technical specifications

ISRAEL RAILWAYS LTD

INFRASTRUCTURE DIVISION

TRACK AND RIGHT OF WAY DEPARTMENT

Technical Specifications

for

Mechanical Trackside Lubricator for

Various Types of Rails

No. E-01-0019

June 2013

ISRAEL RAILWAYS LTD

Mechanical Trackside Lubricator for Various Types of Rails Lubricant

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Contents

1 SCOPE 2 2 REFERENCE DOCUMENTS 2 3 DEFINITIONS 2 4 ISR SUPERSTRUCTURE AND LOCAL CONDITIONS 2 5 MECHNICAL TRACKSIDE LUBRICATOR - REQUIRMENTS 3 6 LUBRICANT FILLER EQUIPMENT - REQUIREMENTS 4 7 MANUFACTURE'S TECHNICAL DRAWINGS 4 8 MANUFACTURE 5 9 MARKING LABELING 5 10 MANUFACTURING QUALIFICATION MANAGEMENT 5 11 LIST OF DOCUMENTS TO BE SUBMITTED WITH BIDDER'S PROPOSAL 6

12 LIST OF DOCUMENTS TO BE DELIVERED WITH EVERY ISR ORDER 7 13 PACKING 7 14 WARRANTY AND TRAINING 8 APPENDIXES - APPENDIX A ISRAEL CLIMATE AND ENVIRONEMENTAL CONDITIONS 9 APPENDIX B DSB 82-1 WHEEL PROFILE DRAWING 10 APPENDIX C RAIL HEAD PERMISSIBLE WEAR 11 APPENDIX D LUBRICANT REQUIREMENT 12 APPENDIX E ISR LOADING GAUGE 14 APPENDIX F LIST OF DOCUMENTS TO BE SUBMITTED WITH BIDDER'S PROPOSAL

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1. SCOPE 1.1 This technical specification pertains to the technical requirements for

mechanical trackside lubricators ("MTL") manufacturing, supply and installation. To reduce friction and wear at wheel/rail interface by lubricant the rail gauge side corner and rail gauge side face.

1.2 The MTLs shall be supplied with Lubricant filler equipments.

1.3 The MTLs shall be supplied with installation and adjustment tools for efficiently assembled the MTLs to the rails.

2. REFERENCE DOCUMENTS (*) EN 15427 Railway applications Wheel/rail friction

management - Flange lubrication. EN 16028 Railway application Wheel/rail friction

management - Lubricants for trainborne and trackside applications

EN 13674-1 Railway applications - Track - Rail - Part 1 Vignole railway rails 46 kg_m and above.

UIC 510-2 Trailing stock: wheels and wheelsets. Conditions concerning the use of wheels of various diameters

(*) latest edition of the referenced document

3. DEFINITIONS Gauge side face: Area "A" as defined in EN15427, section 3. Gauge side corner: Area "B" as defined in EN15427, section 3. ISR: Israel Railways Ltd.

4. ISR SUPERSTRUCTURE AND LOCAL CONDITIONS: 4.1 Nominal track gauge 1435 mm

4.2 Minimum curve radius - 140 m.

4.3 Maximum track gradient - 30.

4.4 Israel climate and environmental conditions as specified in appendix A

4.5 The MTL shall be designed for installation on rail types: 60E1, 60E2, 54E1 and 50E6 (rail types in accordance with EN13674-1).

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4.6 The MTL shall be designed for efficient operation with ISR wheels type - ISR using wheels of several diameters the wheels profile types are in accordance with UIC 510-2, and DSB82-1 wheel type (IC3 trains) see appendix B.

4.7 Rail head permissible wear see appendix C.

4.8 Maximum track load - 22.5 ton/axle.

4.9 Maximum On-Track Vehicle speed - 160km/h.

5. MECHNICAL TRACKSIDE LUBRICATOR - REQUIREMENTS 5.1 The MTL shall be designed to operate properly and efficiently with

lubricant which its properties prescribed in appendix D, and with ISR Superstructure and Local Conditions prescribed in section 4.

5.2 The MTL shall apply lubricant to take effect in the active interface applied in areas "A" and "B" of the rail throughout the intended length of the rail to be lubricated.

