report no. tm-227 - indian railways...page 1 of 40 government of india ministry of railways...
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Page 1 of 40
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
Comprehensive Guidelines on
Procurement, Operation, Maintenance
and Repair of Small Track Machines
REPORT NO. TM-227
TRACK MACHINES & MONITORING DIRECTORATE
RESEARCH DESIGNS & STANDARDS ORGANISTAION
LUCKNOW-226011
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Foreword
1.0 Indian Railways has decided to switch over to complete mechanization by 2024.
Small Track Machines have an increasingly important role to play in this regard.
Various instructions have been issued in connection with Small Track Machines
(STMs) in past. Instructions also exist in terms of IRSTM Manual. RDSO has
recently conducted four workshops at Secunderabad, Pune, Kolkata & Lucknow
in which operators, supervisors and AENs & DENs dealing with STMs
participated. Vendors of STMs also participated in above workshop held at
RDSO, Lucknow. Various aspects of STMs including their procurement,
operation, maintenance and experience in field were discussed during above
workshops.
2.0 It has been noted that various Zonal Railways are following different practices
with regard to operation, maintenance and repair of Small Track Machines. It has
also been noted that field officials (supervisors and operators) are presently facing
problems in maintenance and repairs of these STMs, in general.
3.0 Vendors of STMs also expressed their concern with regard to procurement of
STMs in piecemeal due to which they are not willing to participate in tenders for
supply of these STMs along with provision for their Annual Maintenance
Contract (AMC). Vendors have expressed their willingness to provide effective
AMC services, if procurement of these STMs is done for reasonably sufficient
quantities and AMC services are to be provided at one nominated location in a
division instead of at individual SSE/PWay’s headquarter level.
4.0 RDSO has been entrusted by Railway Board to prepare draft comprehensive
guidelines for Procurement, Operation, Maintenance and Repair of Small Track
Machines. In order to gather the experience and understand the problems
associated with regard to above subject, workshops at four places viz;
Secunderabad, Pune, Kolkata & Lucknow were organized.
5.0 Representative Field officials (DEN/AENs, SSEs/P.Way and operators/
maintainers of STM) from all Zonal Railways participated in these workshops
where the existing organizational setup, practices regarding maintenance,
problems experienced in operations of STMs and suggestions were discussed. In
the concluding workshop at Lucknow, vendors of important and frequently used
Small Track Machines were also invited with a view to discuss the mechanism for
Annual Maintenance Contract of STMs.
6.0 Based on the feedback received from various Zonal Railways and vendors, Draft
Comprehensive Guidelines on Small Track Machines for their procurement,
operation, maintenance and repair has been prepared.
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7.0 These guidelines covering all above issues with regard to procurement, operation,
maintenance and repair of STMs are being issued to have uniformity over all Zonal
Railways. Field officials will also have access to all important instructions and
provisions in connection with various aspects of STMs in one place.
8.0 These guidelines are not exhaustive. Any additional guideline required for special
conditions of field may be issued with the approval of competent authority as per
IRSTMM/ other extant instructions issued from time to time.
9.0 Necessary modifications in IRSTMM, wherever required, will be issued separately.
S.C. Srivastava Jitendra Kumar
Executive Director/TM Director/TM -1
Page 4 of 40
Index
SN Para No.
Description Page no.
1. -- Foreword 2
2. -- Index 4
3. 1.0 General background 5
4. 2.0 List of Small Track Machines for SSE/P.Way and Scale after review 5
5. 3.0 Approved list of Small Track Machines 6
6. 4.0 Maximum Utilized Machines by field unit 7
7. 5.0 RDSO Policy for Small Track Machines for vendor development 7
8. 6.0 Induction/Trial of new type of Small Track Machines 7
9. 7.0 Codal Life 8
10. 8.0 Procurement Policy 8
11. 9.0 Precautions during operation of STMs 10
12. 10.0 Repair and Maintenance of STMs 11
13. 11.0 Training 12
14. 12.0 Other important issues 13
15. -- Annexure-I: Minimum Requiremet of Small Track machines 17
16. -- Annexure-II:List of STMs as on 1.4.2019 18
17. -- Annexure-III:Revised List of STMs 20
18. -- Annexure-IV:Codal life of Frequently Used STMs 22
19. -- Annexure-V:Procurement of STMs with AMC 23
20. -- Annexure-VI:RDSO Letter no TM/SM/Track/Vol 50 dated 13/24.9.18 25
21. -- Annexure-VII:Rly Bd letter no. 2001/RS(G)/779/7Pt I dated29.06.17 26
22. -- Annexure-VIII: Rly Bd letter no. 2001/RS(G)/779/7Pt 2 dated25.06.18 28
23. -- Annexure-IX: Rly Bd letter no. 2001/RS(G)/779/7Pt 2 dated06.11.18 33
24. -- Annexure-X:Model SOP for sanction of Cash Imprest 34
25. -- Annexure-XI: Rly Bd letter no 2019/Trans Cell/Civil/Contractual
Staffing dated 29.04.2019
35
26. -- Annexure-XII: Model SOP for sanction of Hiring of Vehicle 37
27. -- Annexure-XIII: Model SOP for sanction of repair to STMs 38
28. -- Annexure-XIV: RDSO Letter no TM/SM/DO dated 26.12.18 39
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Comprehensive Guidelines on Procurement, Operation
and Maintenance of Small Track Machines
1.0 General background:
1.1 These guidelines covering all the issues with regard to procurement,
operation, maintenance and repair of STMs are being issued to have
uniformity over all Zonal Railways. Field officials will also have access to
all important instructions and provisions in connection with various
aspects of STMs in one place.
