Steel Wire Rope for engineering purpose. IS 4923 : Hollow steel
section for structural use. FEM 9.311 1978: Rules for Design of
Storage & retrieval Machines Structures. 5.1.15 FEM 9.831 1995
: Basis of calculation for Storage & retrieval Machines
Tolerances & Clearances within warehouse. 5.1.16 FEM 9.851 2003
: Performance Data of S/R Machines Cycle Time. 94.
- Standards- AISCAmerican Institute of Steel Construction(Hot
Rolled ,Built Sec.),
- AISI(American Iron and steel institute) (Light Gauge Cold
worked)
- IS:8750- 1987(Design Load)
- IS: 800-1984 Construction in Steel
- IS: 801-1975 Cold Formed Light gauge steel
95.
- Approval of Building Plan from Government Authorities/ BMC/ IIT
?
- PEB Construction: Which Specification is to be followed ?IS or
AES ?
- Canopy and its location ?
- Surface Finish for the structural Members- Weather Shot
Blasting or wire brush ?
- Type of Paint to be used : Polyurethane or Enamel ?
96. Painting
-
- Crane, Transfer Car :Poly Urethane
-
- Structural members :Poly Urethane
-
- Wall cladding :Poly urethane
97. Roof
- Type of Ventilators: Graven typeor powerless ventilators ?
Powerless turbo ventilators to be used
- Safety on the roof approach
- Safety Net / fall protectionrequirement
98. General
- Supply of Steel & Cement : Contractor shall arrange his own
steel and cement.
- Water and Electricity : Shall be provided by Railways but
charged from the contractor at actual based on standard railway
tariff.
- Approval of Building Plan :The approval may be obtained from
government authorities/ BMC/ IITor BMC Licensed engineers or
Chartered engineers of repute.
- Concrete:RMC or Site Mixed Concrete?
- Tax Structure: Works Contract or Supply ?
- Provisioning of Lightening arrestor
99.
- R/R Masonry below plinth : Plaster or pointing to be done
?
- IS 456 of 1978 or of 2000 ? M-25is specified 2000 edition
.
- Emergency Door HMPS- Aluminium ?
- Approved makes of welding electrode, anti termite chemical,
Hardonite?
100.
- Integrity between old building and the new building ?
- Chajja over only the window or over the entire course ?
- Roads and drains around the building ?
- Lightening above the racking area?
101.
- Aluminum wire mesh around the well of the ASRS ?
102. PEB Design 103. PEB BUILDING 104. Pre Engineered Metal
Building ( Major Components)
- Main framing or vertical columns
- Purlins, girts and eave struts
- Sheeting and insulation or prefab panels
- Brick & Cement Board Walls
105. MAIN FRAMING
- Main framing: Itincludes the rigid steel frames of the
building.The PEB rigid frame comprises of tapered columns and
tapered rafters.The tapered sections are fabricatedwherein the
flanges are welded to the web.Splice plates are welded to the ends
of the tapered sections.The frame is erected by bolting the splice
plates of connecting sections together .
106. PURLINS, GIRTS AND EAVE STRUTS
- Purlins, girts and eave struts are also known as secondary
cold-formed members.
- There is no welding involved in their preparation.They are
prepared by just bending the steel coil giving it the desired shape
(Z-shape for purlins and girts, and C-shape for eave struts).
- Purlins : Purlins are the secondary members are for supporting
the roof panels & wall cladding .
107. PANELS AND INSULATION
- Walls & Roof: Single skin profile or ribbed steel
sheets
- Material: Steel sheets made from steel coils.
- Minimum thickness 0.5mm high tensile steel.
- Usezincalume or galvanized bare and permanently colour coated
or plain
- Provision for coating at site after installation.
108. Insulation
- Providefibrous insulation slabs / rolls of non- combustible
Rockwool,
- Aluminum foil laminated, placed over a metal mesh bed created
between the purlins, and then the roofing steel sheetfixed over
it.
- The siding walls can also be insulated by providing a double
skin profile or ribbed steel sheet or cement board sheets on inner
side wall cladding having Rockwool.
- Insulation slab sandwiched in between and held in position with
the help of Z spacers in between the two steel sheets.
- Similarly,a double skin insulated roofing system can also be
erected.The cement boards will give a conventional white finish
after paining
109. PANELS AND INSULATION
- Providepre-fabricated insulated panels, havingtwo single skin
panels (plain steel sheets galvanized / zincalume colour coated)
with polyurethane foam insulation in between.
- These panels can be usedas thermally efficient roof and wall
claddings for buildings .
- Roof is of profile steel sheet with or without insulation fixed
underneath.
