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PAKISTAN RAILWAYS

BIDDING DOCUMENTS

FOR

REHABILITATION OF DE LOCOMOTIVES
ON PPP /BOT BASIS

MARCH, 2019

Chief Mechanical Engineer / Loco


Headquarters Office, Empress Road
Lahore, Pakistan
PH: +92-42-99201740
These Bidding/ Bid Documents (BD) have been prepared by Pakistan Railways (PR). It
has two parts; Part I & Part II. Part I comprises of invitation for bidding, instructions for
bidders, conditions for the competitive bidding and appendices. Part II comprises of
introductions to the projects and technical specifications and scope of works separately for
each loco project.
The information contained in the Bidding Documents and various statements, which reflect
various assumptions and assessments arrived at by PR does not purport to be all-inclusive
or to contain all of the information that the Bidder and its advisers may require or desire in
relation to the Project. The Bidder should form its own views as to what information is
relevant and make its own investigations, projections and conclusions and consult its own
advisers to verify independently the information provided, and to obtain any additional
information that it may require, prior to submitting a Bid.
None of PR, any of its subsidiary, the Government nor their respective directors, officers,
members, employees, agents or advisers shall have any responsibility for the accuracy or
completeness of the contents of the BD (including any opinions expressed) and no
representation or warranty, express or implied, is given by any such person as to the
accuracy or completeness of such information or opinions. In particular, no representation
or warranty is given as to the accuracy, reasonableness or likelihood of achievement of any
future projections, prospects or returns.
Neither PR, any of its subsidiary, the Government nor their respective directors, officers,
members, employees, agents or advisers shall have any responsibility or liability for any
costs, expenses or other liabilities incurred by any participant in the bidding process.
The BD and the information contained therein are confidential and may not be issued,
published, distributed or otherwise divulged to any unauthorized persons.
In submitting a Proposal in response to this BD, each Bidder certifies that it understands,
accepts and agrees to the disclaimers set forth above. Nothing contained in any other
provision of the BD nor any statements made orally or in writing by any person or party
shall have the effect of negating or suspending any of the disclaimers set forth in this
disclaimer.
DEFINITIONS
1. “Government” means Government of Pakistan and all its associated Departments,
Agencies, Autonomous/Semi- Autonomous Bodies, Boards, Universities and similar
other Organizations.
2. “PR” means Pakistan Railways, a Federal Department of Government of Pakistan.
3. “Employer” means Pakistan Railways acting through Chief Mechanical Engineer /
Loco, Pakistan Railways, Headquarter Office, Lahore.
4. “Bidder” means firm / consortia submitted Bid.
5. “Bidding or Competition” means the competition being conducted by Pakistan
Railways to select the Bidder on the terms set out in the Bidding Documents.
6. “Project” means the projects of “Rehabilitation of D.E. Locomotives offered for
participation under Build-Operate-Transfer (B.O.T) or any mode of Public Private
Partnership (PPP) and includes engineering, procurement, construction, finance and
operation (if applicable).
7. “Concession Agreement” means the Agreement to be entered into between
Concessionaire and the Pakistan Railways setting out the rights and obligations of the
Concessionaire in relation to the carrying out of the project, its subsequent
management, operation and handing over to PR.
8. “Concessionaire” means the firm / consortia emerged as successful in competitive
bidding and with whom Concession Agreement will be signed.
9. “Bid or Proposal” means the Technical Proposal and the Financial Proposal.
INTERPRETATION
In this BD, unless the context otherwise requires:
(a) Any reference to a statutory provision shall include such provision as is from time to time
modified or re-enacted or consolidated so far as such modification or re-enactment or
consolidation applies or is capable of applying to any transactions entered in to
hereunder;
(b) the words importing singular shall include plural and vice versa, and words denoting
natural persons shall include partnerships, firms, companies, corporations, joint ventures,
trusts, associations, organizations or other entities (whether or not having a separate legal
entity);
(c) the headings are for convenience of reference only and shall not be used in, and shall not
affect, the construction or interpretation of this BD;
(d) the words "include" and "including" are to be construed without limitation;
(e) references to "construction or up-gradation or rehabilitation" include investigation,
design, engineering, procurement, delivery, transportation, installation, processing,
fabrication, testing, commissioning and other activities incidental to the construction, up-
gradation or rehabilitation;
(f) any reference to any period of time shall mean a reference to that according to Pakistan
Standard Time;
(g) any reference to day shall mean a reference to a calendar day;
(h) any reference to month shall mean a reference to a calendar month;
(i) the attached volumes of this BD or any Addendum issued later on to clarify the Bidders,
if any, form an integral part of this BD and will be in full force and effect as though they
were expressly set out in the body of this BD jointly referred as Bid or Proposal;
(j) unless otherwise stated, any reference to any period commencing "from" a specified day
or date and "till" or "until" a specified day or date shall include both such days or dates;
and
(k) Any reference to Bidding Process shall mean the entire process commencing from
issuance of BD until signing of Concession Agreement with the Concessionaire.
Part I
Table of Contents
SECTION 1: INVITATION FOR BIDDING
SECTION 2: INSTRUCTIONS TO BIDDERS

SECTION 3: CONDITIONS OF THE COMPETITION/BIDDING

SECTION 4: ANNEXURE AND APPENDICES


SECTION 1

INVITATION FOR
BIDDING
SECTION 1: Invitation for Bidding
No. 394-W/565/235/89(Dev) Date: 21-03- 2019.