2.0 List of Small Track Machines for SSE/P.Way and Scale after review:
2.1 Yard Stick:
Existing Yard stick for Small Track Machines has been circulated vide
Correction slip No.5 (issued in Jan’2015) to IR Small Track Machine
Manual-2005. This has been discussed in the workshop on STMs. Based on
feedback received during the workshop, it has been noted that above list is
mostly adequate with following modifications:
(i) Portable DC Welding Generators are now not required in view of
phasing out of built up crossing and, therefore, it is being deleted from
the list of scale of STMs to be maintained with SSEs.However, This
item may be procured on need basis with approval of CTE.
(ii) One Abrasive Rail Cutter should be available with SSE/In-charge also
for use in exigencies.
(iii) Number of Rail Drilling Machines to be kept as 02 per JE/SSE sectional
instead of 01.
(iv) Track jack (Hydraulic/Mechanical) to be kept as 03 per JE/SSE
sectional instead of 02.
(v) Weld Trimmer and Rail Profile Weld Grinder to be increased to 02 per
Welding Unit instead of 01.
(vi) Adequate number of spare machines (at least 20% of the total divisional
requirement) may be kept at Divisional Depot to be used in
emergencies/unit exchange for repair of STMs.
2.2 Accordingly, revised yardstick for Small Track Machines is attached as
Annexure-I
2.3 Annual Divisional review of STMs:
It has come out during the workshops that STMs as per above yardsticks are
generally not available with field officials (SSE/JE/P.Way). It is desirable
that an yearly review of STMs – requirement as per yardstick and its
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availability for each SSE/P.Way should be carried out at the divisional level
in the month of April/May. Indents for shortfall/replacement of STMs, if any,
should be prepared at Divisional level and their procurement may be done in
a centralized manner, either at Divisional or Zonal level. The expenditure on
above may be charged to Revenue or Contingency of Track Renewal Works,
if specific provision for the same does not exist in the sanctioned estimates of
Track Renewal Works.
2.4 Requirement of STMs as per above yardstick for new construction projects
being commissioned in that year should be got made available by concerned
construction unit or may be procured by open line chargeable to concerned
construction project.
3.0 Approved list of Small Track Machines:
3.1 Current vendor list of Small Track Machines is available on RDSO website.
Link is https://rdso.indianrailways.gov.in Vendor Interface Status of
Vendor Registration/Renewal/Upgradation Track Machines & Monitoring
Approved list of vendors of Small Track Machine.
3.2 At present, approved vendor list is being maintained by RDSO for 30 items
for multi-sourcing and 09 items for material under trial as placed at
Annexure-II. It is proposed that following items may be deleted from above
list as some of these items are getting obsolete and/or are not in much use in
field:
(i) Rail Cutting Machine (Saw Type).
(ii) Train Speed Recorder (Wired).
(iii) PC based OMS.
(iv) Abrasive Rail Cutter. Rail Drilling Machine, Chamfering Machine
and Rail Profile Weld Grinding Machine operated by Hydraulic
Common Power Pack.
(v) Similarly, Abrasive Rail Cutter, Rail Drilling Machine, Concrete
Sleeper Breaker and Concrete Sleeper Core Drilling Machine
operated by Hydraulic Common Power Pack may also be deleted
from the list of New Items Under Trial.
(vi) Self Propelled Hydraulic Common Power Pack Cum Transporting
Cart from the list of New Items Under Trial.
3.3 Off Track Tampers (Engine Mounted Version and Power Pack Version)
will be preferably procured and used in those sections where Mobile
Maintenance Units (MMU) system is introduced as per para no. 228 of
IRPWM. However, these may be procured for other sections also with
approval of CTE
The revised list after deleting above items is placed in Annexure-III
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4.0 Maximum Utilized Machines by field unit:
4.1 Based on the feedback received from various Zonal Railways and vendors, it
was noticed that the following five Small Track Machines are most important
for day-to-day activities of cutting, drilling and welding carried out during
Track Maintenance:
i) Abrasive Rail Cutter
ii) Rail Drilling Machine
iii) Weld Trimmer for A.T.Welding
iv) Rail Profile Weld Grinder
v) Compressed Air Petrol pre-heating system equipped with pressure
gauge
vi) Toe Load Measuring Device
4.2 If the maintenance and repair of above listed STMs is taken care of,
majority of the problems felt by field officials will be addressed.
Suggested measures, in this regard, has been deliberated subsequently.
5.0 RDSO Policy for Small Track Machines specifically vendor
development:
5.1 Approval of Specifications and development of vendor for Small Track
Machines and P.Way Measuring Tools has been delegated to RDSO vide
Railway Board letter No.2010/Track-III/TK/11/Pt.I dt.26.6.2018.
