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GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

Particular Specification for

BG Diesel Electric Multiple Unit (for Quazigund-Srinagar-Baramulla section)

MP – 0.0800.58 (Rev – 02) xxxx – 2015

Issued by

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RESEARCH DESIGNS AND STANDARDS ORGANISATION MANAK NAGAR, LUCKNOW – 226011

C O N T E N T S

ISO 9001 : 2008 Specification no. MP-0.0800.58

Revision No: 02 Date of issue: xxxx ’2015

Particular Specification for BG DEMU for Quazigund-Srinagar-Baramulla section

Page 1 of 38

Part Description Page No.

I Coach Structure and Design 2 - 18

(Scope, General layout, Leading Particulars, Body shell, Underframe, Coupling arrangement, driver’s compartment, brake system, Running tests etc.)

II Traction Equipment 19 - 24

(Configuration, scope of supply, Diesel engine, Transmission system, Cooling equipment, Electrical system, Compressor, Alternator, Control system, speed indicator cum recorder, Contractual terms, Service and spare parts catalogues, Spares, Training, Warranty and Particulars to be supplied by supplier etc.)

III Centralized Heating system and Diesel Alternator set for RMHU 25 - 35

(Heating Coil, Blower, Controls with control panel, Diesel Alternator set, Cooling, Controls etc.)

IV Coach lighting 36 - 37

(Wiring, inter cab couplers, distribution fuse board, fans, lights, switches, test certificates & marking)

ANNEXURES S.No. Description Annexure

1. List of Drawings generally applicable in construction of BG DMU coaches for J&K

I

2. Schedule of Requirements for Bonded Mineral/glass Wool Insulation for Integral Coaches

II

2. Layout of Central Heated Driving Power Car (DPC) to RDSO Sketch No. CG - K5028

III

3. Layout of Central Heated Trailer Coach (TC) to RDSO Sketch No. CG – K5029

IV

4. Layout of Central Heated Trailer Coach (TC) with under slung equipment to RDSO Sketch No. CG- K5030

V

5. Tractive effort Vs. speed curve with BHEL electrics GDP-1119

Tractive effort Vs. speed curve with CGL electrics GDP-1146

VI A

VI B




Page 2 of 38

Particular Specification for BG Diesel Electric Multiple Unit (DEMU) for Quazigund-Srinagar-Baramulla section of NR 1. SCOPE 1.1 This specification covers the particular requirements of design, construction, supply and

commissioning into service of fully furnished and finished Broad gauge Diesel Electric Multiple Units (DEMU) for Quazigund-Srinagar-Baramulla section of J&K.

1.2 The standard one unit consists of eight coaches with the following formation:

Formation: 1 DPC + 2 TC + 2 TC (with underslung equipment) + 2 TC + 1 DPC.

1.2.1 The central heated Driving Power Car (DPC) shall be in accordance with RDSO drg. No.CG- K5028.

1.2.2 The central heated trailer coach shall be in accordance with RDSO Drawing No. CG-K

5029. 1.2.3 The central heated trailer coach (TC) with underslung equipments shall be in accordance

with RDSO drawing no. CG-K5030. 1.3 This specification consists of three parts as follows: Part I : Coach Structure and Design Part II : Traction Equipment Part II I: Centralized Heating system Part VI : Coach Lighting 1.4 This specification read with IRS Specification No.R-35-75 for coaching stock is intended to

include everything requisite to the construction of these coaches, notwithstanding that everything required may not be mentioned herein.




Page 3 of 38

Part - I

Coach Structure and Design

1. CONTRACT DRAWING 1.1 A list of drawings generally applicable for the construction of these coaches is given in

Annexure-I. 2. LEADING PARTICULARS 2.1 The leading particulars of the DPC and TC shall be as follows:

(i) Gauge 1676 mm (ii) Length over body DPC = 21417 mm TC = 21337 mm (iiii) Width over body 3245 mm (iv) Height of centre buffer coupler from 1035 mm rail level under tare (v) Overall height of the coach from rail 3886 mm level to centre of roof under tare (vi) Height of side buffer from rail level 1105 mm under tare for DPC (vii) Height of floor from rail level under tare 1282 mm (viii) Distance between bogie centers 14783 mm (ix) Bogie wheel base 2896 mm (x) Axle capacity DPC 20.32 t TC 16.25 t (xi) Wheel Diameter

DPC TC New 952 mm 915 mm Fully worn 877 mm 813 mm (xii) Braking self-lapping Electro-pneumatic (EP) brake system (xiii) Max. Operating speed 100 km/h (xiv) Max. Test speed 110 km/h 3. MAXIMUM MOVING DIMENSIONS 3.1 The coaches shall conform to maximum moving dimensions to EDO/T-2202. 4. BOGIE 4.1 The general arrangement of DPC bogie shall be as per ICF drawing No.DMU/DPC5-0-0-

501. 4.2 The TC bogie shall be as per ICF Drg.No.DMU/TC4-0-0-401.




Page 4 of 38

4.3 The axle box springs of the above bogies shall be suitably designed for the loads encountered in service and shall conform to RDSO Technical Specification No.WD-01-HLS-94 (Rev.2).

4.4 Dashpot oil and grease for axle box roller bearing shall be suitable for satisfactory

performance at temperature - 10ºC to 120ºC.

The following brands of grease and oil shall be used. 1. Grease for a) Axle Box roller bearing (i) 2760B grease of shell Alvania for bearing supplied by NEI (working temp. range -20°C to

+ 120°C) (ii) Roller bearing grease L222 of FAG for bearing supplied by FAG ((working temp. range -

25°C to + 130°C) b) Slack adjuster (i) Servogem RR1 of IOC ((working temp. range -10°C to + 120°C) (ii) Balmerol multi-grease LL3 of Balmer Lawrie (working temp. range -20°C to + 130°C) (iii) Lithon RR3 of HP ((working temp. range -20°C to + 120°C) 2. Oil for Dash Pot & Side bearer i) Servoline 100 with pour point less than -10°C. ii) Balmer Lawrie Protomac 100R with pour point -18°C. iii) Yantrol 100 with pour point less than -10°C. a) Shock absorber Escorts make : i) 473100 Servo shock absorber oil of IOC with -30°C pour point. (ii) HP shock absorber oil RW with -30°C pour point. Gabriel Make : i) As per Gabriel spec. with -30°C pour point. ii) HP shock absorber oil RW with -30°C pour point. IAI : Power shock 25 of Apar Industries Ltd. with -30°C pour point. 5. BODY SHELL 5.1 Shell Structure 5.1.1 The shell shall be of integral, welded lightweight construction, generally as per the

layouts shown in the scope of this specification. The weight of the coaches shall be as low as possible consistent with adequate strength. The underframe of the DPC shall be suitably designed to withstand the load of power pack and other accessories, in addition to the passenger load.

5.1.2 The roof of the DPC shall have an opening for lowering the power pack and alternator

from top with the help of a crane. The opening shall be provided with a watertight cover. Since the engine room area shall have a few large openings, an underframe of heavy design may be considered, while maintaining the essential features of a tubular girder.




Page 5 of 38

5.1.3 The main structural members of the coach shell shall be of pressed steel plates and sheets conforming to approved specifications, assembled and welded together in suitably designed jigs.

5.1.4 The complete shell structure shall be of stainless steel and IRS-M-41. The trough floor

shall be of austenitic stainless steel to AISI 301. The sole bar complete, cross bearers, body pillars complete and side wall upto a height of 600 mm from the bottom edge of the coach shall be of ferretic stainless steel AISI 409M. The rest of the shell structure shall be of IRS-M-41.

5.1.5 The coach shell shall be designed to meet the following details:

(i) A vertical load of 2.165 t/m uniformly distributed for passenger area. The weight of the various equipments mounted in the DPC (power pack, main generator, auxiliary generator, compressor, radiator etc.) shall be considered as concentrated loads and shall be simulated as such during load/strain gauge testing.

(ii) A horizontal squeeze load of 102t applied at the centre line of the CBC. (iii) A combination of loads specified at (i) & (ii).

5.1.6 The stresses estimated by an approved method shall not exceed 213M Pa, 233 M Pa and 226 M Pa for members made of austenitic stainless steel AISI 301, Ferretic Stainless Steel AISI 409M and IRS-M-41 respectively.

5.1.7 End walls should have anti-telescopic features. 5.1.8 Pillars, sole bar, sidewall upto window level shall be coated with bituminous emulsion. 5.1.9 Each completed shell shall be tested for leakage through roof, body sides and ends at

the works of the contractor, who shall provide a test rig to the satisfaction of the inspecting officer.

5.1.10 Manufacturer shall furnish all the sub-assembly drawings along with actual balancing

calculation, maximum axle load of DPC, brake power calculation and stress calculation of shell etc. for approval of RDSO before manufacturing.

5.2 Flooring 5.2.1 Compartment, Doorway and Vestibule Gangway .1 Floor construction arrangement shall consist of 2mm thick PVC sheet to Schedule of

Technical Requirements for flexible vinyl flooring for use in coaching stock No.C-8515 (Rev.2) with update amendments, laid over 12mm impregnated compressed laminates to RDSO Specification No.C-9407 (Rev.2). In addition to this, 3mm aluminium chequered plate to IS: 737 HS 20W shall be laid over PVC sheet in the doorway passages. Skirting of 150mm height shall be finished with PVC sheets and properly anchored to the compreg board. The finished floor shall be free from bulges, depression and cracks. All joints in PVC sheet shall be hot air welded.




Page 6 of 38

.2 The openings in the flooring for the passage of pipes and cables shall be constructed as to prevent any seepage of the oil and in addition give effective protection against the spread of any fire originating beneath the body.

5.2.2 Engine Room of DPC .1 The floor of the engine room shall consist of galvanized chequered steel plates. The

chequered steel plates shall be of type-C to IS –3502, laid directly on the steel supports secured to the corrugated steel floor sheets. Minimum average weight of zinc coating should be 1,000g/m2. The steel chequered plates shall be directly secured to the steel support frame. No timber/Aluminium or any other inflammable material shall be used for flooring of engine room.

5.3 Doors 5.3.1 All body side doors shall be provided with internal safety catches at top and bottom with

padlocking arrangement at top only. One door on either side of the coach diagonally opposite shall be provided with staples for padlocking from outside.

5.3.2 The body side doors shall also be provided with carriage door lock suitable for

locking/unlocking with standard key from outside. 5.3.3 The compartment door of trailer coach shall be of sliding type similar to LHB drawing No.

