Draft specification of LHB COACHES -ver-2 …rdso.indianrailways.gov.in/works/uploads/File/Draft specification... · ALL METAL INTEGRAL LIGHT WEIGHT LHB DESIGN RAIL CARS ... MCF Modren

Ref: CG‐WI‐4.2.1‐1(Rev.01) Page 1 of 106

Date of issue: Jan. ‐2018 Spec. No. RDSO/2017/CG/B/01

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Prepared By (Rajeev Baiswar, SSE/D/Carr.)

Checked By (S.S Raypa, DD/Carr.)

Approved By (Mohd. Saquib, Dir/Carr.)

INDIAN RAILWAYS

PARTICULAR SPECIFICATION

FOR

ALL METAL INTEGRAL LIGHT WEIGHT LHB DESIGN RAIL CARS

WITH FIAT BOGIE HAVING AIR SPRING IN SECONDARY SUSPENSION

(FULLY FURNISHED)

(BROAD GAUGE - 1676 mm)

(FOR PROCUREMENT THROUGH OPEN TENDER)

S.No. Month/Year of issue Revision / Amendment

Page No. Reason for Amendment

1. Jan-2017 ---- ---- First Issue

Issued By: Carriage Directorate

Research Designs and Standards Organization

Manak Nagar, Lucknow – 226011



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Contents

Glossary........................................................................................................... 5 CHAPTER 1........................................................................................................... 7 Definitions and interpretation............................................................... 7 CHAPTER 2........................................................................................................... 9 General requirements............................................................................... 9 2.1 Background………………………………………………………………………… 9 2.2 General……………………………………………………………………………….. 10 2.3 Objective………………………………..……………………………………………. 11 2.4 Scope…………………………............................................................................ 11 2.5 Eligibility criteria 11 2.6 Variants of LHB design (EOG/HOG) cars 12 2.7 Clause by clause comments ………………………………………………… 12 2.8 Refrences to various standards.......................................................... 13 2.9 Infrastructure requirments............................................................... 14 2.10 Laboratory facilities..…………………………………………………………. 18 2.11 Firm’s responsibility……………………………......................................... 19 2.12 Contract drawings……….……………………………………………………. 20 2.13 Approval of design…………………………………….................................... 20 2.14 Materials…………………………………………………………………………….. 21 2.15 Standard specifications………………………………………………………. 22 2.16 Marking of material & parts..……………………..………………………… 22 2.17 Execution of work……...……………….………………………………………. 23 2.18 Welded joints…………………………. …………………….……………………. 24 2.19 Welding equipment and accessories..………….………………….……. 25 2.20 Inspection…….. …………………….…………………….................................. 25 2.21 Proto type……………………..………………….…………………….................. 26 2.22 Guarantee…………………………………………………………………………… 27 2.23 Size & format of drawings (mechnical)………………………………..... 28 2.24 Method of filling mechanical drawings……………………………….. 28 2.25 Binding………………………………………………………………………………… 28 2.26 Photograph…………………………………………………………………………. 28 2.27 Free supply items...………………………………………………………………. 29 2.28 Purchase of raw materials semi-finished items and finished

items…………………………………………………………………………………. 29

2.29 Service conditions........................................................................................ 29 2.30 Track parameters........................................................................................ 30



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CHAPTER 3......................................................................................................... 31 Technical requirements (mechanical)................................................... 31 3.1 Scope…………............................................................................................... 31 3.2 Contract drawings..................................................................................... 31 3.3 Leading particulars..................................................................................... 31 3.4 Gauge and moving dimensions.................................................................. 32 3.5 Station platforms……………................................................................... 32 3.6 Railcar body shell........................................................................................ 33 3.7 Underframe…………………………………………………………………………. 34 3.8 Sidewall…………...………………………………………………………………..... 35 3.9 Endwall……………………………………………………………………………..... 36 3.10 Roof…………………………………………………………………………………..... 36 3.11 Car body fabrication………………………………………………………..... 37 3.12 Exterior painting........................................................................................ 38 3.12.1 General………………..................................................................................... 38 3.12.2 Surface prepration..................................................................................... 39 3.12.3 Exterior primer…...................................................................................... 39 3.12.4 Putty…………………...................................................................................... 39 3.12.5 Hand grinding………...................................................................................... 40 3.12.6 Undercoat/surfacer................................................................................... 40 3.12.7 Top coat………………...................................................................................... 40 3.13 Interior painting........................................................................................ 41 3.13.1 General………………..................................................................................... 41 3.13.2 Interior primer…...................................................................................... 42 3.14 Painting of underframe assembly......................................................... 42 3.15 Insulation………………………........................................................................ 423.16 Buffing gear…..…...................................................................................... 42 3.17 Couplers and draft-gear........................................................................ 43 3.18 Air brake system………….......................................................................... 43 3.19 Doors………………………….......................................................................... 44 3.19.1 Body side entrance doors....................................................................... 45 3.9.5.2 Saloon doors (for ac variants only)................................................... 45 3.9.5.3 Compartment sliding door (for fac variant only)......................... 45 3.9.5.4 Vestibule doors (for all variants except gen. Sec. Class......... 48 3.9.5.5 Lavotary doors…….…….......................................................................... 50 3.9.5.6 Loading doors…….…….......................................................................... 50 3.20 Side and door windows (for ac variants only)................................ 51 3.21 Side and door windows (for non ac variants only)....................... 53 3.22 Lavotary windows...…….......................................................................... 53 3.23 Vestibules…………….…….......................................................................... 54 3.24 Partition frames (for ac variants)...................................................... 54 3.25 Partition frames (for non ac variants).............................................. 55 3.26 Fresh water tanks……………………………............................................... 55 3.27 Railcar interior….……………………………............................................... 56 3.28 Floor………………….……………………………............................................... 57 3.29 Interior panelling……………………………............................................... 57 3.30 Air ducts and diffusers (for ac variants only)............................... 58



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3.31 Lavatories………….……………………………............................................... 59 3.32 Outside wash basin arrangement..……............................................... 60 3.33 Seat/berths & chairs..………………………............................................... 61 3.34 Luggage racks………...………………………............................................... 62 3.34.1 Light luggage racks in compartment of sleeper cars............... 62 3.34.2 Light luggage racks (for chair car variants)................................ 63 3.34.3 Luggage racks (for non ac general second class cars)........... 63 3.35 Handholds and ladder…………………………………................................ 63 3.36 Roller blinds………………………………………………................................. 64 3.37 Curtains……………………………………………………................................... 64 3.38 Foot step………………………………………………….................................... 64 3.39 Bogie…………...………………………………………………………………………. 65 3.40 Connection car body- bogie…………………………………………………. 66 3.41 Anti-pilferage……………………………………………………………………… 66 3.42 Other passenger amenities…..……………………………………………… 66 3.43 Exterior colour scheme……..…………..…………………………………… 67 3.44 Interior colour scheme……..…………..…………………………………… 67 3.45 Marking……………………………………………………………………………… 67 3.46 Tail lamp brackets……….……..…………..…………………………………… 67

CHAPTER 4........................................................................................................... 68to89

Technical & Functional requirements (electrical)............................................. APPENDIX I. LIST OF MECHNICAL DRAWINGS (RCF & LHB).........................

90

APPENDIX II. STANDARDS/SPECIFICATIONS....................................................

94

APPENDIX III. FIREWORTHINESS MATERIAL....................................................

97

APPENDIX IV. DETAILS OF EXISTING LHB VARIANT CARS………………………… 98

APPENDIX V. PARTICULARS OF CONTRACT WORK TO BE FURNISHED BY THE FIRMS………………………………………..………………………………………

99

APPENDIX VI. MAXIMUM MOVING DIMENSIONS…………..………………………………

100

APPENDIX VII. RAIL CAR PROFILE…………………………..………………………………

101

APPENDIX VIII. Annexure Of Electrical………………..………………………………

102



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Glossary The following abbreviations are used in this Specification:

Abbreviation

Full Name

IR Indian Railways RDSO Research Designs and Standards Organization RCF Rail Coach Factory, Kapurthala. ICF Integral Coach Factory, Chennai MCF Modren Coach factory , Raebareli. AAR Association of American Railroads

AC Alternating Current

ASHRAE American Society of Heating, Refrigeration and Air-conditioning Engineers

BG Broad Gauge

BS British Standards

DB Dry Bulb

DC Direct Current

EN Euro Norm (European Standard)

EP Electro Pneumatic

FEM Finite Element Method

IEC International Electro technical Commission

IEEE Institution of Electrical and Electronic Engineers

IRS Indian Railway Standard

IS Indian Standard

ISO International Standards Organization

EOG End On Generation

RMPU Roof Mounted AC Package Unit

Km/h Kilometers per hour

LED Light Emitting Diode

MCB Miniature Circuit Breaker

PCB Printed Circuit Board



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PIS Public Information System

PA Public Address

RAMS Reliability, Availability, Maintainability and Safety

SI System International

SIL Safety Integrity level

UIC International Union of Railways

WB Wet Bulb

WC Water Closet (i.e. a flush toilet)

VRLA Valve-Regulated Lead–Acid

PACIL Passenger Alarm Chain Indication Light

LS NON AC 2nd Class (EOG/HOG) CAR

LWSCN NON AC 2nd Class SCN (EOG/HOG) Car

LWACCN AC -3T Sleeper (EOG/HOG) Car

LWACCW AC-2T Sleeper (EOG/HOG) Car

LWFAC AC-1st Class Sleeper (EOG/HOG) Car

LWCBAC AC Hot Buffet Car (EOG/HOG) Car

LWLRRM Generator Cum Luggage& Brake Van

LWSCZAC AC 2ND Class Chair Car

LWFCZAC AC Executive Class Chair Car



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Chapter 1 Definitions and Interpretation

Unless the context otherwise requires, capitalised terms not defined in this Specifications and Standards, shall have the same meaning ascribed to such terms in the Agreement. Capitalized terms which are not defined herein or in the Agreement, shall have the same meaning ascribed to such terms in the applicable standards. The abbreviations used in this Manual shall have the full form ascribed to them in the Glossary.

In this Manual of Specifications and Standards (the “Manual”), the following words and expressions shall, unless repugnant to the context or meaning thereof, have the meaning hereinafter respectively assigned to them:

Term Definition

Firm

Person or Company with whom the order for supply of the work has been placed by IR.

IR Shall Mean the Indian Railways on behalf of the President of Republic of India

Contract Means the contract agreement , the letter of acceptance, the letter of tender, these conditions , the specification , the drawing, the schedule, and further documents (if any) which are listed in the contract agreement or in letter of acceptance.�

Inspecting Authority Shall Mean the organization or its representative nominated by the IR to inspect on his behalf.

Sub-Contractor Means any person, firm or company from whom the main firm ( to whom order was placed by IR ) may obtain any material or fittings to be used for the work.

Engineers Means officials of the R.D.S.O./RCF/Railway Board, Ministry of Railways.

Purchaser Means Railway Board for and on behalf of The President of India.

Contract Drawings Means the drawings, which are included in Appendix-I of this specification for the guidance of the contractors. The RCF/LHB drawings mentioned in this specification should be collected/ purchased from RCF, Kapurthala.

Maintenance Shall include visual inspection, adjustment, replacement or repair carried out on any equipment, sub-system or system, which results



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in such equipment, sub-system or system being preserved within maintenance tolerances or returned to its design tolerances.

Maintainability Shall mean the probability that a maintenance action for a equipment or system, under specified conditions of use, can be carried out at a specified time interval when the maintenance is undertaken in normal conditions and following Good Industry Practices.

IP or Ingress Protection Shall mean the degree of protection provided by enclosures in accordance with IEC 60529.

Site Means the contractor’s works, except for the purpose of testing and commissioning of the stock.

L-10 Shall mean the life of a bearing in accordance with ISO 281.

Railcar Shall mean a passenger carrying railcar, built in conformity with the provisions of this specification.

Rail Level The plane which passes through the top of the cross-sectional centre line of both running rails.

Service Shall mean the railway service available for the use of passengers.

Specifications and Standards

Shall mean the specifications and standards relating to the quality, quantity, capacity and requirements for the passenger trains comprising the railcars and the equipment, sub-systems or systems thereof, as set forth in this Manual.

Sub-system Shall mean and include all equipment(s) forming part of such sub-system.



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Chapter 2 General Requirements

2.1 Background

Indian Railways (IR) requirement of passenger rail cars has been met with by ICF, RCF and MCF wholly owned Production Units of Indian Railways. Presently, ICF, RCF and MCF are manufacturing passenger rail cars in excess of their installed capacity and are fully engaged in manufacture of high value and sophisticated design rail cars. The unfulfilled requirement of rail cars of Indian Railways needs to be met with by additional procurement through trade. Accordingly, Indian Railway is planning to procure LHB design rail cars through open tender. For this purpose, Particular Specification no. RDSO/2017/CG-B-01 for LHB design (EOG/HOG) cars suitable for open tender has been prepared. This specification spells out requirements for Design, Manufacture, Supply and Commissioning of LHB design rail cars. The infrastructural requirements for bulk order manufacture of 200 nos. LHB design (EOG/HOG) rail cars per annum and for developmental order have also been included. Rail car builder is expected to have machinery and plants for sheet metal work, plate fabrication, welding, painting, etc. for fabrication of shell and for furnishing of rail car, adequate covered space for manufacture of minimum 20 rail cars per month, storage and inspection space for 5 to 6 rail cars for inspection and movement of rail cars in one hook, well documented system for demonstration of sound manufacturing practices in use and necessary supporting infrastructure like drawing office, laboratory and testing labs. Covered space requirement for a developmental order manufacturers, may match the need of quantity of the developmental order so placed. Squeeze testing of prototype LHB design (EOG/HOG) rail cars shell has been planned to be carried out to validate quality of process control on manufacturing processes especially welding involved in fabrication of RCF design rail car shell. Bidders are expected to provide necessary documents as a proof of availability of infrastructure and LHB design (EOG/HOG) rail car manufacturing flow chart alongwith the bid. Bidders are expected to have complete clarity in terms of manufacturing processes involved in manufacture of LHB design (EOG/HOG) rail cars. Successful bidder is expected to carefully examine and bring out deficiency, if any before commencement of manufacture of LHB design (EOG/HOG) rail cars so that the possibility of bidder seeking relaxation at the time of actual manufacturer of rail car is mitigated.



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2.2 General

2.2.1 This specification describes the requirements for design, manufacture, supply, testing, and commissioning into service of modern fully furnished and finished BG, integral, light weight LHB design integral Cars of EOG/HOG design.

2.2.2 The LHB design (EOG/HOG) rail cars shall be manufactured as per RCF design. The firm, whom contract has been awarded, will be provided latest manufacturing drawings of relevant variant of LHB design rail car free of cost but after taking the incidental charges (photocopying/printing and cost of CD/DVD/USB device or any other electronic media and their writing etc.) by Rail Coach Factory, Kapurthala (RCF). The firm shall require entering into an agreement with RCF so that design, drawings and technical guidance provided for manufacture of LHB design rail cars. The design, drawings and technical guidance provided will not be used for other than scope covered in this tender. Design, drawings and technical guidance provided for manufacture of LHB (EOG/HOG) design rail cars to the firm are the sole property of Railways (IR) thus Intellectual Property Rights (IPR) of design, drawings and technical guidance lies with IR only.

2.2.3 The LHB design (EOG/HOG) rail cars shall be manufactured as per relevant variant of LHB coach layouts mentioned in annexure-I (Table-A).

2.2.4 The firm shall, in addition to observing and complying with this specification, be bound by the standard terms and conditions of contract that may be applicable for the design, construction, supply, delivery and commissioning into service of LHB design rail cars.

2.2.5 This specification is intended to include everything requisite to manufacture LHB design (EOG/HOG) rail cars, notwithstanding that everything required may not be mentioned herein.

2.2.6 Should there be any doubt as to the meaning of the clauses the vender should at

once notify the authority inviting tender who may send a written instruction to all venders. It shall be understood that every endeavor has been made to avoid any error which can materially affect the basis of the tender and the vender to whom contract has been awarded, shall take upon himself and provide for the risk of any error which may subsequently be discovered and shall make no subsequent claim on account thereof.

2.2.7 All the provisions contained in RDSO’s ISO procedure laid down in document no. QO-D-7.1-11 dated 19.07.2016 (titled “Vender-Changes in approved status”) and subsequent versions/amendments thereof, shall be binding and applicable on the successful vender/vendors in the contract floated by Railways to maintain quality of the product supplied to Railways”.



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2.3 Objective

The objective of this document is to set guidelines for manufacture and to define the criteria for technical evaluation of light modern fully furnished and finished BG, integral, light weight LHB design (EOG/HOG) integral rail cars.

2.4 Scope

This specification is issued in four parts. Chapter-I of this specification spells out the Definitions and Interpretation , Chapter-II of this specification spells out the General Requirements, Chapter-III of this specification spells out the Mechanical Requirements of the LHB design (EOG/HOG) rail cars and Chapter-IV spells out the Electrical Requirements of the LHB design (EOG/HOG) rail cars.

Chapter-I Definitions and Interpretation Chapter-II General Requirements Chapter-III Technical Requirements (Mechanical) Chapter-IV Technical & Functional Requirements (Electrical)

2.5 Eligibility Criteria:

2.5.1 Bulk Order: Bulk purchase will be done from the established manufacturers who have successfully executed regular order of main line passenger coaches/Electrical Multiple Units (EMU)/Diesel Multiple Unit to IR or any other organization in the past and the same should have been in operation for at least two years with satisfactory performance. The bidder should also meet the requirement of tendered technical specification.

2.5.2 Developmental order: Developmental orders may also be considered on firms who have requisite infrastructure facilities including plant and machineries as laid down in the technical specification. Covered space requirement for a developmental order manufacturers, may match the need of quantity of the developmental order so placed. The firm must also have adequate experience and expertise of manufacturing/testing and commissioning reasonably sophisticated equipments and machinery, such as the sub-assemblies of LHB coaches (viz. Bogie-frame, Underframe, Endwall, Sidewall , and Roof . While it is not mandatory for builder to be served by a Railway siding, he should be able to transport the rail cars to nearest Railway station . The developmental order can be considered subject to clearance of RDSO based on the capability-cum-capacity assessment of the firm with requisite credentials, as per technical specification. While submitting the offer, item-wise comments on



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facilities/technical requirements as indicated in this specification should be submitted by the tenderer. Tenderers should also submit detailed flow chart to be adopted for the manufacture of LHB design (EOG/HOG) rail cars as required by the technical specification.

2.6 Variants of the LHB design (EOG/HOG) cars

2.6.1 LHB Design (EOG/HOG) cars will generally be in the following variants :-

AC (EOG/HOG) Cars

AC First class sleeper Car AC 2-Tier Sleeper Car AC 3-Tier Sleeper Car AC Hot Buffet Car AC Generator Car cum Luggage cum Brake van AC 2nd Class Chair Car AC Executive Class Chair Car

NON AC (EOG/HOG) Cars General Second Class Car General Second Class Sleeper Car

2.6.2 Generally railcars shall be supplied having different variants of LHB design rail cars as per specific order from IR.

2.6.3 RCF drawings for major assemblies/sub-assemblies for all variants listed in clause 2.6.1 are mentioned in annexure-I of this specification.

2.6.4 Firm has to refer drawings of particular variant of LHB (EOG/HOG) cars for

which order has been placed by IR and manufacture the rail cars accordingly.

2.7 Clause by Clause Comments:

2.7.1 The bidder shall furnish clause by clause comments on compliance or otherwise of each clause of this specification. The bidder shall indicate deviations in their offers clearly against the respective clauses and also furnish lists of deviations as per the tender. Complete details as required vide the respective clauses shall be furnished by the bidder.



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2.7.2 The comments like ‘noted’ against the respective clauses shall be considered as ‘not complied’ for the specific clause. Therefore, the bidder shall clearly indicate the compliance or otherwise by writing ‘complied’ or ‘not complied’.

2.8 References to Various Standards

2.8.1 In addition to the provisions of this specifications, the codes, standards and specifications applicable for design of the passenger cars and for their operation and maintenance are:-

a) RDSO specifications b) ICF/RCF/MCF Specifications c) Indian Standards (IS) d) IEEE e) EN f) UIC g) AAR h) BS i) IEC j) ISO k) NF-F l) ORE m) VDE n) UL

2.8.2 In case of any conflict or inconsistency between the provisions of the codes

specified in clause 2.8.1 above and the provisions contained in this specification, the provisions contained in this specification shall apply.