5.3 The MTL shall work independently and do not require external energy source, and shall provide uniform amount of lubricant direct to areas "A" and "B" by each passing wheel.

5.4 The MTL reservoir shall be designed with a capacity of 9-12 kg.

5.5 The MTL pumping lubricant quantity per stroke shall be 0.1-0.15 gram.

5.6 The MTL shall be installed to the track without rail drilling and shall be conformed to ISR nominal track gauge.

5.7 The MTL shall be designed with two lubricant distribution units.

5.8 The MTL shall include a means of checking and adjusting the amount and position of lubricant dispensed.

5.9 The means of adjusting the height of the lubricant application unit shall be separate from the means of installing to the rail.

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5.10 The MTL shall be on a safe distance from the on-track vehicles, in such a way that it cannot be damaged as a result of rail maintenance work (see ISR Loading Gauge appendix E).

5.11 The MTL components shall be designed and manufactured from materials which the nature and main characteristics and chemical composite shall be stated and their fluffiness to the requirements of the relevant standards and could not be modified without approved by ISR.

5.12 The means shall be provided in the MTL to indicate the quantity of lubricant remaining in the lubricant reservoir.

5.13 All parts which are non-metallic shall be made of hot weather resistant materials, suitable for use at temperature of up to 70C and under high corrosion conditions. Plastic parts shall be UV protected. Israel climate condition should be considered (see appendix A).

5.14 The MTL reservoir shall be cleaned and corrosion protected before painting. The painting shall be done with two layers - premier layer and second layer. The second paint layer shall have high resistance to the environment condition including UV sun radiation, and corrosion environment, and high resistance to wear. All other metallic parts shall be corrosion protected.

6. LUBRICANT FILLER EQUIPMENT- REQUIREMENTS 6.1 The lubricant filler equipment shall be a manually device and shall be

designed for quick and efficient lubricant filling with minimum hands dirty and soiling the ballast and the ground.

6.2 The lubricant filler equipment shall enable filling the lubricator reservoir efficiently. It shall include all means to pump lubricant from tanks (pails, kegs, drums) with different sizes and capacities.

7. MANUFACTURE'S TECHNICAL DRAWINGS 7.1 The manufacturer shall submit, together with its proposal, a complete set of

technical drawings with dimensions, tolerances and material main characteristics of the MTL for 60E1, 60E2, 54E1 and 50E6 rails of:

The assembled MTL, Blow up drawings, Components drawings.

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7.2 The manufacturer shall submit, together with its proposal, a complete set of technical drawings and material main characteristics of the lubricant filler equipment.

The assembled lubricant filler equipment, The operation of lubricant filler equipment drawing.

7.3 The manufacturer shall submit, together with its proposal, a complete set of technical drawings and material main characteristics of the installation and adjustment tools.

8. MANUFACTURE 8.1 The MTL shall manufactured in accordance with the technical drawings

submitted by the manufacturer and approved by ISR, and must present a clean surface, smooth and free from blow-holes, flaws, cracks, folds or other faults.

9. MARKING LABELING 9.1 Each MTL shall be inscribed with at least the following marks: The manufacturer mark, The last two figures of the manufacturing year, The product identification type.

9.2 lubricant filler equipment shall be inscribed with at least the following marks:

The manufacturer mark, The last two figures of the manufacturing year, The product identification type.

9.3 Installation and adjustment tool shall be inscribed with at least the following marks:

The manufacturer mark, The last two figures of the manufacturing year, The product identification type.

10. MANUFACTURING QUALITY MANAGEMENT 10.1 The supplier shall have quality management system for the MTL

manufacturing processes in accordance with all the requirements of this technical specification.

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11. LIST OF DOCUMENTS TO BE SUBMITTED WITH BIDDER'S PROPOSAL

11.1 The manufacturer shall submit reference list of the MTLs which have been manufactured and supplied.

11.2 The manufacturer shall submit technical information regards lubricant spread affectivity (including lubricant distance along area "A" and area "B").