1 10113.0.22.135.001. 5.3.4 Engine Room .1 A removable hatch type door shall be provided on each side of engine room of DPC.

The door shall be watertight and shall blend with coach profile. Bolts shall secure the removable hatched type doors so that only the railway staff from the interior of the engine room can open them.

.2 A single hinged swing door leading from the driver’s compartment to engine room for

staff use shall be provided. It shall be located on the partition to suit the arrangement of the engine room and secured by a lock to RDSO drawing No. CG-K4054, which can be opened by railway staff from the driver’s cab.

.3 A single hinged swing door leading from the engine room to radiator compartment for

maintenance shall be provided. It shall be located on the partition to suit the arrangement of the engine room and secured by a lock to RDSO drawing No. CG-K4054, which can be opened by railway staff from the engine room.

.4 Drain pipe of stainless steel dia.38 mm of suitable length having top end of bell mouth

type fitted with steel mesh should be provided in whole area of engine room & radiator room compartments at one meter apart.

.5 Painting inside the engine room shall be done with fire retardant PU paint to RDSO

specification No.M&C/PCN/100/2004 Part I to IV. 5.4 Windows




Page 7 of 38

5.4.1 Bigger windows to 1400 mmX1000 mm shall be provided. The window shall be permanently fixed upto head level with movable in the upper portion as shown in layout drawings.

5.4.2 Windowsill arrangement shall be made leak proof against the ingress of water as a

means to prevent corrosion of sidewall and other parts of the shell. 5.4.3 The window arrangement shall be completely air tight when closed. 5.4.4 Windows shall be polycarbonate material to RDSO spec. No.

ELRS/SPEC/L.O.Glass/0016. 5.4.5 Four emergency windows, two windows on each side should be provided for the rescue

of the passenger in every coach. The border of the emergency window should be painted with fluorescent paint inside the compartments and should be suitably labeled.

5.5 Driver’s Compartment .1 Aerodynamic nose profile to RDSO drawing No. SK-K2046 with latest alteration shall be

provided on driving end. .2 Single wider lookout glass shall be provided in the end wall of the driver’s compartment

and this shall be of stone proof polycarbonate sheet to RDSO Spec. No.ELRS/SPEC/L.O.Glass/0016.

.3 Fixed sun-control film affixed to the front look out glass shall be provided. .4 Pneumatic type windscreen wiper to RDSO Spec. No.C-K306 with a long handle for

manual operation shall be provided. 5.6 Water wriggles

Continuous water wriggles shall be provided from one end of the coach to the other, formed by upsetting the sides of the roof sheets. Gutters of suitable design of pressed shape shall be welded directly to the roof skin over the doorways.

5.7 Roof ventilators 5.7.1 Austenitic Stainless Steel TRA type roof ventilators to ICF drg. No.WLRRM4-7-3-402

with latest alteration shall be provided as shown in the layout drawings. 5.8 Insulation 5.8.1 The inside of the roof shall be provided with 25mm thick bonded mineral/glass wool

thermal insulation and shall comply with schedule of requirements as detailed in Annexure-II.




Page 8 of 38

5.8.2 Bonded glass/mineral wool shall be applied with ‘CRPX’ compound or other approved adhesive, which should not have exceeded its recommended shelf life at the time of application.

5.8.3 The partition walls of engine room shall be insulated to eliminate transmission of heat

and noise of engine to the driver’s compartment and passenger compartments. For this purpose an air gap of atleast 30mm shall be provided between the side panels of the partitions and this space shall be filled up with fibreglass, crown 150 or similar material approved by RDSO.

5.9 Vestibules 5.9.1 The non-driving ends of DPC and both ends of TC shall be provided with UIC type of

vestibules and rolling shutters with locking arrangement as per RDSO specification no.C-8812 (amendment slip 1 of 1998) in which the rubber is fire retardant in terms of UIC specification for resistance to flame.

5.10 Lifting pads 5.10.1 The body shall be subjected to repeated lifting by overhead cranes or jacks. Suitable

brackets or pads shall be provided for lifting of coach body, which shall not damage the coach body. They shall be provided on DPC and TC and shall be marked in a readily distinguishable manner.

5.11 Trap doors 5.11.1 Suitable trap doors shall be provided on the flooring for inspection of under slung

equipment, which need attention during service. The design of trap door shall be such that it can be conveniently lifted when attention to equipment is required but strong enough to withstand normal passenger loading. The trap door shall remain in flush to the floor of the coach.

6. CENTRE BUFFER COUPLER 6.1 Scharfenberg semi permanent couplers for the inter coach coupling of the unit and

automatic coupler between the unit shall be provided. For driving end of Power Car, provision shall be made for fitment of hook and 635mm long side buffer.

6.2 The couplers shall allow coupled coaches to negotiate curves of radius 152.4 meters

radius and shall be capable of passage in either direction over standard 1 in 8½ turnouts, and shall function satisfactorily with a difference in head stock heights of adjacent coaches up to 75 mm.

6.3 The Scharfenberg automatic and semi permanent couplers shall be provided with

arrangement for coupling of brake pipes besides mechanical coupling. Provision shall also be made for fitting an electrical cable contactor box on to the coupler at a future date. The coupler shall be tight lock and shall not develop slack in service.

6.4 The automatic head shall be capable of uncoupling through hand operated lever, which

will give a visual indication of the coupler position, which may be set in the open, neutral




Page 9 of 38

or closed position. It shall be easily accessible for operation and shall have provision for fitment of fitting of pneumatic release from driver’s cab at a later date. Automatic coupling shall take place satisfactorily when coaches are brought together at speeds between 1kmph and 15kmph. The gathering range shall be 75mm vertically on either side of centre line of the coupler.

6.5 The laminated bearing spring supports of approved design for automatic and semi-

permanent couplers to facilitate coupling of coaches shall be provided. 7. BRAKE SYSTEM 7.1 All coaches shall be equipped with self-lapping Electro-pneumatic brakes of approved

design, and shall fulfill the requirements as given in following clauses. The suppliers shall supply the detailed drawings; specifications and testing procedure for rubber components; valves and cocks used in the brake system and shall guarantee satisfactory working of the system and components for at least 36 months from date of delivery or 24 months from date of commissioning whichever is earlier.

7.2 The brake power shall be adequate to get EBD less than 1000m in gross load condition

and no skidding of wheels in tare condition. 7.3 The brakes shall be operable from any selected driver’s compartment with the train

running in either direction. 7.4 The inter-coach pipe connection shall permit easy coupling / uncoupling of units. 7.5 Permit variation in braking force during application without passing through release

(excluding operation with triple valves). 7.6 Provide quick and simultaneous application and release (excluding operation with triple

valves). 7.7 Permit operation as straight air brake with triple valves in emergencies such as electric

control failure or train parting. 7.8 Permit driver to change compartments for reversing direction of train operations, the

brakes must remain on until the driver takes control in the other compartment, which must be possible without any other action in the vacated compartment.

7.9 Safeguard against concealed failure or partial failure of power on any position of the

electric control, which could result in failure to apply brakes. 7.10 Provide deadman’s application valve in conjunction with master controller to give

emergency application. 7.11 Permit bleeding off and releasing brakes by hand on each coach individually from either

side from platform or rail level, for which purpose suitable release rods shall be provided. 7.12 Permit easy access and removal for maintenance. 7.13 Provide guard’s emergency application from any selected driver’s compartment.




Page 10 of 38

7.14 The component units of this brake system shall meet the following requirements: - 7.14.1 Driver’s Brake Valve shall be of self-lapping type. 7.14.2 Brake Cylinder: One brake cylinder shall be provided for each wheel of Driving Power

Car and each axle of Trailer coach to RDSO spec. No.C-K013. each driving power car (DPC) will have 8 nos. of 8”x3-3/4” brake cylinder with in-built slack adjuster and with hand brake trunion. (The stroke length at which the slack adjuster starts functioning shall be 40mm).

Each Trailer coach (TC) will be provided with 4 nos. of 8”x3-3/4” brake cylinders with in built slack adjuster and without trunion. (The stroke length at which the slack adjuster starts functioning shall be 32mm).

7.14.3 The brake rigging shall be capable of easy adjustment to cater for maximum tyre wears

of 38mm on radius of driving tower car wheels and 51mm on radius of Trailer coach wheels. No adjustment on the brake rigging between successive renewals of brake blocks shall be necessary. There shall be no obstruction to movement of the brake rigging at any stage of its working so as to result in sudden reduction of brake power.

7.14.4 A Control Governor shall be connected to the automatic brake pipe to prevent motoring

until the brake system is adequately charged, and also to cut out motoring on brake application from the dead-man’s handle or emergency application.

7.14.5 Strainers, dirt collectors and filters shall be placed as close as possible to the equipment

they serve. They shall be accessible for measurement and cleaning, and shall be provided with isolating cocks, which can be seen and operated easily.

7.14.6 The passenger emergency alarm shall not operate the brakes. 7.14.7 An approved arrangement shall be provided to cool the air leaving the compressor and

shall have a water-collecting reservoir and drain cock (Automatic Blow Down Cocks is preferred) in addition to automatic drain valve.

7.14.8 Twin tower heatless regenerative type air dryers to RDSO Specification

No.MP.0.01.00.09 (Rev. 0.00), March 2001 shall be provided to supply dry and clear air to the electro-pneumatic, pneumatic equipment and air springs to avoid condensation of the moisture in the system.

7.14.9 Application of any type of brake shall result in simultaneous cutting off of the power to the

driving axles. 7.14.10 Adequate safety straps shall be provided below the moving components of the brake rigging and other components to prevent falling on the track in the event of failure of any component. All the brake rigging pins/joints should be provided with bulb type cotters. 7.15 Parking Brake & Hand Brake




Page 11 of 38

7.15.1 Spring applied Parking brake arrangement to RDSO drg. no. CG-K4028 with two separate magnet valve, one for application & one for release, both energize to apply along with 3/2 selector valve should be provided on DPC.

7.15.2 The power cables of TM should be so arranged on either side of centre pivot so that

parking brake cylinder while on run and on load does not hit the cables. 7.16 Literature and Drawings 7.16.1The supplier shall submit brake schematic diagram showing the various valves, detailed

colour coded flow path & air from various valves during operation flow paths of current from different valves during operation along with description to the complete system with the offer. Pamphlets covering schematic diagram, installation drawing of individual assembly shall be submitted along with the offer for proper appreciation of the system offered by the supplier.