2.8.3 The latest version of the aforesaid codes, standards and specifications at the time of award of the contract shall be considered applicable.

2.8.4 The specifications and standards stipulated in this Manual are the minimum. The

firm may adopt alternative internationally recognized codes and specifications, if it can demonstrate to the IR that such alternative is superior or more pertinent to the passenger cars than the specifications and standards provided in this



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specification. The firm shall seek prior written approval of the IR for any alternative specifications and standards proposed to be used.

2.8.4.1 The actual mix of features required in different variants of LHB design (EOG/HOG) passenger cars shall be as per the contract with IR.

2.8.4.2 All materials (including surface coatings, metals, insulants, adhesives, fluids, grease etc.) used in the manufacturing of the passenger cars shall not give rise to health hazards for the users, crew and staff.

2.8.4.3 The firm shall manufacture the LHB design (EOG/HOG) passenger cars based on RCF/RDSO drawings, standards, specifications and in accordance with good industry practice.

2.8.4.4 The specification has been prepared for the general guidance of the firm

to prepare the key designs for the proposed LHB design (EOG/HOG) passenger cars.

2.8.4.5 Lubricants and cooling oils: The firm shall study the currently used lubricants/cooling oils in Indian Railways and employ as far as possible such lubricants/oils. Full lubrication scheme and schedule for the railcars shall be submitted. Where imported lubricants or cooling oil are being used, firm shall study and furnish details of equivalent Indian lubricants/oils.

2.9 Infrastructure Requirements:

2.9.1 The LHB design (EOG/HOG) car manufacturing works must be served by a Railway siding connected to a Railway station or railway yard to facilitate easy movement of the stock from/to the manufacturing unit. Alternatively firm will have to transport the rail cars to the nearest Railway station from whom it can be moved.

2.9.2 Ensure that the firm is having ISO: 9001 certifications to cover the entire

manufacturing activities. If the firm is not ISO: 9001 compliant with respect to activity of rail car manufacture, ISO certification for rail car manufacturing prior to prototype approval shall be obtain.

2.9.3 Adequate covered bay area served by EOT cranes to enable out turn of at least twenty rail cars per month should be provided for manufacture of sub-assemblies and assembly of LHB (EOG/HOG) rail cars. The EOT cranes should be provided, with suitable lifting tackles. Covered space requirement for a developmental



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order manufacturers, may match the need of quantity of the developmental order so placed.

2.9.4 A covered area for holding at least 4 rail cars should be provided for painting of LHB (EOG/HOG) rail cars, so that adequate time is available for drying of paint before application of next coat. The covered area should be cemented. This is in addition to the covered area under the EOT cranes, for assembly & sub-assembly activities. For developmental order manufacturers, a paint booth to hold one coach at a time is essential.

2.9.5 There should be adequate covered storage area free from accumulation of rain water/flooding for storing steel, bogie etc. There should be no water logging. The storage area should be at adequately higher level than the surrounding area to protect the stores from accumulated water.

2.9.6 The storage area provided should be adequate to store 3 months requirement of steel, bogies. The storage area for bogie should be provided with a track. Bogies should be parked properly on the track.

2.9.7 Ensure that a system exists for protection of bogies and grease drums to prevent

ingress of dust/moisture.

2.9.8 Ensure that detailed documented procedures and work instructions are available for the following activities before undertaking manufacture:

i) Welding procedure indicating welding sequence, type of electrodes, current rating.

ii) Surface preparation before painting including shot /grit blasting. iii) Painting of rail cars.

2.9.9 A separate line, of adequate length for holding at least 5 rail cars for inspection

and 5 rail cars for testing in dispatch line should be provided for final inspection and testing of LHB design (EOG/HOG) rail cars by the purchaser’s inspecting Engineers. For developmental order manufacturers, a separate line of adequate length for holding at least one rail car for inspection & one rail car for testing in dispatch line is essential.

2.9.10 The dispatch line should be provided with a pit of the length of minimum one

LHB design (EOG/HOG) rail car length and level track of LHB design (EOG/HOG) rail car length for checking of rail car buffer height.

2.9.11 The premises should have adequate covered storage area to store

components/sub-assemblies such as brake equipment, coupler, bogies, and other bought-out and free supply components, which are likely to deteriorate if stored in open.



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2.9.12 The firm should have the following M&P for manufacture of LHB design (EOG/HOG) rail car.

i) Profile cutting machine for cutting plates/sheets to the required profile up to 20 mm.

ii) Edge planning/milling machine for edge preparation (other than portable).

iii) Shearing machines up to 12 mm. iv) Plate bending machine up to 12 mm. v) Hydraulic press of suitable capacity for Side wall Windows forming. vi) 100t-800t press brakes for manufacture of various channels and

stiffeners. vii) Laser cutting and welding machine. viii) Roll bending machine. ix) Adequate number of welding sets with current rating between 300-

450A, metal Inert Gas (MIG) welding equipment sets (400-600A) and oxy-acetylene gas welding and cutting equipment should be available.

x) Robotic welding machine for Bogie side frame & bolster welding. xi) CNC spot welding machine. xii) Bogie frame machining center. xiii) Air brake test rig. xiv) Synchronized screw jacks of 15t capacity, 5 (4+1) for lifting of

assembled rail cars. xv) Drilling and boring machines of various sizes. xvi) 2 EOTs crane of 15t/20t capacity or higher for lifting of coach shell. xvii) Adequate no. of EOT cranes of suitable capacity in shell assemble

area, plate shearing & press area, underframe, roof, sidewall assembly & end wall assembly area.

xviii) Compressors with free air discharge at pressure of 7 bars. xix) Adequate nos. Forklifts of 3t capacity and 5t capacity and Diesel /

Battery driven tow truck of 1-3t capacity. xx) Traverser wherever layout demands its requirement. xxi) Facilities for carrying out radiographic testing of critical welds in

house or have a contract with a reputed agency for carrying out radiographic testing.



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xxii) Shot blasting machine or Grit/garnet blasting machine with the provisions of manual blasting of shadow area and for exterior surface preparation of the rail car before painting.

xxiii) Plate blasting machine for cleaning the profile cut plates. xxiv) Tumbler blasting machine for cleaning of trade procured small

components. xxv) Bogie frame blasting machine. xxvi) Hand grinding machine. xxvii) Portable air plasma cutting machine for cutting of stainless steel. xxviii) PVC sheet welding machine. xxix) Wood cutting bend saw. xxx) Wood laminate press. xxxi) Portable drill machines for wooden panels. xxxii) Adequate numbers of Dip-lorries / Dummy-trollies. xxxiii) Equipment for skin tensioning of sheets.

2.9.13 The firms should set up the following before undertaking production. These will be checked by the inspecting authority for availability at the time of prototype inspection:

a. Jigs for marking and drilling operations. b. Gauges for inspections of various components and assemblies. c. PU Paint booth for painting of rail cars. d. Painting booth for bogie frame. e. Paint oven for drying of coatings. f. Jigs and fixtures to ensure fitting accuracy of underframe, Body side

wall assembly, roof assembly, end wall, and sub-assembly of components.

g. Jigs for shell / Bogie frame assembly. h. Stands for welding of bogie bolster. i. Motorized/mechanical welding manipulators to ensure down-hand

welding of underframe, roof assembly, end wall and rail car shell assembly.

j. Static load testing machine for testing of assembled bogies. k. Testing and charging facilities for batteries before mounting.



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l. Facilities for conducting shower test/leakage test. m. Facilities for checking MMD of the LHB (EOG/HOG) rail cars.

2.9.14 The LHB design (EOG/HOG) rail car manufacturers should either have in-house facilities for manufacture of jigs and fixtures required for LHB design (EOG/HOG) rail car manufacturing or procure them from reputed manufacturers.

2.9.15 A drawing office is essential for preparation of manufacturing drawings and for

preparing drawings for obtaining purchaser’s approval for various alterations/relaxation.

2.9.16 The LHB design (EOG/HOG) rail car builder must provide himself with latest

issues (available at the time of award of contract) of all drawings and specifications (Railways, National and International), which may be required for manufacture of LHB design (EOG/HOG) rail car.

2.9.17 Ensure that a system exists for approval of vendors for bought-out items. The Sub vendors should also be ISO 9001:2008 compliant. In case vendors is not ISO 9001:2008 compliant, specific dispensations from RDSO should be taken for procuring products and services.

2.9.18 A system to monitor that the items required to be purchased from RDSO/RCF approved sources are procured from the same and proper care is exercised in ensuring updating of the approved vendor list. Indian/International standards shall be followed for such items for which approved RCF/RDSO sources not exists.

2.9.19 The Company/Firm should have adequate nos. of qualified Engineers having

degree in Mechanical/Production Engineering with suitable experience in every department and supervisors, fitters, machinist have possessing minimum qualification of Diploma/ITI in Mechanical/Production Engineering.

2.9.20 The Company/Firm should have on their regular payroll, a team of qualified

electrical supervisors and artisans possessing minimum qualification diploma in Electrical and ITI (Electrical / Wireman) respectively.

2.9.21 Welders/ welding supervisors should be qualified and certified by approved / recognized welding institute/test houses. The welders must be qualified and certified by approved / recognized welding institute/test houses. Ensure that a



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system exists to test the welders as per requirement of IS: 7310 and IS: 817 and proper records are maintained.

2.10 Laboratory Facilities:

a) The firm should have facilities for checking chemical composition of steel by wet method or spectrograph.

b) At least one number of Hardness testing machine. c) All gauges and measuring instruments are to be calibrated periodically

as per ISO norms. d) Digital/Dial Elko-meter min. 2 numbers for measuring thickness of paint

coating. 2.10.1 The rail car manufacturer should process within his works

mechanical/electronic weigh bridge or load cell arrangement facility with printing arrangement suitable for weighment of a complete rail car at a time.

2.10.2 The bidder should also submit a detailed flow chart of the processes to be

adopted for the manufacture of LHB design (EOG/HOG) coaches, giving details of the following:

a) The processes proposed to be carried out in-house with details of M&P to be used.

b) The processes proposed to be out sourced with the name of the vendor and his credentials.

2.10.3 The bidder should submit along with the offer a newly drawn layout diagram of his works showing the various assembly and sub-assembly areas, location and alignment of track, duly marking the location of various machinery and plant including the location of EOT cranes with capacity.

2.10.4 The capacity assessment of the firms shall be carried out by the purchaser.

2.10.5 The bidder is expected to manufacture major sub-assemblies like Underframe, Side wall, Roof and End wall & Bogie frame in house or these items will have to be purchased from RCF approved sources. Moreover, it would also be desirable if the bidders are having infrastructure for in-house manufacture of major structural members/components.



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2.10.6 Safety items like components of brake, bogie etc., shall be purchased from RDSO approved venders.

2.11 Firm’s Responsibilities:

2.11.1 The firm shall ensure that all the latest specifications (available at the time of award of the contract), CAIs (Carriage Alteration Instructions), Carriage Instructions and Modification Sheets as issued by Engineers (RDSO/RCF) from time to time are incorporated during the manufacture of the LHB design (EOG/HOG) rail cars. Any changes in the design / drawings should be approved by Engineers before implementation.

2.11.2 The firm shall be entirely responsible for the execution of the contract in accordance with this specification and the conditions of contract, and for the satisfactory performance of the stock in service notwithstanding any approval which the Engineers may have given to (i) the detailed drawings prepared by the firm, (ii) of a sub-contractor for material, (iii) of other parts of the work executed by the firm, (iv) of the tests carried out by the firms or by the Engineers or by the Inspecting Authority.

2.11.3 The firm shall further, notwithstanding any exercise by the Inspecting Authority of the power of superintendence, be responsible for the sufficiency of the packing, marking etc. of all important parts of the work to ensure their delivery without damage. The firms shall comply with the instructions of the Inspecting Authority, if in his opinion further precautions other than those adopted by the firms are necessary for the proper execution and safe delivery of all parts of the work.

2.11.4 In the event of the firm failing to carry out any work, for which he is liable under this clause, within a reasonable time, or if in the opinion of the Engineers the urgency of the case demands it, the purchaser may, without prejudice to his other rights under the contract, carry out the work himself at the expense of the firms.

2.11.5 The firm shall prepare and display work instructions at prominent locations for ensuring control on processes involved in manufacture of relevant variant of LHB design (EOG/HOG) coaches.

2.11.6 The tenderer shall submit manufacturing flow chart along with the bid document for relevant variant of LHB design (EOG/HOG) coach.

2.12 Contract Drawings:



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2.12.1 Contract drawings listed in Appendix-I of this specification give the critical requirements for all LHB design (EOG/HOG) coaches to be delivered. These drawings shall be provided on CD/DVD/USB device or any other electronic media.

2.12.2 The contract drawings and other drawings provided by the Engineers are not

guaranteed to be free from discrepancies and may be modified to suit the requirements of this specification duly getting the drawing approved by RDSO/RCF or as subsequently directed by the RDSO/RCF, without claim by the firms for extension of time or increase of price, except as provided for under the conditions of contract.

2.12.3 If, in any case, dimensions figured upon a drawing differ from those obtained by

scaling the drawing; the former shall be taken as correct.

2.12.4 No modification to the contract and approved drawings shall be done except with the prior approval of the Engineers.

2.12.5 Where the tolerances have been indicated on drawings, the fittings shall be

manufactured strictly within such tolerances. Where no particular tolerances have been indicated on the drawings, relevant IS specification should be followed.

2.13 Approval of Design

2.13.1 After the contract is signed, the firm shall within 60 days of signing of contract, furnish to IR the detailed schedule programme for submission of design documents for approval, which shall be staggered over a 120 day period, to enable IR to plan for expeditious clearance.

2.13.2 The passenger cars layouts are defined by the distribution of seats/Berths,

toilets, partitions, on board/underslung equipments, emergency exit, lights, fans, laptop /mobile charging sockets etc. Firm has to develop layouts for particular variants of LHB design (EOG/HOG) rail cars for which order has been placed to him by IR. Firm shall prepare layouts of rail cars on the basis of the RCF layout drawings listed in annexure-I (Table-A) and same shall be got approved from RDSO.

2.13.3 "Approval” to the drawings denotes “general acceptability” of the design

features. Notwithstanding such an approval, the firm will be wholly and completely responsible for the performance of the complete system and



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equipment supplied by him. The RDSO will not be responsible for the correctness of the dimensions indicated on the drawings, the materials used or the strength of parts. The firm shall, when submitting proposals or designs for approval of RDSO, confirm that it meets all the requirements of specification and draw specific attention to any deviation or departure from the specification involved in his proposals or designs.

2.13.4 The design shall be developed in SI units and firm shall submit the complete material / technical specification of components. The specification shall specifically be indicated on relevant drawings/documents. Alternatively drawings/documents developed by RCF can be used.

2.13.5 In case of any discrepancy, clause by clause compliance to the

specification given as per clause 2.7.1 shall only be considered. Other details given by bidder shall be considered only for indicative purpose and shall not amount to the acceptance of the design/equipments/ scheme.

2.13.6 The firm shall furnish details of its “Quality Assurance and Control System” at the design approval stage for the approval of RDSO. The quality checks to be made at various stage of manufacture, final assembly and commissioning with tolerance would be indicated . The system would also cover the quality assurance for bought out items.

2.14 Materials:

2.14.1 All materials used in the construction of the coach shall be of the quality

specified and shall comply with the most recent issue of the relevant Standard Specification.

2.14.2 The firms shall submit to the Inspecting Authority a list showing the names of the makers/suppliers from whom they propose to obtain the materials and fittings for work under the contract, sending copies of the orders to the Inspecting Authority.

2.14.3 All castings shall be true to dimensions, homogenous and free from defects and have their mating surfaces smooth and true to shape. Castings shall be properly annealed where required. Malleable cast iron where specified, shall be made by a process approved by the Inspecting Authority.



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2.14.4 The material used shall be to the entire satisfaction of the Inspecting Authority, who may adopt any means, he may consider necessary to satisfy himself that material of the requisite quality is used throughout the execution of the work.

2.15 Standard Specifications:

Materials used for the construction of the LHB design (EOG/HOG) coaches shall, unless otherwise specified in this specification or permitted by the Engineers in writing, conform to the specifications listed in Appendix-II and shall satisfy the relevant stipulations therein regarding physical and chemical properties and tests. In the event of revision of any specification, the latest revision shall be applicable. The firm may, however, use alternative materials or fittings with the written approval of the Engineers.

2.16 Marking of Material & Parts:

2.16.1 Materials and finished parts shall be marked as follows: -

2.16.2 Rolled sections shall be marked at the steel works with the makers’ name,

specification, grade and year of manufacture.

2.16.3 Forgings and Castings: All important castings and forgings shall be marked with makers’ name or initials, year of manufacture, ‘IR’ and part number.

2.16.4 General: All castings and forgings other than those mentioned above, shall have ‘IR’ and appropriate part number stamped/cast on it except where the part drawings show no marking instruction.

2.16.5 All brought out items /components shall be RDSO/RCF approved sources and duly inspected by Authorized Inspecting Authority.

2.17 Execution of Work:

2.17.1 The LHB design (EOG/HOG) coaches shall be manufactured using the

processes at least to the standards used by IR’s Production Units.

2.17.2 All components and sub-assemblies shall be interchangeable in whole and/or in part unless otherwise relaxed by the Engineers in writing.



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2.17.3 Sheets and plates shall be carefully straightened and flattened by stretching or by pressure. Plates shall be sheared when cold and their edges evenly finished. Welded components or members shall be correctly matched and accurate levels and clearances shall be ensured to result in perfect welds.

2.17.4 Hot Pressing: Steel plates shall be pressed into shape at one heat by hydraulic or mechanical pressure, and no re-heating shall be allowed without the special permission of the Inspecting Authority. All plates shall be perfectly flat and free from buckle, wave and defects of any kind. Any straightening required shall be done in cold condition by hydraulic/mechanical pressure. Where members of the frame fit into each other, the inside and outside corners shall be flanged square with as small a radius as possible in the corners. Care shall be taken that the metal is not reduced in thickness in the operations of flanging. All pressed members shall be made accurately to dimensions, and duplicate with one another, each piece shall be checked for size and shape by special gauges to be furnished by the firms.

2.17.5 Cold Pressing: Where pressed sheet members are called for, the pressing

shall be done cold by hydraulic or mechanical pressure adequate to ensure proper bending without any adverse surface effect or damage by using suitable dies and operating speeds. The bending shall be accurate to enable interchangeability of the pressed components.

2.17.6 All closed sections of the coach shall be properly cleaned and provided with

protective paints for prevention of corrosion. 2.17.7 The firms shall attend to and forthwith execute all directions in reference to the

work, which may from time to time be given by the Engineers or their deputies. 2.18 Welded Joints:

2.18.1 Electric/MIG/MAG/Oxy-Acetylene welding shall be employed as specified in

the drawing. Electric welding of steel shall comply with IS Specifications and RCF/RDSO welding codes. Welding shall be performed in such a manner that it presents a smooth appearance.

2.18.2 Welding methods used in RCF for manufacturing of LHB design (EOG/HOG) coaches shall be adopted.



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2.18.3 All welds shall be homogenous and show physical properties similar to those of the parent metal. Finish welds shall be perfectly free from all defects such as porosity, burnt metals, inclusions etc. and shall present a smooth appearance.

2.18.4 Size of the weld and the sequence of welding shall be carefully chosen to avoid secondary stresses being set up in the construction. Suitable post-fabrication heat treatment shall be adopted wherever found necessary to relieve the secondary stresses set up in the construction even after taking due precautions in course of fabrication.

2.18.5 Where welding of high tensile steel is specified, the steel shall be of weldable quality and permit welding without pre-heating.

2.18.6 The area where welding is to be performed, shall be well cleaned to remove paint, scale or rust immediately before welding.

