Technical Specification for Bogie Turn Tables for CRWS_ Bhopal

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Technical Specification for Bogie Turn Tables for CRWS_ Bhopal Powered By Docstoc
					ANNEXURE TO TENDER No: 60.07.8061

Technical Specification for Bogie Turn Tables for CRWS, Bhopal.

1. Scope of Work.

   The scope of work includes design, manufacture, supply, installation, testing and
commissioning of the turntables. Civil work such as foundation, electric connections, wiring
and cabling, water supply and drainage connections shall be responsibility of the contractor.
Note: The foundation is required to be casted in Black Cotton Soil, therefore it should
be RCC foundation above M-25 grade.

2. General description of the works.

   Bogie turntables, shall be provided for transfer of bogies from one tract to another for repair and
overhaul. The turntables shall be installed inside concrete pits. The top of the turntables shall be flush
with the workshop floor for workshop vehicular traffic.

  The scope shall include steel beams, bearers, curb angles, bed plates and all other associated fittings
required for support of bogie turntables in the machine pit or workshop and all necessary supports,
rail bolts and fastenings for all equipments.

3. Specific requirement of Bogie Turntables.

  Four ( 4 nos. ) bogie turntables shall be provided at the final/bogie shop of the Coach
Rehabilitation Workshop, Bhopal.

3.1 Operating Principle.

    The turntables shall be designed for transport of bogies from one track to another track in the
final/bogie shop area.

   The turntables shall allow bogies with a maximum weight of 10 tonne to roll on for turning.

   The turntables shall be designed for manual turning by one person with an operating lever. The
turning shall be endless in both clockwise and counter-clockwise directions.

  The turntables shall be integrated with manual-operated lock bars for securing the turntables in
place during bogies rolled on or off the turntables.

3.2 Turntable Construction.

   The turntables shall be constructed of circular platform decks with 3800 mm in diameter. The
decks shall sit on center pivots at the centers and castors on the peripheries for turning.
    Two pairs of rails shall be mounted and positioned in perpendicular to each other across diameter
on the deck of each turntable to accommodate bogies. The track gauge shall be 1676mm. The rail
shall be 60Kg.( UIC) and mounted with 1:20 inwards slope.

3.2.1 Platform Deck.

  The turntables and supporting frame shall be constructed of welded structural steel box section,
wide flange beam, standard ‘I’ beam or reinforced beam fabricated from structural shapes.

    The turntables shall be designed to sustain the rollover load of workshop vehicles, such as forklift
trucks, with a maximum axle load of 60 kN at any point.

   The turntables shall be covered with galvanized steel chequered plates and flush with the fail top
level to allow normal traffic. The plates shall be stiffened and minimum 8 mm thick with maximum
deflection not exceeding 1/1000 of the span. The plates shall be removable and fixed with flush bolts.

3.2.2. Center Pivot.

   Center pivot shall be provided and equipped with a self-aligning spherical roller thrust bearing to
facilitate turning operation. Centre pivots shall be designed to take up any horizontal loads.

3.2.3. Castor.

   Castors shall be provided along the periphery to facilitate turning operation. The castor wheels
shall be manufactured form high quality steel for reliability during the service life and equipped with
anti-friction bearings for quiet operation.

3.2.4. Running surface.

  Running surface for castors shall be designed with considerations of surface wearing and load
bearing without deformation. Surface replacement if necessary shall be made possible.

3.2.5. Lock Bar.

   The mechanical locking device shall be provided and located at each 90 degree segment of
rotation. The tracks on turntable shall be aligned with adjacent embedded tracks when bogie
turntables are in their locked position at any 90 degree of rotation. Lock bars shall be accessible with
the bogies on the turntables for locking and unlocking operations.

  Lock bars shall be flush with the shop floor level for both locked and unlocked positions. The bars
shall not be easily removable from the turntables.

3.2.6. Tolerance.

  The gap between the turntable deck periphery and the pit ring shall be within 5 to 10 mm.
 The track rails on turntable decks shall be aligned with the rails embedded on the shop floor. The
rails shall be positioned within tolerances of ± 2.5 mm for track alignment, ±2 mm for rail top and
±1.5 mm for track gauge.