7.16.2 The supplier shall submit testing procedure, specification etc. for different valves and

brake system as a whole. The supplier shall also indicate the maintenance facilities required for proper upkeep of the equipment. Offer should also include requirements of spares for a period of 3 years. The cost of spares will also be given in the offer.

7.16.3 The supplier shall submit copies of the instructional, maintenance and test specifications

at the rate of one copy per five DEMUs in soft (CD) and printed form covering the following:

.1 assembly drawings of various components and schematic diagram with

description of individual item and system as a whole duly colour coded. .2 assembly and disassembly instructions. .3 trouble shooting instructions. .4 testing procedure/specification of individual item. .5 wearing limits of wearing components. .6 rubber kit and spring details. .7 overall dimensions and mounting details of individual items. .8 particulars of cable entry, if any. .9 weight of various components. .10 lubrication chart (equivalent indigenous lubricant may be indicated). .11 Colour coded cross sectional drawing of different valves.

7.17 Inspection and Testing 7.17.1Before manufacturing of prototype, the supplier will submit the drawings of brake system

for approval of RDSO. The detailed colour coded drawings will be submitted along with technical details of brake valves/equipment used on brake system. The drawings will be evaluated and if found suitable, prototype manufacturing will be started by the manufacturer. Manufacturer will be in constant touch with RDSO for design review and prototype development. After manufacturing of the prototype it will be taken up for inspection.

7.17.2 Prototype inspection will be carried out by RDSO. In general, the inspection will be

carried out according to UIC/RDSO specifications. The supplier will however submit




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detailed type tests, inspection scheme etc. The test scheme should include testing of complete system as well as testing of individual brake valve/equipment. Supplier should get prior approval of test scheme from RDSO/Board before actually conducting prototype inspection.

7.18 Performance Guarantee 7.18.1The equipment supplied by the supplier shall guarantee the equipment against design and

manufacturing defects for a period of two years from the date of commissioning. Not withstanding anything that may be specified in this specification, the final responsibility for suitability of the design shall lie with the supplier who shall undertake to carryout all modifications and alterations to equipment supplied by them for satisfactory functioning in accordance with this specification as may be necessary during guarantee period. Such modification shall be carried out on all units by the supplier free of cost.

7.18.2 Any damage or unsatisfactory performance of any equipment noticed during the

guarantee period shall be rectified or replaced free of cost. The replaced components shall further be under guarantee for two years from the date of their fitment. If replaced component gives unsatisfactory performance in service; it shall be replaced by modified and improved component by the supplier free of cost.

7.19 After-Sale Service The contractors shall arrange from the suppliers of the brake equipment to provide staff

to supervise the placing of the stock in service, and to train staff in the operation and maintenance of the equipment if required by the Purchaser. Pamphlets in English/Hindi bound in hard covers and soft copies (CD) shall be supplied in advance of delivery of the first consignment of coaches, and in numbers to be specified by the Engineers.

7.20 Piping and Pipe Fittings 7.20.1 Seamless stainless steel pipes to spec. ASTM A269 TP316SS, which can be bent cold,

shall be used. The layout of piping shall be designed to keep all pipes, especially the brake cylinder pipes, as short and straight as possible. Bends should be used throughout, but where elbows have to be used, they shall be of round type. Where the pipes themselves are bent, their internal area shall be maintained uniformly.

7.20.2Double ferrule pipefitting consisting of body, front ferrule, back ferrule and nut. The body

and nut will be of carbon steel to ASTM A-108 Grade II with electro copper zinc plating with chromium passivation. The front ferrule and back ferrule will be made from stainless steel to ASTM A 269 TP 316 SS and confirming to ICF specification no. ICF/MD/SPEC-166/ Rev.00/01.

7.20.3Flexible hose connections conform to spec. SAE100R1 shall be used only where

absolutely necessary. 7.20.4All pipes shall be adequately clamped to the frame assembly and NFTC strips should be

placed between frame and pipe for support. Polypropylene type of clamp with MS plate shall be used




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7.21 Brake Blocks:

The composition ‘K’ type brake blocks (non-asbestos type) of keyed Brake Block design shall be used. The Brake Head and keyed composition Brake Block being interchangeable with those shown in RDSO Sketch No. SK-79093 for driving power car and RDSO/SK-98146 for Trailer coach, but shall suit the diameter of the wheels. The design shall permit quick and easy renewal of the slippers and their adjustment without necessity of going to pits. Tie-rods or rubbing plates of approved design shall be provided to prevent the brake blocks riding down the wheel tapers. The 20.32 t axle load bogies should have brake cylinder pressure of 1.6 kg/cm² and 16.25 t bogies at a brake cylinder pressure of 3.8 kg/cm².

7.22 Equipment in the driving cabs: Following equipments to be provided in the driving cab:

i) Electro-pneumatic driver’s brake controller. ii) Self-illuminated push button for remote control of EP brake system. iii) Indicator light for availability of power supply for EP brakes. iv) Audible-cum-visual warning system in front of the driver against failure of the EP

brake. 7.23 Test: Electro-pneumatic brake shall be tested after complete assembly of the equipment of

each coach as follows: 7.23.1 With the brake applied electro-pneumatically the main reservoir pressure must not drop

more than 0.8kg/cm2 in one hour on the DPC or more than 1.0kg/cm2 in one hour on one ‘4-car unit’. The air panel circuit shall be isolated while conducting this test.

7.23.2 With the brakes applied pneumatically in an emergency application, the pressure in any brake cylinder shall not drop more than 1 kg/cm2 in one hour. The emergency shall be affected by opening a coupling cock, which shall remain in open for the duration of the test.

8 PASSENGER EMERGENCY ALARM COMMUNICATION 8.1 The passenger emergency alarm communication shall be independent of the brake gear

and shall consist of trembler type bells operated electrically by pulling alarm handles provided in each passenger compartment. The bells should sound simultaneously in all drivers compartments in the train and shall be sufficiently loud to be heard above the prevalent noise and shall ring continuously till switched off. The arrangement of the alarm bells shall be generally to RDSO Sketch No.62228.

8.2 The alarm handles shall be of stainless steel and shall be connected to the alarm

apparatus by 3.2mm galvanized steel wire rope or chain enclosed in steel conduits. 8.3 The alarm system shall also provide external indicators on both sides of one end of each

coach, which shall give a visible indication of the coach from which the alarm handle has been pulled and shall operate an electrical switch of the design shown in RDSO Sketch No.62251. The switch shall stop the alarm bell ringing when the indicator is reset to its normal position. Supply to the passenger emergency alarm communication system shall be through the driver’s control key switch.

9 PRESSURE GAUGES




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9.1 Gauges should be self-illuminated with L.E.D. and flush mounted. 9.2 All the pneumatic gauges shall be calibrated in steps of 0.1kg/cm2 pressure and least

count should be 0.1kg/cm2. 9.3 Following gauges shall be provided in the cab to indicate to the driver regarding air

pressure level in various parts of the system. .1 MR pressure gauge .2 Brake pipe pressure gauge .3 Parking brake gauge .4 Brake cylinder pressure gauge, .5 Auxiliary reservoir pressure gauge. .6 Any other gauges, which are required as per the system, offered. 9.4 Brake pipe pressure gauge should preferably be of 6” diameter. Other gauges should

also be of at least 4” diameter. Gauges should be provided as per RDSO’s approved drawing Nos.SK.DP-3508 to 3516 and SK.DP-3518.

10 WARNING HORN 10.1 Two pneumatic horns shall be mounted vertically in front of the driver’s compartment and

these shall be operated by two robust foot operated valves on driver’s side and hand operated valve on Guard’s side either side of the driver’s control desk. Horn covers similar to ICF drg no. ICF/SK-3-5-269 should also be mounted to prevent theft and ingress of water into the horns.

11. SIGNAL BELLS

An electric signal bell system shall be provided between driver’s compartments and shall consist of single stroke bell and two switches (one for each doorway) in each driving cab. The bells shall be operated from the battery circuit. A push button switch is to be provided in passenger alarm bell circuit for train operation to enable its use in the event of failure of normal guard’s signal bells.

12. CATTLE GUARD

Cattle guard to ICF drawing No. DMU/DPC3-2-6-301shall be provided at the driving end of the DPC.

13. HEAD CODE 13.1 On the driving end wall of each driver’s compartment, head codes of suitable design shall

be provided to indicate: - 13.1.1 Train destination in 3 languages. 13.1.2 Route in 2 languages. 13.1.3 Train No. in English. 13.2 The head codes shall be illuminated by lamps suitably placed and controlled

independently. When the frame containing the head code is shut, light shall not show in




Page 15 of 38

the driver’s compartment. A model of the head code arrangement shall be made and approved by the Engineers before manufacture is commenced.

14. FIRE PREVENTION MEASURES 14.1 Fire prevention measures shall be in accordance to RDSO ‘Code of Practice for

Prevention of Fires on DMU Stock’ No. CMI-K402 issued on Dec. 2004. 15. P.A. SYSTEM 15.1 Bi-directional Public address system with inter communication between the train driver

and the passenger, throughout the train shall be provided for announcement from driving cab. Passenger communication shall be driver initiated and under no circumstances cab-to-cab communication be relayed to the passenger compartment. Each coach shall also be equipped with passenger information display system for displaying current information about next destination, and advertisement etc.

16. INTERIOR FURNISHING 16.1 The interior finish and furnishing must be to the best standards of coachwork, and shall

combine a good and clean appearance with durability and serviceability. The interior surfaces, such as walls, partitions, bulkheads etc. shall be rounded and joints shall be avoided. All surfaces liable to frequent handling shall be finished with materials suitable for periodical washing or cleaning, and shall be of a colour which will not show up stains.

16.2 The materials used for finishing and furnishing shall be suitable for use under all climatic

conditions and shall be fire retardant, non-hygroscopic and vermin & rot proof. 16.3 Ceiling and Paneling 16.3.1 The interior ceiling shall be of 1.5mm thick NFTC sheet confirming to RDSO specification

No. C-9511 with latest revision and paneling shall be with FRP to RCF’s specification No. MDTS-084. The moulding and fixings of FRP panels shall be similar to LHB design with minimum visible screws.