2.18.7 The finished welds shall be free from all defects, such as porosity, inclusion, etc., and shall be homogeneous and shall show physical and mechanical properties similar to those of the parent metal. The works shall be securely held in position by means of tack welds, clamps or jigs before welding is commenced to prevent relative movement of the parts to be welded, and in approved frames of fixtures where welding is liable to cause distortion and the welding sequence designed to prevent distortion in the finished assembly. Important stress bearing weld joints shall be radio graphed at the discretion of the Inspecting Authority. To ascertain the quality and strength of the welds, non-destructive tests shall be carried out at the discretion of the Inspecting Authority at the cost of the firms and their sub- contractors.

2.19 Welding Equipment and Accessories LHB design (EOG/HOG) car manufacturers must ensure that welding and gas cutting equipment / accessories meet IS or International requirements. Some specifications are listed below for guidance:

A. Power sources: Power sources must correspond to one of the following IS specifications:

I. Specification for DC Electric Welding Generators to IS: 2635.



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II. Specification for Single Operator Rectifier type DC Arc Electric Welding Power sources to IS: 4549.

III. Specification for Single Operator AC/DC Arc Electric Welding Power sources to IS: 6008.

IV. Multiple –operator power sources may be covered by any manufacture’s national or International Specification.

B. Rubber insulated cables to IS: 9857.

C. Equipment for eye and face protection during welding to IS: 1179.

D. Leather gauntlets to IS: 2573 (Type-1).

E. Electrode holders to IS: 2641.

F. Return current clamps to IS: 2641.

G. Welder’s brush to IS: 4517.

2.20 Inspection:

2.20.1 The whole of the materials, or fittings used for works covered by the specification shall be subject to inspection by the Inspecting Authority, and shall be to his entire satisfaction.

2.20.2 The Inspecting Authority shall have the power to:

2.20.3 Adopt any means he may think advisable to satisfy him-self that the materials or fittings specified are actually used throughout the manufacturing.

2.20.4 Take samples for such tests, as he may consider necessary by an approved metallurgist selected by him, whose report shall be final and binding on the firms.

2.20.5 Visit at any reasonable time and without previous notice the firm’s works to inspect the progress and quality of the work and the firm’s shall provide free of charge all equipment, labour, gauges, etc. required by him for this purpose.



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2.20.6 To reject any material or fittings that do not conform to the relevant

specification or good practice, which shall be marked in a distinguishable manner, and shall be disposed of in such a manner as the Inspecting Authority may direct. Such rejected parts shall be replaced by the firm’s without extra charge.

2.20.7 Tests of materials and fittings shall as far as possible is carried out at the works of the makers of the materials or fittings. The firm’s shall provide such additional materials or fittings as may be required or arrange for test pieces to be incorporated in forging and castings as required by the Inspecting Authority and for their removal in his presence for test purposes. All tests in the works of the firm’s and their sub-contractors, independent tests shall be paid by the firm.

2.20.8 No work shall be dispatched or packed until it has been passed by the Inspecting Authority, but such passing shall in no way exonerate the firm’s from their obligation in respect of quality and performance of the rail cars.

2.20.9 In the event of dispute between the Inspecting Authority and the firm, the decision of the engineer shall be final and binding.

2.21 Prototype

2.21.1 The firm shall manufacture duly equipped prototype cars of the LHB design (EOG/HOG) car variants as per the order.

2.21.2 LHB design (EOG/HOG) coach body shell shall be subjected to squeeze test at the firm’s works. Squeeze test is essentially required to validate the quality of fabrication processes especially welding. RDSO shall conduct squeeze test in consultation with the firm’s and necessary infrastructure for the squeeze test shall be developed by the firm’s.

2.21.3 The firm shall be responsible for carrying out improvements and modifications

as may be considered necessary after tests at his own expense.

2.21.4 The firms shall manufacture a prototype of each variant of LHB design (EOG/HOG) coach (for which contract has been awarded) well in advance of series production for inspection and approval of engineer.



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2.21.5 Series manufacture shall not be proceeded with until prototypes have been approved by the IR or its authorized representative. The firm shall associate with IR for instrumented trials for evaluation of cars.

2.21.6 Firm shall not proceed with any proposed relevant modification arising out of

prototype test unless it is approved by IR.

2.21.7 During the prototype tests/ trials or during the warranty period, if any problems are thrown up or feedback information is obtained, which warrants a re-check of the design/ manufacture/ quality of the equipment and components, action will be taken as may be necessary by the firm to carry out the required investigations and to incorporate the improvements considered most appropriate, with approval of IR , to reach compliance with the specification & to ensure specified reliability and performance without any extra costs to the IR. Such improvements will be carried out in all cars and will be validated for the warranty period.

2.21.8 Modifications mutually agreed to and complying with the specification, will be incorporated by the firm at his own cost in the cars in a manner approved by IR. Drawings incorporating the modifications as found necessary as a result of test, trial and feedback will be submitted to IR.

2.22 Guarantee

2.22.1 The firm shall be responsible for any defect or failure of railcars or equipment

providing the railcars due to defective design, material or workmanship up to 24 months from the date of placement in service or 36 months from the date of delivery whichever is earlier. The firm shall replace such equipments during the guarantee period at his own expenses. Further should any design modification is required to be made in any part of the equipment, the period of 24 months would commence from the date when the modified part is commissioned in service.

2.23 Size & Format of Drawings (Mechanical) Drawing submitted shall be of full sizes as they are originally prepared. The dimensions, weight, capacity, etc. shall be in SI units. Hard copies (print) of all the drawings shall be provided and soft copies of the drawings also be submitted in CDs/DVDs & USB drives. Soft copies of all drawings shall be



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submitted in image form as well as any one format (like part, iges, cgm….etc) which can be editable in Unigraphics NX CAD software.

2.24 Method of Filling Mechanical Drawings

To facilitate filling of drawings, it is essential that each drawing submitted for approval is marked so that it can be identified. The firm is, therefore, required to ensure that all prints are marked legibly at the right hand bottom corner. The following information in English language is required in respect to each drawing:-

a) Firm’s drawing number. b) Firm’s name and date of submission. c) Contract number given by the IR. d) Description of drawings. e) Relevant specifications and material specifications.

2.25 Binding

Each set of drawings/documents together with a set of photographs shall be suitably bound within a cover of superior quality durable material with the title block printed on the outside of the cover.

2.26 Photographs

2.26.1 While first batch of each variant of railcars under construction, coloured photographs of various assemblies and sub-assemblies, especially the bogie/rolling assembly and the body in various stages of production, and of part which cannot be conveniently photographed after assembly such as sidewall, end wall and roof framing , underframe , etc shall be taken.

2.26.2 After completion side and three quarter views of each type of rail cars and views of the interior furnishing shall be taken.

2.26.3 The photographs shall not be less than 380x255mm for the side views of the

completed cars, or less than 255x200 mm for other views.

2.26.4 Prints along with the soft copy of these photographs shall be furnished to IR.



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2.27 Free Supply Items: Wheel sets duly machined and without bearing at the rate of four wheel sets per LHB design (EOG/HOG) cars will be provided to the firm as a free supply item.

2.28 Purchase of Raw Materials Semi-finished items and Finished items: All items other than free supply items, which are purchased by the coach manufacturer, should be purchased from RDSO/RCF approved sources only. The list of approved sources can be taken from RDSO and RCF.

2.29 Service Conditions

i. Maximum Temperature in Sun : 70ºC ii. Maximum Temperature in Shade : 45ºC iii. Ambient temperature inside the non air-

conditioned coach : 0ºC to 55ºC

iv. Altitude : Sea level to 652m v. Humidity : 100% Saturation vi. Rainfall : Fairly heavy vii. Atmosphere during hot weather : Dusty viii. Environment : Railcars shall also be working

in coastal area with salt laden and corrosive atmosphere.

2.30 Track Parameters

The following shall be the track standards of the test and operating sections.

S. No. Parameters

Specified Values

High speed Routes Main Line Routes

A. Unevenness (Base 3.6m) 6mm in general and 10 mm at 15mm



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isolated spots B. Alignment

(Versine for chord of 7.2 m) 5mm in general with10 isolated 7mm on curves and 10mm on straight

7mm

C. Twist (Base 3.6m)

2mm/m with isolated spots of 3.5mm/m

3.5mm/m

D. Gauge Variation +6mm -3mm

±6mm

E. Gauge widening on curves .

i. For curves up to 40, the gauge variation shall be from +13mm to -3mm

ii. For curves more than 40, the gauge variation shall be from +19 mm to -0 mm.

Chapter 3

Technical Requirements (Mechanical)

3.1 Scope

Chapter-III of specification spells out the technical requirements of the LHB design (EOG/HOG) coaches.

3.2 Contract Drawings:

Drawing approved by RCF/RDSO shall be followed for manufacture of the LHB design (EOG/HOG) cars.

3.3 Leading Particulars:

The leading particulars of the LHB design (EOG/HOG) cars shall be as follows:

a. Gauge : 1676mm

b. Length over body : 23540 mm



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c. Length over buffers : 24000 mm

d. Width over body : 3240mm

e. Buffer centers : 1956 mm

f. Height of centre line of CBC & Buffers from rail level under the tare condition

: 1105 mm +0/-15 mm

g. Max. Buffer drop : 75mm

h. Overall height of coach from rail level to centre of roof under tare condition.

: 4039/4250 mm

i. Floor Level : 1320 mm

j. Maximum Distance apart for bogie centers if bogie vehicles are used

: 14900mm

k. Maximum Distance apart between any two adjacent axles if bogie vehicles are used.

: 12345mm

l. Wheel Base : 2560mm

m. Maximum load per axle (When fully loaded)

: 16.25 t

3.4 Gauge and Moving Dimensions:

3.4.1 The LHB design coaches shall conform to the Indian Railways Schedule of Dimension – 1676 mm gauge revised 2004 with latest amendments. for 1676 mm gauge track.

3.4.2 For all variants of LHB design (EOG/HOG) rail cars (except AC-3 tier variant), coach profile for 3240mm wide integral coaching stock to RDSO SK-83167 (latest. alt.) within Maximum Moving Dimensions 1D diagram of Schedule of Dimension 2004 (Revised) with latest amendments.



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3.4.3 Coach profile of LHB AC-3T (EOG/HOG), 3240mm wide integral coaching stock to RDSO SK-72227 (latest. alt.) within Maximum Moving Dimensions 1D diagram of Schedule of Dimension 2004 (Revised) with latest amendments.

3.5 Station Platforms

3.5.1 The Passenger cars shall allow passengers to board and alight from the train

at station platforms between 760 mm and 840mm above rail Level.

3.5.2 In addition to the requirement stated in Clause 3.5.1 above, mainline passenger railcars shall allow passengers to board and alight from the train at station platforms having height around 455 mm above Rail Level.

3.5.3 The trains may be maintained or stored in areas that have only ground-level access. It is required that the passenger cars have the capability for ground-level maintenance access, passenger emergency evacuation and fire/rescue access to the car interior.

3.6 Railcar Body Shell: 3.6.1 The car body shell shall be of integral design. The manufacturing of the body

shell for a particular variant for which order has been placed by IR, shall be strictly in accordance with RCF’s Body Shell Drawings applicable to that variant. The details of RCF body shell drawings are mentioned in annexure-1 (Table-A).

3.6.2 The main structural members of the coach shell shall be pressed steel plates

and sheets conforming to approved specifications assembled and welded together in suitably designed jigs.

3.6.3 The coach body shell shall be designed to meet the following loads cases in

accordance to specification UIC 566 OR :-

Load Case-I Horizontal Compression force of 2000KN at CBC rear stops according to clause 1.2.1.1 of UIC 566 OR with design mass vehicle body in working order (without bogie masses).

Load Case-II Horizontal Compression force of 2000KN at location of Buffers according to clause 1.2.1.1 of UIC 566 OR with design mass vehicle body in working order (without bogie masses).



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Load Case-III Horizontal Compression force of 400KN in end wall area, 350mm above center line of coupler/buffers according to clause 1.2.1.1 of UIC 566 OR with design mass vehicle body in working order (without bogie masses).

Load Case-IV Horizontal Compression force of 300KN in end wall area, at the height of cantrail to clause 1.2.1.1 of UIC 566 OR with design mass vehicle body in working order (without bogie masses).

Load Case-V Superposition of Compression force of 2000KN at CBC rear stop according to clause 1.2.2.1 of UIC 566 OR with with a vertical load FZ = 1.3 (m1+m2)x g [N].

Load Case-VI Superposition of Compression force of 2000KN at Buffers according to clause 1.2.2.1 of UIC 566 OR with with a vertical load FZ = 1.3 (m1+m2)x g [N].

3.6.4 The definition of design masses m1 & m2 shall be in accordance to clause

1.2.1.3 of UIC 566 OR.

3.6.5 Load Case-II & Load Case-VI is applicable for AC Generator Car cum Luggage cum Brake van only.

3.6.6 The stresses estimated by an approved method shall not exceed 221.6 MPa (22.6 kgf/mm2) for members made from Corten type steel to IRS: M-41 , 212.8 MPa (21.7 kgf/mm2) for members made from Ferritic steel to C-K201, X2CrNi12 and 156.9 MPa (16.0 kgf/mm2) for members made from Austentic steel to C-K201, X5CrNi1810 for the load cases I to V.

3.6.7 For the load case VI referred above, the stress should not exceed 90% of the lower yield point or proportional limit of the material in the load carrying members of the shell and 95% of the lower yield point or proportional limit of the material in the end construction. The estimated vertical deflection of the shell at the centre of coach shall also not exceed 14.9 mm under any load cases detailed in clause 3.6.3 above.

3.6.8 Each completed shell shall be tested for leakage through roof at the works of

the coach builder and same test for leakage is repeated for fully furnished



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coach also. To carry out this test, the coach builder shall provide a test rig to the satisfaction of the inspecting authority.

3.7 Underframe:

3.7.1 Material: Under frame shall be manufactured from corrosion resistant structural

steel to IRS: M41-97.

3.7.2 Underframe arrangement shall be as per RCF drawing mentioned in annexure-1.

3.7.3 Sole Bar : These are continuous members on each side running throughout the

length between body side doors. These shall be adequately braced together to withstand the horizontal, vertical and lateral forces and capable for jacking the lift of coach. Sole bar shall be manufactured from corrosion resistant structural steel to IRS: M41-97.

3.7.4 Trough Floor: Trough floor shall be pressed out from 1.25mm thick stainless

steel sheet conforming to specification C-K201 , X2CrNi1810 (Austenitic steel, AISI 301).

3.7.5 Underframe Front part: It shall be of robust design for mounting draw and

buffing gear and to with stand load described in para 3.6.3.

3.7.6 Body Bolster: It shall be fabricated from steel plates of requisite thickness to Specification IRS: M41-97 and shall be as per RCF drawing no.----------------

3.7.7 Cross Members: Adequate number of transverse cross bearers shall be

welded between Solebars as per applicable drawings to withstand the vertical load at floor as described in para 3.6.3.

3.7.8 Welding parts below Underframe: The brackets of robust design shall be

provided for suspensions of various under slung items. The provision of all welding parts on underframe shall be as per RCF’s drawing for welding parts on underframe mentioned in annexure-I (Table-B).

3.8 Side Walls:

3.8.1 Side wall arrangement both L.H & R.H shall be as per RCF drawing mentioned

in annexure-I (Table-B).



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3.8.2 Components of sidewalls shall be manufactured from stainless steel to RDSO

specification C-K201, X2CrNi12 (Ferritic steel, 409M).

3.8.3 Side wall sheets: Side wall sheets to be manufactured from 2 mm thick stainless steel to RDSO specification C-K201, X2CrNi12 (Ferritic steel, 409M). Side wall sheet module blanks for window opening to be prepared on Hydraulic press/Laser cutting machine. Side wall sheet modules to be manufactured by welding side wall sheets on Butt seam welding machine.

3.8.4 Body pillars: Body pillars shall be pressed out of 2.5mm thick stainless steel

sheet 409 M (Ferritic) to RDSO specification C-K201.

3.8.5 Cantrail: It shall be manufactured from 4 mm thick stainless steel to RDSO specification C-K201 , X2CrNi12 (Ferritic steel, 409M). It connects together the body pillars to the roof structure by welding to form integral shell. Running as a continuous member over complete length of coach this should be of adequate strength and rigidity.

3.8.6 Side wall modules to be prepared on Side wall jig by assembling/ welding

horizontal vertical body pillars and side wall sheets.

3.9 End Walls:

3.9.1 Components of End wall shall be manufactured from stainless steel to RDSO specification C-K201, X2CrNi12 (Ferritic steel, 409M).

3.9.2 End wall construction (both Power Panel & Non Power Panel ends) shall be as

per RCF drawing mentioned in annexure-1 (Table-B). 3.9.3 The End wall structure shall be adequately strong to withstand the test loads

described at Para 3.4.1.3.

3.9.4 Dye Penetrate test shall be carried out for examination of welded joints.

3.9.5 End wall construction assembly shall be fabricated using End wall assembly jig to avoid undulations and distortions during welding.

3.10 Roof:



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3.10.1 Carlines of roof shall be of stainless steel to RDSO specification C-K201, X2CrNi12 (Ferritic steel, 409M).

3.10.2 Roof sheet shall be manufactured in three parts , in which middle portion of roof is constructed with 2mm plain stainless steel sheet to RDSO specification C-K201, X2CrNi1810 (Ferritic steel, 409M) and side roof sheets shall be made of 1.7 mm thick stainless steel sheet to RDSO specification C-K201, X2CrNi1810 (Austnatic steel, AISI301) with corrugation.

3.10.3 Manufacturing of Roof shall be in accordance to RCF’s drawing mentioned in

annexure-1 (Table-B).

3.10.4 Joints of roof sheets shall be smooth and water tight and roof sheets shall be welded on Butt seam welding machine.

3.10.5 In case of Non AC variants of LHB type (EOG/HOG) cars, opening for mounting ventilators shall be provided at locations shown in RCF Roof assembly drawings mentioned in annexure-1 (for non AC variants). These openings shall be adequately strengthened for fitment of ventilators. The ventilators shall be provided as per RCF drg No LG16132 with latest alt.

3.10.6 The roof shall sweep down on to the side wall and form flush finish.

3.10.7 Gutters of suitable design of pressed shape shall be welded directly to the roof skin over the door way.

3.10.8 Roof assembly shall be done in single piece for complete coach on Roof assembly jig.

3.10.9 Dye Penetrate test shall be carried out for examination of welded joints.

3.10.10 Kerosene oil test shall be carried out on weld joints of Roof sheets prior to unloading of Roof assembly from Roof assembly jig for minimization of water leakage during shower test.

3.11 Car Body Shell Fabrication:

3.11.1 Manufacturing of Car Body Shell shall be in accordance to RCF’s drawing

mentioned in annexure-1 (Table-A).



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3.11.2 The car body shell fabrication shall be done by assembling Underframe, End walls, Side wall modules, and Roof on Shell assembly jig.

3.11.3 Skin tensioning of fabricated coach shell shall be carried out to remove bulging and minimize undulations.

3.11.4 Welding of partition frames, back pieces for mounting of seats, luggage racks

etc. on car body shell shall be carried out after skin tensioning of Car Body shell.

3.11.5 Welding of partition frames, back pieces etc. on car body shell shall be done

in accordance to RCF drawings listed in annexure-I (Table-D).

3.11.6 Fitment of Body side doors, Hand holds etc. shall be carried out as a part of Body shell fabrication.

3.11.7 In case of Non AC variant HB design (EOG/HOG) cars, window bars shall be

welded on window openings in Sidewall.

3.11.8 Body pillars shall be welded to the solebar. Longitudinally they shall be connected through horizontal members.

3.11.9 In case of Non AC variants of LHB design (EOG/HOG) cars, body side

window openings adjacent to door towards compartment shall be provided with eight protection bars. All other body side window openings, except emergency window openings, shall be provided with four protection bars.

3.12 Exterior Painting: 3.12.1 General

3.12.1.1 The Exterior painting shall be done using PU paint to RCF specification no.

MDTS-094 (with latest revision).

3.12.1.2 The PU paint shall be procured from RCF/RDSO approved source only. PU painting shall be done with the help of airless spray guns.

3.12.1.3 First of the firm shall adopt the Shot blasting/ Grit blasting and other surface preparation methods to prepare rough surface required for exterior and



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interior primer coating. Surface roughness shall be confirming to Sa 2½ standard.

