Rail Infrastructure Development Company (Karnataka) Limited (K-RIDE) has floated bids, for Yesvantpur-Channasandra and Baiyyappanahalli-Hosur Doubling Projects: Flash Butt welding of new/second hand 60kg/52kg/260R rails (90UTS/72 UTS) Rails/Panels at site using rail cum Road Mobile Flash Butt welding plant including USFD testing of welded joints.
- Tender Reference Number: KRIDE/2023-24/OW/WORK_INDENT11
- Name of Work: Yesvantpur-Channasandra and Baiyyappanahalli-Hosur Doubling Projects: Flash Butt welding of new/second hand 60kg/52kg/260R rails (90UTS/72 UTS) Rails/Panels at site using rail cum Road Mobile Flash Butt welding plant including USFD testing of welded joints.
- Estimated Cost of Work: INR 2.83 Crores
- EMD: INR 4,25,150 /-
- Period of Work: 18 Months
- Document Download / Sale Start Date: 06th Oct, 2023
- Document Download / Sale End Date: 06th Nov, 2023
- Bid Submission Start Date: 06th Oct, 2023
- Bid Submission End Date: 06th Nov, 2023
- Tender Opening Date: 06th Nov, 2023
General:
Indian Railway Standard Specification for “Flash Butt welding of new/second hand 60kg/52kg/260R rails (90UTS/260R/72 UTS) Rails/Panels at site using rail cum Road Mobile Flash Butt welding plant including USFD testing of welded joints”.
Manual for Flash Butt Welding of Rails (Revised January 2012) with uptodate correction slips issued by RDSO and USFD testing of welded joints conforming to Manual Ultrasonic Testing of Rails and welds2022 with uptodate correction slips issued by RDSO can be seen from the KRIDE office.
These specifications shall be applicable for all works covered in this contract. It is presumed that bidders have gone through the above (including latest correction slips) before quoting the rates.
Special conditions of contract for Mobile Flash Butt Welding of Rails:
These instructions are laid down for execution of flash butt welding work at site/depot/on track by a robust and sturdy, self-propelled Rail-cum-Road Vehicle mounted Flash Butt Mobile Welding Plant (hereinafter called RCRV-MFBWP), which should be suitable for aligning and welding of rails/panels to produce long welded rails on running/non running lines as laid down in Manual for Flash Butt Welding of Rails (Revised January 2012) with up to date correction slips issued by Research Design and Standard Organization (RDSO), Ministry of Railways, Lucknow (Manual for FBWR ).
Scope of Work:
- The work involves carrying out Flash Butt welding of rail joints including USFD testing of welds executed at site using contractor’s own labour, own Rail cum Road Vehicle mounted Flash Butt Mobile Welding Plant (RCRV-MFBWP), USFD machine, own infrastructure and all other tools & plants in-situ on non-running lines / running lines or cess / ballasted bed in existing lines etc. at various locations on South Western Railway.
- Flash Butt Welding of rails/rail panels shall conform to the specifications in the Manual for FBWR and USFD testing of welded joints shall conform to Manual Ultrasonic Testing of Rails and welds-2022 with up to date correction slips issued by RDSO.
- The contractor has to make his own arrangement for positioning/movement of rail or rail panels, pull and align the rail for creating gaps, end cleaning of Rails, welding and stripping of welded joints, grinding and final finishing of welded Joints etc. complete.
- The contractor shall arrange adequate labour, competent supervision, equipment for grinding, welding, stripping, pre and post straightening as required. All the machineries, equipments, tools and plants, labour, transportation, fuel etc., required for the work in complete shall be arranged and provided by the contractor at his own cost.
- Rails to be welded will be of 60kg/52kg (90UTS/260R//72UTS). The welding process and methodology will be governed by the Manual for FBWR and guidelines issued by RDSO from time to time.
- Rails as mentioned above will be supplied by KRIDE at locations along the section on cess or in yards. KRIDE may also offer rails already linked in the track. It shall be the responsibility of the contractor to pull and align the rails supplied on cess/ depot as required and directed by the Engineer –in – charge with the rails in “head on” position without allowing the rail ends to contact with soil.