16.3.2 The ceiling of engine room shall be of 1mm thick Sheet Steel to IRS-M-41. 16.4 Partition 16.4.1 The interior partition wall of passenger compartment shall be of thick ply board glued with

additional 1.5mm thick HPL sheets on both sides. The HPL sheets used for interior panels shall be RCF’s specification No.MDTS-086

16.4.2 Paneling of Sidewalls and partitions of engine room shall be 1mm thick sheet steel to

IRS-M-41. 16.5 Seats and seat frames 16.5.1 The seats shall be designed to combine comfort and pleasing appearance and shall

permit easy cleaning, both of the seat and the backrest. The seats shall be firmly fixed to the frame, which shall be robust enough to stand overload and shall provide easy access to the floor below the seat for cleaning and washing.




Page 16 of 38

16.5.2 All seats shall be cushioned properly vented and upholstered with vinyl coated fabric

confirming to RDSO specification No.C-9503 (Amendment 2 of 1998). The covering and cushioning material shall be of fire-retardant quality. Polyurethane Foam cushions as per RDSO Spec. C-8914, Rev-I suitably moulded to required shape shall be used for the seats. The sheets shall be similar to LHB design.

16.5.3 Seats for Driver’s Compartment .1 Two seats shall be provided in each driver’s compartment, one for the driver behind the

controls, and the other for the guard. The driver’s seat shall be of swiveling type with folding to permit the driver to manipulate the controls either while sitting or standing. The seat frame or swiveling arrangement shall be of robust design, easy to operate and hold in any desired position. The seat shall consist of upholstered polyurethane to RDSO Spec. No.C-8914 (Rev.1), foam cushion secured firmly to the frame in pilfers proof manner and shall have a light backrest.

.2 The guard’s seat shall be of the folding type, fixed to a rigid frame which will not obstruct

movement in the compartment when the seat is not in use. The seat shall be upholstered similar to the driver’s seat. The guard’s and driver’s seats in the driving cab shall be without springs but with latches so that they can be latched when folded. A footrest shall be provided in front of the driver’s seat.

16.6 Luggage racks 16.6.3 Light fabricated stainless steel/FRP luggage racks shall be provided in the

compartments. The racks shall be capable of taking load of 74.4 kg. per meter in service, and 131 kg. per meter in static tests.

16.7 Interior colour scheme 16.7.3 The interior colour scheme shall be as follows:

Floor to cant rail in Compartments, doorway Passages. As per approved colour scheme. Flooring of compartments 2mm thick PVC flooring sheet of spectrum blue

confirming to RDSO/Spec.C-8515 (Rev.2). Ceiling White Paint. Upholstery Approved shades as per RDSO’s letter

No.MC/CB/Cushion dt.18.6.98. 17 EXTERNAL FITTINGS & FURNISHINGS 17.1 Footsteps shall be provided at all body side doors. 17.2 Steel step iron shall be provided below the entrance to the driver’s compartment and

shall be so located as to provide a convenient foot holds without infringement of the maximum moving dimensions.




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17.3 Destination boards and number plates with mounting brackets shall be provided on both

sides of the coach. 17.4 Suitable taillights and flasher lights shall be provided on driving end of DPC. 17.5 A tailboard of approved design such as could be operated from inside the driving cab

shall be provided on the DPC at an approved location. 17.6 An underslung fuel tank of 2500 lts. capacity shall be provided on the DPC. 18 EXTERIOR COLOUR SCHEME

The exterior colour scheme shall be approved by Railway Board / RDSO. 19 MARKING

Coaches shall be marked generally to drawing No.CSC-1728. Coach number particulars shall be allotted by Northern Railway.

20 NOTICES

The notices to RDSO drawing No. SK-K3028 shall be fixed in each compartment above each doorway and semi-bulk head at the entrance. The notices shall be printed in black letters on a white background, on vitreous enamel plates secured to the walls by pop rivets.

21 ANTI-PILFERAGE MEASURES

While securing compartment fittings, anti-pilferage measures shall be incorporated generally in accordance with RDSO Sketch-71200 with latest alteration.

22 TESTS ON MECHANICAL PARTS 22.1 The following tests shall be conducted on mechanical parts on prototype driving car:

(i) Squeeze load test under load conditions as specified in clause 5.1.5 of part 1 of this specification.

(ii) Tests on brake equipment (on individual coaches as well as on complete unit) (iii) Tests on parking brake arrangement.

22.2 The test scheme for above tests shall be finalized after completion of prototype in

consultation with the manufacturer. 23 CLEARANCES 23.1 The first unit to be completed shall be placed on level straight track and the buffer and

coupler height, spring height, bogie clearances and other clearances shall be checked under tare, normal load and crush load conditions. The unit shall under these conditions, be passed through a structure representing the maximum moving dimensions as per MMD of EDO/T-2202.




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24 TARE WEIGHT 24.1 The tare weight of prototype DPC and TC shall be taken by using load cells, approved by

the inspecting officer. 25 RUNNING TESTS 25.1 The following running tests shall be conducted on the rake to assess its speed potential

and brake capabilities:

(i) Oscillation trials on prototype unit to assess the riding quality at a speed 10% higher than the designed operating speed.

(ii) Braking distance trials from the maximum operating speed.

25.2 The test scheme for the above trials shall be finalized before conducting the trials in

consultation with the manufacturer.




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Part - II

Traction Equipment 1.0 Broad Gauge, diesel-electric multiple unit Power car with nominal axle load of 20 t and fitted with a

1400 hp fuel efficient diesel engine and AC/DC transmission, complete in all respects, shall be assembled, inter alia, with :- • One fuel efficient diesel engine for traction capable of producing not less than 1400 hp

(Continuous rating) under standard conditions along with either GAC or PG Woodward actuator or better to be supplied by the engine manufacturer) and excitation control & speed governing system.

• Electrics:

BHEL One BHEL make Traction Alternator model TA 7003 BX. Four BHEL make TM 4303 DY model Traction Motors One Kerala Electrics make Auxiliary Generator with voltage

regulator. One complete set of BHEL make Propulsion control equipment.

or

CGL

One CGL make Traction Alternator model C 1012 TA. Four CGL make C 1005 TM model Traction Motors One HMTD make Auxiliary Generator with voltage regulator. One complete set of CGL make Propulsion control equipment.

2.0 OPERATING REQUIREMENTS (half worn wheels)

BHEL CGL

• Maximum test speed : 110 km/h 110 kmh • Maximum operating speed : 100 km/h 100 km/h • Gear ratio : 20:91 20:91 • Motor Grouping : 4P 4P • Continuous speed : 42.9 km/h 44.34 km/h • Maximum tractive effort at start : 15200 kg 14600 Kg. • Continuous rating tractive effort : 7100 kg 6840 kg • Installed power (standard) : Approx. 1400 hp Approx.1400 hp • Power input to traction (site) : 1310 hp 1310 hp • Speed Vs TE characteristics : RDSO Graph no.

GDP -1119 RDSO Graph no. GDP -1146

3.0 CLIMATIC CONDITIONS The DEMU power equipment shall be in continuous operation under the following atmospheric and climatic conditions: -

• Ambient temperature : 45ºC (occasional peak value of 50ºC) • Altitude : Sea level to 600 m • Humidity : 40% - 100% • Maximum temperature : 55ºC• Minimum temperature : -20ºC




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4.0 Diesel Engine (for traction) with Lubrication & Cooling System

4.1 The Power car shall be powered by a fuel efficient diesel engine capable of producing not less than 1400 hp at 1800 rpm (Continuous rating) under standard conditions. The engine shall be adjusted to deliver 1317 hp to the alternator under site conditions. The engine shall be fitted on the prototype only after type approval by RDSO. OEM shall specify the correct grade of fuel suitable for operation of diesel engine under given climatic condition as per clause 3.0.

4.2 Cooling System: Side mounted radiator and hydraulically driven fan assembly, with panels for the

proposed engine and its accessories shall be provided. For ventilation of engine room, fan of adequate capacity driven hydraulically shall be provided. The hydraulic pumps and motors used for cooling will be of fixed displacement types. Hydraulic circuit with supporting calculation shall be submitted by the tenderer for assessment of adequacy of the offered system. The engine cooling circuit will be provided with heater of 2kW capacity (on the junction box) for keeping the water warm. The heater will be suitable for 230 Volts AC, single phase supply equipped with thermostat to control the temperature within specified limit. The tenderer shall indicate any other alternative measures, suitable for operations even at -20 Deg.C without heating.

4.3 Hydraulic Oil system: The Hydraulic oil tank will be provided with 2 heaters of 2kW capacity for keeping the oil in warm condition. The heaters would be suitable for 230 Volts AC, single phase supply equipped with thermostat to control the temperature within specified limit.

4.4 Lubrication System: The engine oil sump will be provided with heater of 2kW capacity for keeping the oil in warm condition. The heaters would be suitable for 230 Volts AC, single phase supply equipped with thermostat to control the temperature within specified limit. OEM of engine will also specify specification of engine oil used.

5.0 TRANSMISSION Transmission of power form the engine shall be done by means of a directly coupled self ventilated traction alternator, four axle hung nose suspended traction motors. An 18.5 KW auxiliary generator shall be provided. Propulsion control equipment shall also be provided. All electrical machines and control equipment shall generally conform to relevant IEC Publications and shall be type and routine tested as per RDSO approved test programme. Type testing of equipment shall be carried out by RDSO unless specifically waived by RDSO in case of proven equipment. The temperature rise limits given in the IEC Publication shall be reduced by 20 ºC to work out the applicable limits for alternator, traction motor and other machines to account for higher ambient temperatures in India.

6.0 TRACTION ALTERNATOR

BHEL CGL

• Make and Type : BHEL model TA 7003 BX CGL model C 1012 TA• No. per DPC : One One • LV Cont. rating

(DC) : 1660 A, 557 V, 1800 RPM 1660 A, 563 V, 1800 RPM

• HV Cont. rating(DC)

: 1030 A, 900 V, 1800 RPM 1100 A, 850 V, 1800 RPM

• Temperature rise : TIa-70ºC for stator & TIf- TIa-70ºC for stator & TIf-70ºC




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limit 70ºC for field where TIa and Tif are the established temperature indices for armature and field insulation respectively.

for field where TIa and Tif are the established temperature indices for armature and field insulation respectively.

• Insulation : Class H Class H • Ventilation : Self-ventilated Self-ventilated • Excitation : LCC of GAC / G&EC25A of

Sirveen Control Systems supplied with the engine suitable for BHEL alternator model TA 7003 BX.

LCC of GAC / G&EC25A of Sirveen Control Systems supplied with the engine suitable for CGL alternator model C 1012 TA.