3.12.1.4 The exterior colour scheme of different variants of the cars listed in clause 2.5.1 shall be got approved from IR.

3.12.1.5 The paint coating shall be tested in accordance with relevant latest Indian/international standards.

3.12.1.6 Anti graffiti clear coating shall be provide on exterior painting of LHB design

(EOG/HOG) cars. 3.12.2 Surface Preparation

Either of the following two surface preparation methods may be adopted followed by the application of primer, surfacer and finish for car body shell :-

1. Blasting with non-abrasive blasting media (for a profile of

20-40 microns) followed by cleaning with compressed air. Or

2. Cleaning, degreasing and application of suitable solvent based Etch primer (for a profile of 15-20 micron)

3.12.3 Exterior Primer

3.12.3.1 Solvent based exterior primer paint having anti-corrosive property shall be applied on coach exterior.

3.12.3.2 The material shall have good adhesion on the substrate and shall have good compatibility with subsequent coats of two pack unsaturated polyester based putty, two pack polyurethane based under coat paint and two pack polyurethane based top coat paint.

3.12.3.3 Solvent based primer shall be applied with airless spray equipment immediately after surface preparation.



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3.12.3.4 The primer shall be suitable for spray application and it may also be suitable for application by brush for touching up smaller area.

3.12.4 Putty:

Apply putty on all spots and seam welding joints by using putty knives of sizes 12”, 9”, 6”, 2” and 1” as required. Allow it to dry giving sufficient time at least 2 hrs. Three coats of putty shall be applied.

3.12.5 Hand Grinding:

3.12.5.1 Rub the surface using 150-grade water proof emery or with the help of Orbital Sander with water to even out the surface and to remove the excess putty. Then wash thoroughly and allow it to dry giving sufficient time at least 2 hrs.

3.12.5.2 Gently rub the exterior of the shell having 220-grade water proof emery or with the help of Orbital Sander with water to obtain an even surface. Wash it thoroughly and allow it to dry giving sufficient time at least 2 hrs.

3.12.6 Undercoat/Surfacer

3.12.6.1 Two pack Polyurethane surfacer shall be used and shall be mixed in the ratio recommended by the manufacturer of the paint. The consistency of the surfacer shall be smooth, uniform and suitable for spray application.

3.12.6.2 Polyurethane surfacer is to be used over primed/putty applied surfaces for

protection of exterior of railcars. The material is used with the object of getting smooth, uniform and non absorbent base for PU top coat paint. The material shall have good compatibility with two pack PU top coat paint, polyester based putty and epoxy zinc phosphate primer.

3.12.6.3 Undercoat/Surfacer shall be provided for getting better surface adhesion. This undercoat should be applied using airless spray equipments.

3.12.6.4 The spray gun shall be thoroughly cleaned before use. The pressure ratio of air cylinder to hydraulic cylinder shall be adjusted in accordance with the viscosity of the material to be sprayed. The material shall be sprayed carefully so as to obtain an even and uniform coat having a dry film thickness



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of 30 microns minimum per coat. The mixed paint shall allow good spraying properties on vertical panels and the film when dry shall be free from sags, runs, streaks and any defects.

3.12.7 Top Coat

3.12.7.1 Two pack polyurethane enamel shall be used and shall be mixed in the ratio

recommended by the manufacturer of the paint. The consistency of the polyurethane enamel shall be smooth, uniform and suitable for spray application.

3.12.7.2 The spray gun shall be thoroughly cleaned before use. The pressure ratio of air cylinder to hydraulic cylinder shall be adjusted in accordance with the viscosity of the material to be sprayed. The material shall be sprayed carefully so as to obtain an even and uniform coat having a dry film thickness of 40 microns minimum per coat. The mixed paint shall allow good spraying properties on vertical panels and the film when dry shall be free from sags, runs, streaks and any defects.

3.12.7.3 02 nos. top coats shall be applied using airless spray equipments and

multiple top coatings shall be done as required.

3.12.7.4 Polyurethane enamel used shall have good spraying properties on vertical parts. The film when dry shall be free from sags, runs, streaks, and any other film defects.

3.12.7.5 The colour of the top coat shall be as per exterior colour scheme, which has been got approved from IR.

3.12.7.6 The finish of the top coat shall be smooth, uniform and fully glossy.

3.12.7.7 Dry film thickness shall be of 40 microns minimum per coat and there should

be no visible damage or detachment of film.

3.12.7.8 Minimum gloss value at 60º angle of incidence shall be 85.

3.13 Interior Painting:

3.13.1 General



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Following steps shall be considered:

(i) The interior of coach shall be thoroughly be cleaned prior to painting.

(ii) Grit/Shot collection.

(iii) Pick up electrode bits and other pieces present inside the shell.

(iv) Use compressed air to clean the interior of Roof, Sidewalls and End walls so that all the Grits accumulate on the trough floor.

(v) Suck the grits from the trough floor by using grit collection plant.

(vi) After completion of the work unload the grit collected from the plant and move it to the Grit blasting /Shot blasting plant.

3.13.2 Interior Primer:

Apply PU primer using airless spray equipments immediately after grit / sand blasting and allow it to dry giving sufficient time.

3.14 Painting of Underframe Assembly:

3.14.1 Clean all the welded joints by Shot blasting/ Grit blasting.

3.14.2 Apply PU primer and Anti corrosion paint with the help of airless spray

equipments immediately after Grit / Sand blasting and allow it to dry giving sufficient time.

3.14.3 Repeat the process on the topside after turning the underframe bottom side down.

3.14.4 Allow complete drying before taking the underframe for further assembly.

3.15 Rail Car Insulation:

3.15.1 The rail car insulation shall comprise glass fibre insulation mats from window level upwards and roof. The insulation below window bottom level shall



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comprise corrugated plastic film insulation, as prescribed in ALSTOM LHB’s drawing No. 1 10113.0.21.120.001. The mats in roof shall be fixed by means of nails, using suitable gun. The insulating material of plastic film insulation shall conform to RCF’s Specification No. MDTS-088. Thermal conductivity of Glass fibre insulation mats shall conform to DIN 52612. The insulation shall be provided on all sides in such a manner as to give ‘μ’, the over all thermal co-efficient of heat transmission in K Cal/Sqm/hr/deg. Celsius approximately as under:

Roof 0.602 Floor 0.936 Sidewall 1.290 Glass Window 1.376

3.15.2 Thermal insulation shall be applied on the interior surface of the shell after spraying with solution for protection against corrosion and sound insulation.

3.15.3 The partition walls separating air-conditioned and non-air conditioned spaces shall also be insulated against heat and noise.

3.16 Buffing Gear:

3.16.1 The LHB design AC Generator Car cum Luggage cum Brake Van shall be equipped with side buffers at both ends of the car. No. of side buffers per car shall be 04 (Four).

3.16.2 The Loco side buffers assembly to RCF drawing MI004277, shall be used on AC Generator Car cum Luggage cum Brake Van alongwith the Center Buffer Couplers.

3.16.3 Buffer assembly and its components shall meet the requirements of RDSO

specification no. MP-0.41.00.02, with latest revision (specification for Loco side buffers assembly).

3.16.4 The General arrangement of this buffer assembly shall confirm to RDSO drawing no. LA/BD-153/M , with latest alteration, except the mounting holes on the base of buffer casing, overall length of buffer and shape & size of the plate.



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3.16.5 The face plate of both the side buffers shall be as per drawing no. LP22102 and LP22103 for L.H & R.H respectively.

3.17 Couplers and Draft-Gear

3.17.1 Each coach shall be provided with High tensile AAR ‘H’ type Tight Lock

Centre Buffer Coupler at both ends of the coach and should be capable of being coupled with AAR type “E” / H centre buffer couplers fitted on locomotives.

3.17.2 The draft gear should preferably be balanced type in terms of latest revision of RDSO specification no. RDSO/CG/2011/CG-03.

3.17.3 The “Coupler System” should allow a vertical angle of deflection of ± 7 deg. and horizontal angle of deflection of ± 18 deg.

3.17.4 The coupler shall, in conjunction with the draft-gear automatically effect mechanical coupling in straight lines, curves with radius greater than 175m and also (with some limitations) in transition between straight lines and a curve. It shall permit separation of cars manually from the track.

3.17.5 Height of the coupler shall be 1105mm (+0 / -15 mm) in the same alignment

of the under frame structure under tare.

3.17.6 The design of coupler head shall enable coupling of two couplers with a maximum vertical displacement of their centre lines of by 90mm without manual assistance and horizontal gathering range of the coupler heads shall be 110mm on either side of longitudinal centre lines of the cars without manual assistance.

3.17.7 The coupler shall be equipped with a self-centring device to prevent the coupler from swinging transversely when uncoupled. The couplers shall care for all suspension conditions and dynamic movements encountered during operation.

3.17.8 Mounting of couplers shall be as per LHB drawing no. 1 10113.0.05.000.001

with latest alt.



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3.17.9 The couplers shall be easily replaceable in the event of becoming damaged.

3.18 Air Brake System:

3.18.1 The LHB design (EOG/HOG) cars shall be fitted with graduated release twin

pipe air brake system to RCF’s drawing mentioned in annexure-I.

3.18.2 Passenger emergency alarm system visual indication shall be provided, near both the doorways at one end of the coach.

3.18.3 Emergency Pull Box shall be provided at locations as indicated in RCF’s drawing no. mentioned in annexure-I.

3.19 Doors

3.19.1 Body Side Entrance Doors 3.19.1.1 All cars except AC Generator Van and General Second Class Cars, shall

have minimum 04 (four) body side entrance doors, 02 (two) on each side.

3.19.1.2 Number of body side entrance doors on each side of AC Generator Van and General Second Class Car (LS) shall be 02 (Two) and 06 (Six) respectively. In AC Generator Van no. of doors at each side will be 01 (One) and in General Second Class Car (LS), no. of doors per side will be 03 (Three).

3.19.1.3 For all variants of LHB design (EOG/HOG) cars entrance doors for L.H &

R.H sides shall be as per RCF layouts of doors drawings listed in annexure-I (Table-C).

3.19.1.4 The minimum opening of passenger door shall be 825mm. 3.19.1.5 Body side entrance doors shall be vibration free and insulated against heat

and sound transmission. 3.19.1.6 Body side entrance doors are provided with window.

3.19.1.7 Body side doors shall be provided with internal safety catches at top with

pad locking arrangement and one door on either side of the coach



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diagonally opposite shall be provided with staples for pad locking from outside. (ICF drawing or RDSO drawing shall be adopted for safety catches).

3.19.1.8 The body side doors shall also be provided with carriage door lock suitable for locking / unlocking with standard square key both from inside and outside.

3.19.2 Saloon Doors (For AC Variants Only)

3.19.2.1 Saloon doors in each variant of AC cars shall be as per the RCF layouts of

doors drawings listed in annexure-I (Table-C).

3.19.2.2 Door leaf built by stainless steel/aluminium profiles with hardened safety glass & ventilation grid applied to the frame by means of EPDM rubber gasket with locking string.

3.19.2.3 The shutter carries external and internal handles along with hand safe gasket.

3.19.2.4 Ventilation grid made up of stainless steel/aluminium extrusion shall be

provided for air passage applied on the bottom of the shutter by means of EPDM rubber gasket.

3.19.2.5 Doors shall be as light and rigid as possible.

3.19.2.6 Doors should have smooth running without jerks and noise.

3.19.2.7 The doors should have pleasant and good looking appearance. 3.19.2.8 Maximum Force necessary for opening/closing the door in this case shall be

5 to 6 Kg.

3.19.2.9 Door closing mechanism should have time delay device to increase the closing time of doors at the time of closing stroke. It should take 30 sec to 120 sec before closing. The time delay device should be adjustable. Movement should be slower at end of closing of stroke for last 200mm (0.05m/s).



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3.19.2.10 The shutter may optionally have a lock, for the locking of the door in closed position, actuated by square key.

3.19.2.11 The free passing through height of open door shall be 1865 mm minimum.

3.19.2.12 The minimum door opening of Saloon Sliding door shall be 600 mm.

3.19.3 Compartment Sliding Doors (For First Ac Only)

3.19.3.1 Compartment sliding doors in LHB design First AC cars shall be as per the RCF drawing for layouts of doors mentioned in annexure-I (Table-C).

3.19.3.2 Door leaf built by stainless steel with hardened safety glass & ventilation grid applied to the frame by means of EPDM rubber gasket.

3.19.3.3 The shutter carries external and internal handles along with hand safe gasket.

3.19.3.4 Ventilation grid made up of stainless steel extrusion shall be provided for air passage applied on the bottom of the shutter by means of EPDM rubber gasket.


3.19.3.6 Doors should have smooth running without jerks and noise.

3.19.3.7 The doors should have pleasant and good looking appearance.

3.19.3.8 Maximum Force necessary for opening/closing the door in this case shall be 5 to 6 Kg.

3.19.3.9 Door closing mechanism should have time delay device to increase the closing time of doors at the end of closing stroke. It should take 30 sec to 120 sec before closing. The time delay device should be adjustable. Movement should be slower at end of closing of stroke for last 200mm (0.05m/s).

3.19.3.10 Move mechanism should work smoothly work for 3, 50,000 cycles.

3.19.3.11 Weight of the one complete door assembly must not increased 60 Kg.



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3.19.3.12 Door should meet the mechanical strength requirement as per UIC 566.

3.19.3.13 Fire characteristic of the door unit shall be as per appendix-6 of UIC 564 (2).

3.19.3.14 The shutter may optionally have a lock, for the locking of the door in closed

position, actuated by square key.


3.19.3.16 The minimum door opening of Saloon Sliding door shall be 600 mm.

3.19.4 Vestibule Doors (For All Variants Except Gen. Sec. Class)

3.19.4.1 No. of vestibule doors in each variant of LHB design (EOG/HOG) cars except General Second class cars, shall be 02 (Two). General Second class cars shall be without vestibule doors.

3.19.4.2 Vestibule doors comprise of manually operated, having two sliding shutters with operating speed of 0.1m/sec (approx.).

3.19.4.3 Vestibule doors in variants of LHB design (EOG/HOG) cars shall be as per the RCF drawing for layouts of doors mentioned in annexure-I (Table-C).

3.19.4.4 The vestibule doors should have pleasant and good looking appearance.

3.19.4.5 Maximum Force necessary for opening/closing the door in this case shall be 5 to 6 Kg.

3.19.4.6 Move mechanism should work smoothly work for 3, 50,000 cycles.

3.19.4.7 Weight of the one complete door assembly must not increased 100 Kg.

3.19.4.8 Door should meet the mechanical strength requirement as per UIC 566.

3.19.4.9 Fire characteristic of the door unit shall be as per appendix-6 of UIC 564 (2).



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3.19.4.10 As per para 4.2.5 of UIC-564-2 OR, the end doors should be fire prevention door i.e. in case of fire, spreading of fire, smoke and heat should be avoided for 15 minutes, so that fire is prevented from developing in adjacent rail car.

3.19.4.11 Fire barrier frame composed of stainless steel profile should house special

bars of silicate calcium, which stressed by temperature of a possible fire, expand upto six times their own volume sealing in this way the fire passage remaining between the shutters and the head wall of the vehicle.

3.19.4.12 Fire barrier frame should also house the horse hair brushes which keep the insulation and which are used as sealing surface for the rear gaskets installed on the shutters.

3.19.4.13 Locking device placed inside the stainless steel special external handles that lock the doors (closed) when a 1000 C environment temperature is generated by the fire.

3.19.4.14 Door leaf shall be made of sandwitch construction of stainless steel frame with stainless steel sheet on both sides filled with phenolic foam to IS:13204-1991, density=30Kg/cubic meter inside the door leaf.

3.19.4.15 Door closing mechanism should have time delay device to increase the closing time of doors at the time of closing stroke. It should take 10 sec to 120 sec before closing. The time delay device should be adjustable. Movement should be slower at end of closing of stroke for last 200mm (0.05m/s).

3.19.4.16 Door leaf of Endwall door has Sandwich construction with an aluminium/stainless steel frame. External and internal surfaces have sandwich construction with a Fire barrier.

3.19.4.17 Doors shall be equipped with a square key lock which shall be operated by square key from inside and with a handle/square key from outside (both in open and closed position).

3.19.4.18 Each shutter has a replaceable toughened and transparent glass window.

3.19.4.19 It should be possible to open the door during closing stroke also.




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3.19.4.21 Vestibule doors shall be of double leaf and should have smooth running

without jerks.

3.19.4.22 The free passing through height of open door shall be 1865mm minimum.

3.19.4.23 The minimum door opening of Endwall doors shall be 675 mm.

3.19.4.24 Door shall be provided a square key lock which shall be operated from both inside and outside (both in opened and closed position) with provision of locking the door in open position for standard opening 770mm and for reduced opening 675mm.

3.19.5 Lavatory Doors

3.19.5.1 Lavatory door comprises of shutter/shutters for closing of lavatory room, operated by manual handling.


3.19.5.3 Door leaf of Lavatory doors has Sandwich construction with an aluminium/stainless steel frame. External and internal surfaces have sandwich construction and the shutter carries external and internal handles along with hand safe gasket.

3.19.5.4 Ventilation grid made up of stainless steel/aluminium extrusion is provided for the air passage, applied on the bottom of the shutter/shutters. If it is not included, suitable means for proper air circulation must be provided.

3.19.5.5 The doors should have pleasant and good looking appearance.

3.19.5.6 The door is equipped with release lock which can be closed from inside by knob and outside by square key.


3.19.5.8 The minimum door opening of lavatory doors shall be 600 mm.



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3.19.5.9 The strength of the lavatory doors shall be as per UIC566 OR and the doors shall be able to resist the loads without deformation or damage.

3.19.5.10 The design of all parts and components of lavatory doors shall meet the Fire prevention requirements.

3.19.6 Loading Doors ( For Generator Van Only)

3.19.6.1 Loading doors shall be provided in AC Generator Van cum Luggage cum

brake Van.

3.19.6.2 The minimum door opening of loading doors shall be 1500mm.


3.19.6.4 The mechanical strength of the loading door has to meet the requirement of UIC 566 OR.

3.19.6.5 All materials used, especially profiled joints, are to be resistant to chemical substances of purifying agents.

3.19.6.6 Loading doors shall be vibration free and of modular design.

3.19.6.7 The doors shall be sealed against draughts and water. Any ingressed water shall drain rapidly.

3.19.6.8 The doors shall be as light and rigid as possible.

3.19.6.9 The design of all parts and components of loading doors shall meet the requirements fire prevention requirements.

3.20 Side and Door Windows (For AC Variants)

3.20.1 No. of Side windows and their locations in each variant of AC cars shall be as

per the RCF drawing for layout of windows, listed in annexure-I (Table-C).

3.20.2 Provision of window in body side entrance door shall be as per RCF drawing no LS51001, with latest alt.



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3.20.3 Window design must allow passengers to have a good vision on the outside and especially on the station information.

3.20.4 All side windows shall be double glazed with outer glass laminated and inner glass toughened. Side windows shall be designed in a way that suitable transmission coefficient shall be ensured according to Indian climate conditions.

3.20.5 The body-side and door windows shall be designed to minimize solar gain and provide a level of thermal insulation consistent with the requirements of the air conditioning system.

3.20.6 All glass shall be tinted. The colour may be achieved by tinting the body of the glass.

3.20.7 Saloon windows shall be provided and be flush mounted with the exterior of the car body.

3.20.8 Each window, including glazing shall meet the requirements and of sufficient strength to resist penetration of solid steel ball when tested as per annexure ‘A’ of IS: 2553 Part-II.

3.20.9 Glazing shall imperatively be safety glass (compound or toughened) and the thickness shall be selected to withstand mechanical stress and contribute to sound and heat insulation.

3.20.10 All side windows and door window shall transmit less than 5% of the incident ultra violet radiation.

3.20.11 Glazing strength shall meet the requirements of UIC 564-1/ UIC 566 OR Equivalent Standard.

3.20.12 Glazing of windows shall be strong enough so that it will not to be removed by unarmed person and shall resist to an act of vandalism and shall be high enough to prevent easy breakage.



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3.20.13 Window seals shall be designed to prevent ingress of water to the inside. The sealing material shall be so selected that it lasts at least the mid life interval overhauls of car body.

