Delhi Metro Rail Corporation Limited (DMRC) has floated open e-tenders from eligible applicants, who fulfil qualification criteria for Installation of drive gear bearing monitoring devices/sensors for 17 nos of RS-3 and 5 nos of RS-9 trains on Line-5.
- Tender Reference Number: ORW-1466
- Name of Work: Installation of drive gear bearing monitoring devices/sensors for 17 nos of RS-3 and 5 nos of RS-9 trains on Line-5.
- Approximate Cost of Work: INR 307.45 Lakh
- EMD: INR 3,07,449/-
- Completion Period: 01 Year
- Document Download/Sale Start Date: 09th Oct, 2023
- Document Download/Sale End Date: 09th Nov, 2023
- Pre Bid Meeting Date: 17th Oct, 2023
- Bid Submission Start Date: 03rd Nov, 2023
- Bid Submission End Date: 09th Nov, 2023
- Tender Opening Date: 10th Nov, 2023
Scope of Works:
Drive Gear Bearing Monitoring system shall comply with the specifications as given in Technical Specifications. All the components/hardware etc. required for complete installation, testing & commissioning as well as the smooth operation of the Drive Gear Bearing Monitoring system shall be provided by the contractor.
The contractor shall provide all required hardware such as bolts, nuts, washer, brackets and other fasteners free from corrosion as required for installation of Drive Gear Bearing Monitoring system components as per railway standards.
Contractor shall carry out Installation of items on train designated/offered by DMRC in presence of DMRC staff. Making provision of installation for all the sensors, their mounting arrangements, fixing and machining required for the speed sensor cover to be installed shall be done by contractor without any additional cost.
- DMRC will provide all the assistance in finalisation of provisioning of required power supply (110 V DC) for the monitoring system. Necessary arrangements for power supply such as installation of MCBs, grommet, lugs and conduit etc shall be done by contractor without any additional cost.
- Testing of the installed systems on test track and mainline shall be done by DMRC in presence of Contractor. Basic Training for the staff for analysing the retrieved data to be provided by the contractor.
All types of analysis and computation of the data received in terms of numeric/graphs or any other suitable form for speed, vibration and temperature shall be done (for a period of 01 year from the date of handing over of installed and commissioned system on the last train, contractor shall be willing to extend the analysis and computation work of data for next 4 years on same terms, conditions and rate) and apprised timely by contractor to DMRC.
Contractor is responsible for informing the DMRC in case of any event that requires intervention within 3-4 months or requires immediate action by suitable means – Email/Text message/telephonic call.
The contractor shall be able to install Drive Gear Bearing Condition Monitoring System on Rolling Stock on “in service” trains without having to take them down for major modifications. The contractor shall mount a data concentrator on the Train Body (Either inside or under the Car frame); therefore once the bogie is dismounted from the car, it shall not require any configuration.
All cables (Power and communication cable) must be protected by fire retardant shrinkable sleeve throughout its routing. All cables are to be routed through suitable and railway grade conduits/grommet/glands. Long lasting and as per railway standards proper wire numbering to be done for all power and communication cables.
The Drive Gear Bearing Monitoring system shall fully meet the requirement of EMI/EMC for Railway application as per EN 50155. Communications to and from the sensor nodes shall be wired/wireless. 2G/3G/4G/5G Cellular or satellite communications shall be used to send data to and from the train.
Data compression and filtering will be part of the “on train” systems so that communications can be achieved effectively with 2G/3G/4G/5G cellular data communications. The communication from the sensors shall be free from interference by passenger communication systems such as Wi-Fi, Bluetooth and cellular radio.
The communication from onboard concentrator to server shall be encrypted and protected from any interception by outside agencies. The contractor shall design the Drive Gear Bearing Monitoring System in such a way that vibration data shall be captured at time intervals based on speed.
If required, it should be held in a buffer on board the concentrator and then transmitted to a central database for processing, analysis and alert. In the event of cellular network not being available, the data shall be held for the entire required time until cellular network coverage becomes available and then data must be transmitted at the earliest.
- The data holding buffer must be designed accordingly. In case of communication failure with the server preferably alternate arrangement for data downloading shall be adequately provisioned.
- The contractor shall be responsible to support against breakdown/failure of any of the Drive Gear Bearing Monitoring system’s components during the Defect Liability Period (DLP) of two years (24 Months) from the date of handing over of installed and commissioned system on the last train.
- The list of warranty spares to be maintained by the contractor at site to provide support during the warranty period shall have to be furnished by the contractor as per Annexure-I of ERTS.
- Train for installation commissioning will be given to the contractor when the contractor confirms the availability of all the required material and only after all the materials are ready for installation at the depot itself.
When the train is offered for installation of the Drive Gear Bearing Monitoring system, the contractor has to complete the work within 5 days in all respects. Any damage to any components of the train/system during working must be borne by the contractor.
Commissioning and Testing:
- Contractor shall be responsible for carrying out performance tests of the Drive Gear Bearing Monitoring system.
- Consignee will have the right to witness any of these tests at any stage of test progress. The commissioning test of the complete vehicle will be performed by the contractor for the Drive Gear Bearing Monitoring assembly at consignee premises.
At present 21 Trains of 4 Car and 1 Train of 6 Car at Line 5 are available for installation of Drive Gear Bearing Monitoring System.