SUBJECT: INVITATION OF BIDS FOR REHABILITATION OF


D.E.LOCOMOTIVES ON PPP /BOT BASIS

1. On behalf of Pakistan Railway, Government of Pakistan, the Chief Mechanical


Engineer/Loco invites proposals / bids for rehabilitation of the following locomotives:

i. Rehabilitation of 30 Diesel Electric Locomotives (AGE-30) manufactured by


General Electric USA.
ii. Up gradation and modernization of 44 Diesel Electric Locomotives (DPU-30)
manufactured by Dalian Locomotives and Rolling Stock Works China.
iii. Up gradation and modernization of 25 Diesel Electric Locomotives (DPU-20)
manufactured by Dalian Locomotives and Rolling Stock Works, China.
iv. Rehabilitation of 20 Diesel Electric Locomotives (GMU-30) manufactured by
Electromotive Diesel (EMD), USA.
2. The Bidder can submit Bid / Proposal for any one, more than one or all projects as
stated above.
3. Separate proposal for every project is to be submitted by the bidder.
4. The bidding procedure shall be Two Stage in accordance with Rule 36 (c) of Public
Procurement Rules – 2004.
5. It is mandatory for proposals to be prepared using Standard Forms of BD. However,
bidder can provide additional information if desired so.
6. In case a Bid is submitted as a consortium or a JV, all members thereof are required to
furnish a memorandum of understanding legally binding all members, jointly and
severally using the format defined in Annex-A Format of Consortium or JV, and a
power of attorney in favour of the lead member using the format defined in Annex-B
Format of Authorization of Lead Member.
7. The Bids / Technical proposals are to be submitted in separate sealed envelopes at the
following address not later than 23rd April, 2019 till 11:00 Hrs.

Yours truly,

(Samin Ullah Ghandapur)


Chief Mechanical Engineer / Loco
Pakistan Railways, Headquarter Office
Empress Road,Lahore.
042 – 99201740
SECTION 2
INSTRUCTIONS TO
BIDDERS
SECTION 2: INSTRUCTIONS TO BIDDERS

2.1Competitive Bidding Procedure


2.1.1 A pre-bid conference shall be convened as per following schedule:
Date & time:10th April, 2019 at 11:00 Hrs
Venue: Office of Chief Mechanical Engineer / Loco, Pakistan Railways,
Headquarter Office, Lahore.
2.1.2 The Bidding will be done based on Two Stage bidding procedure in accordance with
Public Procurement Rules – 2004 (Rule No. 36,c), which is explained below:
a. First Stage:
i. the bidder shall first submit, according to the required specification, a technical
proposal without price;
ii. the technical proposal shall be evaluated in accordance with specified evaluation
criteria and may be discussed with the bidders regarding any deficiencies and
unsatisfactory technical features;
iii. after such discussions, all the bidders shall be permitted to revise their respective
technical proposals to meet the requirements of the procuring agency;
iv. The procuring agency may revise, delete, modify or add any aspect of the
technical requirements or evaluation criteria, or it may add new requirements or
criteria;
 Provided that such revisions, deletions, modifications or additions are
communicated to all the bidders equally at the time of invitation to submit
final bids, and sufficient time is allowed to the bidders to prepare their revise
bids:
 Provided further that such allowance of time shall not less than fifteen days in
the case of national competitive bidding and thirty days in the case of
international competitive bidding;
v. The bidders not willing to conform their respective bids to the procuring agency’s
technical requirements may be allowed to withdraw from the bidding without
forfeiture of their bid security;
b. Second Stage:
vi. the bidders, whose technical proposals or bids have not been rejected and who are
willing to conform their bids to the revised technical requirements of the
procuring agency, shall be invited to submit a revised technical proposal along
with the financial proposal;
vii. the revised technical proposal and the financial proposal shall be opened at a time,
date and venue announced and communicated to the bidders in advance; and
viii. The revised technical proposal and the financial proposal shall be evaluated in the
manner prescribed above. The bid found to be the lowest evaluated bid shall be
accepted:
 Provided that in setting the date for the submission of the revised technical
proposal and financial a procuring agency shall allow sufficient time to the
bidders to incorporate the agreed upon changes in the technical proposal and
prepare their financial proposals accordingly.
2.1.3 Concession agreement will be signed by PR with selected Bidder.
2.2 Qualification / Evaluation Criteria

2.2.1 The rates of foreign exchange to be used for tender evaluation shall be Inter bank rates
issued daily by the State Bank of Pakistan and applicable to similar transaction on the
day bids are opened.
2.2.2 The weightage/ratings for technical and financial proposals would be as under:

a. Technical : 70 %
b. Financial : 30 %
2.2.3 The offers shall be graded as per evaluation criteria enclosed with the technical
specifications (Part-II). The minimum marks required to qualify for opening of financial
offer shall be 80% and subject to be specifically declared as technically suitable.

2.2.4 The tender with the lowest evaluated cost but not necessarily the lowest submitted
price may be considered but, the Employer does not bind himself to accept the lowest
or any tender and reserves the right to reject any or all tenders.
2.2.5 The Bidder failed to meet the mandatory requirement or failed to secure minimum
qualifying score shall not be considered for further processing and not allowed to
participate in second stage.
2.2.6 Marks indicated in evaluation criteria are the maximum and marking will be in between
0 and maximum marks.
2.2.7 The comparative financial position/statement will be prepared on proportionate basis.
Those at first position (lowest) will be given full marks, whereas others will be awarded
proportionally lower marks.
2.2.8 Pre bid clarifications and any other clarification will prevail over the original tender
documents.

2.1 Bidding Documents (BD)


The purpose of BD is to define the conditions, procedures, information requirements
and evaluation criteria that apply to the Bids to be submitted by the Bidders.