3.20.14 Four nos. of emergency windows shall be provided at the locations shown in

RCF drawing for Layout of window arrangement, mentioned in annexure-I (Table-C).

3.20.15 Door windows shall have a window similar to the windows provided in the car body as far as possible in respect of solar gain, thermal insulation, replacement criteria, strength, resistance to pressure, and the transmission of light, and solar heat gain.

3.20.16 Door windows shall be replaceable without removal of the door leaf.

3.21 Side and Door Windows (For Non Ac Variants)

3.21.1 Window sill arrangement shall be made leak proof against the ingress of water as a means to prevent corrosion of side wall and other parts of the shell.

3.21.2 All glass and louvers shutters shall be of FRP.

3.21.3 Glass shutters of all body side and door windows shall be provided with spring loaded balancing device.

3.21.4 Body side door windows shall be provided with 9 protection bars. In addition, a center stiffener flat shall also be provided on these body side door windows as shown in RDSO Sketch CG-K5068 with latest alteration.

3.21.5 Four nos. of emergency windows shall be provided at the locations shown in

RCF drawing for Layout of window arrangement, mentioned in annexure-I (Table-C).

3.21.6 All other body side windows shall be provided with four protection bars.

3.22 Lavatory Windows



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3.22.1 Hopper window having both fixed and openable part shall be provided in

lavatories of all variants of LHB design (EOG/HOG) Cars. The lower part of the window shall be fixed and upper part shall be openable .In case window is not provided in lavatory, it shall be ensured that the stale air is exhausted out of the car.

3.22.2 The hopper window is designed in such away so that the opening part must be hinged. The system allows two fixed positions for the opening part of the lavatory windows i.e. fixed and opened at approximately 30º angle.

3.22.3 The hopper part is fitted with handle which has integrated locking device.

3.22.4 The lavatory windows shall be translucent.

3.22.5 It is possible to change the both glasses of lavatory from inside of the car.

3.22.6 Glazing strength shall meet the requirements of UIC 564-1/ UIC 566 or Equivalent international Standard.

3.22.7 Glazing of windows shall be strong enough so that it will not to be removed by unarmed person and shall resist to an act of vandalism and shall be high enough to prevent easy breakage.

3.22.8 Window seals shall be designed to prevent ingress of water to the inside. The sealing material shall be so selected that it lasts at least the mid life interval overhauls of car body.

3.23 Vestibules

All sleeper car ends shall be fitted with vestibules. The vestibule arrangement shall be of UIC flange type rubber bellows to LHB’s Drg. No. 1.10113.0.24.100.001. The vestibule arrangement should be rugged, easily maintainable and shall consist of fire resistant material.

3.24 Partition Frames (For Ac Variants)

3.24.1 Partitions walls shall be aesthetic pleasant and have sufficiently good wear and tear properties and shall be of made with light weight material aluminium



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honeycomb core pasted between HPL sheets to RCF specification MDTS097 with latest revision.

3.24.2 Partition frames shall be of modular design and bolted to the carbody. Overall

thickness of honeycomb partition walls shall be 20mm.

3.24.3 Both the transverse and longitudinal side Partition walls of AC Rail cars shall be provided up to Roof height.

3.24.4 Partitions pillars shall be aesthetic pleasant and have sufficiently good wear

and tear properties and shall be of made with aluminium alloy or stainless steel as per relevant RCF drawings of partition frame arrangement.

3.24.5 Partition frames of AC Chair cars of both second class and executive class variants are made of stainless steel (C-K201, X2CrNi12, 409M) metal frame with HPL sheets over it.

3.24.6 Both the transverse and longitudinal side partition walls of AC railcars shall be provided up to ceiling height.

3.24.7 Colour of partition frames and partition pillars shall be as per interior colour scheme of the rail car.

3.25 Partition Frames (For Non AC Variants)

3.25.1 Partitions walls shall be aesthetic pleasant and have sufficiently good wear and tear properties and shall be of made stainless steel (C-K201, X2CrNi12, and 409M) metal frame with HPL sheets over it.

3.25.2 Partition frames shall be of welded to carbody at body shell stage. Overall thickness of partition walls without HPL sheet panelling shall be 20mm.

3.25.3 Expanded material shall be used at top and bottom sides of the partition frames at transverse side for air ventilation.

3.25.4 Expanded material shall be used at bottom sides of the partition frames at longitudinal side for air ventilation.



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3.25.5 Partition walls at transverse side of Non AC General Second Class rail cars shall be provided about 600mm above luggage rack above transverse seats and the remaining space between roof and partition shall be covered with suitable expanded material grid for proper ventilation.

3.25.6 Colour of partition frames and partition pillars shall be as per interior colour scheme of the rail car.

3.26 Fresh Water Tanks

3.26.1 Under-slung and interconnected water tank/s as per RCF drawing shall be

provided.

3.26.2 Water shall be suitably pressurised or pumped for supply of water from tank/s to lavatories. In addition, each lavatory shall be provided with one overhead water tank of minimum 30 litter capacity.

3.26.3 In general there will be two water tanks of capacity 685 litre and one tank of

450 litre. However no. of tanks may vary according to water requirement of the particular variant of the car. Mounting of fresh water tank assembly shall be as per RCF drawing for mounting arrangement of water tank for the particular variant listed in annexure-I (Table------).

3.26.4 The design of Fresh water tank shall be as per RCF’s drawings listed below:

S.N Description of Water Tank Details of RCF Drawing

1 Fresh water tank 685L (Left) complete CC63005 with latest alt.

2 Fresh water tank 685L (Right) complete CC63968 with latest alt.

3 Fresh water tank 450L complete LP63101 with latest alt.

3.26.5 The design of the tanks shall be provided with a discharge facility and shall be easily cleanable when necessary.

3.27 Railcar Interior



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3.27.1 The passenger cars Interiors are defined by the distribution of seats/berths/chairs, panelling, toilets, partitions, on board equipments, lights etc. It shall be designed in order to fit with long distance transport capacity requirements and comfort needs. The firm shall follow the RCF’s drawings for railcars interior arrangements.

3.27.2 Aesthetically pleasant Interiors shall be provided.

3.28 Floor

3.28.1 Floor construction in passenger room shall consist of 2 mm thick Polyvinyl

Chloride (PVC) flooring sheets laid over 16 mm thick Makore Wood floor panels with low weight and good heat and insulating characteristics screwed upon the anti-vibration mounts (decoupling arrangement). Between Makore Wood panels and corrugated trough floor 30 mm thick RESONAFLEX Alu a special plastic foil compound material shall be placed. In doorways and gangways, the thickness of RESONAFLEX shall be 25 mm. Floor arrangements in passenger area, doorways and vestibule area shall be to relevant RCF’s drawings.

3.28.2 In passenger area, the PVC is fixed by gluing it onto the Makore wooden

floor panels and is fixed by means of watertight hot air welding. The PVC layers shall rise upto a height of 250 mm on the sidewall and shall be edged by means of aluminium profiles also meant for mounting the seats.

3.28.3 2 mm thick corundum filled PVC layer shall be glued in the doorway areas

between body side doors and the gangway areas between the lavatories.

3.28.4 The finished floors shall be free from bulges, depressions and cracks and shall render a smooth finish.

3.28.5 The PVC sheets for the above applications shall be to RCF’s Specification

No. MDTS-083.

3.29 Interior Panelling

3.29.1 Interior panelling includes sidewall panelling, passenger room ceiling, endwall panelling, doorway panelling etc.



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3.29.2 The interior Sidewall &Ceiling panels shall be of FRP panels to RCF’s Specification No. MDTS-084. The moulding and fixing of FRP panels shall be similar to ALSTOM LHB’s design as per drawing No. 1.10113.0.21.310.001 and 1.10113.0.21.410.001, with minimum number of visible screws.

3.29.3 Interior panelling arrangement shall be as per relevant RCF drawing for

interior panelling arrangement, listed in annexure-I (Table-D).

3.29.4 Colour and pattern of the interior panelling shall be similar to LHB design (EOG/HOG) cars manufacture by IR and complete interior colour scheme of all the LHB car variants for which order has been placed by IR shall be got approved.

3.29.5 The design of interior fittings shall be safe under all conditions of passenger impact, during emergency braking and buffing under full load condition.

3.29.6 All interior surfaces must be finished with good blending and good slow ageing properties to provide a pleasant, high-quality interior and for ease of cleaning and maintenance.

3.29.7 Interior panels should be of modular design, easily and rapidly removed and replaced independently from each other by specialist personnel, but difficult to dismantle for non-specialists.

3.29.8 Since these measures cannot be totally effective, the fittings and materials shall be easily cleanable (paint, graffiti, glue, etc.). They shall therefore withstand frequent use of various cleaning products (alkaline or acid detergents, petroleum solvents, mechanical action of brushes) without losing their colour or a noticeable deterioration of their surface aspect.

3.29.9 As far as possible, fastening devices, fixings and securing screws shall not be visible from within the saloon.

3.29.10 Gaps between all interior lining panels, kick strips, seat/berth shell, etc. shall be minimized. Suitable cushioning at panel joints shall be provided to suppress noise.

3.30 Air Ducts and Diffusers (For AC Variants Only)



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3.30.1 The cold and warm air is carried from the one or two carriage ends via a

supply duct through perforated ceiling or supply air grills in to the railcars.

3.30.2 The design of duct shall ensure that the air supplied over the entire duct length with a uniform flow and inlet rate into the passenger compartment. The ducting is connected to the RMPU.

3.30.3 Modular type duct shall be provided as per RCF duct arrangement drawings

listed in table-E of appendix-I. Considerations shall include, but are not limited to, thermal insulation performance, as required, to prevent condensation on the exterior of the duct under all conditions, acoustic insulation such that the interior noise requirements are met, weight, appearance, and ability to repair.

3.30.4 The air velocity within the duct work is not specifically limited but shall be such that, in combination with the acoustic insulation, shape, and diffuser design, the interior noise and vibration requirements.

3.30.5 Fresh air shall be drawn from grilles into the suction plenum. The grille shall be designed to prevent water ingress resulting from adverse weather or train washing.

3.30.6 Conditioned air from each unit shall be directly introduced into duct discharge into the car through ceiling outlets.

3.30.7 The duct shall be constructed from anodized aluminium material and all edges and joints of duct insulation shall be sealed.

3.31 Lavatories

3.31.1 All sleeper & chair cars (generator van) shall generally include four & three

modular design toilets respectively. However no. of toilets and distribution of toilet type in all cars shall be as per respective variant of RCF layout drawings mentioned in annexure-I (Table-A).

3.31.2 Indian style toilets shall be of squatting type with washing facility and western

style toilet shall be of sitting type with aesthetically pleasing light weight rugged composite material.



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3.31.3 The number of lavatories with Indian style/Western style in each variant of

LHB design (EOG/HOG) cars shall be as per RCF’s Lavatory arrangement drawings.

3.31.4 All Lavatories of each car shall be equipped with Bio-tanks.

3.31.5 Generally car wise Indian and western style toilets are:

Rail Car type No. of Indian style toilets

No. of western style toilets

LS 04 Nil LWSCN 03 01 LWLRRM 01 01 LWACCN

03 01

LWACCW 03 01 LWFAC 03 01 LWCBAC 01 01

3.31.6 Modular toilets made of FRP material shall be provided. Lavatory module for

Indian style shall be to LHB’s drawing No. 1.10113.0.30.000.003 Alt. ‘B‘and for western system to LHB’s drawing No. 1.10113.0.30.000.005 Alt. ‘C’.

3.31.7 Each toilet shall be ergonomically designed , odorless, easy to maintain,

require less maintenance, environment friendly and shall include the following equipment:

i. Mirrors ii. Wash basin iii. Toilet paper dispenser ( In Western style WC) iv. Liquid soap dispenser & soap holder v. Waste container vi. Coat hooks (Two) vii. Lighting viii. Grab handle ix. Water tap near WC and 01 bowl/mug for water with stand. x. Lavatory engaged / free indication light shall be provided at both

ends inside the railcar at convenient location, this light shall be generally visible throughout the railcar.



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3.31.8 Suitable device for extraction of foul air from toilets shall be provided.

3.32 Outside Wash Basin Arrangement

Wash basin shall be provided outside the lavatories in doorway area as per RCF layout drawing mentioned in annexure-I. The fittings of outside wash basin in general will include:- • Wash basin & drain pipe • Liquid soap dispenser and soap stand • Decorative mirror with bevelled edged and etched lining near border. The

size should be compatible with wash basin. There should not be any distortion even of mild nature in mirror’s view.

• Decorative Mirror lights with sufficient illumination level with etched glass cover.

• Covering of wash basin drain pipe with built-in type dust bin.

3.33 Seats/Berths & Chairs

3.33.1 The seats/berths & chairs shall provide an adequate level of comfort, have a good appearance and be scuff and vandal resistant and their mountings shall be capable of withstanding the loads arising in service conditions.

3.33.2 The seats/berths & chairs arrangement with the size, colour, profile and shape of the individual seats/berths chairs shall be according to RCF’s seats/berths & chairs arrangement drawings (Table-C, annexure-I) for a particular variant of the car.

3.33.3 The Middle and Upper berths of all sleeper cars shall have arrangement

which shall provide resistance to passenger movement longitudinally along the vehicle during acceleration and braking etc.

3.33.4 The head room between the berths in sleeper cars shall be adequate for

passengers.

3.33.5 Silicon foam cushioning material to RDSO specification RDSO/2013/CG-13 with latest amendment/revision shall be used in Seats/Berths & chairs.



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3.33.6 Seats/Berths & Chairs shall be upholstered and shall not have sharp edges or protrusions that could cause injury to passengers or staff.

3.33.7 Fire retardant upholstery to RDSO specification shall be used for the

seats/berths & chairs.

3.33.8 Seat/Berth modules in similar situations in a vehicle shall be interchangeable.

3.33.9 The lower seats/berths shall be cantilevered out from the sidewall in a similar way as in existing LHB rail cars, to provide a clear unobstructed car width floor, for ease and speed of cleaning. The seating arrangement shall in itself be easy to keep clean and shall not impede the cleaning of any other part of the car interior. The seat /berth fixtures shall be arranged so that no fixing or strut is visible. Permanent fixings shall form part of the floor and body sides.

3.33.10 The proposed minimum seat/berth depth, measured from the seat's/berth’s forward edge to the forward surface of the seat's/berth’s back, minimum seat/berth width and leg room shall be as per RCF seats / seat & Berth arrangement drawing mentioned in table-C of annexure-I .

3.33.11 Seats/Berths shall meet the requirements of UIC 566 OR equivalent

standard.

3.33.12 Reclining chairs with armrest and backrest shall be provided both in executive and 2nd class chair cars. Design of Chairs shall be as per RCF specification MDTS-----.

3.33.13 Middle armrest(s) of chair cars shall be of movable type.

3.33.14 Reclining chairs shall be equipped with bottle holder, snack table, magazine

bag and adjustable foot rest etc.

3.33.15 All seats/berths shall be serially numbered according to relevant RCF drawing, applicable for a particular variant of LHB design (EOG/HOG) cars.

3.34 Luggage Racks

3.34.1 Light Luggage Rack In Compartment of Sleeper Cars



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The firm shall provide at least one light luggage rack in each compartment of all sleeper railcars at a suitable height above window. Due care shall be taken in its design so as to avoid any injury to passenger. These racks shall run longitudinally along the sidewalls and securely fixed, however fixing may be done on partition wall in case of two berth coupe in Ist AC cars. The luggage racks shall be of sufficient strength to adequately support luggage and resist damage due to vandalism. The luggage racks shall be lightweight and injury free but of sturdy design and to be tested according to International standards.

3.34.2 Luggage Rack (For Chair Car Variants)

The firm shall provide at least two luggage racks (LH & RH) at longitudinal side in all variant of chair cars at a suitable height above window similar to chair car variant of existing LHB cars. Luggage racks shall be of modular design and due care shall be taken in its design so as to avoid any injury to passenger. Luggage racks shall be securely fixed and shall run longitudinally along the sidewall. The design of the luggage rack shall be large enough for oversized luggage and prevent sliding of the luggage. The luggage racks shall be of sufficient strength to adequately support luggage and resist damage due to vandalism. The luggage racks shall be lightweight and Injury free but of sturdy design and to be tested according to UIC 566 or equivalent International standards. These racks will be opened and presented at its bottom an area with glass, allowing the vision of luggage by passenger from his seat.

3.34.3 Luggage Rack (For Non AC General Second Class Cars ) The Firm shall provide at least two luggage racks at transverse side in each compartment at a suitable Height above the transverse seats and a light luggage rack above longitudinal seats, similar to existing LHB type General Second Class cars . Due care shall be taken in its design so as to avoid any injury to passenger. Luggage rack at transverse side securely fixed and shall run transversally along the partition walls. Similarly luggage rack above longitudinal seats shall run along the sidewall. The design of the luggage rack shall prevent sliding of the luggage. The luggage racks shall be of sufficient strength to adequately support luggage and resist damage due to vandalism. The luggage racks shall be lightweight but of sturdy design and to be tested according to UIC 566 or equivalent International standards.



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3.35 HANDHOLDS AND LADDER

3.35.1 Handholds and Ladder shall be seamless, corrosion resistant material tubing with satin finish. The design of any joints in the handholds or ladder shall resist the effects of vibration, or of passengers moving or twisting them.

3.35.2 The Handholds and ladders shall suffer no permanent deformation when subject to loading conditions arising in service, in accordance with UIC 566 OR.

3.35.3 Ladder shall be provided in all sleeper cars for stepping up on upper/middle berth.

3.35.4 The design of Handholds and Ladder shall be injury free.

3.36 ROLLER BLINDS

Manually operated roller blinds in shades matching with car interiors shall be provided in AC chair car & AC Executive chair car variant rail cars specified in clause 2.6.1.

3.37 CURTAINS

3.37.1 A curtain track shall be provided at the top of the window area and aisle side along the length of the car for curtain installation. The curtains shall be free hanging at the bottom, but secured in the open position with a tie-back of the same fabric that is permanently attached to the curtain and secured with heavy duty Velcro-style hook and loop fastener.

3.37.2 Fire retardant Curtains to RDSO specification in shades matching with car interiors shall be provided in AC First class & AC Two tier rail cars.

3.38 FOOT STEP Foot Step shall be provided at all body side doors in all the railcars. The design of the foot step shall be skid free. These shall be provided as per



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RCF’s drawing no.LW41106 (latest alt.) so that it is possible to board the train from the platforms (as defined in Clause 3.4).

3.39 BOGIE

3.39.1 The general arrangement of the bogie shall be to RCF/FIAT’s Drawings with springs as under:

a) Primary Suspension springs:

Rail car type

Details of Inner Spring Details of Outer Spring

AC Chair Car

FIAT’s Drg. No. 1267412 FIAT’s Drg. No.1267411

AC Chair Car Executive Class (EOG)


AC -3T Sleeper (EOG)


AC-2T Sleeper (EOG)


AC-1st CLASS Sleeper (EOG)


AC Hot Buffet Car (EOG)


Generator Cum Luggage & Brake Van

FIAT’s Drg. No. 1277143 FIAT’s Drg. No. 1277142

NON AC 2nd Class (LS)

LG01101 LG01100

NON AC 2nd Class SCN(EOG)

LG01101 LG01100

b) Secondary springs:

Rail car type

Details of Air Spring



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AC Chair Car Air spring of 120KN Capacity AC Chair Car

Executive Class (EOG/HOG) AC -3T Sleeper (EOG/HOG) AC-2T Sleeper (EOG/HOG) AC-1st Class Sleeper (EOG/HOG) AC HOT Buffet Car (EOG/HOG) Generator Cum Luggage & Brake Van NON AC 2nd Class (LS) Air spring of 140KN Capacity NON AC 2nd Class SCN(EOG/HOG) Air spring of 140KN Capacity

3.39.2 The bogie side-frame shall be fabricated as a single piece. Manufacturing of the bogie frame shall be as per RCF drawings no. LW03002 (latest alt.).

3.39.3 The bogie side-frame shall be painted as per RCF specification MDTS-166, Rev-2.

3.40 CONNECTION CAR BODY-BOGIE Car body –bogie connection for Generator cum Luggage & Brake Van shall be as per LHB drawing no. 1 11012.0.01.100.001 (latest alt.) and for rest of the variants, LHB drawing no. 1 10113.0.01.100.001 (latest alt.) shall be followed.