5.2 In compliance of Railway Board’s instructions, draft guidelines conforming
to ISO procedure, which is followed by all Directorates of RDSO, has been
framed along with necessary deviations required specifically to Track
Machine Directorate. These detailed guidelines covering all aspects of
vendor development, quality audit and delisting/upgradation etc. may be
accessed on RDSO Website on the following address:-
https://rdso.indianrailways.gov.in Vendor Interface Status of Vendor
Registration/Renewal/Upgradation Track Machines & Monitoring
Guidelines/Instruction for Vendor of Small Track Machines (To be
uploaded after approval of DG)
6.0 Induction/Trial of new type of Small Track Machines:
6.1 The vendor seeking approval for a new type of machine/tool, which does
not figure in the current list of approved type of machine/tools, needs to
apply in the same manner as applicable for developmental category/multi
sourcing. All the procedure and steps right from submission of application
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to approval by competent authority will also be same as applicable for
developmental category/multi-sourcing except with the following
difference:
“For new items, initially only broad functional specifications would be
issued by RDSO for the development of the product on trial basis and after
satisfactory performance of the equipment thus procured, regular technical
specifications would be drawn and uploaded on RDSO website”.
6.2 After due deliberation, RDSO will recommend the initial approval for trial
only, proposing some of the Zonal Railways to procure and use the new
item alongwith suggested trial quantity and the period of trial before
regular adoption. Items to be inspected by inspecting officials should also
be included in the Functional specifications being issued by RDSO. The
performance report of the new type of machine/tool will be submitted by
the Zonal Railways after prescribed time and use. Performance report shall
be submitted by Sr. DEN of the division to RDSO through Zonal Railway
{CTE/CE(TMC)}. The performance report will be put up to the
Directorate head, who will decide for its regular use or otherwise.
6.3 Sr. DEN/Co. of the division can also induct a new machine for trial which
is not included in the approved list of STMs of RDSO for adoption with
approval of CTE. Thereafter, the performance report of the machine shall
be submitted to RDSO, if found suitable, through CTE or CE/TMC of
Zonal Railway.
7.0 Codal Life:
7.1 Codal Life of Machines: Presently, there are no instructions existing in
regard to Codal Life of Small Track Machines. This is causing problem in
condemnation of old/unserviceable machines and placing fresh demand on
replacement account. It was experienced that Codal Life of above five
STMs need to be fixed on an urgent basis in a range of 4 to 6 years. A
letter no. TM/SM/Track/51 dated 26.02.19 was sent by RDSO to all Zonal
Railways for recommending Codal Life of different STMs based on field
experiences. Based on the replies submitted by Zonal Railways, Codal
Life of maximum utilized machines as mentioned in Para 4 has been
fixed by RDSO and is attached as Annexure-IV.
8.0 Procurement Policy:
8.1 Centralized Procurement: Procurement of STMs should be done for bulk
quantity at Divisional/Zonal level as discussed in Para 2.3 & 2.4 above. A
Centralized depot in each division should be earmarked for supply of
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Small Track Machines. This will encourage the existing approved vendors
to participate in tenders having provisions of AMCs as discussed in Para
1.3 above. The defective/in-operational machines will be brought to
nominated divisional depot where representative of vendors will attend
these machines. This will also obviate the unwillingness of suppliers of
STMs to attend for repairs in remote locations of SSEs/P.Way.
8.2 Consignee: SSE/P.Way/STM or SSE/P.Way Incharge of nominated
Divisional Depots should be nominated in each division to receive the
supply of STMs for the entire division. These machines should be
accepted only after due inspections as stipulated in the specification of
machines. It was noted that the consignees need to be technically upgraded
regarding the existing Acceptance Criteria laid down in the specification.
It is proposed that SSE/STMs responsible to carry out these inspections
before acceptance of these machines should be trained by TMM
Directorate of RDSO for 3 days to technically equip them for carrying out
prescribed Acceptance Tests. Railway may nominate their SSEs/STM to
RDSO in consultation with Executive Director/Director/TMM for period
of 3 days. RDSO will conduct special training programme every year.
8.3 Reserve for Unit Replacement: It was noticed that none of the Zonal
Railways have procured STMs as per the yardsticks laid down in Indian
Railway Small Track Machine Manual (IRSTMM-2005) correction slip
No.5. Due to non-availability of adequate number of STMs, machines are
required to be unnecessarily transported from one SSE/P.Way to another,
which results in mishandling and multi-handling causing wear and tear of
machines. Moreover, when these machines undergo any repair or are
brought to existing divisional depots, the work of Track Maintenance
suffers till their repair. It is suggested that whenever a machine is brought
to divisional depot for repair, it should be replenished by additional
machine already available in depot. It is suggested that procurement of all
the machines in future should be done alongwith 20% extra to be kept as a
reserve with divisional depot.
8.4 Procurement with Annual Maintenance Contract (AMC):
The existing guideline in IRSTMM (Correction Slip No.1) issued vide
Railway Board’s letter no. 2004/Track-III/TK/13 Vol. II dated 12.04.2012
is reproduced as below:
All Small Track Machines & tools shall be purchased under one year
manufacturer’s warranty. It is desirable to have AMC for 5 years along
with procurement.
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Accordingly, procurement of STMs should be done as per above and L-1
should be decided based on combined cost of initial procurement and
AMC cost.