- 4 Car trains consist: DT-1—– M-1—-M-2 —DT-2
- 6 Car train consist: DT-1—– M-1—-T-3 —–M-3—-M-2—-DT-2
- (DT stands for Driving Trailer Car, M stands for Motor Car, T stands for Trailer Car)
Scope of extension from 4 car to 6 car shall exist for all proposed/installed items without making any changes (other than software) in the installed system i.e. drive gear bearing system shall be capable of conversion from 4 car to 6 car trains as and when required with just software changes. There should not be any compatibility issue from the software side, at the time of car extension.
Line-5 trains are of MRMB (Mitsubishi, Rotem, Melco, and BEML) make. There are a total of 23 trains at Line-5, out of which 18 trains are of RS-3 stock (2010 vintage) and 5 trains are of RS-9 stock (2016 vintage). These RS-3 and RS-9 trains have completed thirteen and seven years of service respectively.
Each Motor car has two bogies, and each bogie has two drive gears of M/s Voith make, installed with two types of gears and bearing system. Each drive gear has four bearings, two input bearings and two output bearings. Both input and output bearings are of SKF make.
Already, input bearings replacement of all the RS3 and RS9 trains have been done in-house during the C-2 check. However, output bearings have not been replaced so far and till date original bearings are running in the trains. These output bearings which have not been replaced till date are susceptible to failures.
The overhauling/replacement criteria for the bearings, recommended by OEM of the Drive Gear is 8,40,000 Kilometres (every C-2 Check) running of the trains. Currently earned kilometres by RS-3 trains are on an average of 15 Lakh KM. In view of the critical application of the drive gear bearings and present running life, it is required to monitor the conditions of these bearings in real time to obviate any failures and the repercussions thereto.
DMRC wishes to install train mounted, ‘On Board Drive Gear Bearing Condition Monitoring System’ that will monitor the health and safety of the bearings of the drive gear that would finally result in improved safety, improved reliability, higher utilisation, increased up-time and reduced operation cost of the DMRC assets by enabling Predictive Maintenance and reduction in sudden catastrophic failures of these drive gear bearings.
The ‘On Board Drive Gear Bearing Condition Monitoring System’ shall enable Predictive Maintenance of the drive gear bearings by meeting the following functionalities:
- Improving safety by early warning of distress in or impending failures in drive gear bearings, using the vibration signature of the sensors that are strategically placed on the Gear Box itself.
- Improvement in reliability of these drive gear bearings by detecting early signs of deterioration in the drive gear bearings, thus providing ample time for planning maintenance and avoiding sudden breakdown in service.
- Enabling scientific decision-making for maintenance of the drive gear bearings based on accurate deterioration trend and quantified indices of state of health by implementing fault failure analysis of these drive gear bearings to plan condition-based maintenance rather than time-based maintenance.
- Ability to Install On Board Drive Gear Bearing Condition Monitoring System on Rolling Stock on “in service” trains without having to take them down for major modifications thereby reduced cost of installation, increased train availability and prevention of train service disruption while reaping benefits of such predictive maintenance systems.
- The proposed system should be capable of being used with existing roller bearings and running systems on board the DMRC Rolling Stock without having any structural modifications in the stock.
- Easy operation of the On Board On board Drive Gear Bearing Condition Monitoring System by simple, automatically generated and actionable alerts.
- Options to enhance the functionality and capability of this system in the future without requiring major replacement of the existing equipment monitoring system. That means on-air update of firmware to enhance the edge computing capability of the concentrator.
- A single sensor shall be capable of monitoring both vibration and temperature condition data when fitted to the bearing assembly.
- The sensor shall communicate to the data concentrator reliably through wired or wireless means of communication. In case of a wired system the cable from sensor to onboard concentrator shall be routed in such a manner that it shall not cause hindrance for removal of Bogie from Coach during maintenance.
- The sensor shall send the live temperature and vibration data to onboard data concentrator and shall not experience lag more than 60 seconds.
- The sensor node should be deployed on the drive gear box with suitable arrangement without disturbing the existing assembly.
- Sensor nodes shall be common to all gear drive assembly types. Customization may only be required for the fixing bracket arrangement.
- Sensor housing and all other installation accessories shall be surface treated to protect it against corrosion.
The tenderers will be qualified only if they have successfully completed or substantially completed similar works during the last five years ending the last day of the month previous to the month of tender submission as given below:
- At least one “similar work” of value of ₹245.96 Lakh or more, or
- At least two “similar works” each of value of ₹153.73 Lakh or more, or
- At least three “similar works” each of value of ₹122.98 Lakh or more
The “Similar works” for this contract shall be “Design/Manufacture/Supply, Installation and Commissioning of monitoring systems for various characteristics such as vibration and temperature etc for various types of bearings in Rolling Stock of Railways/Metro Trains in India or Abroad”.
If the tenderer is a JV/Consortium having foreign partner(s) and above work(s) have been executed by the foreign partner of JV and the work(s) were done in the country of the foreign partner, then in addition to this the foreign partner must have executed works (which need not be similar in nature) of total put together of value ₹122.98 Lakh or more outside the country of the foreign partner.
Tender document can only be obtained after registration of tenderer on the website https://eprocure.gov.in/eprocure/app
Source: DMRC- Tender | Image Credit (representational): DMRC