2.2 Submission, Receipt and Opening of Proposals


2.4.1 The Bidder can participate in more than one project. However, any bidder participating
in any specific project independently will not become the part of any JV / Consortium
in that project. Any bidder becoming the part of any JV / Consortium in a specific
project will not become the part of any other JV / Consortium in the same project. The
proposals found with such issues will be rejected.
2.4.2 For the Bidder if comprises of a Consortium or JV shall remain the same for all the
projects, if applied for more than one project.
2.4.3 Any firm being part of one Consortium / JV cannot become part of any other
Consortium or JV.
2.4.4 The Bidder can submit Bid / Proposal for any one, more than one or all projects.
However, separate proposal for every project is to be submitted by the bidder.
2.4.5 The Proposal, as well as all related correspondence exchanged by the Bidders and the
Employer, shall be written in English language. Any document in other language(s)
must be supported by its translation in English.
2.4.6 In preparing their Proposal, Bidders are expected to examine in detail the documents
comprising the BD. Material deficiencies in providing the information requested may
result in rejection of a Proposal.
2.4.7 The Bidders are required to submit original and two copies of Technical Proposal.
2.4.8 In addition to above the Bidder are required to provide soft copy of Technical Proposal
on CD-Rom or USB.
2.4.9 An authorized representative of the Bidders shall initial all pages of the original
Technical Proposal. The authorization shall be in the form of a written power of
attorney accompanying the Proposal or in any other form demonstrating that the
representative has been duly authorized to sign. The signed Technical Proposal shall be
marked “ORIGINAL”.
2.4.10 The Technical Proposal shall be marked “ORIGINAL” or “COPY” as appropriate. All
required copies of the Technical Proposal are to be made from the original. If there are
discrepancies between the original and the copies of the Technical Proposal, the original
governs.
2.4.11 The original and all copies of the Technical Proposal shall be placed in a sealed
envelope clearly marked “TECHNICAL PROPOSAL” followed by the name of the
assignment. The Employer shall not be responsible for misplacement, losing or
premature opening if the outer envelope is not sealed and/or marked as stipulated.
2.4.12 The Proposals must be sent to the address indicated below and received by the
Employer not later than the time and the date mentioned below, or any extension
granted thereof. Any proposal received by the Employer after the deadline for
submission shall be returned unopened.

Chief Mechanical Engineer / Loco,


Pakistan Railways, Headquarters Office,
Empress Road, Lahore.
+92-42-99201740

Last Date of Submission–23rd April, 2019 not later than 11:00 Hrs.

2.4.13 The Employer shall open the Technical Proposals half an hour after the deadline for
their submission.
2.4.14 The Bidder shall elaborate in the Technical Proposal the detailed methodology and
procedure for executing the project. The Bidder must clearly specify the type of PPP
mode proposed for the project.
2.4.15 Financial Information or Financial Model is not required at this stage. Bidders are
requested not to disclose any financial aspects.
2.4.16 The Bidder must provide methodology in the Technical Proposal separately for each
project if intend to participate in more than one project.

2.5 Clarification and Amendment of Bidding Documents

2.5.1 Bidders may request a clarification of any of the Bidding documents, seven days prior
to last date of proposal submission. Any request for clarification must be sent in writing,
or by standard electronic means to the Employer’s address. The Employer will respond
in writing, or by standard electronic means and will send written copies of the response
(including an explanation of the query but without identifying the source of inquiry) to
all Bidders. Should the Employer deem it necessary to amend the BD as a result of a
clarification, it shall do so following the procedure as stated in para below.
2.5.2 At any time before the submission of Proposals, the Employer may amend the BD by
issuing an addendum. To give Bidders reasonable time in which to take an amendment
into account in their Proposals the Employer may, if the amendment is substantial,
extend the deadline for the submission of Proposals.
2.6 Evaluation of Technical Proposal
2.6.1 The evaluation committee shall evaluate the Technical Proposals on the basis of their
responsiveness to the requirements of BD, applying the evaluation criteria, sub-criteria
specified in Qualification / Evaluation Criteria in DB. Being Two stage bidding
procedure, the Employer may call any or all Bidders for technical discussions. As a
result of technical discussion or at Employer’s own requirement, the Employer will
issue amended / revised proposal to all bidders.
2.6.2 The bidders shall be allowed to resubmit their revised / amended technical proposals,
meeting the PR’s requirements along with Financial Proposal. Sufficient time shall be
given to the Bidders to incorporate the agreed upon changes in the Technical Proposal
and to prepare the required financial proposal.
2.6.3 The bidder shall have to fulfill the mandatory clause as given in annexures.

2.7 Public Opening and Evaluation of Financial Proposals


2.7.1 The revised Technical Proposal along with the Financial Proposal shall be opened
publically at a date, time and venue announced in advance for which each Bidder shall
be notified in writing. The opening date shall be set so as to allow interested Bidders
sufficient time to make arrangements for attending the opening.
2.7.2 A Committee will evaluate the revised Technical Proposal along with the Financial
Proposal. As a result of evaluation, Preferred Bidder, whose technical and financial
proposals is most conforming to the requirement of PR and whose financial offer
including concession period found to be most suitable to PR shall be selected for
executing Concession Agreement.
2.7.3 The Evaluation Committee will correct any arithmetical / computational errors. When
correcting computational errors, in case of discrepancy between a partial amount and
the total amount, or between word and figures, the formers will prevail. Such
corrections shall be binding upon Bidders.

2.8 Integrity Pact


2.8.1 To comply with requirement of Public Procurement Regulatory Authority (PPRA), the
successful Bidder shall sign and stamp the Integrity Pact.

2.9 Submission to Public Private Partnership Authority (PPPA)


2.9.1 To comply with the provision of PPPA Act, 2017, the Implementation Agency (i.e.,
Pakistan Railway) is required to obtain approval from PPPA. Therefore, the finalized
proposal including technical and financial model will be submitted to PPPA for
approval before award of concession agreement.