• Alternator Curve : BHEL curve no. TME/401234C CGL curve no. CGL/M/D/059A

7.0 TRACTION MOTOR

8.0 TRACTION RECTIFIER

BHEL CGL • Make and Type : BHEL make BHD R62-32 HIRECT make Hirect

SH30C725 • No. per DPC : One cubicle per power car One cubicle per power car• Short time duty

rating (DC) : 3000 A 3000 A

• Continuous rating (DC)

: 1800 A, 563 V 1700 A, 563 V

• Ventilation : Self-ventilated Self-ventilated • No. of bridges per

cubicle : 3 3

• Device arrangement per bridge

: 1 x 1 x 6 1 x 1 x 6

9.0 AUXILIARY GENERATOR

BHEL CGL • Make & Type : Kerala Electricals make

KEL A 18122 FM or equivalent

HMDT Engineering make BA 18130 or equivalent

• Number per DPC : One One • Continuous rating : 18.5 KW 18 KW • Insulation - Armature

field : Class H Class H

• Drive : Belt-driven-drive taken Belt-driven-drive taken

BHEL CGL • Make and Type : BHEL make TM 4303 DY CGL make C1005 TM• No. per DPC : Four Four• Continuous rating : 415 A, 563 V (IEC - 20ºC) 415 A, 563 V (IEC - 20ºC)• Max. permissible speed : 2772 rpm 2880 rpm • Max. permissible current : 750 A 750 A• Insulation-Armature & field : Class H Class H • Ventilation : Self-ventilated Self-ventilated • Traction-Motor Curve : BHEL curve no.

TME/401333 CGL curve no. CGL/M/D/052A R1

Armature and suspension bearings shall be of RDSO approved makes. For traction motors, only roller suspension bearings should be used.




Page 22 of 38

from alternator end from alternator end • Ventilation : Self-ventilated Self-ventilated

10.0 CONTROLS AND GAUGES

Adequate control equipment including gauges, instruments and cab safety devices shall be provided for safe and satisfactory operation of the Power car and the Driving trailer car. The controls shall be so arranged in the cab that it will be within easy reach of the driver from all driv-ing positions. All gauges shall be of proven and reliable design. Graduations of all gauges shall be in metric units. Following gauges shall be provided in the cab: - • Diesel engine lube oil pressure gauge. • Cooling water temperature gauge (Electronic). • Fuel oil pressure gauge. • Boost pressure gauge. • Traction motor load Ammeter. • Air brake gauges • Battery charge and discharge ammeter. • Water level indicator (Electronic) • Speed indicator cum recorder. The following audio-visual signals or reference panel lights shall be provided in the cab for single and multiple operation of the Power cars: - • Low lubricating oil pressure. • Radiator water temperature too high. • Engine shut-down • Wheel slip indication • Battery discharge indication. • Aux. Gen. failure indication. • Low idle rpm indication. • Power ground. • Cranking contactor welding indication • Traction control supply ON • Alternator overload • Alternator winding temperature • Alternator bearing temperature • Engine trip • Rectifier fuse failure • Rectifier cooling fan failure • Aux. alternator failure • Motor overload failure • Motor earth fault • Parking brake applied • Drive function released • Common annunciation • Train parting indication • Multiple operation status The following safety devices, inter alia, shall be provided: • Water temperature too high - Transmission cut-off and engine returned to idle. • Low water in radiator - Power to transmission cut-off and engine shut down.




Page 23 of 38

• Low lube oil pressure - Power to transmission cut-off and engine shut down. • Engine speed too high (Over speed trip) - Power to transmission cut-off and engine shut

down. • Power ground - Transmission cut-off and engine returned to idle.

Adequate protection of an approved design shall be provided against electrical overloads and grounding. The following minimum operating controls for multiple unit operation of all Power cars from any cab of Power or Driving trailing unit shall be provided: - • Notch control • Brakes • Forward and reverse movement control • Sanding Safety interlock shall be provided to prevent Power cars in MU operation from being moved when all the Power cars are not set for propulsion in the same direction.

11.0 SPEED INDICATOR / RECORDER 11.1 Speed indicating and recording equipment of 0 -160 km/h range, shall consist of an axle

box mounted opto-electronic speed sensor, one junction box, one speed indicator, one recorder cum indicator unit with micro controller containing FLASH EEPROM internal memory for calculating and recording the journey data. A portable FLASH memory card is used for external memory. The equipment shall conform to RDSO specification No.MP-0.3700-07 (Rev.03) of April’2003. Cab of one DPC shall have one recorder-cum-indicator and that of other DPC shall have one indicator only.

12.0 CABLES & OTHER ELECTRICAL FITTINGS

Electron Beam Irradiated Power & control cables of standard metric sizes shall be provided as per RDSO Specification No. ELRS/SPEC/ELC/0019 (Data Sheet 2A and 2B), REV.0. Terminal ends for control cables and wire shall conform to RDSO Specification No.MP- 0.5200.04. • The Power car shall be equipped at both ends with standard headlights to RDSO specification

for Twin Beam Head Light with 24 halogen lamps for electric, diesel electric and EMU no. ELRS/SPEC/PR/0024, Dec, 2002 and specification for DC-DC Converter for electric loco. /diesel electric loco No. ELRS/SPEC/DC-DC Converter/0021, July, 2002.

• Aspect lights, cab lights/ conduits etc. shall be of type available indigenously. • The power car shall be provided with Marker light to RDSO specification for LED Marker light

for electric loco/diesel electric loco No. ELRS/SPEC/ PR/0022, October, 2002. • The Power car shall be provided with flasher lights to RDSO Spec. for LED based Flasher

light units for electric loco/diesel hydraulic loco/EMU/DMU No. ELRS/SPEC/Flasher Light/0017(Rev.0) of Dec’ 2001.

13.0 COMPRESSOR

3.1 One belt driven air compressor ELGI make type TRC 2507 or equivalent similar to the one used

in existing 1400 hp DEMU, shall be provided in each DPC. OEM shall specify the correct grade




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of compressor oil suitable for operation of compressor under given climatic condition as per clause 3.0.

14.0 PIPING

All pipe joints will be as per ICF standard practice. Schematic piping to suit the engine shall be to the relevant ICF drawings. Flexible pipes shall be provided at all the locations prone to vibrations.

15.0 LUBRICATION

Grease nipples shall conform to IS specification No. 4009. All the grease nipples & adapters, where used, shall be tack welded to prevent them from unscrewing and falling off in service.

16.0 ROLLER BEARINGS

Roller bearings used on the power car at various locations shall be such which can be inspected easily. Pre-packed bearings are not preferred for auxiliary equipment.

17.0 FIRE EXTINGUISHER

Three Halon 1211 type fire extinguishers shall be provided, one in the engine compartment and the others in the cabs.




Page 25 of 38

PART - III Centralized Heating system and Diesel Alternator set for RMHU

1. GENERAL:

1.1 This Part covers requirements for centralized heating system of Coaches to take care of

cold climatic conditions. It is divided in two parts as under: Part – A: Roof Mounted Heating Unit (RMHU) with controls Part – B: DA set for heating load requirements.

1.2 This specification covers design, manufacture, testing and supply of switch board cabinet consisting of all the power/control switchgear equipment related to control of one diesel alternator GENSET rated at 320 kVA, 1500 rpm (with matching alternator) with output of 415 Volts, 3 phase, 50 Hz at NTP.

1.3 The tenderer shall supply all the equipment, such as DA sets, power and control panel

with interlocking system etc. The Tenderer shall have adequate experience in the supply and commissioning of similar equipment for rolling stock application at ICF and / or RCF.

1.4 Type tests of all the major equipment shall be approved by RDSO/ICF. The tenderer

shall undertake installation, commissioning and testing, of the above equipment on the DEMU, at ICF. The tenderer shall be allowed to utilize material handling, welding & pipe bending facilities available in ICF, free of cost.

1.5 A clause-by-clause comment on the specification shall be furnished with tender. Any

clause not commented upon would be deemed to have been accepted.

1.6 The scope of supply of equipment per consist of 8 coach HHP DEMU formation shall include:

S. NO ITEM DESCRIPTION Qty / DEMU A. M/s. Sidwal make Roof Mounted Heating Unit (RMHU),

Model No. SR-11000 DHU consisting of

1. Heating coil, 11.5 kW ( 1 No. in each DPC and 2 Nos. in each TC)

14

2. Blower Motor, 3- phase, 415 V, 1.1 kW (1 No. In each DPC and 2 Nos. in each TC)

14

3. Control Panel with controls (1 No. In each DPC and 2 Nos. in each TC)

14

B. DA set for heating load requirements. 1. Engine with 320 kVA rating, horizontal under slung diesel

engine with all standard accessories including cooling, air, exhaust equipment.

2

2. KEL alternator model TA 3560L of 320 kVA rating suitable for 415 VAC, 4 wire, 3 phase, 50 +3 Hz or equivalent of proven design for rail power car application with filtration arrangement for under slung mounting and operation.

2

3. Power and control panel for DA set with mounting arrangement on the coach.

2

4. Skid mounting arrangement with AVMs for DA set 2




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2. Part – A: Centralized heating system for coaches 2.1 CENTRALIZED HEATING SYSTEM: 2.1.1 Each coach shall have the provision of centralized heating system to take care of cold

climatic conditions. 2.1.2 Each coach shall have the provision of Roof Mounted Heating Unit (RMHU) that shall

provide heating for the coach. 2.1.3 Each trailer coach shall be provided with 2 sets of (RMHU + Blower) arrangement. 2.1.4 Each DPC shall be provided with one set of (RMHU + blower) arrangement at non-

driving end. 2.1.5 Ducting arrangement inside the trailer coaches and DPC’s shall be provided with tapered

guide plate without partition on the lines of current design adopted for AC coaches. Stainless steel plate of 0.8 mm thickness shall be used.

2.1.6 There shall be two GENSET’s of 320 kVA capacity each, one fitted in TC3 and another in

TC4 for supplying electrical power to all the RMHU’s and blowers of the rake consisting of (DPC + 6 TC + DPC). However, at a time only one GENSET shall be in use and another shall be kept for redundancy. Adequate interlocks shall be provided on lines of existing EOG power cars.

2.1.7 Layout of ducting arrangement, RMHU and GENSET shall be as per RDSO drawing No.

CG – K5030. It shall be possible to accommodate the DA Set in under frame portion of coach within the permissible moving dimensions. The minimum clearance of 102 mm of DA set from rail level should be maintained with worn wheels in fully loaded conditions.