During the workshop at Lucknow, the issue of AMC was discussed in
detail with vendors of STMs and it was agreed by them to participate in
tenders for supply of STMs with provision of AMCs, if procurement is
done in bulk quantity and AMC services are to be provided at one
nominated place in divisions.
A model for procurement of STMs along with AMCs as detailed in
Annexure-VII, have been discussed with vendors of STMs and they have
expressed their consent on same. This has been discussed in CE/TMCs
Seminar at IRICEN on 4th
& 5th
April’2019 and in CTEs Conference at
Railway Board on 10th
& 11th
April’2019 also.
It is desirable that further procurement of STMs should be done based on
above model, as detailed in Annexure-V.
8.5 Information related to supplier: The field officials face the problems of
non-availability of vendors’ contact details for repair of STMs even
during warranty period. To overcome this problem, the Purchase Order
must include warranty period and vendor’s contact number in bold
letters. Such details should also be maintained at Divisional Depot and a
copy of P.O. alongwith Operation and Maintenance Manual should be
given to field SSE/P.Way also while supplying the machine.
8.6 The Small Track Machines should be procured from RDSO approved
vendors or their authorized dealers as per letter No.TM/SM/Track/Vol.50
Dt.13/24.09.2018 (Annexure-VI). Furthermore, all the instructions issued
vide Board’s letters No. 2001/RS(G)/779/7/Pt.1 dated 29.6.2017,
2001/RS(G)/ 779/7/Pt.2 dated 25.06.2018 & 2001/RS(G)/779/7/Pt.2
dated 06.11.2018 (Annexure-VII, VIII & IX respectively) should also
be complied with.
9.0 Precautions during operation of STMs:
Organization for operation of Small Track Machines: It has been noted
that normally trained and dedicated operators for different types of STMs
are not available in field and most of these STMs are being operated by
Trackmen. These trackmen are also generally not nominated and keep
changing due to which there is lack of feeling of ownership. Furthermore,
these trackmen normally do not have adequate knowledge and expertise
for safe and satisfactory operations of these machines. Because of this,
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STMs remain idle/unutilized due to even small issues which can be easily
handled by operators themselves having adequate knowledge of trouble
shooting. Furthermore various provisions regarding schedule maintenance
of STMs as prescribed in IRSTMM are generally not being followed in
field.
It is desirable that Small Track Machines are normally handled/operated
by trained and dedicated operators to be nominated from Trackmaintainer
category. These Trackmen may be given training by vendors at the time of
supply of STMs. Furthermore training regarding various items to be
checked in daily/weekly/monthly maintenance schedules should also be
imparted to these operators. This has been discussed in detail in para 11
ahead.
10.0 Repair and Maintenance of STMs:
10.1 Repair of Old Machines: The existing provision in IRSTMM (correction
slip No.1) for setting up Divisional Depot for repair of STMs is
reproduced below:
For major repairs, machines to be sent to “Divisional Maintenance
Centre” for track machine which will have necessary supervisory, skilled
and unskilled staff. For day to day and minor repair, Sub-Divisional
Maintenance Depot may be set up at Sub-Divisional Head Quarter.
However, it was noted that only a few Zonal Railways (CR, SER, SECR,
NR & WCR) have developed Divisional Depots as stipulated above. Even
if the new mechanism for procurement of new STMs with AMCs is
implemented, it is to be noted that Centralized Divisional Depots are
required to be established for repair of STMs.
The following measures may be adopted in field -
i) Centralized Divisional Depots for STMs: The existing guideline for
setting up Centralised Divisional Depots must be implemented
uniformly across each Division of Indian Railway without any further
delay.
ii) Posting of Incharge SSE/JE(STM): One SSE/P.Way/STM or JE
P.Way/STM should be immediately posted in each Division to look
after exclusively all the affairs of STMs viz; record keeping for
procurement, all matters pertaining to departmental repairs and AMCs
and inspections of STMs at the time of procurement.
iii) Infrastructure: Necessary infrastructure may be provided in the
beginning in the form of a big hall for repair and an office for
SSE/P.Way/STM at a suitable place like Track Depot etc.
iv) Imprest: An imprest of atleast Rs.1,00,000/- should be available with
SSE/P.Way/STM for purchasing spare parts and other expenses. Full
powers for sanctioning of cash imprest to supervisors is vested with
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DRM/ADRM. Copy of Para no. 1(A) of Part (C) of model SOP is
enclosed as Annexure-X.
v) Staff: Normally two technicians or ITI holders Track maintainers and
four Track Maintainers/Technician/Khallasi/Artisan Khallasi should be
posted with SSE/P.Way/STM for repair of old machines. The work of
02 Track Maintainers to be deputed may also be outsourced as
envisaged in Railway Board’s letter no. 2019/Trans
Cell/Civil/Contractual Staffing dated 29.04.2019 enclosed as Annexure
XI.
vi) Mobility: A Multi Utility Vehicle with each SSE/P.Way/STM should
be provided for transportation of machines. This vehicle will cover one
section (approximately 200 kms) in one go during which it will not
only collect the defective machines but will also return the repaired
machines covering each SSE/P.Way in that section. This vehicle will
also be utilized for transportation of machines to nearby local market
for repair and for procurement of spares.