11.3 The manufacturer shall submit spare parts list.

11.4 The manufacturer shall submit together with his proposal quality management system process for MTL manufacturing in accordance with all the requirements in this technical specification and quality management system based on ISO 9001:2008.

11.5 The manufacture shall submit certificates of approving use on electrified track with 25 kV AC and on non-electrified track with CWR and jointed track and the relevant technical documents.

11.6 If manufacturer uses welded assembly steel. weldability shall be tested and the certificate shall be submitted for ISR's approval.

11.7 The manufacturer shall submit process procedure for protection against corrosion and painting.

11.8 The manufacturer shall submit environmental certificates for the painting used.

11.9 The manufacturer shall submit technical information for the corrosion protection.

11.10 The manufacturer shall submit 2 magnetic copies of all the manufacturing technical drawings.

11.11 The manufacturer shall add to the technical drawings 2 softcopies the relevant technical descriptions of the MTL. And 2 softcopies signed and approved installation, lubricant filling, maintenance (include an inspection and a method for fault diagnosis to check that the lubricator is not partially or fully blocked or misaligned and all components are securely installed to their mountings, maintenance intervals) and safety manuals.

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11.12 The manufacturer shall declare in a signed document the estimate for the MTL and it components life cycle.

11.13 The manufacturer shall submit the nature and main characteristics of the metallic and non-metallic material and chemical composite for every component.

11.14 The manufacturer shall submit 2 magnetic copies of all the manufacturing technical drawings and the relevant technical descriptions of MTL and its components, the lubricant filler equipment and the installation and adjustment tool.

12. LIST OF DOCUMENTS TO BE DELIVERED WITH EVERY ISR ORDER

12.1 Each order shall be delivered with certificate that each components has manufactured according to technical drawings submitted and the requirements of this technical specification.

13. PACKING 13.1 The MTL components shall be packed in wooden boxes and will put in

container. The wooden box arrangement shall enable easy and safe unpackaged and storage the goods.

13.2 The dimensions of the wooden shall be according to EN standard, to enable maximum effective storage capacity in containers. It shall be possible to put at least 3 wooden boxes one on the other. Each package gross weight shall not exceed 1 tone.

Each package shall be labeled with the following details: o Component name and type; o Production batch number; o Date of manufacture; o Component barcode; o Component quantity in box; o Gross and net weight; o Manufacturer recognition number or name; o ISR recognition number; o ISR order number; o Ordinal number on the packing list. The labeling shall be with black letters and shall be on 3 spots on the package (one on top of the package and the two others on the sides).

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13.3 The installation and adjustment tools shall be packed separately.

13.4 The lubricant filler equipments shall be packed separately.

14. WARRANTY AND TRAINING 14.1 The warranty period for the MTL shall be 2 years.

14.2 The warranty must be valid for unlimited volume of traffic.

14.3 During the warranty period no incipient cracks, fractures and clearly critical damage through corrosion may occur especially on welded connections. All the repairs of defects and replacing the various components shall be included in the basic price.

14.4 Training course for MTL installation and maintenance shall be take place on-track in Israel by the manufacturer qualified crew. ISR shall have the right to document the training course including by video camera or other digital means.

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APPENDIX A ISRAEL CLIMATE AND ENVIRONMENTAL CONDITIONS

A.1 Climate and Environmental Conditions Max. ambient temperature 50 C (shade) Min. ambient temperature -5 C Relative humidity 10 to 90 % Altitude -400 to +800 meter Sunny 3300 hours per year UV Radiation 360 to 600 MJ/m per year Rainfall 400 to 800 mm/year

A.2 Dust Conditions in the atmosphere Maximum Half Hour

Value* Maximum Daily Value*

Average

NOx 1064 560 71 SO2 780 260 21 O3 312 143 84 Suspended Dust

- 350 100

*(Microgram per m atmosphere)

A.3 Suspended Particulate Matter (SPM) Particle size to 0.5-1 micron

A.4 Sea Salt Concentrations in the Atmosphere Salt Element Na* Cl* SO4* Position Dry Wet Dry Wet Dry Wet Sea Air at Coast Line 7.3 16.0 12.0 22.0 5.3 7.0 600 m from Shore 3.1 4.8 4.2 7.9 1.9 2.0 6000 m from Shore 1.1 1.4 1.5 1.7 1.3 1.4 * (Micrograms per m atmosphere)