2.1.8 In the existing DEMU, there are 5 MU jumpers on each side of end wall. On one side of

the vestibule, 5 male couplers and on other 5 female couplers are provided. It has been provided to give flexibility in case of reversing the coach.

2.1.9 With heating arrangement, one additional MU jumper for feeding the hotel load has to be

provided. In case enough space for providing additional MU jumper is not available, the coupler arrangement should be modified to accommodate additional coupler required by foregoing the flexibility of reversibility of existing DEMU.

2.1.10 The system shall provide hotel load supply to all the coaches through one feeder running

throughout the rake. Inter-Vehicular (IV) couplers comprising of junction boxes, sockets, plugs and dummy sockets, similar to those used in existing EOG System on Rajdhani/Shatabdi trains shall be used.

2.1.11 Provision for interlocking between two DA sets shall be made so that if one DA set is ON,

the another DA set can not be made ON inadvertently. At a time, only one DA set can supply hotel load power to the feeder.

2.1.12 In case of train parting due to accident etc., interlocking system shall be able to shut

down the running DA set.




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2.2 ROOF MOUNTED HEATING UNIT (RMHU) 2.2.1 Each RMHU shall consist of heating coil of 11.5 kW and 3-phase, 415 V blower motor of

1.1 kW capacity. 2.2.2 Each RMHU shall deliver 4000 m3 / Hr air at 20 mm static pressure. 2.2.3 The complete body of the RMHU shall be made from stainless steel. 2.2.4 The filters of fire retardant material shall be used. Design of the filter shall be easy for dry

cleaning. 2.2.5 Heater inside the RMHU shall be in two banks of equal capacity. Each bank of the heater

shall have it’s own overheat protection system which shall prevent overheating by cutting OFF the power supply in case of high heat generation.

2.2.6 In addition to the thermal sensor mentioned at 2.2.5 above, each heating bank shall have

a physical fuse link disconnect controller, which shall physically cut OFF 3-phase power supply to the heater in case of excessive heating.

2.2.7 There shall be an interlock to electrically switch OFF the heater in case the blower motor

trips on overload. 2.2.8 Fresh air openings shall be provided on each side of the RMHU, which will be connected

through duct to the end wall of the coach on both sides through waterproof louvers and filters.

2.2.9 The fresh air assembly and duct will be made from fire retardant and waterproof canvas.

A wire cage shall be installed inside the flexible duct to prevent it from collapsing. 2.2.10 The insulation in the RHMU shall be glass wool jacketed in the two layers of stainless

steel sheet to prevent fire. 2.3 CONTROL PANEL FOR ROOF MOUNTED HEATING UNIT (RMHU) 2.3.1 Control panel for RMHU shall be provided in the coaches and shall be located facing the

sidewall, leaving enough space for attending the end wall wiring. 2.3.2 Control panel shall consist of MCB’s for main power supply, blower motor and for each

banks of the heater. 2.3.3 One contactor for blower motor and two contactors for the heater, one for each bank of

the heater, shall be used. Ratings of the contactors shall be sufficient for the application. A bus-bar shall be used for distribution of the power supply.

2.3.4 LED light indications for ON and OFF conditions of blower motors and heaters shall be

provided. 2.3.5 In case hot air supply from heater is not required, it should be possible to operate the

blower motor alone without the heater for air ventilation. 2.3.6 Electronic thermostat shall be provided to control the heating though sending return air

with temperature range from 18° C to 22° C with ± 1° C allowed variation.




Page 28 of 38

2.3.7 Meters shall be provided for continuous indication of temperature inside the coach and out side ambient temperature.

2.3.8 The control circuit wiring shall be elastromeric / PTF multistand, tin coated. 2.3.9 Harting type connectors, one for power and another for control circuit shall be provided

for the RMHU. 2.3.10 There shall be WAGO type terminals in the control panel for power and multi pin

SAMEER make waterproof connectors for the control circuit. 2.3.11 The harness connecting the RMHU and the control panel shall be through fire retardant

reinforced flexible conduit 2.3.12 The complete RMHU unit and blower motor shall be required to work under J&K

atmospheric conditions and the unit shall be suitable for rugged service normally experienced for rolling stock where locomotives are expected to run up to a maximum speed of 100 kmph in varying climatic conditions existing throughout India.

3. Part – B: Diesel Alternator set for Heating load requirements 3.1 General 3.1.1 This part of specification covers the requirement of under slung diesel alternator set for

heating load requirement of Trailer coaches of BG HP DEMU of 8 coach consist comprising of A under slung diesel generating set complete with all standard / special accessories; diesel engine, alternator, power and control panel with instrumentation/safety system for DA set.

3.1.2 Since this DA set will be required to operate only during the time ambient conditions are

expected to go lesser than 23 ºC , for the optimum designing of the DA set equipment, following ambient conditions shall be considered:

• Ambient temperature : 25ºC • Altitude : Sea level to 1200 m • Humidity : 40% - 100% • Minimum temperature : -10ºC

3.1.3 Working Conditions:

-Train Speed : 100 kmph max. -Vibration & Shocks : a) Maximum vertical acceleration : 3.0 g b) Maximum lateral acceleration : 2.0 g c) Maximum longitudinal acceleration : 5.0 g d) Frequency and amplitude: Sinusoidal form of vibrations, the frequency ‘f’ lies between 1 Hz and 50 Hz and their amplitude ‘a’, expressed in mm, is given as a function ‘f’ by the equations: a = 25/f for values of ‘f’ between 1 Hz and 10 Hz a = 250/f2 for values of ‘f’ between 10 Hz and 50 Hz

3.1.4 Equipment and auxiliaries mounted above and below under frame shall not cause vibration on the car floor, walls, ceiling panels, handholds or seat frames in excess of 2.0




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mm peak-to-peak amplitude for the frequency range from1.4 Hz to 20 Hz and in excess of 0.8mm per second peak vibration velocity for the frequency range above 20 Hz.

3.1.5 Suitable anti-vibration mountings (AVM) of proven design for under slung mounting of DA

set for rolling stock application as recommended by the supplier shall be provided to absorb the continuous vibrations and shocks encountered during service. AVM shall be suitable for under slung mounted power pack of diesel alternator set mounted under the coach floor. The supplier shall submit detailed drawings for mounting the Diesel alternator assembly for approval of the same by RDSO/ICF.

3.1.6 Positive mounting of power pack should be done to avoid possibility of falling down in

case of breakage of bolts. The mounting arrangement shall be finalized in consultation with ICF before undertaking manufacture.

3.1.7 Noise in stationary conditions, with Diesel alternator set in working condition at full load,

measured on a high level platform, at platform level, at a distance of 1500mm from platform edge should not exceed 85 dB.

3.1.8 The diesel alternator is required to work continuously with load varying from 75% to

100% of the connected load and under service conditions prescribed above, normally with Diversity factor of (D.F) 0.8 and occasionally with Unity DF for short duration. The system shall have 10% overload capability for one hour in every 12 hours of continuous working

3.1.9 The capacity of under slung DA set will be 320 kVA, 415 Volts, 3 phase, 4 wire, 50 Hz,

1500 RPM as per above ambient conditions. 3.1.10 There will be two DA sets, one mounted on Trailer coach no. 3 & the other one on Trailer

coach No.4 (TC3 and TC4). One of the DA sets will be kept as standby. 3.1.11 Fuel tank of 1500 liters capacity will be provided for each DA set. 3.2 Diesel Engine for underslung mounted DA set 3.2.1 One horizontal diesel engine of proven design of indigenous make shall be offered. The

continuous rated output of each diesel engine shall be not less than 340 hp under site conditions.

3.2.2 The tenderer shall furnish the test certificate from UIC or any other statutory body in

respect of his claim regarding the power output. The diesel engine supplied shall be capable of operating reliably under extreme climatic conditions prevailing under site condition.

3.2.3 The diesel engine shall work satisfactorily with fuel oil to Indian Standard Specification

No.1460 Grade A, but shall also be able to function in a trouble free manner even with Grade B fuel oil to the same specification.

3.2.4 Air inlet to the diesel engine shall be from inside the Trailer Car with proper ducting

arrangement from the filters. 3.2.5 Piping from air cleaner to the turbo driven air handling unit or compressor shall be in the

scope of supply.




Page 30 of 38

3.2.6 The exhaust pipe shall be taken through main member/ end wall / side wall of the coach

leading to roof top. The silencer will be mounted adjacent to one of the RMHU. The silencer shall be provided on the dished roof top.

3.2.7 Silencer, expansion pipe, exhaust pipe, cladding of silencer and exhaust pipes with

suitable insulation shall be in the scope of supply. Re-usable type cladding shall be provided by OEM.

3.2.8 Filters for engine intake air shall be part of supply and of adequate air flow

capacity/filtering efficiency, to ensure satisfactory performance under dusty environment. 3.2.9 The tenderer shall supply the complete system including engine starter, cranking battery

charger and suitable alternator for charging 290 Ah starter battery. Also the coach will have a provision of plug-in arrangement for charging from an external source.

3.2.10 The engine manufacturer shall provide necessary safety device to protect the engine

against hot engine, low lube oil pressure, engine over speed and low water levels etc. 3.2.11 Lubrication System: The engine oil sump will be provided with heater of 2kW capacity

for keeping the oil in warm condition. The heaters would be suitable for 230 Volts AC, single phase supply equipped with thermostat to control the temperature within specified limit. OEM of engine will also specify specification of engine oil used.

3.3 COOLING EQUIPMENT 3.3.1 The diesel engine will have cooling system with suitable underslung mounting with

excess capacity of 30% towards choking. The complete technical details of the Radiator and its fan shall be furnished to RDSO / ICF.

3.3.2 The cooling system shall be adequately pressurized and vented to avoid all possibilities

of cavitations. The maximum operating water temperatures shall normally not exceed 95◦ Celsius.

3.3.3 Electric motor driven radiator fan shall be provided. The motors will be suitable for 415

VAC, 4 wire, 3 phase, 50 Hz. The power for these motors will be taken from the DA set as has been used for EOG power car application.

3.3.4 The radiator fan, its drive motor and the complete set of accessories shall be in the

scope of supply. 3.3.5 The tenderer shall supply installation drawings for the radiator and fan with details of fan

drive and mounting arrangement. 3.3.6 The tenderer shall provide the technical information with drawings and circuit. 3.3.7 The engine cooling circuit will be provided with heater of 2kW capacity (on the junction

box) for keeping the water warm. The heater will be suitable for 230 Volts AC, single phase supply equipped with thermostat to control the temperature within specified limit. The tenderer shall indicate any other alternative measures, suitable for operations even at -20 Deg.C without heating.