3.41 ANTI-PILFERAGE MEASURES

While securing compartment and lavatory fittings, anti-pilferage measures shall be incorporated to prevent pilferage of parts and components.

3.42 OTHER PASSENGER AMENITIES

1.0.1 Each cabin of sleeper rail cars shall have provision of Mirror, Bottle Holder,

Magazine Bag, Coat Hook and Snack table.

1.0.2 The Mirror, Bottle Holder, Magazine Bag , Coat Hook and Snack table shall be of injury free design and aesthetically pleasant.



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3.43 EXTERIOR COLOUR SCHEME

The exterior colour scheme of the LHB design (EOG/HOG) cars shall be in accordance to RCF drawing for a particular variant mentioned in annexure-1 (Table-E). The exterior colour scheme for each variant shall be got approved from IR.

3.44 INTERIOR COLOUR SCHEME

The interior colour scheme of the LHB design (EOG/HOG) cars shall be in accordance to RCF drawing for a particular variant.The interior colour scheme for each variant shall be got approved from IR.

3.45 MARKING

External marking of LHB design (EOG/HOG) cars shall be in accordance to RCF drawing for a particular variant mentioned in annexure-1 (Table-E).The exterior colour scheme for each variant shall got approved from IR.

3.46 TAIL LAMP BRACKETS

Tail lamp bracket to IRS drawing No. C/BF-1113 shall be fitted at each end of shell.

***************



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Chapter 4

Technical & Functional Requirements (Electrical)

4.1. Scope

This chapter spells out the technical & functional requirements (electrical) of the LHB design (HOG) coaches.

4.2. General Requirements (Coach)

4.2.1. Major coach electrics, cables, HVAC system etc. intended to be used should be

of proven design for rolling stock application. Supplier shall submit the support documents to establish provenness of equipment/system/subsystem. In case of imported equipment/assembly/sub assembly, complete technology should be transferred.

4.2.2. Equipment offered should have power to weight ratio/EER comparable to

International Standards.

4.2.3. The bidder shall furnish clause-by-clause comments / compliance or otherwise of this specification duly bringing out the deviations clearly. Compliance or otherwise shall be clearly indicate by writing ‘complied’ or ‘not complied’. The comments like ‘noted’ against the clauses shall be considered as ‘not complied’.

4.2.4. Bidder shall submit complete technical data of major equipment/assemblies/sub

assemblies as per enclosed annexures 4-A, 4-B, 4-C, 4-D & 4-E in appendix VII.

4.2.5. After the contract is signed, the supplier shall furnish to RDSO and the

purchaser the detailed schedule programme for submission of design documents for approval which shall be suitably staggered, to enable RDSO to plan expeditious clearance.

4.2.6. The supplier shall prepare detailed instructions, drawings & specifications for

proper installation, operation and maintenance of the supplied equipment/assemblies/sub-assemblies and make them available to purchaser & RDSO.

4.2.7. The supplier shall submit a technical plan to purchaser and RDSO giving

details of overall system design. This document will be prepared and submitted



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for approval within one month of the award of the contract to freeze the overall system design.

4.2.8. Complete information on individual equipment testing and commissioning at

site/ on train, its interface with other equipment and combined system testing shall also be provided. The relevant customize hardware, if any, required for the purpose as above shall also be supplied to RDSO.

4.2.9. Software packages modules for scrutinizing the design calculations, ratings,

performance evaluation & simulation studies of major equipment/system viz. HVAC unit, train line, air distribution, lighting system etc. shall be supplied. In case the package/module run only on customized hardware, the same shall also be supplied.

4.2.10. Planning and provision of comprehensive training to IR staff regarding design,

system engineering, assembly / testing / trouble shooting /commissioning of electrical & HVAC system shall be in the scope of the supplier. Panel shall be powder coated to thickness minimum 60 microns Grey shade No. 6102/08038 of M/s Nerolac paints or 877 of M/s Berger paints or any other reputed make after giving requisite surface treatment.

4.2.11. The equipment shall be of modular construction and would facilitate easy handling during installation and replacement for repairs. It shall also facilitate easy trouble shooting and in-site repair.

4.3. Safety requirement 4.3.1. Materials used in the manufacture of coach shall be selected to reduce the heat

load, rate of heat release, propensity to ignite, rate of flame spread, smoke emission and toxicity of combustion gases and shall meet the requirement V0 UL-94. While manufacturing the coach, UIC: 564-2 shall be followed for fire protection and fire fighting measures.

4.3.2. The Coach shall comply with internationally recognized fire safety standards.

4.3.3. High voltage equipment and cables shall be adequately protected to eliminate

any possibility of development of dangerous voltages due to leakages etc. to parts of equipment etc., which are directly accessible to passengers and maintenance staff.

4.3.4. Proper interlocks shall also be provided for ensuring that high voltage equipment cannot be opened and charged conductors cannot be exposed. It should be possible to open and attend to equipment only after supply has been disconnected and required safety measures have been taken.



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4.3.5. Relevant clause of Indian Electricity rule shall be followed, keeping in mind the statutory and regulatory requirements.

4.3.6. All equipment working at voltage higher than 110 V shall be earthed to the

coach body/ earth wire and fail-safe protection scheme shall be provided to isolate the equipment with poor insulation, which may be dangerous for passengers.

4.3.7. Earthing symbol shall be provided at all locations working on more than 230 V.

4.4. Reliability 4.4.1. Besides fully meeting the functional requirements, the equipment shall

incorporate high standards of reliability duly optimizing operating cost and performance.

4.4.2. Supplier shall declare quantitative reliability data of major equipment system/ sub-system, expressed in terms of Mean Time Between Failures (MTBF) and / or Mean Distance Between Failures (MDBF), based on operations on proven coaches fitted with similar equipment for a minimum of 3 years or 4,50,000 Kilometres run in revenue service, whichever is later, for evaluation. MTBF and or MDBF shall be declared for the ambient temperatures of 45º C, 50º C & 55º C.

4.4.3. Failure is defined as:

“A coach in service should be considered to have failed, when through some electrical or HVAC defect: -

a) Either coach is unable to complete its booked working in its nominated rake.

Or b) A delay of not less than 30 minutes is caused to any train included in the

booked working of the day. Failures of all coaches, whether employed on commercial or departmental service, are to be included.”

4.5. General Design Requirements

4.5.1. General Governing standards/ specifications for reference: -

UIC 564-2 Regulation relating to fire protection and fire -fighting measures in passenger carrying railway vehicles or assimilated vehicles used on international service

IEC 60529 Degree of protection provided by enclosures



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IS:2026 Specification for power transformers: General IS: 11171 Specification for Dry type Power transformers IS: 1885 (Pt. XXXVIII) Electro-technical vocabulary for transformers IS: 1271-85 Thermal evaluation and classification of electrical

insulation. IS: 13730 Polyester or polyesterimide over coated with polymide-

imide enameled round copper wire, Class 200. IS: 6911-92 Stainless steel plate, sheet and strips IS: 617 Cast Aluminum & its alloys ingots and casting for

general engineering purpose. IS:4454(IV) and IS:7906(I) and (II)

Cold rolled springs (stainless spring steel wires grade 2)

AISI-304 Specification for Stainless steel Bars & section IEC 60947-1 2004 Specification for low voltage switchgear and control gear

– part 1 General rules. UIC: 532 Electric power supply for trains taken from the train

vehicle UIC: 554-1 Power supply to electrical equipment on stationary

railway vehicles from local mains system or another source of energy at 220 V or 380 V, 50 Hz

DIN EN 15085-2-2008 Welding of Railway vehicles Part – 2: Qualification of manufacturer of welded rolling stock materials, Quality Assurance.

ELRS/SPEC/ELC/0019 (Rev-3)-Feb-2011(latest)

Electron beam irradiated cable

IS: 10118-1982 Code of practice for selection, installation and maintenance of the switchgear and the control gear.

IS: 8623 , IEC 60947, 60898

Temperature rise test for panels, switchgears and MCBs

IS: 8828-1996 Electrical accessories, circuit breakers for over current protection for household and similar installations.

IEC 61386 Conduit system for cable management. IEC 61373 Railway application for rolling stock equipment for

shock and vibration test. NFF 16-101 & 102 and UL -94

Smoke and fire toxicity requirements

UIC 550 Power supply installation for Passenger stock.

4.5.2. Notwithstanding the contents of this specification, the supplier shall ensure that the equipment supplied by them is complete in all respect so as to ensure the desired operation/ performance of their equipment on coaches.



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4.5.3. The equipment design shall incorporate all essential features necessary to yield high passenger loading, low maintenance requirements, easy maintainability, high reliability in operation and high efficiency.

4.5.4. The entire equipment shall be designed to ensure satisfactory and safe operation under the running conditions, especially under sudden variations of passenger loading, abnormal operation and short circuits etc. The design shall also facilitate convenient erection, inspection, maintenance and in–situ replacement of the components of the system.

4.5.5. All components of control electronics, and PCBs shall be suitably protected against moisture and dust. The protection level shall be furnished by the supplier during design approval.

4.5.6. All the equipment shall comply with the latest editions of IEC specifications

unless otherwise specified. 4.5.7. The temperature rise shall be measured according to the procedure stipulated

by relevant IEC and shall comply with the limits specified and the ambient conditions defined in this specification.

4.5.8. Major equipment viz Power and control panel (for Non AC coaches only)

Transformer, Batteries, Regulated Battery Charger (RBC), Mono-block pump (for AC Coaches only) etc. shall be under slung.

4.5.9. All under slung/externally mounted equipment/assembles shall be minimum IP:

65 protected or better. All equipment/assemblies/sub-assemblies mounted underframe of the coach shall be adequately protected/strengthened against hitting of ballast / cattle carcasses etc. on run.

4.5.10. All equipment/assemblies/sub-assemblies shall be subject to environmental

tests as stipulated in para no. 2.29 of chapter 2 of this specification & vibration & shock tests as stipulated in IEC 61373.

4.5.11. All equipment shall be designed to give full rated output from minimum supply

voltage to maximum supply voltage of system on which coaches are to be operated. Freedom from dust and protection from surges will be ensured. The converter / inverter system and transformer will be capable of withstanding the maximum short circuit current under fault conditions and these will be established as well. As such in case of any dead short circuit across the outgoing terminals of converter/inverter systems, the system shall provide adequate protection so that no damage is caused to the converter / inverter system.

4.5.12. All power and control devices of power equipment shall be IGBT based.



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4.5.13. Train lines feeders and inter vehicular couplers layout shall be such that they are accessible to maintenance staff only. Details of the arrangement shall be furnished at the design stage.

4.5.14. The control equipment, contactors, relays, switches, and such other devices shall represent the latest and proven technology established under the most severe operating conditions defined in this specification with particular regard to maintainability and reliability. Wherever considered necessary, the contacts should be duplicated to provide redundancy. The use of relays and contactors shall be to bare minimum.

4.5.15. Rotating machines:

i. Vacuum pressure impregnation of the stator winding must be done

using solvent less varnish having thermal index above 200° C.

ii. In the case of squirrel cage motors, Aluminium alloy die cast rotor construction will be preferred.

iii. L-10 life of bearings will not be less than 1, 00,000 working hours when

calculated as ISO recommendation R-281. The bearing design will be such that no greasing or any intermediate attention may be required to be given for at least three after each greasing/adopting maintenance schedule as recommended by manufacturer.

iv. All auxiliary motors separately & combined equipment assembly like

blower motor, condenser motor, mono block pump etc. will be subjected to prototype tests as per relevant IEC specification. If the operating conditions of the auxiliary machines differ from the specified test conditions in relevant IEC publications additional tests will be carried out.

4.5.16. Exhaust system shall be provided in each toilet as per requirement of ASHRAE

standard.

4.5.17. All the equipment/assemblies/sub-assemblies vandalism to adequately take care of pilferage.

4.5.18. Electronic Equipment/ Sub-assemblies:



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a. Equipment cases should be tropicalized and assembled in a dust and damp protecting enclosure manufactured in accordance with IEC 60529. Electronic equipment should be designed, constructed and tested in accordance ELRS/ SPEC/ SI/ 0015. The number of different types of electrical equipment and components should be minimized.

b. The maximum recorded temperature under worst loading condition shall be corrected for 55° C and compared with maximum permissible temperature (for power devices at junction). The thermal margin available shall be compared with safety margin declared by the manufacturer under worst loading condition even at lowest power factor the corresponding temperature of power devices shall have a margin of minimum 10° C.

c. The maximum temperature rise of electronic devices on the PCB should

not exceed approximately 20° C for industrial grade components suitable for 85° C environment, when measured at half inch away from identified critical components. In case it is exceeding this limit use of MIL grade component shall be considered.

4.6. Power supply system for coaches: 4.6.1. Power supply requirements for HVAC and lighting / Fans loads henceforth

referred, as Hotel load, on all the coaches shall be fed from either Generator car or locomotive at 750V through end to end feeders (train line).

4.6.2. HOG power supply from locomotive shall be 750V+5%/ -2%, 50 Hz 3 phase sine wave 3 wire. Voltage between phase to earth shall be less than 0.8 kV (peak). The total voltage harmonic distortion shall be less than 10%. Total current unbalance expected up to 15% of the rated out put current.

4.6.3. 4.5.3 Power supply from the DA set shall be 750V+5%/ -2%, 3 phase, 4-wire, 50 Hz.

4.6.4. There shall be two independent train lines (feeders) run from one end to other

end of the rake. 4.7. Each coach shall have:

(i) 2 set of Train lines (feeders) (ii) Two sets of Inter Vehicle couplers, and dummy sockets. (iii) One feeder selector arrangement with indication and interlocks.

4.7.1. Train line (feeders) cables, terminals and IV couplers shall have adequate

capacity to cater full train load of 24 AC coaches under prescribed worst operating conditions.



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4.7.2. Neutral of the feeder lines of the transformer shall be isolated from the earth in

the coaches and the same is grounded shall be solidly grounded in the power car along with alternator neutral point (in case of EOG system).

4.7.3. 750V, AC, 3- Phase 3/ 4 wire train line supply shall be reduced to 415 / 240 /

110 V, 3- phase, 4- wire, by the transformer of adequate capacity for feeding the coach electric loads.

4.8. Operating voltages of major coach electric equipment will be as under: -

(i) HVAC (415V, 3 phase) (ii) Regulated Battery Charger (RBC) (I/P 415V, 3 phase) (iii) Pantry / Mini Pantry. (230V, 1 phase) (iv) Mobile / Laptop charging sockets.(110 V, 1 phase) (v) Water raising pump (415V, 3 phase) (vi) Lighting, fan, controller (110V DC)

4.8.1. DC Voltage mains shall be fed from the coach battery to serve the electrical

equipment like coach illumination and other control equipment.

4.8.2. DC supplies other than 110V dc for use by equipment like wheel slide protection system, PA system, toilet control etc. shall be derived through suitable dc-to-dc converters.

4.9. Electrical cabling wiring and Components

4.9.1. Electron beam irradiated / chemically cross linked, thin walled, halogen free,

low smoke and less toxic copper cables as per relevant international standards and the good Industry practice for rolling stock application shall be used.

4.9.2. The insulation/sheathing material shall be of EPDM / EVA and shall be fire survival type according to EN: 50264.

4.9.3. At locations in the coaches where high temperatures are likely to be

encountered, special cables shall be used. 4.9.4. The coach wiring shall be concealed in polyamide conduits with their

associated accessories (halogen free fire retardant) suitably laid for attention and trouble shooting in course of service without need for opening of body side and ceiling board panels on the coach.

4.9.5. Electrical junction box and distribution boards will be provided with suitable

inspection covers away from passenger area access.



Signature

Name & Designation




4.9.6. The coach wiring shall also be protected against short circuits, overloads and

excessive leakage. 4.9.7. Shielded e-beam halogen free cable shall be used in wiring in order to minimize

the EMI with suitable earthing wherever is required.

4.9.8. It shall be ensured that the total voltage drop between the battery and any of the farthest light/fan point shall not exceed 3 volts at battery voltage 108 ± 02 volts.

4.9.9. The cables for wiring in the coaches and equipment shall use high grade electrolytic copper stranded conductors tinned in accordance with Good Industry Practice.

4.9.10. The layout of the cables shall be such that there is no contamination by oil. Cable routes shall be so divided to optimize length of cables.

4.9.11. Cables and connections carrying different types of voltages shall be physically

segregated from each other. For vital circuits, adequate numbers of spare control wires shall be provided with clear identification.

4.9.12. Cable layout shall be according to EN: 50343. 4.9.13. Loading of power cables shall be such that in no case conductor temperature

shall exceed maximum temperature according to data sheet minus 10 degree Celsius. The power cable layout shall ensure equal sharing of current in all power cables.

4.9.14. All connections shall be terminated on terminal bars manufactured in

accordance with Good Industry Practice. The terminals and wire cable ends shall be suitably marked to facilitate correct connections. It shall be ensured that not more than two wires are terminated at one point.

4.9.15. Plugs and sockets shall be used to connect pre-assembled units to facilitate maintenance and ensure a better layout.

4.9.16. No cable having a conductor size of less than 1.5 sq. mm shall be used except

for multi core cables where 1.0 sq. mm cable is permitted. Smaller size cables for internal wiring of panels, control cubicles, consistent with the mechanical and electrical requirements, may be adopted.

4.9.17. Cables shall be properly secured and routed in the suitable Polyamide alleys/

trays/ ducts whenever the cable shall cross the door/ passage area.

4.9.18. With the exception of I V coupler, all under frame cables should be installed in fixed cable ducts or metallic conduits. Cable ducts should include removable



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covers to provide access to the cables. Cables contained within the ducting should be clamped securely along the length of the cable runs to prevent chafing of cables. Cables should be securely clamped in strain relief cable glands at the entry and exit point of ducts and conduit for dust water entries. Ducts and conduits should be designed to preventing the entering of the water.

4.9.19. The cable shall be derated to take care of the adverse ambient conditions. The

maximum short circuit temperature shall not exceed 250° C. 4.9.20. The following operation and environmental factor will specially be kept in view

while selecting the cable: -

i. Excessive vibrations that are experienced because of prevalent track conditions in India.

ii. Prevalence of high temperature, heavy rain and humidity for the most part of the year.

iii. Operation of the coaches over a humid and salty terrain in which the climate varies from high rainfall for 4-5 months and extremely dusty atmosphere during rest of the year.

4.9.21. Suitable protective devices (HRC fuses /MCBs) should be provided on both end

positive & negative end of 110V dc.

4.9.22. When wires are run through the carline openings in the roof, adequate precautions shall be taken to prevent damage to cable insulation while drawing cables through such openings.

4.9.23. Wherever cables traverse through holes, orifices, slits, apertures etc. with sharp

metal edges, such openings shall be provided with fire retardant grommet. The lining or grommets provided will be such that it shall not get dislodged by vibration, whipping action, extremes of heat, cold, dry or moist weather and ageing.

4.9.24. The cable should not have any intermediate joints and should be terminated in

junction boxes, terminal boards. 4.9.25. The bending radius of the cables shall not be less than 4R. 4.9.26. Two separately protected lighting circuits shall be used, such that in the event

of one tripping, the others provide evenly distributed lighting throughout the coach.

4.10. Technical requirements of the major electrical Equipment: 4.10.1. Inter Vehicular Electrical Couplers 4.10.1.1. Each coach shall have two sets of IV couplers, and dummy socket.



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Name & Designation




4.10.1.2. Electrical Couplers will also carry earth wire for earthing of power equipment

on coach.

4.10.1.3. IV couplers shall be capable of making proper electrical connections between adjacent coaches during the run on tracks having curves of minimum radius 152.4 meters and shall be capable of passage in either direction over standard 1 in 8½ turnouts and shall function satisfactorily with difference in head stock heights of adjacent coaches up to 100mm.

4.10.1.4. Complete I.V coupler assembly shall have IP 67 degree of protection as per

IEC: 60529 under vibration condition. 4.10.1.5. A heat shrinkable, fire retardant polyamide sleeve shall be provided covering

some portion of lugs and cables. 4.10.1.6. Cable shall be crimped appropriately in coupler plug pins & socket tubes, so

that possibilities of its loosening & presence of air during service may be eliminated.

