IRCON invites tender for USFD testing of rails and welds for Sawalkote-Banihal section of USBRL project

December 12, 2023 Rail News, Tender

IRCON International Limited has invited an online e-Tender for USFD Testing of welds as per Indian Railway Standard specification for Ultrasonic Testing of Rails/Welds, revised – 2020 with latest amendments and manual for Ultrasonic Testing of Rails and Welds, revised – 2022 with latest correction slips issued by RDSO with contractor’s own A – Scan machines and operators in connection with construction of Sawalkote-Banihal Section of Udhampur-Srinagar-Baramulla Rail Link Project, Jammu & Kashmir. (Package: USFD Test/USBRL).

  • Tender Reference Number: IRCON/J&K CELL/JAT/14/1014/K-B/O.Tender/USFD/585
  • Name of Work: USFD Testing of welds as per Indian Railway Standard specification for Ultrasonic Testing of Rails/Welds, revised – 2020 with latest amendments and manual for Ultrasonic Testing of Rails and Welds, revised – 2022 with latest correction slips issued by RDSO with contractor’s own A – Scan machines and operators in connection with construction of Sawalkote-Banihal Section of Udhampur-Srinagar-Baramulla Rail Link Project, Jammu & Kashmir. (Package: USFD Test/USBRL).
  • Estimated Cost of Work: INR 42.95 Lakh
  • EMD: INR 86 Thousand
  • Completion Period: 03 Months
  • Document Download/Sale Start Date: 11th Dec, 2023
  • Document Download/Sale End Date: 01st Jan, 2024
  • Bid Submission Start Date: 26th Dec, 2023
  • Bid Submission End Date: 01st Jan, 2024
  • Bid Opening Date: 02nd Jan, 2024

Scope of Works:

USFD testing of welds including USFD testing of point and crossing as per updated correction slips and USFD testing of SEJ with hand probing excluding tongue rail of SEJ in the running track, as instructed by Engineer-in-charge, by need based concept (NBC) system including gauge face corner defect (GFCD) shall be tested by contractor with their A – scan machines.

Testing and reporting is to be done as per the Indian Railway Standard Specification for Ultrasonic Testing of Rails/Welds, Revised – 2020 with latest amendment(s) & Manual for Ultrasonic Testing of Rails and Welds, Revised – 2022 with latest amendment(s). In case of any conflict, the decision of Engineer- in-charge shall be final & binding upon the contractor.

The testing of Alumino Thermite welds and Flash Butt welds falling in the test length like normal rail testing excluding flange testing along with other USFD testing.i.e SEJs, Turnouts etc. shall also be covered and defects to be marked accordingly. USFD testing shall be done as directed by Engineer-in-Charge. The decision of Engineer-in-Charge shall be final & binding upon the contractor.

USFD testing of welds using contractor’s own RDSO approved hand operated Digital Ultrasonic Weld Tester, as per Indian Railway Standard Specification for Ultrasonic Testing of Rails/Welds, Revised – 2020 (with latest amendments) & Manual for Ultrasonic Testing of Rails and Welds, Revised – 2022 (with up to date correction slips) and as directed by Engineer-in-charge for testing of Flash Butt & A.T welds.

Besides the above the work will include:

  • The Ultrasonic flaw detector should be able to ultrasonically scan/test the sectional area of the rail as per the figure given in clause 5.2.1 (b) of Indian Railway Standard Specification for Ultrasonic Testing of Rails/Welds, Revised – 2020.
  • The defect detection level reliability should satisfy Clause 6.4 of the Indian Railway Standard Specification for Ultrasonic Testing of Rails/Welds, Revised – 2020 with latest amendment(s).
  • The capability of the test system shall be verified as per provisions of Clause 6 of Indian Railway Standard Specification for Ultrasonic Testing of Rails/Welds, Revised – 2020 with latest amendment(s).
  • The calibration of USFD testing equipment should be done as per ‘Manual for Ultrasonic Testing of Rails and Welds Revised – 2022 with latest amendments.
  • Required standard test pieces (Rail testing) shall have to be manufactured & supplied by the contractor at his own cost. The rail for making the standard test piece will be supplied free of cost by the railway to the contractor.
  • This standard test piece is to be returned back to the railway after completion of the contract at a destination decided by Engineer-in- Charge or his authorised representative. No additional payment shall be made to the contractor for fabrication of aforementioned test pieces.
  • All the USFD machines should be maintained properly by the contractor and get them inspected periodically by RDSO at specified frequency or as instructed by Engineer-in- charge and shall be in good working condition at all times during the full currency of contract.
  • The correctness of machine working shall be to the satisfaction of the Engineer- in-Charge or his authorised representative and his decision shall be final & binding upon the contractor.
  • All the operators, at all times during the period of execution of contract, should possess a valid competency certificate issued by RDSO as per Clause 7 of the Indian Railway Standard Specification for Ultrasonic Testing of Rails/Welds, Revised – 2020 with latest amendment(s).
  • The Contractor shall have to propose the names of at least 02 nos. RDSO approved USFD operators for Rail testing & at least 03 nos. RDSO approved USFD operators for Weld testing after award of LoA which shall be further verified & approved by concerned Engineer.
  • A minimum no. of 01 nos. USFD A – scan DRT/SRT machines with operators shall have to be deployed by the contractor for this work which may have to be increased as per instructions of Engineer-in-Charge or his authorised representative based on the workload.
  • The identified sections may be modified/changed as per requirement during the work. The decision of the Engineer-in-Charge or his authorised representative and his decision shall be final & binding upon the contractor.
  • The daily test reports should be prepared with the test results obtained, in the format given by the Railway, duly signed by the Contractor’s Operator/Engineer and should be submitted to the Engineer-in-charge or his authorised representative the next day of testing for necessary action.
  • A bar chart/Line diagram should be maintained by each USFD team/Operator mentioning date wise testing done with respect to the Railway km/jurisdiction tested. Daily test report should contain all the items as listed in para 10.1.1 of Indian Railway Standard Specification for Ultrasonic Testing of Rails/Welds, Revised – 2020 with latest amendment(s).
  • However, the flaws classified as ‘IMR’/’IMRW’ should be reported immediately (by telephone & SMS (or) WhatsApp Message or both) to the Engineer of concerned jurisdiction. Non-compliance of this instruction will carry a penalty of Rs. 5000 per occasion. In addition to above-mentioned pattern of reporting, contractor will have to report the entire day’s working in:
    • The format as mandated by Railways (in hard copy), along with soft copy as per RDSO Specification.
  • A – Scan data record along with its software & its storage device which shall be USB Drive or External Hard Disks of sufficient capacity. Sufficient numbers of storage devices have to be made available by the contractor, at its own cost, to ensure storage of the entire A – Scan data record of the entire work of 3 years duration which should be retrievable at once.
  • Complete soft copy of A – scan records should be made available to concerned field officers at the end of every month.
  • The maximum length of Track to be tested would be 6 track km per day per DRT machine with two operators (6 rail km per day per SRT machine with one operator) & 30 nos. welds testing per operator per day per machine.
  • 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 Rails/Welds, Revised – 2020 with latest amendment(s) and as per provision of the Manual for Ultrasonic Testing of Rails & Welds, Revised – 2022 with latest correction slips. This marking of flaw shall be ensured by the contractor’s USFD teams.
  • In case any train accident occurs because of rail fracture /weld fracture due to an internal detectable flaw by USFD (till next round of USFD testing of welds done or 1 year from date of testing whichever is earlier), the firm will be disqualified for this type of work in future including encashment of Performance Guarantee for the work in hand.
  • RDSO shall act as a third party to investigate whether the defect was detectable at the time of USFD testing or not. The decision of RDSO shall be final and binding on both the parties. Accordingly, the certification by the Engineer that the Railway has no claim on contractors will be issued.
  • The contractor must have to use A – Scan USFD machines fitted with data logger along with geo- tagging & date stamping features.
  • The contractor may be permitted to make use of the existing facility if available in IRCON office/Rest house 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 ensure his own accommodation for their stay during the period of contract.