Full powers for sanctioning of Hiring of vehicles for select senior
supervisors is vested with DRM. Copy of Para no. 47(C) (ii) of Part C
of model SOP on Hiring of vehicles is enclosed as Annexure-XII.
vii) SOP: The existing powers in Model SOP (Para no.31 (D) of Part-A)
issued by Railway Board is considered sufficient as it empowers the
JAG and Senior Scale officer of Division for an expenditure of
Rs.50000/- and Rs.25000/- respectively without financial concurrence
for repair of a machine in each case with an annual ceiling limit of
Rs.10 lakhs and Rs.5 lakhs respectively. Copy of model SOP is
enclosed as Annexure-XIII.
10.2 Repair of new machines through AMC: New machines should be
procured along with AMCs only as discussed in para 8.4 above. The OEM
will repair/attend these machines in centralized depot of divisions.
Railway may extend available minor facilities like space, electricity and
water etc. to facilitate these maintenance and repair without any extra cost.
11.0 Training:
11.1 Exclusive training module in zonal/divisional training School:
There is no separate module of training for STM Operators in any Zonal
Railway. Track Maintainers are imparted only the initial training in
Divisional Training Centre. It is suggested that there should be an
exclusive module of training in Divisional Training Schools to be given to
STM Operators encompassing the working of STMs, Do’s & Don’ts,
Periodic Maintenance Schedules and demonstration of its working in field.
It is recommended that this training should be given at an interval of 3
years.
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The training for STM Operators should include various safety precautions
while working on track, working instructions including Do’s & Don’ts and
various maintenance schedules along with common trouble shootings for
frequently used machines, such as, Abrasive Rail Cutter,
Rail Drilling Machine, Weld Trimmer for A.T.Welding, Rail Profile Weld
Grinder, Toe Load Measuring Device and general exposure to other
STMs.
11.2 Training by OEM at Division /STM depot or at manufacturer’s
premises:
Even during the procurement of STMs through vendors, merely a
demonstration of its working is given to a few Operators residing near the
consignee’s place. This aspect was discussed in detail with the vendors
during workshop at Lucknow. Vendors have agreed to impart another round
of refresher training also for training of Operators after three months of
supply if it is incorporated in Tender Conditions.
It is recommended that tenders for STMs should be invited with the
condition that vendor/supplier will impart at least 2/3 days initial training on
working of concerned STM alongwith its trouble shooting measures to the
nominated operators by railways at the time of supply at nominated depot.
The initial training should be followed by a refresher training of 1 / 2 days
after three months of initial training at centralized depot of division or
divisional training centre. Vendors shall also provide brochures containing
directions, Dos & Don’ts about the machine and its working in Hindi and
local language at the time of supply and during training.
12.0 Other important issues:
12.1 Cadre for Small Track Machines from Track Maintainer:
STMs are being operated in field by P.Way staff in Track Maintainer
category. Only very few Railways viz; SECR & SER have created a
separate cadre of STM staff for their maintenance at Centralized Divisional
Depot. Non availability of a separate cadre for Operation of STMs results
not only in lack of ownership of machines but also in non fixing of
responsibility in case of failures of Track Machines. It is suggested that
STM Operators should be nominated within the existing BOS of Track
Maintainer category to operate individual STMs. For this purpose, options
should be collected from Track Maintainers to be posted for operation of
STMs. This will facilitate the daily/weekly maintenance schedule of
machines and will also avoid the multi-handling of machines which are
major causes of failure of machines. Moreover, the artisan staff (Blacksmith
& Welder) who play an important role in working of STMs may be allowed
to be selected from Track Maintainer category also. Presently, the AVC for
selection of Blacksmith and Welder does not include the Track Maintainers
in various railways.
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12.2 Proposed organizational setup: Proposed Organization Chart for
Centralized Divisional Depot for STM is given below:
Sr.DEN/Coord.
DEN/Track
AEN/Open Line
(under whose jurisdiction Centralized Depot lies).
SSE/STM
Two technicians or ITI holders Track maintainers and four Track
Maintainers/Technician/Khallasi/Artisan Khallasi along with a
nominated vehicle
It is desirable that operation of STMs in fields (at SSE/JE level) should be
done by dedicated/nominated Track Maintainers with ITI background or
technical aptitude.
12.3 Proposed promotional avenue: The Technicians/STM for Divisional Depot
should be part of cadre of Technicians of Divisions to provide better
promotional avenues to attract suitable staff to this organization. For Track
Maintainers posted in STM depot, the seniority will be maintained in their
regular category of Track Maintainers. The promotional prospects of STM
operators in field at SSE/JE level should be part of regular Track Maintainer
category.
12.4 STMs for Yards: It is noted that most of the work in Yards is normally done
in turnout areas. Electricity supply is normally available in Station Yards
and, therefore, it is desirable that electric driven STMs, such as, Abrasive
Rail Cutters, Rail Drilling Machines etc. are extensively used in Yards as
they are easy to handle being lighter in weight and requires lesser
maintenance in general. Provision of power points near turnouts or at other
suitable location in Yard may be planned for the same. RDSO is developing
specifications and vendors for these machines. At present specifications for
these machines are loaded on RDSO Websites for comments of the industry.