4.10.1.7. Cables connected with the coupler plug shall not hang lower than the lower

most port of the coupler and shall be suitably secured to arrest dangling to avoid hitting during run.

4.10.1.8. The design shall cater for relative movements between the coaches. There

shall be no disruption and sparking due to vehicle movement behavior under worst conditions of operation.

4.10.1.9. Insertion/removal of the electrical couplers shall be possible to be

accomplished by one person and shall be possible with longitudinal axis misalignment between coaches of eight degrees and 100 millimeters difference in head stock height.

4.10.1.10. Couplers shall be so configured that any plug unit can couple to any socket of

the adjacent coach. 4.10.1.11. Contacts shall be spring loaded, of silver surfaced alloy, shall have surface

capacity, shape and positive action to prevent fouling in coupling, shall maintain positive contact under all specified operating conditions and shall be capable to work even with the impacts to which the coupler may be subjected to, in service.

4.10.1.12. All couplers shall be fully EMI / EMC compliant. 4.10.2. 750/415 V, Step down Transformer



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4.10.2.1. 750 / 415 V, step down under-slung transformer of adequate capacity (minimum 60 kVA) shall be provided in each AC coach.

4.10.2.2. 750/415V/step down under-slung transformer of adequate capacity (minimum

9 kVA) shall be provided in each non AC EOG coach. 4.10.2.3. The current density of the 750 V winding wire shall not be more than 1.0

amp/mm² and 415 V winding shall not more than 1.45 amp/mm². LV winding shall be near the core and HV winding outside.

4.10.2.4. Technical requirements of the transformer shall be as under:

KVA Rating As per hotel load requirements Nominal input voltage 3 Phase, 3/ 4 wire, 750 V ± 5% (line to line), 50Hz

±3%,THD <10% Nominal output voltage 3 Phase, 4 wire, 415 V ± 5% (line to line), 50Hz ±

3%, Class of insulation H Efficiency >96% from half load to full load Noise level <60db at 1.0 m distance UCC overall impedance 4% (max.) Protection level of stainless steel housing and terminal box

IP-67

Vector configuration Star -Star (Yy) Winding wire Super enameled copper winding wire as per to IS:

13730 Pt. 13, 13730 Pt. 29 Max. temp. rise 115ºC

4.10.3. Heating, Ventilation and Air Condition Unit 4.10.3.1. HVAC unit should be mounted on roof of the coach. There should be at least

two HVAC units in each coach. The control & regulation of both the unit shall be controlled by single controller unit.

4.10.3.2. The control system for the units should be microcontroller with a facility to provide remote monitoring.

4.10.3.3. HVAC units shall utilize Refrigerant R 407C or any other eco-friendly HFC

refrigerant having zero ozone depletion potential and A1 safety category as per ASHRAE standard.

4.6.1.1 HVAC units shall be designed to meet the following ambient & inside conditions

inside: -

conditions Dry Bulb Wet Bulb %RH



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Outside (dry summer) 50ºC 25ºC --- Outside (wet summer) 40ºC 28ºC --- Inside (dry & wet summer) 23 -25ºC --- 40-60 Outside (Winter) 4ºC --- Inside (Winter) 19-21ºC - -

4.10.3.4. The cooling capacity of each HVAC unit shall be adequate to maintain above

conditions inside the coach under worst ambient conditions i.e. outside dry summer condition and with maximum number of passengers. In no case capacity shall be less than 7.0 TR at specified ambient condition mentioned in clause No. 4.7.3.4 of this specification.

4.10.3.5. All the equipment/assemblies/sub-assemblies shall be capable of continuous

functioning without detriment to the operation of cut-outs, circuit breaker, or overload in ambient temperatures between 0º C and 55º C and relative humidity up to 100 %.

4.10.3.6. There will be temperature control in individual cabin of First class AC sleeper

coaches. The write-up on the individual control shall be furnished before finalizing the concept.

4.10.3.7. The air conditioning system shall deliver quality of air inside the coach as per

ASHRAE norms. 4.10.3.8. There would be two independent refrigerant circuits in each HVAC unit. Blower

fan may however be single (common to both refrigerant circuit). 4.10.3.9. In the event of leakage of refrigerant in air-conditioning unit/units, harmful

quantities of the refrigerant shall not be released inside the coach and there shall be an arrangement for forced ventilation of the coach.

4.10.3.10. The HVAC system shall provide a high rate of air renewal/ replacement;

maintain constant temperature taking into account the frequent door opening and high user density. The units shall be compact, roof mounted and shall have low power consumption.

4.10.3.11. In the event of incoming power failure to all air-conditioning units exceeding

2 (two) minutes, a minimum of 3600 cubic meter per hour of fresh air shall be introduced to coach and distributed evenly through the passenger areas. For this application either an inverter of suitable rating will be provided inside the RMPU but easily accessible for maintenance point of view or brushless 110V dc & permanent magnet blower motor shall be employed.

4.10.3.12. The design of the ventilation unit shall be such that CO2 level inside the

coaches with payload shall not exceed the permissible threshold limit of the order of 700 PPM above the CO2 concentration in air outside the coach.



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Name & Designation




4.10.3.13. Condenser and evaporator coil shall be designed with copper tubes and

copper fins.

4.10.3.14. The structure shall be made of SS 304 as per IS 6911.

4.10.3.15. Coach interconnection/ Bellows shall be made of fire retardant material. 4.10.3.16. Under any circumstances, the noise level of the HVAC unit should not be

more than 65 dB(A) when mounted on the coach. 4.10.3.17. The refrigerant compressor shall have scroll technology suitable for rolling

stock application. 4.10.4. Power and control Panel 4.10.4.1. One Integrated modular type Power and control Panel (switch board cabinet)

shall be provided on board in the cabin area of each AC coach. In addition to requisite switchgear, all the electrical assemblies/controllers of the electrical systems viz. HVAC, pantry equipment, water lifting pump, passenger announcement and information system, lighting and fans etc. as well as mechanical system viz. EP brake, wheel slip- slide, toilet systems etc. shall be accommodated in the integrated power and control system.

4.10.4.2. There shall be a provision of energising the coach through stationary 415 V

power supply form either ends of coach.

4.10.4.3. Necessary interlocks and protection shall be provided for safe operation in different combinations of power supply sources.

4.10.4.4. There shall be a provision of disconnecting the train line (feeders) supplies in

each coach to enable safe working in it after earthing the coach electrical circuits .

4.10.4.5. Following are minimum protections for 750 V and 415 V circuit in Panel:

i. Under voltage and over voltage. ii. Single phase protection. iii. Phase reversal protection. iv. Insulation monitoring with indication of 750 V, 415V, 110 AC and

110 V DC circuits.

4.10.4.6. The panel shall be designed so that all the critical MCB, indications and push buttons shall be visible from outside the panel. Operation of the MCB/ push



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buttons should be possible without exposing the switchgear like contactors and relays.

4.10.4.7. The panel shall be designed in such a way that no voltage more than 110 AC/DC is exposed to passenger’s access. 750 V compartment shall be additionally secured to avoid any accident access.

4.10.4.8. All the openings and cable entries shall be suitably covered /shrouded to

restrict entry of water/dust/external objects/rodents. 4.10.4.9. Lock and key provisions shall be made for main switchgear compartment.

Suitable provisions for auto lock shall be made to avoid door rattling during the run due to unintended opening of doors.

4.10.4.10. The outgoing/incoming terminal connections shall be brought out to a adequate rated cage clamp type terminal block/MCB. The terminal blocks shall be located for easy access.

4.10.4.11. Separators/intermediate plates shall be provided between adjacent terminal

blocks, wherever required.

4.10.4.12. All cables leading to a terminal block shall be properly secured /clamped before termination.

4.10.4.13. It shall be ensured that not more than two wires are terminated at one point.

4.10.4.14. The ends of the internal wiring of the panel shall be fitted with crimping

sockets (wherever required) and designated ferrules. Rings/tubular crimping sockets shall be used with suitable palm size to prevent loose connections during vibrations. Only copper crimping sockets of approved make shall be used.

4.10.4.15. Two earthing terminals shall be provided on top and bottom of the panel on diagonally opposite ends. Earthing of the metal parts/sub- assemblies inside the panel shall also be done as indicated with suitable wire size as determined vide 7.4.3.1.7 (a) of IS: 8623 (Pt-I) – 1993 or latest.

4.10.4.16. All the devices fitted in the power & control panel shall allow access for easy

maintenance.

4.10.4.17. The control elements taking power from the battery shall be capable of operating between 90 V and 138 V, d.c.



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Name & Designation




4.10.4.18. LED fittings with a working voltage of 110V dc along with a switch/ socket point shall be provided inside the power and control panel for ease of the maintenance staff.

4.11. Coach Illumination 4.11.1.1. Eco friendly, Energy efficient, modern state of the art LED based lighting, in

luminaries meeting flame, smoke and toxicity requirements shall be recessed into the ceiling panels. The light fittings shall be simple, and arranged not to trap dirt, moisture and insects.

4.11.1.2. Lighting shall be arranged in such a way that it fully matches interior of coach.

4.11.1.3. Each lighting fixture module shall have a translucent diffuser protected

against ultra-violet radiation, degradation and discolouration and shall be fully sealed at its periphery to prevent water, dirt, and dust ingress to the inner surfaces. The entire arrangement shall be free from rattling under prescribed conditions.

4.11.1.4. The lighting fittings shall be of an accepted robust construction, and

preferably hinged for access to components mounted on the back. This shall be in a manner, which does not significantly increase heat input to the coach.

4.11.1.5. The numbers and spacing of the lighting shall be such as to achieve a

minimum lux level of 300 over the whole coach area, measured at a height of 1.20 m above floor level. The difference of lighting level in any place at 1.20 m height level from the Coach floor level shall not exceed 50 Lux.

4.11.1.6. The lighting output shall be a warm white light. Light sources shall not dazzle

passengers, nor limit horizontal vision, particularly at night (observation on the outside).

4.11.1.7. The internal lighting device for passenger’s area shall comply with EN 13262

or equivalent standard. 4.11.1.8. LED used in the luminare shall have minimum life of 5000 burning hours at

125° C junction temperature. 4.11.1.9. The Contractor shall submit documents related to service life of luminaries

during the design stage which shall be as per the best international practices.



Signature

Name & Designation




4.11.1.10. The Contractor shall submit layout of fittings and control circuit for review by the Purchaser/RDSO.

4.12. Laptop / Mobile charging Sockets

110V AC Electrical sockets on each berth for charging batteries of portable electronic devices like cell phone or for powering a laptop computer / Mobile charging shall be provided.

4.13. Emergency lighting In each coach, at least four LED based standalone emergency light units shall be provided which will work even after failure/disconnection of coach battery / train line supply. The emergency light shall provide illumination level in steps for period of 12 hours & lux level shall be 20 lux (min.).

4.14. Pantry Equipment in AC Hot Buffet Car 4.14.1. Integrated modular pantry unit shall compromise of the following:-

Equipment Capacity Quantity per buffet

car Deep Freezer 230 Liters 01 Bottle cooler 90 Litres 01 Hot Case with 21 stainless steel fabricated food trays

140 Meals 01

Oven toaster 16 liters 02 Water Boiler with purifier 30 Litres 01 Water Boiler without purifier 30 Litres 02 Double door frost free refrigerator 310 Litres 01

4.14.2. Pantry shall be equipped with modern Induction heating based cooking

system and service tables.

4.14.3. Adequate no. of sink and insect killer shall be provided in pantry area.

4.14.4. Pantry shall fulfill the ergonomical and Hygienic requirements. 4.14.5. Environmental requirements with respect to temperature, humidity and

corrosions shall be taken into consideration.



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Name & Designation




4.14.6. Suitable opening shall be provided for smoke emission through Electric Chimney to outside the coach for each Induction heating based cooking range.

4.15. Mini Pantry 4.15.1. Following equipment to be provided in all the AC two tier and AC three tiers

coaches:

Equipment Capacity Quantity per buffet car

Refrigeration unit consisting of following: -

a) Bottle cooler(3-50C)

b) Deep freezer compartment ( -18-250C)

c) Cooling compartment ( 3-50C)

90 bottles of one litre each 90 Cups of 300 ml. 90 tetra pack of 200 ml

01

Hot Case with 18 stainless steel fabricated food trays

90 Meals 01

4.15.2. Following equipment to be provided in AC two tier and AC three tiers

coaches:

Equipment Capacity Quantity per buffet car

Refrigeration unit consisting of following:-

d) Bottle cooler(3-5�C) e) Deep freezer compartment

( -18-25�C) f) Cooling compartment ( 3-5�C)

130 bottles of one liter each 130 Cups of 300 ml. 130 tetra pack of 200 ml

01

Hot Case with 18 stainless steel fabricated food trays

130 Meals 01

Water boiler 30 Liters 01 Soup warmer 30 Liters 01 Sink and other accessories

----- As per requirement



Signature

Name & Designation




4.16. Back-up Battery

4.16.1. Each coach shall be equipped with adequately rated sealed battery suitable

for rolling stock application having nominal system voltage 110 V.

4.16.2. The backup battery shall utilize a sufficient number of cells to ensure that it is capable to supply emergency load for at least 45 minutes in case of failure of battery charger or its supply with the battery charged to 80% of its full capacity, before the voltage level at any device falls below 90 V. Non-essential load shall be shed after 30 seconds of failure of battery charge supply. This feature shall be demonstrated during testing.

4.16.3. The proposed list of equipment of the emergency systems shall be able to

run minimum 180 minutes in emergency condition:-

(i) 50% coach lighting. (ii) All exterior lights. (iii) Ventilation blower fans, but not air conditioning. (iv) Communication systems including public address, passenger

emergency alarm, surveillance system and train radio. (v) Brake controls (vi) Door controls (vii) Essential controls

4.16.4. Battery charging characteristic to be as recommended by battery

manufacturer. 4.17. Passenger Alarm Chain Pulling Indication Light (PACIL)

LED based Passenger Alarm Chain Pulling Indication Light (PACIL) shall be provided outside toilets of the Coach.

4.18. Reservation chart illumination light Two numbers reservation chart illumination lights shall be provided near diagonally opposite doors out side the coach.

4.19. Tail Lamp Red color, flashing at rate of 55-65 per minutes LED based tail lamp shall be provided, on one of the end wall of SLR coaches.

4.20. Wheel set Earthing arrangement



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4.20.1. Each coach shall be provided with earthing arrangement for the wheel set to prevent return current flow through the axle bearing.

4.20.2. The earthing system shall act as current bridge that creates a connection by means of wiper contact (brush) from stationary bogie frames to rotating wheel set.

4.20.3. The equipment is required for earthing of the bogie with wheel diameter up to 928mm and operational speed up to 160Kmph.

4.20.4. The earthing wires should of braided stainless steel. 4.20.5. The technical requirements shall be as under:-

Allowable current 400 Amp Maximum current 600 Amp for five minute. Short circuit capacity 10kA for 10 mili seconds Nominal Voltage 500V

4.21. Specific Requirements for Non-AC Second class & 3-Tier Sleeper Coach 4.21.1. 750/415V equipment like power and control panel, transformer, Isolation

device, battery charger and batteries shall be under slung. Only 110 volt dc feed shall be brought from under frame to super structure junction-box for control &distribution.

4.21.2. Use of Mono-block pump for lifting water from under-slung tank will not be

acceptable because of these coaches being unmanned. 4.21.3. All coaches must have vestibule to allow the escorting electrical staff

accommodated in last coach (SLR) or generating van to have free access to entire coaches of train.

4.21.4. Each coach shall be provided with four terminal boards to RDSO’s Drg. No.

SKEL-3929 outside the coach on end walls , one each at the four corners of the coach at lower level to enable emergency connection to be made between adjacent coaches. On these terminal boards, the outer terminal shall be connected to the positive and the inner terminal shall be connected to negative.

4.21.5. The side light fittings shall be provided on both the side walls of the guard’s

compartment. 4.21.6. All Non – AC sleeper Coaches should be providing with night-lights cum berth

numbers indication light, which should be controlled by separate switches. The night-lights shall also display the berth nos. when switched ON.



Signature

Name & Designation




4.21.7. One number of battery charging terminal board shall be provided centrally on the side of the under-frame, near the battery fuse box, to facilitate charging of the battery from external supply.

4.21.8. Adequate number of min 400 mm sweep, 110V sensorless BLDC fan with FRP

blade should be provided in Non-AC passenger Cars to provide uniform air delivery in the passenger area. One no. of 225 mm seep 110V sensor less BLDC, fixed type bracket fan shall be provided in each lavatory of non AC coaches.

4.22. Approval of Design

4.22.1. The design shall be evolved based on the broad requirements given in this

specification and sound engineering practices with specific consideration to the specified passenger loading and environmental conditions.

4.22.2. The supplier shall deliver all necessary data, designs, calculations, drawings

and specifications referred in their drawings or design documents in English language to RDSO for examination and shall provide explanation and clarification on the documents. Approval or decision by RDSO shall normally be given within 3 weeks of submission of all clarifications by the supplier to the satisfaction of the RDSO. Supplier shall depute his technical experts to RDSO for discussions for expeditious finalization of design documents. After the final design is approved the supplier shall furnish complete set of approved documents complete with all referred standards/specifications drawings/documents and equivalent Indian Standards wherever applicable.

4.22.3. It may be duly understood that approval of design means approval of general

design features. Notwithstanding the approval, the supplier shall wholly and completely be responsible for the performance of the complete system and equipment supplied by him. Mere RDSO’s approval will not absolve supplier from his overall responsibility for satisfactory performance.

4.22.4. The supplier shall be responsible for carrying out improvements and

modifications based on the service feedback at his own expense on all the equipment supplied, provided such modifications/improvements are decided to be necessary jointly between supplier and RDSO for meeting the requirements of reliability, performance & safety etc.

4.22.5. All the drawings shall be of full sizes. The dimensions, weight, capacity, etc.

shall be in SI units. All drawings shall be submitted in CDs in latest Auto CAD format along with the complete setup for reading, editing and taking the prints. This would include supply of relevant software and customized hardware, if any.



Signature

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4.22.6. While the equipment is under manufacture, photographs/video shall be taken of the various assemblies and subassemblies and submitted to RDSO for reference & record.

4.22.7. All major equipment assemblies/sub-assemblies shall bear serial number as

per RDSO’s approved format. Where the sub-assemblies / components of the main assemblies are not inter-changeable, the sub-assemblies shall also be marked with the serial number of the main assembly of which they form a part.

4.22.8. All equipment/cubicle shall be provided with rating plates & danger plates if

operating voltage exceeds 230V as approved by RDSO on anodized Aluminum with embossed letters.

4.22.9. The supplier shall submit the test protocol for each equipment and complete

assembly/ coach for approval before carrying out the testing as per applicable standards.

4.20 Maintenance manual, spare parts catalogue & material specification

a. The detailed operation, maintenance and service manual shall be prepared for the supplied equipment and 40 copies of the same shall be supplied free of charge. The draft contents of the manuals shall be submitted for approval of the RDSO.

b. Detailed spares parts catalogue listing all components manufactured

or purchased by the supplier along with their rating, source & schematic position etc. (40 copies) each shall also be supplied free of charge. Supplier shall furnish purchases.



Signature

Name & Designation




Appendix- I. LIST OF MECHANICAL DRAWINGS (RCF & LHB)

i. RCF/ LHB Drawing nos. related to Major areas of rail car manufacturing are listed below in table A to E.

ii. Drawing nos. with alteration no. are provided in table A to E, however latest alteration of a particular drawing at the time of the award of the contract shall be considered.

iii. Additional drawings required for rail car manufacturing shall be arranged from RCF, Kapurthala by entering into agreement.

