Delhi Metro Update: Tender invited for Ultrasonic Flaw Detection testing of AT welds and rails in line 1, 2, 5 & 7 of DMRC Network

October 29, 2022 Rail News, Tender

Delhi Metro Rail Corporation Ltd.(DMRC) has invited open e-tenders from eligible applicants, who fulfil qualification criteria for Ultrasonic Flaw Detection (USFD) testing of AT welds and rails (using B Scan Machines) in line 1, 2, 5 & 7 of DMRC network.

  • Tender Reference Number: OCP-1211
  • Name of Work: Ultrasonic Flaw Detection (USFD) testing of AT welds and rails (using B Scan Machines) in line 1, 2, 5 & 7 of DMRC network.
  • Approximate Cost of work: INR 181.66 Crore
  • EMD: INR 60,553 Thousand
  • Completion period of Work: 03 Years
  • Document Download / Sale Start Date: 28th October, 2022
  • Document Download / Sale End Date: 28th November, 2022
  • Pre-bid Meeting: 10th November, 2022
  • Bid Submission Start Date: 21st November, 2022
  • Bid Submission End Date: 28th November, 2022
  • Tender Opening Date: 29th November, 2022

Objective:

  • The objective of the contract is to carry out Ultrasonic Flaw Detection (USFD) testing of Welds & Rails (using B Scan Machines) in line 1, 2, 5 & 7 of DMRC Network” In full recognition of this objective, and with full acceptance of the obligations, liabilities and risks which may be involved, the Contractor shall undertake the execution of the Works.

General:

  • The work of the Permanent Works shall be done in accordance with Employer’s Requirements and the other requirements of the Contract.
  • The Works shall be executed to the highest standards available using proven up-to-date good Engineering practices.
  • The Specification shall in any case not specify standards which, in the Engineer’s opinion, are less than or inferior to those described in the Technical/Maintenance Specifications contained in the Tender Documents.

Scope of Work:

  • The Ultrasonic Flaw detection (USFD) testing of AT welds & Rails is to be done using “B – Scan Machines” and is to be done by agency certified by RDSO to carry out USFD testing of Welds & Rails using “B- Scan Machines”.
  • Testing and reporting is to be done as per the technical specification for ultrasonic testing of Rail/weld in case of any conflict, the special conditions of the contract shall prevail. The frequency of testing shall be governed by DMRC track manual & its relevant Correction slips.
  • The work is carried out as per the specifications of RDSO and USFD Manual along with their updated correction slips.
  • The Ultrasonic flaw detector should be able to test ultrasonically the sectional area of the rail as per the sketch given in Clause 3.48 of Employer’s requirements. In case the contractor is not able to detect the complete area given in the sketch, he should indicate the area to be tested with his machine along with the percentage of the area covered in the head portion.
  • The minimum defect detection level reliability percentage vis-à-vis size should satisfy clause 6.3 of the Indian Railway Standard Specification for Ultrasonic Testing of Rail/ Weld. The capability of the test system shall be verified before testing begins to ensure compliance of the specification.
  • This may be done using known rail defect methods – where the test system runs over a test track containing known defects of various sizes and types or by defect audit verification method where numbers of rails defects detected by contractor during inspection run are audited by physical examination.
  • For this purpose suitable methods should be employed for example hand probing of rail length selected at random containing 5% of the detected defects and if required physical examination by breaking open the defects which were over reported / under reported / not reported in any of these two testing. In case it is considered necessary to carry out sizing of the flaws detected the same can be accomplished using procedure contained in Annexure-2.
  • The calibration should be done as per RDSO specification. The calibration should be done as per the technical specification for USFD issued by RDSO with updated correction slips.
  • The required rail for standard test pieces will have to be manufactured by the contractor at his own cost. The rail for making the standard test piece will be supplied by the DMRC, free of cost. This standard test piece is to be returned back to the DMRC after completion of the contract at a destination decided by Engineer-in-Charge.
  • The USFD machine (B- Scan Machine) should be maintained properly by getting it inspected periodically and shall be in good working condition. The correctness of machine working shall be to the satisfaction of the Engineer-in-Charge or his representative.
  • The operators should have the competency certificate issued by RDSO or ASTM-II in Non Destructive Testing using “B Scan Machines”. The operator should have the competency certificate issued either by RDSO or should possess competency certificate of level-II from Indian Society for Non-destructive testing (ISNT/American Society (ASNT) for Non-destructive testing and shall have minimum two years of practical experience in ultrasonic examination. This is to be read in conjunction with clause 7 of the Technical Specification.
  • The Engineer-in-Charge of the work here will be JGM/Track/O&M.
  • The tenderer should indicate the average length of track to be tested by him per Block per night.
  • The required kms and their due date of testing of each section will be scheduled by the DMRC and the tenderer shall progress the work accordingly. There should not be any overdue testing of kms.
  • Testing shall also cover testing of Alumino Thermite welds and Flash Butt welds falling in the test length like normal rail testing excluding flange testing and the mark defects accordingly.
  • Contractor will test the entire length of rail from one end to other including glued joints.
  • Gauge face corner testing shall necessarily be done on all rails irrespective of presence of rail top surface irregularities.
  • Detection and marking of the suspect locations in the rail shall be the responsibility of the contractor and defects shall be marked to an accuracy of +/- 50 mm.
  • Confirmation of suspect locations shall be done along with DMRC officials with the same machine, in the presence of contractor’s personnel. 90% of suspect locations marked by the contractor shall generally get confirmed. Any disputes shall be mutually verified. The reporting shall be done by the defect data logger. In the case of any dispute which is made against the contractor and subsequently judged in the contractor’s favour, DMRC shall be responsible for payment of any costs accumulated by the contractor that are related to the resolution of the dispute.
  • Once a suspect is identified by contractors, the operator DMRC’s representative will identify the actual Rail defect location and this shall be provided to the Contractor for entry in the daily Suspect Report.
  • Marking of the flaw location on the rail / weld and categorization of flaw shall be as per clause 5 of Indian Railway Standard Specification for Ultrasonic Testing of Rail/ Weld as per RDSO with updated correction slips.
  • Reporting Suspect Defects: The Contractor shall record all noted suspect indications (except bolt holes and bond wires) using the Data Logger and scrutinized report in the approved pro forma given by the customer. This shall be given to the Engineer-in-Charge or his representative daily.
  • The report of the previous day’s inspection shall be handed over to the Engineer-in-charge on the following day preferably, but not later than the third day of testing. One hard copy of the report and the balance in soft copies shall be provided. “B” Scans of the required suspects shall be provided only in soft copies. Kindly note that sizing of the defect has not been tendered and is not included to be done as per the offer.

Un-testable length of Rails:

  • Point & Crossing: Cast Manganese Steel Crossing area can be classed as untestable. Tongue portion length from ATS to JOH can be classed as untestable. However, the remaining length of rail in Point & Crossing shall be tested as and if desired by Engineer In-charge or his representative.
  • Rail surface contamination (rail pitting / rail rust / rail grinding marks / grease). Small portion of the rail, which due to surface contamination prevents the operator from maintaining the required rail foot signal as detailed in accordance with the requirements U15 can be classed as un-testable. However, the remaining portion shall be tested as per IRUSFDM, including Gauge Face Corner testing.
  • Wheel Burns / Squats / Scabs / shelling. Any portion of the rail, which due to any of the following prevents the walking stick operator from maintaining the required rail foot signal as detailed in accordance with the requirements of U15, can be classed as un-testable. In addition, any visible surface feature which prevents the propagation of ultrasound into the rail can be classed a visible defect with a possible underlying defect that may not be detectable squats / shells)
  • The contractor shall impart basic training to Supervisors/Officers of the DMRC to make them conversant with USFD testing of AT welds & rails “Using B Scan Machine “technology.
  • DMRC will depute one competent personnel, not below the rank of Sr. Maintainer, along with the contractor’s USFD team who will take immediate action like imposing speed restrictions in case some IMR flaw is reported.
  • The daily test reports should be made with the test results in the format given by the DMRC duly signed by the Contractor’s Engineer and submitted to the Engineer-in-Charge on next day of testing for necessary action. Daily test report should contain all the items as listed in 10.1.1 of the Indian Railway Standard Specification for Ultrasonic Testing of Rail/ Weld. However, the flaws classified as ‘IMR’ should be reported on the same day.
  • The contractor will have to use a USFD machine fitted with DATA LOGGER. In this case, the contractor will give the results in a soft copy as per the instructions of Engineer-incharge or his representative at least twice in a week along with the reports.
  • The contractor shall be permitted to make use of the existing facility if available in P.Way office / workshop for battery charging at free of cost. If such a facility is not available / not feasible, the contractor shall make his own arrangements. No additional payment shall be made on this account.
  • The tenderer shall provide his own accommodation to his staff for their stay during the period of contract. However, he will not be permitted to construct a temporary accommodation in the DMRC premises for their Office and staff. No DMRC accommodation will be provided for this purpose. The rates quoted by the tenderer shall include for all such charges.
  • DMRC will not provide any conveyance to the site of testing. The firm will have to apply for an identity card for the operators/employees who are deployed to execute the work. They have to submit an Indemnity Bond in the prescribed Performa as per format within a week after issue of acceptance letter.
  • The testing shall be carried out at night in non revenue hours in main line and in day shift in Depot (block hours permitted by competent authority).
  • The contractor / their representative / staff should be well conversant with the area and with the working on track as regards safety of traffic, personnel safety and will have to give a certificate to this effect. No compensation will be paid on whatsoever account. Contractor shall indemnify the DMRC for any damage to the property or accident to a person.
  • The list of the technicians, operators and other assistants proposed to be deployed for testing shall be given to the Engineer-in-Charge.
  • All losses force-majeure with Ultrasonic flaw detectors will be borne by the contractor.
  • Ultrasonic flaw detectors and accessories shall be kept in safe custody of the contractor and DMRC shall not be responsible for any loss or damage.
  • All costs during testing will be borne by the contractor.
  • No advance payment towards mobilization shall be paid to the contractor. Monthly on account bills shall be paid to the contractor on request for the work done during the period.
  • The period of completion shall be 3 years and time will be the essence of the contract. This time limit shall be considered from the date of issue of acceptance letter. The work shall be carried out as per the program given by the DMRC.
  • Tenders for USFD testing of rails by outsourcing should be called only with B-scan machines equipped with 9 channels SRT/DRT and two extra 37 degree probes. However for Weld Testing A-Scan machines can be permitted for the time being.
  • RDSO certified USFD operators and machines for the testing are to be made mandatory. To ensure it the contractor has to propose the name of an RDSO approved USFD operator after award of LOA. However, the contractor has to propose the RDSO approved USFD machines to be utilized for testing.
  • B-scan records will be reviewed by AM/Manager as a part of test check. Payment will be subjected to availability of B-Scan data. The data must be preserved for three years for further analysis and necessary action in case of fracture.
  • Software to view the B Scan data should be there as part of the contract.
  • In case of vehicular USFD testing the software should be equipped with play, forward and rewind option and with defect to defect pause features.
  • Provision of geo tagging and date stamping in the B Scan should be kept.
  • In case of detection of any undetected flaw during test check by DMRC, the length of track tested in that particular week will be required to be retested by the contractor without any extra payment. Also records of USFD operators who missed the flaw and the USFD operator who missed 10 flaws in a year will be removed.
  • Maximum delay permitted in testing of a section after it has become due for USFD testing is 15 days. For further delay, a penalty of Rs.5000/- per km per day will be levied on the contractor.
  • For contracts for works tender related to “USFD Testing of Rails/Welds by SRT/DRT/Handheld Testers” whose technical capabilities have already been established by RDSO, Board (ME & FC) have decided to dispense with the Minimum Technical Eligibility Criteria mentioned in Indian Railways Standard General Conditions of Contract.
  • However, Financial Eligibility Criteria as given in Standard General Conditions of Contract will remain unchanged.

The Contractor must provide documentary evidence of:

  • Owning (XX) of RDSO approved machines, or
  • Proof of entering into MOU with manufacture/supplier of RDSO approved vendors for required no of machines as specified in (a) above. (No of machines will be decided by DMRC depending upon workload.)
  • In addition, contractors have to follow all prevalent guidelines and updated instructions issued time to time by DMRC, government of India, Ministry of Railways, Railway Board, RDSO and state government etc.

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