Page 31 of 38

3.4 ALTERNATOR 3.4.1 The alternator shall have a capacity matching with 320 KVA GENSET and produce 3-

phase, 415 V, 50 Hz +3% output at site conditions as specified above. 3.4.2 Alternator shall be of the self-ventilated, brush less design. Voltage regulation of the

alternator shall be of the dual control type i.e. both electric and electronic. The electric control shall be through compound, transformer or magnetic amplifier and electronic regulation through a solid state automatic voltage control both sensing from all the three phases. The combined regulation shall be within +/- 2.5% or better. “Stand-by” facility to ensure regulation within +5%, even in the event of failure of the automatic electronic voltage regulator (AVR/AVRs) shall be provided.

3.4.3 The alternator shall have stator insulation of class ‘H’, rotor insulation of class ‘H’ and

exciter insulation of class ‘F’. Slot liners and slot wedges used in main stator exciter shall be of class ‘H’ and 4KV (min) breakdown voltage. All sleeves shall be of class ‘H’ insulation. All winding wires used in main stator, exciter and main rotor shall be insulated with class ‘H’ insulation and all the wound components shall be impregnated with class ‘H’ varnish by vacuum pressure, impregnation process. Temperature rise limit for Class-F and Class-H insulation shall be 90 deg. C and 115 deg.C, respectively.

3.4.4 The alternator shall be capable of catering to at least 25% of unbalanced load in any one

or two of the phases with the current, in any of the phases, not exceeding the rated current with the regulation maintained at 5% or less and 2.5% or better in manual and AVR mode of operation respectively.

3.4.5 The rotating diodes used for supplying DC power to the main field winding shall be of

current rating equal to at least 2 times, the loading on them under full rated load of the alternator. They shall be of minimum 1000V, PIV rating. Under the full load operating conditions the case temperature of the diodes shall be at least 20 deg. C below, the limit recommended by the manufacturer. Provision of appropriately rated fuses on the input side of the rectifier bridge is desirable.

3.4.6 The terminal box shall be located at the non-drive end. Suitable cut away with a cover

plate having cable entry holes (suitable for 150sq.mm elastomeric copper cables) for output power cables shall be provided. The internal and external cable terminations shall be on a fibre-glass DMC/SMC terminal board located across each other without crisscrossing and suitable for crimped terminations connected palm to palm. The spacing between terminals shall be minimum 75mm between phase to phase and phase to neutral.

3.4.7 In order to prevent dust ingress, the cooling air will be drawn from the inside of the coach

or through the side walls, through dry type air filters and ducts. Subject to the layout permitting, MS ducts in the under frame shall inter connect the alternator and on board ducting. The over all dimensions of the various ducts and their orientation shall be mutually discussed and finalized. These ducts shall be manufactured and installed by ICF. The provision of filters will be in the scope of supply of supplier.

3.5 Power and Control Panel:




Page 32 of 38

3.5.1 Service conditions will as per the clause 3.1.2 of this Part. 3.5.2 Each panel shall comprise of the following:

• Air circuit breaker • Over current relay • Earth leakage relay (feeders) • Vacuum contractors • Meters – frequency, power, voltage • Power supply ON/OFF, toggle switch • Starter battery charger switch • Push buttons (ON/OF, safety loop, ON/OFF, Feeder ON/OFF) • Indication lamps • Core balance transformer (AEL) • Under voltage relay (UVR) • Terminal connectors for interfaces • Time delay relay for the starter solenoid (FSRD) • Low oil pressure relay (LOP) • Common failure relay (CFR) • Alternator failure relay (AFR) • Overspeed indication relay (OSR) • Earth leakage indication relay (ELR) • Alarm relay (AR) • DC control isolation switch (DCIS) • Indication lamp alternator on (AON ) • Indication lamp DC supply on (1DC ) • Indication lamp high temperature fault (HT) • Indication lamp overspeed (OS) • Indication lamp low pressure (LOP) • Indication lamp earth leakage (AEL) • Indication lamp under voltage relay (UVR) • Indication lamp over voltage (OVR) • Indication lamp fault (FAULT) • HRC fuses of required number with two spares • Push button (engine off, raise, lower, hooter off, test switches) • The hooter (H) • Gauges for oil pressures ,oil temp and water temperature • Terminal connectors

3.5.3 Following drawings for the panel will be provided by the tenderer.

i. Power and control panel with layout scheme ii. Line diagram of circuit

3.5.4 All the devices fitted in the switch board cabinet shall allow access for easy maintenance

of all the equipments from the front of the panel. 3.5.5 Panel shall be powder coated to Siemens Grey shade No.6102/08038 of M/s Nerolac

Paints or 877 of M/s Berger Paints, after giving requisite surface treatment.




Page 33 of 38

3.5.6 The internal wiring shall be done wire of approved sources. The size/type of cables shall be as per the rating guidelines of Railways. Cables/wiring shall be colour coded according to phases. Control wiring and power cables shall be segregated according to the voltage and adequately secured with cable ties.

3.5.7 All components provided inside the panel shall be identified by screen/photo printed

legend plates. These should be mounted near the concerned components duly ensuring visibility. Circuits and components shall also be provided with the nameplates indicating the operation/function of the switches/circuits. Balance indicating/measuring swithgear/devices installed on front door shall be indicated by Aluminium anodized legend plates, located by adhesive of approved brand, on the front doors itself. Riveting shall not be allowed on front door. It shall be ensured that:

• The outgoing/incoming terminal connections shall be brought out to a adequately

rated cage clamp type terminal block/MCB.

• Separators/intermediate plates shall be provided between adjacent terminal blocks, wherever required.

• All cables leading to a terminal block shall be properly secured/clamped before

termination. • It shall be ensured that not more than two wires are terminated at one point. • The bending radius for the cables especially feeder cables shall be five times the

diameter (5D). • The power panel shall be complete with all necessary crimping sockets and ferrules

for ready connections. 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. Crimping sockets of sizes smaller than 16 sqmm shall be with metal reinforcement.

• Marking ferrules shall be of computer generated type for easy identification of the

cables with the help of shrinking sleeves (self extinguishing) of suitable size horizontally printed or with the help of multimark carrier label of M/s TYCO or any other approved make.

• All cut outs wherein cables enter/exit the switch board cabinet shall be provided with

V-grooved rubber grommets from protection against sharp edges. 3.5.8 Earthing boss of stainless steel shall be provided on the panel. Earthing of the metal

parts/sub-assemblies inside the panel shall also be done as indicated with suitable wire size.

3.5.9 For earthing, braided copper cables of sizes as indicated below and 300mm in length

duly crimped (suitable for M12 stud size) shall be supplied alongwith each panel.

2x70 sq. mm for Main panel to each body 1x120 sq. mm for Cu bus bar to main panel frame 2x95 sq. mm for Cu bus bar to coach body




Page 34 of 38

2x95 sq. mm for Cu bus bar to clamp S2x1 3.5.10 Manufacturer’s nameplate indicating name and address, S.No.of the panel, Specification

no., month and year of manufacturer and weight shall be fixed on the front door of the panel.

3.5.11 Danger notice plate shall be fixed on front of the lower panel door conforming to IS:2551-

82 for 415 V. 3.5.12 Eectrical wiring diagram and fuse, MCB and terminal codification charts shall be

screen/photo printed and riveted on inner face of the front door of the panel. 3.5.13 All the equipment fitted in the panel shall be easily accessible for replacement/checking. 3.5.14 All rotary switches shall conform to IS:13947(Pt.III)-93 and shall be suitable for universal

mounting. 3.5.15 All fasteners used shall be zinc plated and passivated according to IS:1573-86 and

conforming to IS:1364-92.Suitable EYE BOLTS shall be provided on the top of panel for handling, loading & unloading of the panel.

3.5.16 All the components including paint shall be fire retardant and Panel manufacturer shall

certify this requirement. 3.5.17 General and safety requirements shall be governed by IS:13947 (PT-1)-93 & IS:8623-

93. 3.5.18 The general construction of the switch board cabinet shall be such as to keep various

voltage level separated against each other as far as possible. 3.5.19 The power and control panel for DA set will be subjected to all he necessary tests as per

the requirement like sequence test, insulation resistance test, 3.5.20 Various indication lamps for indicating the following information for each plant shall be

provided on the front door of the panel:

• Alternator ON (one lamp) • DC control supply ON (one lamp)

Indication lamps for indicating faults are as follow:

• High water temperature • Over speed • Low lube oil pressure • Under voltage • Over voltage relay • Alternator Earth Leakage Relay (AEL) • Fault lamp to represent any of the above faults and it is lit when the hooter is

isolated • Air circuit breaker ON • Transformer ON




Page 35 of 38

• Safety loop ON • Starter battery charger ON • 24V O.K. • Indication lamps for the faults are as follows • Feeder earth leakage • Feeder Overload • Starter battery charger defect

4.0 TESTS 4.1 All the type and routine/acceptance tests on major equipment including alternator,

controls and blower motor shall be done as per relevant IEC/IEEE/DIN international standards. Generally following standards shall be followed :

a) Alternator : IEC 60349 b) Control equipment : IEC – 60571, IEC – 60077 c) Blower motor – IEC – 60101

However, if the tenderer proposes a different test scheme, the same can be examined by RDSO on provision of alternative test procedures submitted by the tenderer. 4.2 The supplier shall submit detailed type and routine test programs to RDSO for its

approval. RDSO/ICF may also decide to carry out some special tests on the equipment, which are not covered by relevant IEC specifications. Tests shall be carried out as per mutually agreed test program and the total cost shall be borne by the manufacturer.

4.3 The prototype unit will be tested by RDSO/ICF representatives at the manufacturer’s

premises where all the facilities should be made available for carrying out the prototype test. After successful type test and fitment on the DEMU, the equipment will be kept for field trials for a period of six months.

4.4 All the modifications required due to defects noticed or design improvements found

necessary as a result of the test / trial shall be carried out by the tenderer in the least possible time. Total cost of such modifications/design changes shall be borne by the manufacturer.

5.0 WARRANTY 5.1 The complete system with controls shall be warranted for satisfactory and trouble free

operation for a period of at least 12 months from the date of commissioning or 18 months from the date of supply whichever is earlier. All aspects of workmanship and design shall be covered by this warranty. The supplier shall immediately provide arrangement for rectification of failures reported under warranty.