  • However, he may be permitted, as per extant provisions, to construct a temporary accommodation in the Railway premises for their Office and staff which shall have to be removed after the currency of the contract and it shall infer no right upon the contractor to use that temporary accommodation once that temporary accommodation has been instructed to vacate by the Engineer-in-charge or his authorised representative.
  • No Railway accommodation will be provided for this purpose. The rates quoted by the tenderer shall be inclusive of all such charges.
  • Railway will not provide any conveyance to the site of testing. The firm will have to apply for an identity card (to be carried by the contractor’s operators/team all the time during work) for the operators/employees who are deployed to execute the work.
  • The testing shall be carried out between sunrises to sunset. No night testing will be permitted after sunset.
  • The contractor / their representative / staff should be well conversant with the area and with the working on track as regards to safety of traffic, personnel safety and will have to give a certificate to this effect. No compensation will be paid on whatsoever account. Contractor should indemnify the railway 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 or his authorised representative.
  • At some locations the track is situated in track circuited / HT traction and the USFD tester shall be provided with necessary insulations and shall not cause any failure of circuits.
  • For each such failure, the railway shall impose a penalty of Rs.10,000/-. The decision to impose the penalty by railway shall be final and binding on the contractor.
  • All losses force majeure with Ultrasonic flaw detection in this work will be borne by the contractor. Ultrasonic flaw detector and accessories shall be kept in safe custody of the contractor and Railway shall not be responsible for any loss or damage.
  • Payment for the work will be released by Engineer-In-charge based on measurements recorded, all supporting documents, test checks, penalty for overdue testing and compliance of other conditions of contract etc. provided by the respective Field Officers.
  • The Contractor shall provide all detailed reports to concerned filed officers & all necessary test checks shall be done by the respective officers. The field officers shall then provide a monthly summary report & progress report to Engineer-In-charge.
  • All costs during testing will be borne by the contractor. No advance payment towards mobilisation shall be paid to the contractor. Periodically on account bills shall be paid to the contractor on request only for the work done during the period.
  • The work shall be carried out as per program given by Railway and there should be no overdue as the testing is to be done as per the frequencies stipulated.
  • Indian Railway Standard Specification for Ultrasonic Testing of Rails/Welds, Revised – 2020 with latest amendment(s) & Manual for Ultrasonic Testing of Rails & Welds, Revised – 2022 with latest amendment(s) will be deemed to the part of this tender document.
  • The contractor must ensure that its A – scan machines possess valid approval of RDSO during the entire validity of work.
  • The contractor must ensure that its A – scan machine operators possess valid approval of RDSO during the entire validity of work.
  • In future, if RDSO approved weld testing by A – Scan machines, the same shall have to be ensured by the Contractor, till that point of time, the USFD testing of welds shall be carried out by the contractor by A – scan machines duly approved by RDSO.
  • In case any amendment and/or correction slip and/or revision is issued to Indian Railway Standard Specification for Ultrasonic Testing of Rails/Welds, Revised – 2020 and/or Manual for Ultrasonic Testing of Rails & Welds, Revised – 2022 the same shall be deemed to be part and parcel of this work & subsequent work shall be carried out by the contractor as per updated instructions of engineer-in-charge or his authorised representative. The decision of Engineer-in- Charge shall be final & binding upon the contractor.
  • The USFD testing shall be carried out from Sawlakote to Banihal (IRCON Portion) . The sections & locations of Weld testing shall be communicated time to time by the Railways to the Contractor. The decision of the Engineer-in-Charge shall be final & binding upon the Contractor.
  • Contractor shall ensure that all his workmen are given equipment as is necessary to work in all adverse conditions of weather.
  • All the tools, plants, equipment and other materials used by the contractor shall be of approved type only.
  • No additional payment would be made by IRCON for compiling above conditions mentioned in para 2.4 of SCC.

Eligibility:

The average annual financial turnover during the last 3-years should be at least 30% of the estimated cost.

The bidder should possess the experience of having successfully completed or substantially completed similar works during the last 7-years (ending last day of the month previous to the one in which tenders are invited) which should be anyone of the following:

  • Three similar works each costing not less than the amount equal to 30% of the estimated cost.
  • Two similar works each costing not less than the amount equal to 40% of the estimated cost.
  • One similar work costing not less than the amount equal to 60% of the estimated cost.

Similar Nature of works means:

RDSO approved QAP for Rail Testing with A-Scan Machines & QAP for Weld Testing.

Documentary evidence of: “Owning of at least 01 no. DRT/SRT B – scan RDSO approved machines (equipped with 9 channels) and minimum 03 nos. of RDSO approved Weld Testing Machines” “or” “Proof of entering into MoU with Manufacturer/Supplier of RDSO Approved Vendor for at least 01 no. DRT/SRT A – scan RDSO approved machines (equipped with 9 channels) and minimum 03 nos. of RDSO approved Weld Testing Machines.”

The complete documents can be downloaded from https://etenders.gov.in/eprocure/app

Source: IRCON- Tender | Image Credit (representational): MoR

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