- The contractor shall arrange all the necessary plant & equipment, labour to handle, move and distribute the rails for welding. The contractor shall exercise special care in handling of rails so as not to bend or damage them and shall follow the stipulations of Para no.11 – “Handling instructions for 90 UTS rails- as detailed in Manual for FBWR.
- In addition, the contractor shall maintain an on-site equipment and labour to straighten and re-align rails that may have been bent or damaged during the rail -handling process, to straightness tolerances as specified.
- The contractor shall ensure that the handling rails or welded rail panels shall be such that the sleepers suffer no damage. Rails or welded rail panels shall not be dropped onto place. If rails are being welded away from the exact locations of their use, the welded rail panels shall be stacked on levelled and well drained platforms suitably supported in head-on position near to the site of the use.
- Locations/Sites for setting up of temporary welding depots will be identified by the KRIDE authorised supervisor/ agency.
Flash Butt Welding Plant:
The tenderer along with their offer shall indicate the model of RCRV-MFBW-Machine proposed to be deployed for the execution of work with a detailed Technical Description of the same with System/sub-systems and working mechanisms of the machine.
The Machine deployed should be of reputed make with proven credentials. The machine shall conform to the General, Functional and Technical requirements etc. as prescribed by Railway Board/RDSO guidelines and instructions.
A Photograph and technical literature of the RCRV-MFBW machine proposed to be deployed shall also be enclosed with the tender. The photographs shall also show close-ups of various working assemblies/systems and the full RCRV-MFBW-Machine. The tenderer may also furnish video compact disc showing the working of RCRV-MFBW- Machine in real time under field condition.
The RCRV-MFBW-Machine shall be self-contained and self-propelled vehicle consisting of (i) Flash Butt Welding unit (ii) Carrier Vehicle (Rail cum Road) and capable of executing in-situ welds on Running / Non-running lines / cess / ballasted bed by the side of the existing lines as well as on yards.
The RCRV-MFBW Machine shall be mounted on such a carrier vehicle with all necessary requisites/ attachments / manipulator etc. for carrying out all operations related to welding of rail joints as per Indian Railway’s Manual for FBWR.
The Plant should be designed for welding rails by the Electric-Flash Butt Welding Process. Each welding machine shall be equipped with a brush recorder to produce charts showing traces of electrical impulses and movable platen travel, with simultaneous recording of butting pressure, upset force or pressure (forging) for each weld.
The RCRV-MFBW-Machine should be capable to weld rails of various sections and of various metallurgical properties and various tensile strengths (72 UTS/90 UTS/ 110 UTS/ R 260 grade) specified in IRSS for Flat Bottom Rails (IRS T-12-2009 or later) with up to date A&C slips (hereinafter called specification of rails) continuously to form LWR/CWR in-situ or on cess. The welding head shall be capable of welding single rails to 20 (twenty) rail panels or of any intermediate length or longer lengths in different situations.
The MFBWP shall be capable of welding rails under the following situations:
- Newly laid track in construction sites;
- On running track in mid-section during traffic block;
- On roller line in depot as stationary unit or in travel and stop mode.
- Outside the track:
- At sleeper end.
- Shoulder of track
- Cess welding.
- End cropping and welding.
Ultrasonic Test (USFD):
All welded joints shall be subjected to ultrasonic testing for detecting presence of internal defects in the weld in accordance with Para 10.1.3 of Manual for FBWR.
This test can be done manually by the contractor using his own RDSO approved Digital USFD testing machines. Testing shall be carried out by the contractor’s RDSO approved/certified operator under the supervision of Railway/KRIDE supervisor.
Eligibility:
- To qualify for award of this contract, each tenderer in its name should have in the last five financial years, i.e. from 2017-18 to 2022-23 should have achieved in at least two financial years a minimum financial turnover of Rs. 3.77 Crore.
- The Tenderer/Firm/Company should have satisfactorily completed at least one similar work such as “Rail welding with Mobile Flash Butt Welding Machine ” of value not less than Rs. 1.41 Crores at current FY: 2022-23 price level in the last five financial years. (FY 2017-18 – 2022-23 Including current financial year up to the date of submission of the tender.
- Similar work is defined as “Rail welding with Mobile Flash Butt Welding Machine by RDSO approved firms.”
The complete documents can be downloaded from https://eproc.karnataka.gov.in
Source: K-RIDE- Tender | Image Credit (representational): East Coast Railway