12.5 Multi-utility vehicle to SSE for Small Track Machines:
Operation of STMs necessitate frequent transportation from one place to
another, often remote in nature, alongwith the staff for their operation. Quite
often machines are transported by train which requires loading and unloading
from rail level platform. Due to their mishandling during transportation,
machines become defective. It is suggested that each sectional SSE/P.Way
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should be provided with a Multi-utility Vehicle which will be used for
transportation of men and machinery apart from other uses. This system will
be in line with the maintenance practice adopted in KRCL. . Full powers for
sanctioning of Hiring of vehicles for select senior supervisors is vested with
DRM. Copy of Para no. 47(C) (ii) of Part C of model SOP on Hiring of
vehicles is enclosed as Annexure-XII.
12.6 Inspection of STMs by Officers & Supervisors:
As per para 1.5 of IRSTMM (Correction slip No.2) AENs have to carry out
inspection of STMs once in 6 months while SSE/P.way shall inspect once in
3 months. It has come out during workshops that these inspections are not
being carried out as per schedule in general. Emphasis should be laid on
carrying out these inspections as per schedule and details of these
inspections should be maintained on TMS.
12.7 Inspection of STMs at the time of supply:
Inspection of all STMs should be arranged by consignee itself as per
correction slip no.3 of IRSTMM-2005. However, RDSO can organize
training for inspecting official in this regard on request of CTE(RDSO’s
letter no.TM/SM/Track/51 dated 12.11.2018- Annexure-IX).
At the time of such inspections consignee should make proper record of
testing of machine/consumable before passing it for billing purpose. Small
Track Machine shall conform to the acceptance test satisfactorily as laid
down in the specification of machine. Specifications of machine are
available in the following address.
https://rdso.indianrailways.gov.in About Us List of Specification
Track Machines & Monitoring Specification.
12.8 Feedback of performance of STMs :
Performance report of Machines/vendors under developmental category and
any feedback of performance of existing vendors of machine should be sent
regularly to RDSO to improve specification of machines and to monitor
performance of manufacturer. Unsatisfactory performance/complaint should
be informed to RDSO within warranty/AMC period of items. Such reports
should be sent to RDSO ( at email id [email protected]) with the
approval of CTE/CE/TMCs.
Zonal Railways are also requested to use the web portal for reporting any
type of feedback. The following path may kindly be followed:
The website will open only on Rail-net as http://10.100.5.33.86 login
select Small Track Machines in dropdown next.
Or
Page 16 of 40
http://10.100.2.19 Failure Reporting and Vendor Performance Monitoring login select Small Track Machines in dropdownnext.
It is pointed out that User ID & password for above portal has already been
circulated vide letter no.TM/SM/Vendor Performance/Web portal dated
25.03.2015 & TM/SM/DO dated 26.12.2018. Same is again enclosed as
Annexure-XIV.
****************
Page 17 of 40
Annexure-I
Minimum Requirement of Small Track Machines
S. No. Name of Machine Existing Quantity Proposed
1. Abrasive Rail Cutter 2 per JE/SSE (Sectional)
2 per ART
2 per JE/SSE (Sectional)
+ 1 per SSE(in-charge)
and 2 per ART
2. Rail Cutting Wheel Abrasive Disc As Required Same
3. Rail Drilling Machine 1 per JE/SSE (Sectional)
1 per ART
2 per JE/SSE (Sectional)
1 per ART
4. Heavy Duty Hydraulic Extractor for Jammed
ERCs(10t)
1 per SSE(In-charge) Same
5. Hydraulic Rail Bender (Jim Crow) Heavy Duty 1 per JE/SSE (In-charge)
Same
6. Weld Trimmer Power Pack Version for A.T.
Welding
1 per Welding-Unit 2 per Welding-Unit
7. Rail Profile Weld Grinder 1 per Welding-Unit 2 per Welding-Unit
8. Electronic/ Mechanical Toe Load Measuring
Device
1 per JE/SSE (Sectional) Same
9. Track Jack (Hydraulic /Mechanical) 2 per JE/SSE(Sectional) 3 per JE/SSE(Sectional)
10. Light Weight Rail (Mono) cum Road Trolley 2 Per Gang Same
11. Self Propelled Light Weight Trolley 1 per ADEN Same
12. Hydraulic Rail Tensor (Non-infringing type) 70t
capacity
2 per SSE(In-charge) Same
13. Powered Material Trolley 1 per SSE(In-charge) Same
14. Hacksaw Blade for Cutting Rails As Required Same
15. Box type Gauge cum Level (BG & MG) along
with Spirit Level
1 Per Gang Same
16. Chamfering Kit- Manual/ Battery operated 1 Per Gang Same
17. Magnetic Base type Rail Thermometer 1 Per Gang Same
18. Continuous Rail Thermometer 2 per SSE (In-charge) Same
19. Gang / Worksite Remote Control Hooter 2 Per Gang Same
20. Portable track lifting & slewing
device(TRALIS)
2 sets per
JE/SSE(Sectional)
Same
NOTE-
1. This is the minimum yardstick of the availability of various Small Track
Machines. In this list only minimum requirement is specified and all machines are
not part of this list.
2. The additional requirement of small track machines where ever required shall be
worked out based on requirement of individual Division/Zonal Railway as per the
list of small track machines regularly approved by Railway board and as per local
conditions.