The maximum difference in the horizontal and vertical alignment shall be to a maximum of 5 mm.

3.2.7. Pit Ring.

  The edges of the turntable pits shall be protected with pit rings of steel angle section. The curb
angles shall be notched on the field side of the rails in addition to the gauge side to accommodate
worn wheels, which may strike the curb angle.

3.2.8 Operating Lever.

 One operating lever shall be provided to each turntable for manual turning operation. Two inclined
pockets for attaching the levers shall be provided at 90 degree apart at the rim of each turntable. Wall-
mounted holders shall be provided for storage of the levers.

3.2.9 Maintenance Provision.

   Maintenance access shall be provided for inspection and lubrication of center pivot and casters
through hinged steel covers on the shop floor level.

  Provision shall be allowed for lubrication through a centralized greasing point incorporated into
turntable. Lubrication shall be made by pressure grease fittings to all bearing of pivoting shaft and all
castors. The greasing point shall be accessible to routine maintenance.

  The turntables shall be constructed to allow the entire assembly, except supporting structures, be
conveniently removed from the pit as a single unit. The turntables shall be equipped with lifting eyes,
which shall be removable or flush with the decks.

4. CHECKS AND TESTS : At Site/Testing and Commissioning.

    After delivery and assembly of the equipment at site and completion of installation work,
commissioning tests shall be carried out in presence of a Representative of the contractor to check
that the equipment design makes it suitable to fulfill the stipulated specifications.

   The purpose of the tests is to record and acknowledge that the equipment is capable of performing
regular service under different operating conditions.

   The necessary tools, loads, specimens or equipments required for the tests shall be the
responsibility of the Contractor.


5.1 In the Bid.
A detailed technical note containing the description of the installation and indicating main dimension,
the grade of steels used in this construction and the total weight of main assemblies.

Photographs or sketches of similar equipment with a list of references.

Diagrammatic plan view with main dimensions, showing compatibility between the equipment
dimensions and the provisions indicated in the drawing.

General drawing substantiating the satisfactory mounting of the turntable in the pit, with information

Track axes, levels, clearance between the pit edge of the turntable, references of the sub-contractors,
references and characteristics of the main assemblies, weight of the removable parts and components,
the standards and specifications that the main components used in the installation satisfy.

5.2 At Completion of Work.

   The contractor shall provide the entire documentation for review and approval by the engineer.

The list or complete nomenclature of general drawings and detailed drawings of electronic and
electrical diagrams. Drawings required for maintenance and troubleshooting of the machine.
Maintenance and adjustment manual and functions and among other information, a lubrication
manual including location of lubrication points, type of lubricants, frequencies and quantities. An
operating manual ( start up and user’s instructions ). Complete documentation on motors and major
components. Spare part list with quantities for three years after handover of the works. Anticipated
frequency of replacement and prices with a one-year validity period. A schedule of all lubricants used
shall be provided with details of location, type of lubricant, manufacturer, manufacture’s
identification and frequency of application.


   The contractor shall provide comprehensive training to the Client’s staff to enable safe and
efficient maintenance and operation of the equipment supplied as part of the contract to achieve
maximum reliability and economy of cost.


 The tenderer shall quote in the bid for the maintenance spares, considered essential by him which
may be ordered along with the equipment. These should be sufficient for normal operation and
maintenance of the equipment for a period of three years.
8. Climatic Conditions and Operating Environment.

The equipment shall be required to work under following climatic conditions.

 Maximum temperature during summer – 45 to 50 degree C.
 Relative humidity during rainy season - 80 to 90 %
 Minimum temperature during winter - 3 to 5 degree C.
 Environment                          - Dusty.

9. Reference date of BG Coaches.

    The details of BG coaches to be shunted through track are given below. These may however very

   No. of coaches shunted at a time. : 4 to 6 coaches.
   Weight of coach                    : 60 tones.
   Length of coach over buffers.     : 22297 mm.
   Width of coach.                   : 3251 mm.
   Height of the coach above rail level : 4025 mm


    Bogie Turn Table should be guaranteed to give satisfactory performance for a minimum period
of 12 months from the date of commissioning. All replacements and repairs that the purchaser calls
upon the supplier to deliver or performed and satisfactorily free of cost.

                                                   For Controller of Stores

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