110. Erection of PEB Structure
- The roof is erected with trusses placed over the walls and
profile sheet fixed to purlins and bolted to the trusses.
- The corners of the walls are provided with steel flashings
fixed to the profiled GI sheet on both sides before fixing of the
cement particle boards
111. PAINTS AND FINISHES
- Primary and secondary Members : Coated with one coat (35
microns) of redoxide paint without any special treatment to
steel.
- Shotblasting prior to painting in order to give better
anti-corrosion properties.
112. DOORS AND WINDOWS
- HMPS Steel or aluminum framed doors and windows are fixed to
the purlins or the supporting profiled steel either by bolting to
the flanges already fixed to the purlins..
113. Design Codes
- Frame members (hot rolled or built-up) are in accordance with
AISC (American Institute of Steel Construction) Specifications for
the design, fabrication and erection of structural steel.
- Light gauge cold-formed members are designed in accordance with
AISI (American Iron and Steel Institute) Specification for the
design of light gauge cold formed steel structural members.
114. Design Codes 2
- IS : 8750 - 1987:Code of practice for design loads of buildings
& structures.
- IS: 800 -1984:Code of practice for general construction in
steel.
- IS : 801- 1975:Code of practice for use of Cold formed light
gauge Steel Structural Members in general building
Construction
115. Guidelines for PEB design1 AISI viz a viz IS Spec.
- All designs shall be as per MBMA American standards
unlessspecified as per IS code
- Live load as per American code = 0.57 kn/m^2 and as per IScode
=0.75 kn/m^2.
- As per American code :horizontal deflection = l/180 &
vertical deflection=eh/100 for main frames.
- Wind terrain category 3 is to be selected unless more data is
available.
116. Guidelines for PEB design 2
- In American design , wind coefficients to be followed as given
in MBMA.
- In is design, internal & external building wind
coefficients as per IS -875 (part-3).
- Generally buildings are to be designed as pinned except for
building span >30m or crane capacity of more than 5 tons or
height greater than 9 m.
- Standard purlin laps shall be 385 mm
117. PEB
- TYPES OF LOADS & ASSESSMENT
118. PEB TCCS = TAPERED COLUMN CLEAR SPAN 119. Steps in design
of PEB
- Anchor Bolt design for Moment Condition
- Anchor Bolt design for Shear Condition
- Design of connection plate
120. Erection System 2
- Receiving Materials at site
- Preparation of the First Bay
121. Erection System 3
122. Design Issues ?
- Welding : Single side welding or double sidewelding for PEB
Members ?
- Thickness of hot rolled and cold rolled sections ?
- Support condition to be considered in design as fixed based or
Pin based ?
- Structural Analysis 2or 3 dimensional ?
123. Electrical Issues
- Power requirement of the entire ASRS system shall be broadly
100 KW.
- 70 KW for the ASRSand balance 30 KW for the office
requirement.
- 440 AC supply is to be arranged.
- Underground cable (LT) to be laid from wheel shop to ASRS
location and another LTCable from timber ward SSto ASRS arena.
124. Fire Fighting-1
- Comprehensive fire fightingsystem including fire/ smoke
detection, piping, fire hoses, water sump to be provided by the
contractor.
- Nature of material in the ASRS .
- Steel components: Steel pins, hangers, nuts and bolts, bearings
etc.
- Rubber components: water and air hose pipes, rubber pads,
rubber washers,
- Chemicals : H2SO4 , trichloroethylene, bleaching powder, soda
ash, HCL
- Cloth : Duster cotton, dungri cloth, waste cotton,
- Leather : Safety Boots, Hand gloves
125. Fire Fighting-2
- One Aisle tobe kept separate for paints ,chemicals or other
fire prone material.
- Underground sumpto be created with adequate capacity by
contractor.
- Pumps and motors of adequate capacity to be provided by the
contractor for water pumping.
- Water point shall be provided by the Railways near the
sump.
- Provisioning of traditional fire extinguishers along with two
numberhigh powered pressurized water mist system .
126. Bar-coding and RFID 1
- Bar-coding is to be used for all the components stored in the
ASRS i.e individual components for bigger items such as BSS Hanger,
buffer plunger etc. and alsopackets for smaller items such as nuts,
screws , bolts etc.
- RFID is to be used for each pallet which shall help in tracking
the pallets within the workshop.
127. Bar-coding and RFID- 2
- Material received at CRD Parel shall have Bar code labels
pasted on them. These labels shall be printed by the vendor
supplying material to railways.
- In case Bar codes are not available on the received material,
provision of printing the bar codes and pasting on the consignment
should be incorporated in the system.