2.10 Technical Requirements

2.10.1 The detailed technical parameters applicable to Rehabilitation/modernizations of DE


locomotives all the projects together with the standards and general description of
works required, are set out in Part II. The purpose of Appendix-B is to describe the core
design and construction requirements for the project.
2.10.2 If, for some of the requirements stated in Part II, a Bidder wishes to propose alternatives
to what is specified, it must demonstrate that, these will provide at least equivalent
quality of services with no loss of performance or in relation to the RAMS criteria in
the short, medium and long run.
2.10.3 It should be noted that the design requirements, standards and specifications given in
Par-II are the minimum requirements, and that the Concessionaire is responsible for
ensuring that all works designed and constructed by him, specifications followed and
materials procured meet the basic requirements for efficient operation and working of
the Railway. The Concessionaire is also required to ensure that all works, execution
methods, maintenance activities, materials, etc. meet the national (Pakistan) and
international requirements and standards.
2.11 Contractual Structure
2.11.1 The projects will be Financed, Built, Operated (if applicable) and Transferred by the
Concessionaire.
2.11.2 The Concessionaire, before or immediately after signing of Concession Agreement will
register its firm / consortia with Security and Exchange Commission of Pakistan
(SECP).
2.11.3 For the purpose of construction the Concessionaire or its nominated contractor shall
require to be registered with Pakistan Engineering Council (PEC) and must fulfill the
Bylaws of PEC.(if applicable).
2.11.4 The Concessionaire shall require to be registered with Income Tax and Sales Tax
department of Federal Board of Revenue (FBR).
2.11.5 The relationship between PR and the Concessionaire shall be governed by the
Concession Agreement entered into between the two parties, which will detail the
contributions and responsibilities of PR and the Concessionaire, establish the economic
relationship inherent in the transaction and set out all other terms and conditions
necessary to define the relationship between the two parties. The Draft Concession
Agreement shall be provided at Second Stage.
2.11.6 Subject to and in accordance with the terms and conditions set forth in the Concession
Agreement, PR shall grant to the Concessionaire the right to investigate, study, design,
engineer, procure, construct, finance, operate, maintain and transfer the Project and to
exercise and/or enjoy the rights, powers, privileges, authorizations and entitlements as
set forth in the Concession Agreement (collectively “the Concession”).
2.11.7 The Concessionaire may undertake the Project through a Special Purpose Vehicle (the
“SPV”) incorporated under the laws of Pakistan as a corporate entity, provided that
such company’s shareholding is the same as indicated in the Bid.
2.12 Financial Structure
2.12.1 The Concessionaire will be required to finance the Total Project Budget, and to achieve
Financial Closing by the agreed Scheduled Closing Date.
2.12.2 PR envisages the Concessionaire will secure funding for the Total Project Budget from
a number of sources, including:
a. Debt facilities, including commercial, export credit agency ("ECA”), Local
and International Bank Loaning and International Financial Institutions’
funding facilities raised in local, regional and international markets keeping
in view foreign policies / relations of the Government.
2.12.3 Any of PR assets including locomotives shall not be used as collateral for obtaining
loan.
2.13 Public Sector Contribution / Viability Gap Funding (VGF)
2.13.1 In order to assist the Concessionaire with its financing obligations and to enhance the
economic viability of the Project, the Government will, if requested, make available to
the Concessionaire a capital grant, to be paid upon Completion. The amount of capital
grant requested by each Bidder will be the key financial criterion on which each Bid is
evaluated.

2.14 Model for Rehabilitation of Locomotives


2.14.1 The Bidder should elaborate in Technical Proposal the detailed model under which he
intend to finance and rehabilitate locomotives. Only the methodology of such model
shall be provided for evaluation by the Employer and no financial aspects / figures
should be disclosed at this stage.
2.14.2 The Bidder can offer more than one model of financing and rehabilitation.
2.15 Utilization of PR Facilities
2.15.1 If Bidder intends to utilize PR facilities for rehabilitation same should be clearly
identified in the model / methodology.
2.16 Regulatory Framework
2.16.1 The Project and the Concessionaire will be subject to a regulatory framework.
2.16.2 An independent regulatory body for the railways in the Pakistan will be established,
governed by a board chaired by the Secretary / Chairman of Railways. Its principal
functions will be:

2.16.2(a) To license the providers of certain types of railway services.

The purpose of the licensing regime is to ensure that a person proposing to


provide the specified railway services is of good repute, safe for operation,
financially fit, professionally competent and has adequate insurance cover
for its proposed activities.

The specified services comprise the operation of a train on a railway network


for any purpose, including the carriage of passengers and goods by railway,
the management of a railway network and the management of a station.

2.16.2(b)To monitor and control anti-competitive behavior in railway services


markets

These controls will enable the regulatory body to take steps to curb abuse of
a dominant position and other anti-competitive practices. Actions which are
authorised by the Concession Agreement will not be subject to these
controls.
2.16.2(c)To facilitate access to railway facilities
If a third party is unable to agree terms with the Concessionaire for access
to a railway network in connection with the provision of freight or passenger
services, it can seek a direction from the Regulatory Body requiring the
Concessionaire to grant access. The Concession Agreement may stipulate
circumstances in which the Concessionaire cannot be directed by the
Regulatory Body to grant access.
2.16.2(d)To secure the safety of railway activities
A railway safety directorate within the regulatory body will have powers to
make regulations to ensure the safety of the Railway operation. Approval
from the directorate will be required before new works, rolling stock, plant
or equipment are first brought into use and any person providing railway
services will have first to obtain safety accreditation.
2.16.2(e)To investigate railway accidents and incidents
The regulatory body will have the power, and in some cases the duty, to
investigate and report on railway accidents and incidents.

2.16.3 The Ministry of Railways will be responsible for producing and implementing a
strategy for the development of railways in the Pakistan with the approval of Railway
Board. The Ministry will conduct the tendering of any further concessions and
following the award of a concession will administer, monitor and enforce it.
2.16.4 In carrying out their functions the Ministry and the Regulatory Body will seek to further
the development of the Railway system and railway services as set out in the legislation.
2.16.5 Till the time an independent regulatory body for the Railways is established, the Federal
Government Inspector of Railways (FGIR), who is an independent entity working
directly under the control of Ministry of Railways, will perform all the functions of
proposed regulatory body.
2.17 Project Monitoring during construction / up-gradation
2.17.1 During rehabilitation of locomotives, Project Director Rehabilitation of
Locomotives/MGPR will be responsible for overseeing the Concessionaire’s
activities, including, but not limited to, assessing various performance metrics such as
quality of the work done.
SECTION 3

CONDITIONS OF THE
COMPETITION /
BIDDING
Section 3: Conditions of the Competition / Bidding
3.1 General

3.1.1 The PR may reject all bids or proposals at any time prior to the acceptance of a
bid or proposal.

3.1.2 The PR shall upon request, communicate to any Bidder who submitted a bid or
proposal, the grounds for its rejection of all bids or proposals, but is not required to
justify those grounds and The PR shall incur no liability.

3.1.3 Among other reasons, a Bid may be rejected if the Bidder:

3.1.3.1 Fails to submit the Bid Security in the form and in accordance with the
requirements as stated in the BD.

3.1.3.2 Fails to provide information and technical proposal as stated in the BD.

3.2 Bid Validity


3.2.1 The technical proposal / Bids must remain valid for 180 days from the last date of
submission. The Employer will make its best effort to complete evaluation and
technical negotiations within this period. Should the need arise; however, the
Employer may request Bidders to extend the validity period of their proposals. The
proposals of Bidders who agree to such extension shall be processed further. The
Bidders who do not agree, have the right to refuse to extend the validity of their
Proposals and further processing of their proposal shall be stopped and their bid
security shall be returned.