5.2 Warranty period of any equipment of the system may be extended as per mutual

agreement between RDSO/ICF and supplier if the equipment has undergone major design modifications during the warranty period.




Page 36 of 38

Part - IV

Coach Lighting 1. This covers the requirements of lighting equipment to be installed in the DEMU. Lights

and fans shall be as per layouts mentioned in Annexure – I of this specification. 2. The auxiliary generator provided on the power car shall meet the power supply for the

coach lights to the DEMU. Battery pack shall be provided on each DPC. Power supply to lights and fans is independent of hotel load power provided for heating load, even when 320 kVA GENSET is not in use, so that lights and fans will work normally.

3. All the coaches of the DEMU shall be provided with an emergency electrical connection

for lighting load only. The battery provided on power car in case of auxiliary generator failure will work the lighting load.

4. WIRING 4.1 The code of practice for wiring as per EL/TL/48 shall be generally followed. Each driving

cab shall be provided with a control panel with controlling switches for lighting and fan circuits. Suitable indication lamps shall be provided to indicate the working of the generator and ON/OFF positions of various feeders. The configuration of coupler wires shall be such as to meet the above requirements. The controls of lights and fans shall be possible from any of the driving cabs.

5. INTER CAB COUPLERS 5.1 Power and trailer coaches shall be connected to each other by means of suitable

electrical power couplers and socket arrangements so that the control of lights and fans in all the coaches of the unit is possible from any driving cab. Each end wall of the coach shall have a socket on one side and coupler plug on other side so as to permit flexibility in operation.

6. DISTRIBUTION FUSE BOARDS 6.1 Distribution fuse boards for the entire coach shall be located uniformly along the length of

the coach. Each board shall be accessible through a separate hinged cover. The cover shall be provided with a suitable locking device that could be opened by the same key as for the junction box. A suitable key shall also be provided for keeping the cover in open position.

7. FANS 7.1 Brush less d.c (BLDC) fixed type of fans of 400 mm sweep conforming to

RDSO/PE/SPEC/TL/0021/2000 (Rev.0) with Annexure – H to IS:6680-1992 issued by RDSO in June/2003, shall be provided. Each fan shall be controlled by its own switch. The fan base shall be insulated from the coach body and the coach wiring shall be terminated to 2-way connectors supplied with the fan and fixed on the ceiling.




Page 37 of 38

8. LIGHTS 8.1 Interior: Fluorescent fittings shall be used for lighting the compartment as shown in

layouts indicated in Annexure-I of this specification. 8.2 Exterior: External light fittings will work on 110 V DC. 15W incandescent lamps to IS: 897

shall be fitted at locations as shown in the coach layouts (Annexure-I of this specification). The coach wiring shall be terminated on 2-way connectors to IRS Drg. No.E101/M/B and the connection to the light fitting shall be given from 2-way connectors using flexible wires.

8.3 All the lights shall be grouped into L-I and L-II circuits, which shall consist of essential

and non-essential lights respectively. 50% of the compartment lights and doorway lights shall be wired as essential lights and all the other lights as non-essential lights.

8.4 One electrical socket on either side of the power car shall be provided to facilitate the use

of portable inspection lamp for the examination of underframe equipment. 9. SWITCHES 9.1 Modular switches for the control of compartment fans shall be located on the body

sidewall pillars between windows in the respective bays. All light points shall be wired without individual switch. A separate switch shall be provided in the driver’s cab for control of headlights.

10. TEST CERTIFICATES 10.1 Electrical test shall be carried out on each coach in accordance with EL/L/48. One copy

of test certificate after counter signature by Inspecting Engineer shall be made available to the Railway to which the coach is allotted.

11. MARKINGS 11.1 At either end panel underneath the emergency coupler socket, following shall be

stenciled.

*Junction box provided inside. *

------x------


Revision No.: 02 Date of issue:xxxx ’2015


Page 1 of 2

ANNEXURE-I

LIST OF DRAWINGS GENERALLY APPLICABLE IN THE CONSTRUCTION OF BG

DMU COACHES FOR J& K AREA

Description Drawing No. 1. Layout DPC – CG-K5028 TC – CG-K5029

TC (with underslung power equipment) – CG-K5030

2. Body details i) Max. Moving Dimensions EDO/T-2202 ii) Roof ventilator WLRRM4-7-3-402 1. Compartment fittings

i) Coat Hook ICF/STD-6-4-010 4. Door Fittings i) Step Rail ICF/SK-4-1-007 ii) Safety coach for body side door CA/DW-2237


Revision No.: 02 Date of issue:xxxx ’2015


Page 2 of 2

ANNEXURE-II

SCHEDULE OF REQUIREMENTS FOR BONDED MINERAL/GLASS WOOL INSULATION FOR INTEGRAL COACHES

The material shall have a nominal thickness of 25mm or as specified by the purchaser and shall generally conform to requirements of Group 1 of IS Specification 8183-1976 (Specification for bonded mineral wool for thermal insulation) and the following additional requirements: - 1. a) Bonded Material wool:

The bulk density of the material shall be 48Kg/cu m or 40 Kg/cu m or as specified by the purchaser and shall not vary by more than ±15% of the value specified when tested as per Clause 3.2.1 of IS:8183-1976. The material with upper limit of bulk density of 48 kg.m3 + 15% (i.e.55kg/m3) shall be considered to lie within Group 1 also.

b) Bonded Glass Wool: The bulk density of the material shall either be 24Kg/cu m or 16Kg/cu m or as specified by the purchaser and shall not vary by more than ± 15% of the specified value when tested as per clause 3.2.1 of IS: 8183-1976.

2. The thermal conductivity of the material (K-value) shall not exceed 0.49mW / cm / degree C (0.04KCal / m / h / degree C) for a mean temperature of 50 degree C.

3. It must be suitable for application on steel sheets or other surface with suitable

adhesive and shall firmly adhere to the surface on which it is applied. 4. The insulation must be guaranteed for the above performance for a minimum

period of one year from the date of putting the coach into service. 5. The material shall satisfy all optional requirements given under Clause 3.10.1 to

3.10.7 of IS Specification No.8183-1976. 6. The material shall be addition pass the jolting test described below:- 6.1 Apparatus for jolting test:

The apparatus consists of a steel frame with a slot to accommodate the test panel of size 41x32cm. Provision is made for raising the framework through a height of 25mm and dropping freely on to two rubber blocks with an approximate frequency of 4 cycles per second. The shape of the cam shall be such that it supports the frame with the panel right through. In the last 2mm stroke, a mild shock is given to the panel by making the panel compress against the rubber blocks.

6.2 Test procedure:

300x300mm square pieces of sample from the supply are to be pasted on the panel plate on which the entire system of painting for the roof has already been painted. For bonding for the insulation material, ‘CPRX’ compound or any other approved adhesive may be used. Sufficient flash time may be given after the application of the adhesive before the insulation material is pasted on. The test panel shall not show any lamination and should withstand one lakh jolts in the jolting machine. The material should also not exhibit friability.

ANNEXURE-III

ANNEXURE-IV

ANNEXURE-V

0 15200 0 1520010 14450 10 1445020 13700 20 13700

21.5 13600 21.5 1360030 9900 30 990040 7750 40 775050 6000 50 600060 5050 60 505080 3700 80 370090 3300 90 3300

100 3000 100 3000120 2600

4.1333334.55

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

11000

12000

13000

14000

15000

16000

0 10 20 30 40 50 60 70 80 90 100

Speed (km/h)

Trac

tive

Effo

rt (K

g.)

RDSO GDP - 1119 (MP)

D K.Bhattacharya

C K.Bhattacharya

Appd. Director/EM

ANNEXURE-VIA

PERFORMANCE CHARACTERISTICS 1400 HP BG DIESEL ELECTRIC MULTIPLE UNIT(DEMU)

One Traction Alternetor type : TA 7003One Traction Motor type : TM 4303 AZ

Gear Ratio : 20 :91, Wheel dia : 915 mm (HW)Starting Tractive Effort : 15200 Kg., Continuous Rating : 46.1 Km/h / 6800 Kg.

Motor Combination : 4P FF

CALCULATIONS FOR HHP-DEMU WITH 4-P TRACTION MOTOR COMBINATION

TRACTION ALTERNATOR TRACTION MOTOR IR + 3 EMF EMF TM Characteristics DEMU CharacteristicsAmps. Volts Amps. Volts. at TM volts at 535 volts Speed(Km/h) TE(Kg.) Speed(Km/h) TE(Kg.)2920 39 730 39 34.32 4.68 500.68 35.2 3660 0.33 146402800 314 700 314 33.03 280.97 501.97 35.5 3470 19.87 138802600 345 650 345 30.89 314.12 504.12 36 3180 22.43 127202400 378 600 378 28.74 349.26 506.26 36.7 2875 25.32 115002200 415 550 415 26.60 388.41 508.41 37.8 2580 28.88 103202000 460 500 460 24.45 435.55 510.55 39.1 2250 33.36 90001860 495 465 495 22.95 472.05 512.05 40.5 2020 37.34 80801700 542 425 542 21.23 520.77 513.77 42.3 1760 42.88 70401660 556 415 556 20.80 535.20 514.20 42.6 1710 44.34 68401600 576 400 576 20.16 555.84 514.84 43.6 1600 47.07 64001400 657 350 657 18.02 638.99 516.99 47 1280 58.09 51201200 764 300 764 15.87 748.13 519.13 52 980 74.94 39201100 828 275 828 14.80 813.20 520.20 56.4 830 88.17 33201012 900 253 900 13.85 886.15 521.15 60 700 102.02 28001000 907 250 907 13.73 893.28 521.28 60.9 680 104.36 2720980 923 245 923 13.51 909.49 521.49 62.3 660 108.65 2640

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

11000

12000

13000

14000

15000

0 10 20 30 40 50 60 70 80 90 100Speed (Km/h)

Trac

tive

Effo

rt (K

g)

RDSO GDP - 1146 (MP)

D K.Bhattacharya

C K.Bhattacharya

Appd. Director/EM

PERFORMANCE CHARACTERISTICS 1400 HP BG DIESEL ELECTRIC MULTIPLE UNIT(DEMU)

1 - Traction Alternator C1012TA(CGL), 4 - Traction Motor C1005TM(CGL)

Wheel Dia. : 915 mm(HW), Gear Ratio : 20:91Motor combination : 4P FF, Starting TE : 14600 Kg.

Cont. Rating : 44.34 Km/h at 6840 Kg., Max. Speed : 100 Km/h

ANNEXURE-VIB

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