128. Interfacing of WMS, LMS, ICMS & MMIS
- Contractor shallintegrate the Warehouse Management system,
Location Management system, Inventory control system with that of
the Western Railways Materials Management System( MMIS).
129. Office area , Wash Rooms ,Change Rooms
- Offices presently available.
-
- Progress, receipt, Cash Purchase, Dispatch
130. Location of Offices in the new setup
- Integrated offices shall be located at theNon Dismantled Area
on the ground floor.
- This complex shall have all the offices mentioned in the
previous slide.
- The layout plan of the offices shall be as under.
131. Layout of New Office Complex. Dy. CMM DMS CDMS Computer
Center AMM Office Complex DMS DMS CAVisitors Area
- Granamite Tile flooring with 2X2 tiles.
- Walls with polished veneer 6 mm.
- Particle board partition for office
132. Soil test report 133. What is RFID?
- RFID is an ADC technology(Automatic Data Collection )that uses
radio-frequency waves to transfer data between a reader and a
movable item to identify, categorize, track...
- RFID is fast, reliable, and does not require physical sight or
contact between reader/scanner and the tagged item
134. What Constitutes an RFID System?
- One or more interrogators
- One or more host computers
135. RFID API Software (Communicates with the RFID Reader)
Customer-Specific Application SoftwareHost Computer Host Memory
Space Reader Antenna Application Program Interface (API)
Application Program Interface (API) Components of an RFID System
136. Antenna Reader Firmware Customers MIS Host Application
Software API TCP/IP Power ~ Asset Asset/Tag RFID System Components
(block diagram) Tag Insert 137. RESPONSES COMMANDS Tag Physical
Memory APPLICATIONRESPONSES APPLICATION INTERROGATOR RF TAG
APPLICATIONCOMMANDS Command / Response Unit PHYSICAL
INTERROGATORDATA PROTOCOL PROCESSOR ISO/IEC 15961 ISO/IEC 18000
Encoder Logical Memory AIR INTERFACE ISO/IEC 15962 ISO/IEC 15962
Annexes Logical Memory Map Note: The Logical Memory Mapin the Tag
Physical Memory is given by the Tag architecture and the mapping
rules in the Tag Driver.All the information in the Logical Memory
is represented in the Logical Memory Map Decoder Tag Driver and
Mapping Rules Application Program Interface DEVICE COMMANDS DEVICE
RESPONSES 138. RFID Operation
- Sequence of Communication
- Host Manages Reader(s) and Issues Commands
- Reader and tag communicate via RF signal
- Carrier signal generated by the reader (upon request from the
host application)
- Carrier signal sent out through the antennas
- Carrier signal hits tag(s)
- Tag receives and modifies carrier signal
-
- sends back modulated signal (Passive Backscatter - FCC and
ITUrefer to as field disturbance device)
- Antennas receive the modulated signal and send them to the
Reader
-
- Results returned to the host application
139. RFID Operations 140. What is RFID? -- The Tags
- Tags can be read-only or read-write
- Tag memory can be factory or field programmed, partitionable,
and optionally permanently locked
- Bytes left unlocked can be rewritten over more than 100,000
times
141.
- Programmable Database Pointer
- Mission Critical Information
- Read Only (Factory Programmed)
- WORM - Write Once, Read Many times
- Reprogrammable (Field Programmable)
- Read/Write (In-Use Programmable)
RFID System Basics 142.
- Tags can be attached toalmost anything:
-
- pallets or cases of product
-
- company assets or personnel
-
- items such as apparel,luggage, laundry
-
- people, livestock, or pets
-
- high value electronics suchas computers, TVs, camcorders
What is RFID? -- The Tags 143. Are All Tags The Same?
-
-
- Tag transmits radio signal
-
-
- Battery powered memory, radio & circuitry
-
-
- High Read Range (300 feet)
-
-
- Tag reflects radio signal from reader
-
-
- Shorter Read Range (4 inches - 15 feet)
144.
-
-
- Size (16 bits - 512 kBytes +)
-
-
- Read-Only, Read/Write or WORM
-
-
- Type: EEProm, Antifuse, FeRam
-
- Arbitration (Anti-collision)
-
-
- Ability to read/write one ormany tags at a time
Are All Tags The Same? 145. RFID System Basics
- Attached to and surround by what?
146. What is RFID? -- The Readers
- Readers (interrogators) can be at a fixed point such as
- Readers can also bemobile -- tethered,hand-held, or
wireless
147.
- Uses normal CMOS processing basic and ubiquitous
- Relative freedom fromregulatory limitations
- Well suited for applicationsrequiring reading smallamounts of
data at slowspeeds and minimal distances
- Penetrates materials well(water, tissue, wood, aluminum)