3.2.2 The qualified bidder, entitled for submission of revised technical and financial
proposal in second stage will extend the validity of bid security further six months.

3.2.3 Financial Bids (in Second stage) shall be valid for a period of six months from the
last date of submission of Financial Proposal in Second Stage.

3.3 Bid Security


3.3.1 All Bidders are required to submit a Bid Security with their Bids for a value of Pak
Rs100.00 million in accordance with format attached as Appendix-F, whether the
bidder applied for one project or more than one project.

3.3.2 Bid Security will be returned to all Bidders, except Selected/ Winning Bidder,
within 30 days of the announcement of the selection of the selected Bidder.

3.3.3 The Bid Security of the Selected Bidder will be returned upon furnishing the
Performance Guarantee (will be defined in Second Stage) and signing of
Concession Agreement.

3.3.4 A Bidder's Bid Security may be forfeited for a number of reasons, including:
3.3.4.1 If a Bidder withdraws its Bid during the validity period of the Financial Bid, to
be submitted in Second Stage;

3.3.4.2 If selected Bidder refuses or fails to Sign the Concession Agreement;

3.3.4.3 If selected Bidder refuses or fails to provide required Performance Guarantee.

3.3.5 The Bid Security must be issued by a Scheduled Bank in Pakistan or from a foreign
bank duly counter guaranteed by a Scheduled Bank in Pakistan in favour of the
Employer valid for a period of six months from the last date of submission of
Technical Proposal. The Bidder shall be bound to extend the validity till 28 days
beyond validity period, at the time of issuance of updated or revised technical
requirement for Second Stage by the PR.

3.3.6 The selected Bidder must extend the validity of Bid Security if Bid Validity is
required to be extended by mutual consent of both parties or signing of Concession
Agreement is delayed for any reason.

3.4 Performance Security


3.4.1 The Concessionaire shall, for due and punctual performance of its obligations under
the Concession Agreement, deliver to PR, simultaneously with the execution of the
Concession Agreement, an irrevocable bank guarantee (“Performance Security”)
of an amount, which will be defined in Second Stage of tender. Such Performance
Security shall be valid in accordance with the terms of the Concession Agreement.

3.5 Governing laws


3.5.1 All contracts between the Concessionaire and the PR, including the Concession
Agreement and this BD, shall be governed by the laws of the Islamic Republic of
Pakistan.

3.6 Responsibility for verification of information


3.6.1 All information provided by PR to the Bidders is provided without any liability on
the part of PR. Bidders are required to carry out their own due diligence and
verification of this information.

3.6.2 All information, assumptions and projections contained in the BD and the
Feasibility Study (if available) are indicative only and are provided solely to assist
in preliminary assessment of the Project. Nothing in these documents or in
Feasibility Study or elsewhere shall create any contractual relationship between the
PR and any Bidder. Government of Pakistan nor PR or any of its Consultants,
particularly the Consultants who conducted Feasibility Study will have any liability
or responsibility if the information, assumptions and projections contained herein
or otherwise in respect of Project prove to be incorrect. It is the responsibility of the
Bidder to verify the information, assumptions and projections contained in these
documents or elsewhere.
3.7 Inspection of Locomotives and Site visits
3.7.1 Bidders are invited to inspect locomotives and visit relevant sites of the project, PR
will help in obtaining permissions for inspecting locomotives and visiting the sites,
if required, by the Bidders. PR should, however, be given sufficient notice in
advance of the inspection and visits planned.

3.7.2 All costs incurred by any Bidder in connection with inspection of locomotives and
any site visit will be the sole responsibility of that Bidder.

3.8 Fraud and Corrupt Practices


4.8.1. The Bidders and their respective officers, employees, agents and advisers are
required to observe the highest standard of ethics during the Bidding Process and
during the subsistence of the Concession Agreement. Notwithstanding anything to
the contrary contained herein, or in the Draft Concession Agreement, PR shall reject
a Bid, or terminate the Concession Agreement, as the case may be, without being
liable in any manner whatsoever to the Bidder or Concessionaire, as the case may
be, if it determines that the Bidder or Concessionaire, as the case may be, has,
directly or indirectly or through an agent, engaged in corrupt, fraudulent, coercive,
undesirable or restrictive practices in the Bidding Process. In such an eventuality,
PR shall forfeit in full the Bid Security or Performance Security, as the case may
be.

Following terms shall have the meaning hereinafter respectively assigned to them:

a. “corrupt practice” means the offering, giving, receiving, or soliciting,


directly or indirectly, of anything of value to influence the action of a
public official in the selection process or in agreement execution;

b. “fraudulent practice” means a misrepresentation or omission of facts


or suppression of facts or disclosure of incomplete facts, in order to
influence the Bidding Process;

c. “coercive practice” means impairing or harming or threatening to


impair or harm, directly or indirectly, any person or property to
influence any person’s participation or action in the Bidding Process;

d. “undesirable practice” means (i) establishing contact with any person


connected with or employed or engaged by PR with the objective of
canvassing, lobbying or in any manner influencing or attempting to
influence the Bidding Process; or (ii) having a conflict of interest; and

e. “restrictive practice” means forming a cartel or arriving at any


understanding or arrangement among Bidders with the objective of
restricting or manipulating a full and fair competition in the Bidding
Process.
SECTION 4

ANNEXES
AND
APPENDIXES
Annexure-A
Format of Consortium or Joint Venture
General Information

Name of Project (Please mention the name of project to be bided for)


The Bidders are required to provide following information which is necessary for further
processing of the proposals:
1. Whether, applied as Single Entity or Joint Venture / Consortium, please specify.

2. In case of Joint Venture / Consortium provide the following information along with attached
Form Annexure-2A for all JV partners.

% share proposed for the


Name of Joint Venture / Consortium
S.No. project along with
partners
description of tasks

1. Lead Partner

2. Partner No.1

3. Partner No.2

Note: The bidder may add extra rows, in case of more than three partners.