Table-A: Details of Layouts, General Installation & Car Body Shell

S. No.

Coach Type Coach Code Drawing no. & Alt. Layout General

Installation Car Body Shell (stage –I & II)

1 NON AC 2nd CLASS LS (EOG)

LS5 LG90029 –‘a’ LG90030 –‘nil’ LG10343‐‘c’

2 NON AC 2nd CLASS SCN(EOG)

LWSCN LS90013 –‘nil’ LS90014 –‘a’ LS10203–‘e’ & LS10204‐nil

3 AC ‐3T SLEEPER (EOG) LWACCN LE90009‐‘nil’ LE90007‐‘c’ LE10112‐‘c’ & LE10113‐nil

4 AC‐2T SLEEPER‐ (EOG) LWACCW LW90023 –‘a’ LW90025 –‘a’ LW10196–‘a’ & LW10203‐nil

5 AC‐1st CLASS SLEEPER‐ (EOG)

LWFAC LA90018–‘a’ LA90022–‘b’ LA10158–‘b’ & LA10006‐nil

6 AC HOT BUFFET CAR LWCBAC LH90001 –‘b’ LH90004 –‘f’ LH10100 –‘g’ & LH10122‐nil

7 GENERATOR CUM LUGGAGE& BRAKE VAN

LWLRRM 1.11012.0. 01.000.001‐‘nil’

LP90100 –‘b’ LP10125–‘a’

8 AC CHAIR CAR LWSCZ AC 1.10113.0. 01.000.001‐‘G’

1.10113.0. 19.000.001‐‘nil’

1.10113.0. 20.000.001‐‘F’

9 AC CHAIR CAR EXECUTIVE CLASS

LWFCZAC 1.10112.0. 01.000.001‐‘O’

1.10112.0. 19.000.001‐‘nil’

1.10112.0. 20.000.001‐‘C’



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Table-B: Details of Body shell sub-assemblies

S. No.

Coach Type Drawing no. & Alt.Underframe complete

Welding parts on underframe

Sidewall complete (LH & RH)

End wall complete

Roof complete


LG11265‐‘e’ LG11271 LG15195‐‘nil’ LG16193

2 NON AC 2nd CLASS SLEEPER(EOG)

LS11196‐‘c’ LS11203 LS14121‐‘c’ LS15120‐‘a’ LS16201‐‘a’

3 AC ‐3T SLEEPER (EOG)

LE11105‐‘f’ 1.10113.0.03.095.001

LE14100‐‘b’ & LE14101‐‘c’

1.10113.0.20.120.001‐‘G’

LE16100‐‘f’

4 AC‐2T SLEEPER‐(EOG)

LW11236‐‘c’ 1.10113.0.03.095.001

LW14210‐‘b’ & LW14211‐‘c’

1.10113.0.20.120.001‐‘G’

LW16121‐‘a’

5 AC‐1st CLASS SLEEPER‐(EOG)

LA11101‐‘c’ 1.10113.0.03.095.001

LA14300‐‘nil’ & LA14301‐‘nil’

1.10113.0.20.120.001‐‘G’

LA16106‐‘c’

6 AC HOT BUFFET CAR

LH11100‐‘d’ 1.10113.0.03.095.001

LH14100‐‘f’ & LH14101‐‘f’

1.10113.0.20.120.001‐‘G’

LH16100‐‘f’

7 GENERATOR CUM LUGGAGE& BRAKE VAN

LP11103‐‘b’ 1.11012.0.03.095.001

LP14110‐‘nil’ & LP14111‐‘nil’

1.11012.0.20.120.003 ‐‘A’ & LP15103 ‐‘nil’

1.11012.0. 20.200.001 ‐‘C’

8 AC CHAIR CAR 1.10113.1.03. 000.005‐‘A’

1.10113.0.03.095.001

1.10113.1. 20.110.001‐‘G’ & 1.10113.1. 20.110.002‐‘H’

1.10113.0.20.120.001‐‘G’

1.10113.0.20. 200.001‐‘F’


1.10112.0. 03.000.001‐‘nil’

1.10113.0.03.095.001

1.10113.1. 20.110.016‐‘A’ & 1.10113.1. 20.110.017‐‘A’

1.10113.0.20.120.001‐‘G’

1.10112.0.20. 200.001‐‘B’

Table-C: Details of Layout of Doors, Windows, Partition frame & Seats & berths /

Chairs for LHB Type Coaches

S. No.

Coach Type Drawing no. & Alt.

Layout of Doors

Layout of windows

Layout of partition frame

Seats & berths / Chairs

1 NON AC 2nd CLASS (EOG)

LG56001 LG54005 LG10010 LG61006


LS52001‐'c' LS54109‐'nil' LS61003

3 AC ‐3T SLEEPER (EOG) LE56001–‘g’ LE54100–‘a’ LE10001 LE61002



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4 AC‐2T SLEEPER‐ (EOG) LW56004–‘e’ LW54001–‘a’ LW10003 LW61004


LA56004–‘h’ LA54001–‘b’ LA10005 LA61002

6 AC HOT BUFFET CAR LH56100–‘g’ LH54100–‘a’ LH10001 LH61128

7 GENERATOR CUM LUGGAGE & BRAKE VAN

2.11012.0.22.000.001

1.11012.0.23.000.001

1.11012.0.25. 000. 001

8 AC CHAIR CAR 2.10113.0.22.000.001

1.10113.0.23.000.001

1.10113.0.20. 100.001

2.10113.0.25. 100. 001


2.10112.0.22.000.001

1.10113.0.23.000.001

1.10113.0.20. 100.001

2.10112.0.25. 100. 001

Table-D: Details of other items for LHB Type Coaches

S. No.

Coach Type

Drawing no. & Alt.

Compressed Air brake assembly

Sanitary facilities complete

Coach floor complete

Interior paneling

arrangement 1 NON AC 2nd CLASS LS (EOG) LG36126 LG63225 LG41141 2 NON AC 2nd CLASS

SLEEPER(EOG) 2.10113.0.09. 100.001

LS63110 LS41117

3 AC ‐3T SLEEPER (EOG) 2.10113.0.09. 100.001

LE163001 LE41100 LE44001

4 AC‐2T SLEEPER‐ (EOG) 2.10113.0.09. 100.001

LE163001 1.10113.0.21. 200.003

LW44426

5 AC‐1st CLASS SLEEPER‐ (EOG) 2.10113.0.09. 100.001

LA63003 1.10113.0.21. 200.003

LA42004

6 AC HOT BUFFET CAR 2.10113.0.09. 100.001

LH63001 LH41100 LH44001

7 GENERATOR CUM LUGGAGE & BRAKE VAN

1.11012.0.09. 100.001

1.11012.0.30. 000.002

2.11012.0. 21. 200.001

1.11012.0.21. 000.001

8 AC CHAIR CAR 2.10113.0.09. 100.001

1.10113.0.30. 000.002

1.10113.0.21. 000.001


2.10113.0.09. 100.001

1.10112.0.30. 000.002

LZ41108 LZ44001



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Table-E: Details of AC System arrangement, Air Inlet Duct Arrangement , Marking diagram / Layout of lettering & Carbody painting

S. No.

Coach Type Drawing no. & Alt.

AC System arrangement

Air Inlet Duct Arrangement

Marking diagram / Layout of lettering

Carbody Painting


NA NA LG83010 LG83009


NA NA LS83002 LW83100

3 AC ‐3T SLEEPER (EOG) LE44115 LE44117 LE64002 & LE64003 LW83100

4 AC‐2T SLEEPER‐ (EOG) LW44013 LW44385 LW64009 & LW64010 LW83100


LA44259 LA44260 LA64009 & LA64010 LW83100

6 AC HOT BUFFET CAR LH44101 LH44132 LH64100 & LH64101 LW831007 GENERATOR CUM

LUGGAGE & BRAKE VAN

1.11012.0.29. 000.001

1.11012.0.11.400.001&

1.11012.0.11.300.001

LW83100

8 AC CHAIR CAR 1.10113.0.29. 000.001

1.10113.0.29. 400.002

1.10113.0.11.400.001& 1.10113.0.11.300.001

1.10113.0.11.100.001


1.10113.0.29. 000.001

1.10113.0.29. 400.002

LZ64002 & 1.10112.0.11.300.001

1.10113.0.11.100.001



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Appendix- II. Standards/Specifications 1.1 General 1.1.1 A list of standards/specifications used and applied to the material and workmanship in

existing LHB design (EOG) cars manufactured by RCF/MCF/ICF are mentioned here.

1.1.2 During the design phase, the firm shall provide original copies of the standards used.

1.1.3 The standards shall preferably be provided in electronic format (soft copy). However, in case the same is not available, with the consent of IR, original printed copy can be provided.

1.1.4 Standards are set out of the Standards Organization (in English) in tables B1 to B5.

1.1.5 Where international or national standards are quoted and specified in the specification, the firm may propose to work to equivalent internationally or nationally recognized standards. Not systematically, but if necessary, the IR can require the firm to prove the equivalence between the European and other standards. Submission for Approval are to be supported by a copy of the proposed standards, a detailed comparison of the quoted and proposed standards and, where applicable, an English translation of the proposed standard.

1.1.6 Latest version available of standards/specifications at the time of award of the contract

shall be used.

Table B.1 Indian Standards

Standard Organization

Standard Reference Number

Title or Description of the Standard

IS 2635 DC Electric Welding Generators

IS 4549 DC Arc Electric Welding Power sources

IS 6008 AC/DC Arc Electric Welding Power sources

IS 9857 Rubber insulated cables

IS 1179 Equipment for eye and face protection during welding

IS 2573 (Type-1) Leather gauntlets

IS 2641 Electric Welding Accessories- Specification

IS 4517 Welder’s Brush



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IS 737-HS-20W Aluminium Chequered plate

IS 2074:1992 Red Oxide zinc primer

IS 110:1968

Ready Mixed Paint, Brushing, Grey filler, for Enamels IS: 110:1968for use over primers

IS 5083:1988 Specification for knifing stopper

IS 8662:1993 Enamel Synthetic Exterior (a) Undercoating (b) Finishing for Railway rail cares

IS 524:1968 Specification for Finishing, Exterior, Synthetic

IS 2339:1963 Specification for Aluminum paint for General purposes ,in Dual container

IS 2932 synthetic enamel black paint

IS 120 Ready Mixed Paint, Brushing, Finishing, Oil Gloss for General Purposes (5 Colours)

IS 133: 1993 Enamel interior: (a) Undercoating (b) Finishing

IS 3678: 1966

Ready Mixed Paint, thick white for lettering

Table B.2 RDSO Specifications, Code of practice &Schedule of technical

Requirement (STR)


Specifications Reference Number

Title or Description of the Specification

RDSO R19/95 Wheel and axle assembly RDSO IRS M-28-2002 Welding electrodes & welding rod RDSO IRS M-46-2003

MIG/MAG welding wires

RDSO C-9905 STR for Chrome plated pins

RDSO M&C/PCN/100/2009 PU Paint

RDSO IRS: M-41 CORTEN Steel sheets

RDSO RDSO/CG/2011/CG-03 STR for Silicon Foam as a Cushion Material for IR passenger Coaches

RDSO RDSO/CG/2013/CG-13 STR for CBC with AAR ‘H’ type head and Balance Draft Gear



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Table B.3 RCF Specifications


Specifications Reference Number

Title or Description of the Specification

RCF

MDTS 094 ----------

RCF

MDTS 088 ----------

RCF

MDTS 083 ----------

RCF

MDTS 084 ----------

RCF

MDTS 097 ----------

RCF

MDTS 166, Rev-2 Specification for Bogie side frame painting

RCF EDTS: 200 REV. “ Specification for Tubler crimping sockets for e-beam cables

RCF EDTS: 201 REV. “A” with Amnd no. -1

Specification for Ring tongue type crimping sockets for e-beam cables

Table B.4 International Railway Union

Standard Organisation

Standard Reference Number

Title or Description of the Standard

UIC 566 OR Loadings of coach bodies and their components.

UIC 564-2 Regulations Relating to Fire Protection and Fire Fighting Measures in Passenger Carrying Railway Vehicles.

UIC

564-1 Coaches- Windows made from safety glass

Table B.5 International Railway Union

Standard

Organisation Standard Reference

Number Title or Description of the Standard

DIN 52612 Testing of Thermal Insulating Material.



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Appendix- III. FIREWORTHINESS MATERIAL

Material for interior of the coaching stock shall be bought to the latest specifications of RDSO, which has incorporated fire retardant characteristics. A list of such material is as follows:

Sl. Specification no. Description 1. C-9407 Schedule of Technical Requirements for wood based impregnated

compressed laminates for use in Railways.

2. C-K511 Schedule of Requirements for Natural Fibre Thermoset Composite NFTC) sheets for roof paneling of Railway coaches.

3. C-K513 Schedule of Technical Requirements for Pre-laminated shaded

compreg for use in Railway coaches. 4. C-K514 Schedule of Technical Requirements for Decorative thermosetting

synthetic resin bonded laminated sheets (LP sheets) for use in coaching stock.

5. C-K607 Schedule of Technical Requirements for Dandified Thermal

Bonded Polyester Blocks for use in Railway coaches for Seats and Berths.

6. RDSO/2006/CG-12 Schedule of Technical Requirement for Flexible poly vinyl chloride

(PVC) flooring for use in coaching stock. 7. RDSO/2007/CG-02 STR for FRP windows has been issued to all Railways. 8. RDSO/2007/CG-03 STR for SMC window guides, windowsills and cross members.

9. RDSO/2007/CG-04 Schedule of Technical Requirement for Flexible Load Bearing Polyurethane Foam Cushions for passenger coaches for Seats and Berths.

10. RDSO/2007/CG-05 STR for UIC type Elastomer Flange Connections for Intercommunication between Passenger coaches.

11. RDSO/2008/CG-07 Schedule of Technical Requirements for “vinyl coated upholstery fabric” (artificial lather) for coach seats and berths.



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Appendix- IV

Details of existing LHB variant Cars Table-1

S.N Parameter Dimensions (in mm) 1. Length over body 23540

2. Length over Buffers 24000 3. Width 3240 4. Over all height from rail level 4039 5. Floor height from rail level 1320

Table-2

S.N Type Of LHB AC (EOG) Cars Weight (in tons)

Tare Gross Body Shell

Bogies(02nos.)

1. AC 2ndclass Chair Car 42.5 51.78 9.75 13 2. AC Executive class Chair Car 42.5 49.86 9.75 13 3. AC First class sleeper Car 43.3 45.22 10.0 13 4. AC 2-Tier Sleeper Car 44.5 48.66 10.5 13 5. AC 3-Tier Sleeper Car 45.6 51.36 10.5 13 6. AC Hot Buffet Car 40.8 42.24 10.0 13 7. AC Generator Car cum Luggage cum Brake van 54.93 59.31 11.0 13 8. Second Class Sleeper 36.28 42.91 12.1 13 9. General Second Class 35.29 50.49 12.1 13

Table-3

S.N Type Of LHB AC (EOG) Cars Seating/sleeping capacity

(Passenger/Crew) 1. AC 2nd class Chair Car 78 2. AC Executive class Chair Car 56 3. AC First class sleeper Car 24 4. AC 2-Tier Sleeper Car 52 5. AC 3-Tier Sleeper Car 72 6. AC Hot Buffet Car 18 7. AC Generator Car cum Luggage cum Brake van 5 (04 Crew +01Guard) 8. Second Class Sleeper 80 9. General Second Class 100



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Appendix- V

Particulars of contract works to be furnished by the firms (Mechanical)

Particulars of Rail Cars Length of the rail car, over headstocks… …

Overall height of rail car body above rail level… …

Width between wheel tyre flanges … …

Width between wheel hubs … …

Wheelbase of bogie … …

Distance between bogie centers… …

Axle diameter of bogie … …

at wheel seat… Max.

at gear seat… Max.

(Note: Blank spaces to be filled in by the firm)

Brake equipment… Kgs.

Total tare weight of rail car with full complement of equipment (unloaded)… tonnes

Unsprang mass of two bogies…… tonnes

(Blank spaces to be filled in by the firm)

Tare weight… tonnes

Weight of two bogies….. tonnes

(Blank spaces to be filled in by the firm)



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Appendix- VI

Maximum Moving Dimensions



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Appendix- VII

Rail car Profile: For all variants of LHB (EOG) rail cars (except AC-3tier variant)



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Appendix- VIII

DETAILS OF IV COUPLER FOR LHB EOG TYPE AC COACHES Annexure-“4A”

S.No. Description To be furnished by the firm 1. Manufacturer’s name & Address 2 Model/Type 3. Rating

a) Voltage b) Current c) Power factor

4. Temperature rise at rated current 5. Cable pull out 6. Material and parameters of the

spring

7. Mating cycle 8. Weight

a) Plug assembly b) Socket assembly c) Blind Socket assembly d) Total wt.of Plug, socket &

blind socket with cables

9. Materials along with relevant specification & drawing

a) Plug assembly b) Socket assembly c) Ratchet assembly d) Blind Socket assembly e) Fixed contact pin f) socket Tube g) Control pin

10. Degree of protection for complete coupler unit



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Anneure-“4B”

Details of Transformer

1. Name of the manufacturer 2. Rating

a) KVA ………….KVA b) Rated Primary voltage ………….V c) Rated Secondary voltage ………….V d) Frequency ………….Hz e) Temperature rise i) Winding by resistance method ………….deg.C ii) Core by thermometer method ………….deg.C iii) Terminals by thermometer method ………….deg.C

3. Number of phases …………. 4. Connections i) High Voltage …………. ii) Low Voltage …………. iii) Vector group …………. 5. No load loss at rated voltage ………….W & frequency 6. Load loss at rated current ………….W at 75 deg.C 7. Efficiency at 75 deg.C at unity power factor i) At full load ………….% ii) At three forth load ………….% iii) At half load ………….% iv) At one forth load ………….% 8. No load current at rated voltage &

Frequency 9. Over all dimension and weight i) Length ………….mm ii) Width ………….mm iii) Height ………….mm iv) Weight ………….mm 10. IR value 11. Winding resistance 12. Degree of protection 13. Detailed drawing of i) Terminal arrangement ………………

ii) Marking iii) Circuit diagram iv) Mounting details



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14. Class of insulation & its details ………………. i) Winding ii) Terminal Board

15 Winding wire/strip material 16. Current density of conductor

i) Primary ii) Secondary

17. Core details i) Material & grade ii) Thickness iii) Flux density

18. Details of anti-vibration mounting

a. Make b. Drawing No. c. Part No. etc.

19. Crimping socket’s make & size 20. Make/size of grommet/PG coupler

21. Heat shrinkable sleeve.

ANNEXURE – “4C” Conduit

S.N Manufacturer Model Number

Conduit Size (dia)

Outside Diameter

(mm)

Inside Diameter

(mm)

Minimum Bending Radius

(mm)

1 16

2 20

3 25

4 32

5 40

6 50



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ANNEXURE – “4D” Microprocessor Controller of RMPU for LHB and Double decker AC coaches. QUESTIONNAIRE ON OFFER FOR MICROPROCESSOR CONTROLLER OF RMPU FOR LHB AND DOUBLE DECKER AC COACHES. (To be furnished by the firm at the time of prototype testing) S.No. Description To be furnished by the firm 1. Manufacturer’s name & Address 2 Model/Type 3. Rating

a) Voltage b) Current c) Power Input

4. Temperature Settings 5. Digital Input 6. Digital output 7. Analog Input 8. Analog Output 9. Dimension and weight 10 Details of Relative Humidity Sensor 11. Details of Temperature Sensors 12 No of LP/HP Inputs and limit of LP/HP 13 Details of protection of EMI/EMC 14 Details of LCD display unit for

displaying settings and parameters

15 Details of power cable and control cable 16 Details of relay used 17 Details of main controller used 18 Details of watchdog timer used 19 Details of Real time clock used 20 Details of PCB used 21 Grade of electronic component used

such as capacitor ,resistor, transistor, IC etc.



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Details of RMPU Annexure-“4E” S.N Description To be furnished by the firm

1. Manufacturer’s name & Address 2. Model/Type 3. Rating

a) Voltage b) Current c) Power Input

4. Cooling capacity 5. EER 6. Dimension and weight 7. Details of condenser coil and motors 8. Details of evaporator coil and motor. 9. Details of compressor 10. Details of Relative Humidity Sensor 11. Details of Temperature Sensors 12. No of LP/HP Inputs and limit of LP/HP 13. Details of protection of EMI/EMC 14. Details of power cable and control cable

Documents

Draft specification of LHB COACHES -ver-2 …rdso.indianrailways.gov.in/works/uploads/File/Draft specification... · ALL METAL INTEGRAL LIGHT WEIGHT LHB DESIGN RAIL CARS ... MCF Modren