3. Portable DC Welding Generator may be procured on need basis with approval of
CTE.
4. Adequate number of spare machines (atleast 20% of the divisional requirement)
may be kept at Divisional Depot to be used in emergencies/unit exchange for
repair of STMs.
**************
Page 18 of 40
Annexure-II
Small Track Machines as on 01.04.2019
A. Regular Item
SN Name of Machine Remarks
1. Abrasive Rail Cutter ----
2. Rail Cutting Wheel Abrasive Disc ----
3. Rail Drilling Machine ----
4. Heavy Duty Hydraulic Extractor for Jammed ERCs (10 ton) ----
5. Rail Cutting Machine (saw type) Deleted
6. Hydraulic Rail Bender (Jim Crow) Heavy Duty ----
7(a) Weld Trimmer Power Pack Version for A.T. Welding ----
7(b) Hand Operated Weld Trimmer ----
8. Rail Profile Weld Grinder ----
9(a) Toe Load Measuring Device (Mechanical) ----
9(b) Electronic Toe Load Measuring Device ----
10(a) Hydraulic Track Jack 15t capacity (non-infringing type) ----
10(b) Mechanical Track Jack 8t capacity (non- infringing type)
(Rack & Pinion type)
----
10(c) Mechanical Track Jack 8t capacity (non- infringing type)
(Rack & Pawl type)
----
11. Hydraulic Sleeper Spacer ----
12. Portable DC Welding Generator To be procured on need
basis with approval of CTE.
13. Light Weight Rail (Mono) cum Road Trolley ----
14. Self Propelled Light Weight Trolley ----
15. Powered Material Trolley ----
16. Hydraulic Rail Tensor (Non-infringing type) 70t capacity ----
17. Hacksaw Blade for Cutting Rails ----
18. Box type Gauge cum Level (BG & MG) along with Spirit
Level
----
19(a) Chamfering Kit (Manual) ----
19(b) Chamfering Machine (Battery operated) ----
20(a) Magnetic Base type Rail Thermometer ----
20(b) Continuous Rail Thermometer ----
21(a) Train Speed Recorder (Wired) Deleted
21(b) Cordless Train Speed Logger ----
22. Gang / Worksite Remote Control Hooter ----
23. Hydraulic Track Lifting cum Slewing Device (TRALIS) 15
ton Capacity
----
Page 19 of 40
B. Under Trial Order Item
****************
24(a) Off Track Tampers (Power Pack version) To be preferably procured
and used in those sections
where MMU is
implemented as per para
no. 228 of
IRPWM.However, these
may be procured for other
sections also with approval
of CTE
24(b) Off Track Tampers (Engine Mounted version)
25. Abrasive Rail Cutter, Rail Drilling Machine, Chamfering
Machine & Rail Profile Weld Grinding Machine operated
by Hyd. Common Power Pack
Deleted
26. GPS (Geo Positioning System) based Foot Plate Inspection
Device
----
27. Route Data Preparation System (RDPS) ----
28. P.C. Based Oscillation Monitoring System(PC-OMS) Deleted
29. GPS Based Oscillation Monitoring System(GPS-OMS) ----
30. Track based lubricators (Electronic and Hydraulic type) ----
SN Name of Machine Remarks
1 Abrasive Rail Cutter, Rail Drilling Machine, Concrete Sleeper Breaker
And Concrete Sleeper Core Drilling Machine Operated By Hydraulic
Common Power Pack
Deleted
2 Self Propelled Hydraulic Common Power Pack Cum Transporting Cart Deleted
3 Impact Wrench ----
4 Light Weight Push Trolley ----
5 Light Weight Rail Drilling Machine ----
6 ERC Inserter & Extractor ----
7 Light Weight Abrasive Rail Cutter ----
8 Portable Track Geometry Measurement System ----
9 Battery Operated Rail Drilling Machine ----
Page 20 of 40
Annexure-III
Small Track Machines (proposed)
Regular Item
SN Name of Machine
1. Abrasive Rail Cutter
2. Rail Cutting Wheel Abrasive Disc
3. Rail Drilling Machine
4. Heavy Duty Hydraulic Extractor for Jammed ERCs (10 ton)
5. Hydraulic Rail Bender (Jim Crow) Heavy Duty
6(a) Weld Trimmer Power Pack Version for A.T. Welding
6(b) Hand Operated Weld Trimmer
7. Rail Profile Weld Grinder
8(a) Toe Load Measuring Device (Mechanical)
8(b) Electronic Toe Load Measuring Device
9(a) Hydraulic Track Jack 15t capacity (non-infringing type)
9(b) Mechanical Track Jack 8t capacity (non- infringing type) (Rack & Pinion type)
9(c) Mechanical Track Jack 8t capacity (non- infringing type) (Rack & Pawl type)
10 Hydraulic Sleeper Spacer
11. Portable DC Welding Generator
12. Light Weight Rail (Mono) cum Road Trolley
13. Self Propelled Light Weight Trolley
14. Powered Material Trolley
15. Hydraulic Rail Tensor (Non-infringing type) 70t capacity
16. Hacksaw Blade for Cutting Rails
17. Box type Gauge cum Level (BG & MG) along with Spirit Level
18(a) Chamfering Kit (Manual)
18(b) Chamfering Machine (Battery operated)
19(a) Magnetic Base type Rail Thermometer
19(b) Continuous Rail Thermometer
20 Cordless Train Speed Logger
21 Gang / Worksite Remote Control Hooter
22 Hydraulic Track Lifting cum Slewing Device (TRALIS) 15 ton Capacity
23(a) Off Track Tampers (Power Pack
version)
To be preferably procured and used in
those section where MMU is implemented