Certificate / affidavit that the bidder is not blacklisted by any government department /
authority of any country.
3. For local bidders, National Income Tax number (NTN) of Pakistan and for foreign firms Tax
Registration Number of parent country, in case of JV / Consortium please provide this
information for all partners. (please attach copies of valid registration)
4. Last three years audited reports of accounts of the firm or all the firms in case of JV /
Consortium.
5. Power of attorney to sign the proposals on behalf of JV / Consortium.
6. Joint Venture agreement in case of JV / Consortium executed between all the partners.
Annexure-A-1
Basic Information

1. Name of Firm.

2. Office address in Pakistan.

3. Office address overseas (if applicable).

4. Organization Chart (Please attach).

5. Telephone & Fax

6. e-mail

7. Contact person

8. Place of incorporation / registration of the firm

9. Year of incorporation / registration of the firm

10. Country of origin ( if other than Pakistan)

11. Type of organization (whether partnership / sole proprietorship / public limited company /
private limited company (Attach copy of Memorandum of Article, Memorandum of
Association and registration certificate with Security Exchange Commission or Registrar
of Firm or authorized department of the respective country)
Note: In case of JV / Consortium above information should be provided for all
partners separately.
Annexure-B
Authorization of Lead Firm

We, the undersigned partners of JV / Consortium for the project of (Name of Project), do hereby
authorize M/s (Name of Lead Partner)on our behalf to do all such acts necessary in connection
with our proposal and providing information / responses for the completion of the project.

Name of Signatory: _____________ Name of Signatory: _____________


Designation of Signatory: ________ Designation of Signatory: ________
Name of Firm (Partner-1): _______ Name of Firm (Partner-2): _______
Address of Firm: _______________ Address of Firm: _______________
Telephone No: _________________ Telephone No: _________________
Fax No: ______________________ Fax No: ______________________

Note: The authorization of Lead firm is required to be signed by all the partners.
1.6 Mandatory Requirements
Following shall be the mandatory requirements that each Firm/Constructor/any
partner of Consortium or Joint Venture has to meet with in order to be processed for
evaluation purposes that.

i. Firm/contractor/partner of JV have manufactured and exported at least 100 De


locomotives having GE7FDL/645 E3/EMD 710/ GE EVO series as prime
mover out of which 50 Nos. of D.E. Locomotives working satisfactorily outside
the country of manufacturer having comparable/ similar climatic conditions as
mentioned in Clause-4 as Pakistan Railway intends to recommision/rehabilitate
. Details indicating order No., year of supply, and name of customer, address
and fax No. of customer, Engine model, quantity supplied and performance
certificate by the customer (if any). The bidder will attach the undertaking with
the bid that they will follow the certified OEM specifications throughout the
remanufacturing process and will also render certificate to this fact at the time
of inspection.

ii. The Bidder shall be registered with Income Tax Department of the respective
country. (Registration Certificate be attached)

iii. The Bidder and it’s any Employee was never Black Listed by any Government
/ Semi Government, Autonomous or state owned organization of any country.

Note: If the Bidder fails to fulfill the mandatory requirements, his/their


Application will not be considered for further processing and they shall be
declared disqualified.
Appendix-F

BID SECURITY
(Bank Guarantee)

Security Executed on _______________________________________________________


(Date)
Name of Surety (Bank) with Address: ________________________________________
(Scheduled Bank in Pakistan)
Name of Principal (Bidder) with Address _______________________________________
________________________________________________________________________
Penal Sum of Security Rupees . _____________________(Rs. _____________________)
Bid Reference No. _______________________________________________________
KNOW ALL MEN BY THESE PRESENTS, that in pursuance of the terms of the Bid and at
the request of the said Principal (Bidder) we, the Surety above named, are held and firmly
bound unto ______________________________________________________
(hereinafter called the 'Employer') in the sum stated above for the payment of which sum
well and truly to be made, we bind ourselves, our heirs, executors, administrators and
successors, jointly and severally, firmly by these presents.
THE CONDITION OF THIS OBLIGATION IS SUCH, that whereas the Bidder has
submitted the accompanying Bid dated ______ for Bid No. _______ for_______(Particulars
of Bid) to the said Employer; and
WHEREAS, the Employer has required as a condition for considering said Bid that the Bidder
furnishes a Bid Security in the above said sum from a Scheduled Bank in Pakistan or from a
foreign bank duly counter-guaranteed by a Scheduled Bank in Pakistan, to the Employer,
conditioned as under:
(1) That the Bid Security shall remain in force up to and including the date 28 days after
the deadline for validity of bids as stated in the Instructions to Bidders or as it may
be extended by the Employer, notice of which extension(s) to the Surety is hereby
waived;
(2) That the Bid Security of unsuccessful Bidders will be returned by the Employer after
expiry of its validity or upon signing of the Contract Agreement; and
(3) That in the event of failure of the successful Bidder to execute the proposed Contract
Agreement for such work and furnish the required Performance Security, the entire
said sum be paid immediately to the said Employer pursuant to Clause 15.6 of the
Instruction to Bidders for the successful Bidder's failure to perform.
NOW THEREFORE, if the successful Bidder shall, within the period specified therefor, on
the prescribed form presented to him for signature enter into a formal Contract with the said
Employer in accordance with his Bid as accepted and furnish within twenty eight (28) days of
his being requested to do so, a Performance Security with good and sufficient surety, as may
be required, upon the form prescribed by the said Employer for the faithful performance and
proper fulfilment of the said Contract or in the event of non-withdrawal of the said Bid within

20
the time specified for its validity then this obligation shall be void and of no effect, but
otherwise to remain in full force and effect.
PROVIDED THAT the Surety shall forthwith pay the Employer the said sum upon first written
demand of the Employer (without cavil or argument) and without requiring the Employer to
prove or to show grounds or reasons for such demand, notice of which shall be sent by the
Employer by registered post duly addressed to the Surety at its address given above.
PROVIDED ALSO THAT the Employer shall be the sole and final judge for deciding whether
the Principal (Bidder) has duly performed his obligations to sign the Contract Agreement and
to furnish the requisite Performance Security within the time stated above, or has defaulted in
fulfilling said requirements and the Surety shall pay without objection the said sum upon
demand from the Employer forthwith and without any reference to the Principal (Bidder) or
any other person.
IN WITNESS WHEREOF, the above bounden Surety has executed the instrument under its
seal on the date indicated above, the name and seal of the Surety being hereto affixed and these
presents duly signed by its undersigned representative pursuant to authority of its governing
body.
SURETY (Bank)

WITNESS: Signature
1. Name
Title

Corporate Secretary (Seal) Corporate Guarantor (Seal)


2.