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APPENDIX B DSB 82-1 WHEEL PROFILE DRAWING

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APPENDIX C - RAIL HEAD PERMISSIBLE WEAR

Maximal horizontal wear [mm]

Maximal vertical wear

[mm]

Minimal height of the

rail [mm]

Height of the new rail

[mm]

Type of rail (EN 13674-1)

16 13 140 153 50E6 (U-50) 17 14 145 159 54E1 (UIC-54) 18 17 155 172 60E1 (UIC-60), 60E2

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APPENDIX D LUBRICANT REQUIREMENT

Lubricant requirements are in accordance with EN16028, Annex A, table A.1:

property unit Test method values Appearance - Visual Homogenous Color - ISO 2049 or equivalent Homogenous Consistency (NLGI) - ISO 6743-99 1 or 1.5 Worked grease penetration 60 stroke @ 25C

0.1 mm ISO 2137 or equivalent 290-340

Drop point C ISO 2176 or IP 396 or equivalent 150

Flash point C EN ISO 2592 or equivalent 200

Water content % mass ISO 760 or DIN 51777-2 or ISO 3733 or equivalent 1.0

Water resistance @ 40 C Level DIN 51807-1 or equivalent 1 Adhesion to sheet steel (0.05 mm, 24 h @ 60 C) Stage EN16028, Annex D 1 Volatile components % mass EN16028, Annex E 10

Oil separation/ "bleeding" (168 h [7 days] @ 40 C) % mass

DIN 51817 or its equivalent standard

7% maximum by weight for NLGI No. 1 grease

Corrosion test steel Rating ISO 11007 using water or its equivalent standard 0; 0

Corrosion test - copper Grade DIN 51811 or equivalent 1 Compatibility with elastomers (60 C for 168 h) change in volume for NBR1

% ISO 6072 or its equivalent standard +15/-0

Compatibility with elastomers (60 C for 168 h) change in hardness for NBR1

IRHD ISO6072 or its equivalent standard 8

Identity testing: Using Infra-red, or X-ray fluorescence, or Inductively coupled plasma

Standard laboratory method: DIN 51418-1, DIN 51418-2, DIN 51451, DIN 51820-1 or its equivalent standard

Apparent viscosity (1 cone, s-300 s, D=1000 s-1) @ 25 C

mPas DIN51810-1 or its equivalent standard 150

Apparent viscosity (1 cone, s-300 s, D=1000 s-1) @ 0 C

mPas DIN51810-1 or its equivalent standard 400

Apparent viscosity (1 mPas DIN51810-1 or its equivalent 4000

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cone, s-300 s, D=1000 s-1) @ -25 C

standard

Four ball test wear test rating (300 N, 1 h @ 1500 r/min)

mm DIN 51350-5; Method D or its equivalent standard 0.8

Four ball test Extreme pressure kg DIN 51350-4

Weld load not less than 315kg

Effect of water (water wash-off test) visual EN16028, Annex B

No corrosion after 72 h

Biodegradability % OECD suite or its equivalent standard

>60 after 28 days

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APPENDIX E ISR LOADING GAUGE

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APPENDIX F - LIST OF DOCUMENTS TO BE SUBMITTED WITH BIDDER'S PROPOSAL

F.1. The bidder shall supply technical description for the Lubricant filler equipments. And the means to pump lubricant from tanks (pails, kegs, drums) with different sizes and capacities.

F.2. The bidder shall supply technical description for the installation and adjustment tools.

F.3. The bidder shall supply technical description for the nature and main characteristics and chemical composite of the MTL components materials. And stated their fluffiness to the requirements of the relevant standards.

F.4. the bidder shall submit MTL reservoir paint parameters and painting procedure.

F.5 the bidder shall submit the corrosion protection process for the metallic parts.

technical specifications

Documents

rail gauge

appendixes appendix

isr wheels type isr

appendix e isr loading

50e6 rail types

appendix f list of documents

trackside applications

wheels profile types