as per para no. 228 of IRPWM. However,
these may be procured for other sections
also with approval of CTE
23(b) Off Track Tampers (Engine Mounted
version)
24. GPS (Geo Positioning System) based Foot Plate Inspection Device
25. Route Data Preparation System (RDPS)
26. GPS Based Oscillation Monitoring System(GPS-OMS)
27. Track based lubricators (Electronic and Hydraulic type)
Page 21 of 40
Under Trial Order Item
************
SN Name of Machine
1 Impact Wrench
2 Light Weight Push Trolley
3 Light Weight Rail Drilling Machine
4 ERC Inserter & Extractor
5 Light Weight Abrasive Rail Cutter
6 Portable Track Geometry Measurement System
7 Battery Operated Rail Drilling Machine
Page 22 of 40
Annexure-IV
Codal life of Frequently Used STMs
SN Name of Machine Proposed codal life
( years)
1 Abrasive Rail Cutter
4
2 Rail Drilling Machine
6
3 Weld Trimmer Power Pack version for
A.T. Welding
6
4 Rail Profile Weld Grinder 6
5 a)
b)
Toe Load Measuring
Device(Mechanical)
6
Electronic Toe Load Measuring Device 4
Page 23 of 40
Annexure-V
Procurement of STMs with AMC
Tenders for procurement of STMs should be invited along with warranty for one
year and AMC for 05 years (or balance codal life) as per details given below. The
tenderer will have to quote the basic cost of STMs along with one year warranty and
AMC cost. AMC cost will have two components i.e. charges for service engineers per
visit (Number of visits may be kept as 4-6 per year depending upon critical importance of
the machine and spares availability) and the maximum amount of replacement of spare
parts during the period of AMC. The firm will also have to provide a rate list for various
spare parts, which will be required to be replaced during AMC. However, the actual
payment for replacement of parts will be paid based on parts actually replaced on rates
specified by the firm along with his offer.
SN Item Number Rate Amount
a b (a x b)
1. Basic Cost of machine including 1 year warranty. (a x b)
2. Annual Maintenance Contract cost for 5 years
after expiry of warranty.
(a) Charges for service engineers per visit @ 4 nos.
per year.
12 No. (a x b)
(b) Maximum amount for replacement of spare parts
(including engine) which will be inclusive of
labour rate for replacement (to be paid on the basis
of cost of parts actually replaced as per rate given
separately for different items by tenderer along
with his offer).
Note:
(i) Lowest offer will be decided based on sum of 1&2 above.
(ii) Cost of spare parts shall be paid as per actual utilization based on rate-list given by
the tenderer along with his offer. In case, total cost of spare parts actually replaced
as per rate list is less than the maximum amount indicated, payment for actual
replacement will only be made. However, if it exceeds the maximum amount
indicated by tenderer in item 2(b), no amount in excess of maximum amount will be
paid by the Railway. Any part required to be replaced during AMCs, the rate of
which has not been quoted by the tenderer along with his offer, will not be paid
separately. Released parts shall be returned by the firm to the Railway.
(iii) Each visit shall comprise of minimum two days’ time.
(iv) AMC of STMs will be done at one nominated place in a Division (Divisional
Depot).
(v) Approximately 20% extra STMs will be procured and stocked at Divisional Depot
for unit exchange in lieu of machines brought by field PWIs for repair.
(vi) Procurement of STMs should be preferably done at Zonal/Divisional level once in a
year so that a firm gets order for sufficient number of STMs and is willing for
AMC.
Page 24 of 40
(vii) To start with AMC on above pattern may be done for:
(a) Abrasive Rail Cutter.
(b) Rail Drilling Machine.
(c) Weld Trimmer.
(d) Rail Profile Weld Grinder.
(e) Compressed Air Petrol pre-heating system equipped with pressure gauge
(f) Toe Load Measuring Devices.
(viii) Bank Guarantee (BG) for AMC should be 5% of the total value of PO including
cost of STMs and AMC to ensure due performance by the firm during AMC
period.
(ix) A penalty clause may also be incorporated for delay in attending the
complaints/repairs after 10 days of written intimation regarding same. Similarly,
a penalty clause may also be incorporated for delay in final repair of the STMs
within 30 days of written intimation regarding same.
(x) Necessary taxes may be paid extra as per applicable rates.
*****************
Page 25 of 40
Annexure-VI
Page 26 of 40
Annexure-VII
Page 27 of 40
Page 28 of 40
Annexure-VIII
Page 29 of 40
Page 30 of 40
Page 31 of 40
Page 32 of 40
Page 33 of 40
Annexure-IX
Page 34 of 40
Page 35 of 40
ANNEXURE-XI
Page 36 of 40
Page 37 of 40
ANNEXURE-XII
Page 38 of 40
Annexure-XIII
Page 39 of 40
Annexure-XIV
Page 40 of 40