__________________________
Name, Title & Address
Part II
Table of Contents
SECTION 1: Introduction and Scope of work for Rehabilitation of AGE-30 Locomotives
SECTION 2: Introduction and scope of work for Rehabilitation of GMU-30 Locomotives

SECTION 3: Introduction and scope for proposal for Up-gradation, Modernization and Re
commissioning of DPU-20/30 De locomotives

SECTION 4: Evaluation criteria for AGE-30 class of De locomotives

SECTION 5: Evaluation criteria for GMU-30 class of De locomotives

SCETION 6: Evaluation criteria for DPU-30/20 Class of De locomotives


SECTION 1

Introduction and Specifications/Scope of


work for Rehabilitation and
Up-gradation of AGE-30 Locomotives
SPECIFICATION FOR REHABILITATION AND MODERNIZATION
OF AGE-30 CLASS
DIESEL ELECTRIC LOCOMOTIVES

1) BACK GROUND:

1.1 Pakistan Railways had procured thirty six (30) AGE-30 D.E locomotives from M/s
General Electric, USA and put in service during 1996-98. These De locomotives are
equipped with GE 7FDL L39 prime mover, NYAB CCB air brake systems, UGL flexi
float bogies, GE 752 AH 24/30 traction motors etc. These locomotives have outlived
economical life 20 years. At present, 20 AGE-30 locomotives are in passenger
operation whereas 10 De locomotives are held up for want of spares. Pakistan Railways
intends to rehabilitate and modernize these locomotives to provide service life of
another 15 years. PR intends to rehabilitate and modernize these locomotives with
new/remanufactured diesel engines, traction alternators, traction motors, air
compressors, bogies etc with provision of latest microprocessor traction control system,
to meet the general requirements of Pakistan Railways as given in the specifications.
The rehabilitation work and performance of the rehabilitated and modernized
locomotives shall not be inferior to the new De locomotives as defined by Clauses 2 to
10; 12, 14 to 22, 23, 26, 27, 28, 29, 31, 32, 39, 40, 42 . Rehabilitation and modernization
of these De locomotives would be carried out preferably at Moghalpura Workshop,
Lahore or at any other existing facility on Pakistan Railways.
1.2 The bidders are required to examine AGE-30 locomotives fleet physically in their
interest to ascertain the scope of work involved to avoid any controversy subsequently
at the time of rehabilitation. Any component or system altered or modified during the
modernization which could affect locomotive performance must be supported by
analysis and documentation as defined in the relevant Clauses. If the specification of
components in a system remains the same as in the existing AGE-30 locomotives, the
requirement to carry out analysis will be waived off. The supplier shall submit a list of
such offered components/systems with their tender for examination & analysis. The
supplier is obliged to provide additional analysis as deemed necessary by the Pakistan
Railways on requirement.
1.3 Successful bidder will be responsible for supplying the entire equipment/
assemblies/system/tools with necessary technical information, supervision and training
of Pakistan Railway personnel in the relevant fields required for the rehabilitation,
modernization and subsequent operations of these locomotives strictly according to
OEM specifications. The bidder will submit certificate that they will follow OEM
Specifications and Provide OEM parts during rehabilitation and modernization of all 30
DE locomotives. The scope of supply is outlined in Clause No.40.
1.4 Rehabilitation of all metallic components such as chassis, superstructure, cabin, bogies
etc will be carried out locally and inside of the Pakistan Railways facilities in
Moghalpura, Lahore or at any other existing facility on Pakistan Railways. These works
will be executed by PR workers under supervisors of OEM/supplier according to OEM
standard with available tooling and equipment. There are some works related with the
modernization that have never been done before in Pakistan, and the supplier with full
authorization and on behalf of the manufacturer, has the responsibility to provide
instructions, to guide, supervise and train the personnel of PR, along with the whole
scope of works, until the stage that local PR supervisors and workers are capable to
move the project efficiently forward, without any more assistance. General mechanical
handling equipment, cleaning equipment and material, torching and welding equipment
and material as well as miscellaneous material available in locomotive handling shops
will be PR responsibility. Special equipment, tools or material specifically selected to
bring in this project, and duly listed on the supplier’s proposal will be on supplier’s
responsibility.
1.5 All transportation cost for rebuilding of assemblies abroad on UTEX basis shall be
borne by the bidder.

2. LOCOMOTIVE POWER
2.1 The horsepower for traction shall be in range of 3000 to 3300. This specified power
should be available under the climatic conditions indicated in Clause-5.
2.2 Break-up of power requirement for each of the auxiliaries at rated output, both under
site and UIC conditions shall be provided. The supplier shall indicate the method used
for determining power requirement of each auxiliary. In case these are measured values,
the supplier shall furnish method employed for measurement of auxiliary’s horsepower.

3 PRINCIPAL DIMENSIONS
The locomotive must conform to the Schedule of dimensions given in Appendix-‘A’ of
these ‘Technical Specifications’. The bidder shall submit fully dimensioned outline
diagram of the locomotive, superimposed on the maximum moving dimensions diagram.

4 AXLE LOAD

The maximum axle load shall not be more than 22.50 tons (22.86 tonnes) after
modernization.

5 CLIMATIC CONDITIONS

5.1 Temperature:
Maximum ambient temperature 55 oC
Average of maximum readings 48 oC
Average of minimum readings 17.7 oC
Minimum ambient temperature -5 oC

5.2 Relative Humidity:


Maximum 100 %
Average of maximum reading 48 %
Minimum 02 %
Average of minimum reading 21 %
5.3 The altitude between Karachi-Peshawar varies from a few meters to 705 meters
above the sea level. For purpose of general performance of rehabilitated AGE-
30 D.E locomotives, the altitude of the main line may be assumed as 705 meters
above sea level.

5.4 The climatic conditions over greater part of the country are very severe in respect of
heat and dust. The importance of ventilation and air filtration for supply of clean air to
engine room, traction alternator, air compressor room and traction motors cannot be
over emphasized.
5 LOCOMOTIVE PERFORMANCE

6.1 After rehabilitation, the locomotive should be a fully functional including all standards
for performance of prime mover, Alternator, traction motors, control system,
assemblies, sub assemblies, accessories, safety devices, gauges, air compressors,
brake equipment to meet the requirements of specifications. The bidder should comply
and provide all locomotive performance curves as indicated in Appendix A-1. The
rehabilitated Locomotive should confirm the performance, specifications indicated at
appendix A1, B & B1. The parts included as standard and optional equipment shall be
listed separately indicating item-wise price of optional parts/accessory.

6.2 The bidder must confirm the scope of work for remanufactured Diesel Engine as per
OEM.

6.3 The bidder shall furnish a transmission efficiency curve valid over the speed range of
0 to 150 Kmph.

6.4 The “tractive effort-speed” & “drawbar pull-speed” curves for both freight and
passenger operation shall be submitted.

7. MAIL, EXPRESS AND PASSENGER TRAINS DATA

7.1 The performance characteristic of the rehabilitated and modernized AGE-30


locomotive model (7 FDL-16 L-39) equipped with brand new microprocessor and shall
confirm the locomotive performance as defined in Appendix A1.

8. GOODS TRAINS DATA

8.1 The performance characteristic of the rehabilitated and modernized AGE-30


locomotive model (7 FDL-16 L-39) equipped with brand new microprocessor and shall
confirm the locomotive performance as defined in Appendix A1.

9. ENGINE RATING AND PERFORMANCE

9.1 The diesel engine should be suitable to work with high speed diesel oil specified
below:-

Specifications
S Characteristics
Test Method
.No Winter Summer
(Nov-Feb) (Mar-Oct)
1 Flash point. ASTM D 93 Min. 660C
2 Viscosity Kinematics at ASTM D 445 Min 1.5 Cst
400C.
Max 6.5 Cst
3 Pour point. ASTM D 97 Max 6 0C Max 0 0C
4 Carbon residue conradson. ASTM 189/4530 % Mass Max 0.1
5 Ash. ASTM D 482 % Mass Max 0.01
6 Water. ASTM D 95 % Volume Max 0.05
ASTM
7 Sulphur. D1552/2622/4294 % Mass Max 0.5
8 Gross calorific value. - Min 19000 BTU/ Ib
9 Cetane Index. ASTM Min 45
D 4737/976
10 Corrosion copper strip3 at ASTM D 130 No. 1
1000C.
11 Density at 150C. ASTM Min 0.82 Kg/L,
D 1298/4052 Max 0.87 Kg/L
12 Distillation90% min volume ASTM D 86 Max 365 0C
recovery, 0C
13 Color ASTM ASTM D 1500 Max.2.5
14 Cloud Point 0C ASTM D 2500 Max. -1 Max 5+
15 Sediment, %. ASTM D 473 % Mass Max. 0.01

9.2 15 nos. diesel engine units would be remanufactured and upgraded/equipped with GE
approved EFI system on UTEX basis and shall strictly conform to standard OEM, as
per scope of work attached, specifications viz 3000-3300 H.P. Model GE 7 FDL-16 L-
39. Detailed scope of work is attached as appendix- B. Bidders, if desire, may submit
their proposal for remanufacturing of the diesel engine units as per OEM criteria
detailed scope of work for remanufacturing of the diesel engine may be submitted along
with technical offer.

9.3 Remaining 15 nos. diesel engine units would be remanufactured and


upgraded/equipped with GE approved EFI system with locally qualified engine block
and shall be remanufactured in Pakistan as per OEM standards as per scope of work
attached as annexure-B under the supervision of service engineer of suppliers or
representative of engine manufacturer and shall strictly confirm the standard of OEM
specifications of 3000-3300 H.P. Model 7 FDL-16 L-39. The performance of locally
remanufactured diesel engine shall be as good guaranteed as remanufactured diesel engine
supplied against this contract. Bidders, if desire, may submit their proposal for
remanufacturing of the diesel engine units as per OEM criteria detailed scope of work
for remanufacturing of the diesel engine along with offer.

9.4. The Bidder shall clarify that the diesel engine offered will work satisfactorily with the
types of fuel oil mentioned in Para 9.1. Information regarding the extent of periodical
maintenance requirements between general overhauls, based on the experience on other
railroads, with similar types of fuel oil shall be given.

9.5. In case the engine is de-rated from test conditions to suit the site conditions, the derating
factor shall be specified. At the same time the formula/ curve used for derating engine
output in relation to altitude, humidity and ambient temperature shall be furnished.
9.6. The remanufactured diesel engines must be capable of running in normal service for a
distance not less than 750,000 KMs between periodical overhauls and not less than
1,500,000 KMs between major overhauls.

9.7 Low idling speed of diesel engine, maintaining full ability of powering all necessary
auxiliaries resulting in appreciable fuel saving is desirable.

9.8 The locomotives should be capable of working 2500 KMs without any maintenance.
10. FUEL CONSUMPTION:

10.1. The Bidder shall provide curves showing Brake Specific fuel Consumption of re-
manufactured diesel engine against engine speed at each throttle notch under:

(i) UIC standard conditions


(ii) At ambient temperature of 55º C and altitude of 705 meters above sea level.
10.2 The Bidder shall state the specific fuel consumption in liters per traction
horsepower/hour of re-manufactured locomotive at (a) full throttle (b) ¾ throttle, for
fuel oil specified in para 9.1.The specific fuel consumption shall be determined by
standard load testing of the locomotive. All auxiliaries shall be functioning with the
compressor unload and auxiliary generator supplying normal current for operating and
control functions including head-lights and classification lights at both ends of the
locomotive with batteries fully charged.

10.3 For supplied remanufactured engine, the fuel consumption tests may be carried out at
the manufacturer’s works and Pakistan Railways workshops under the supervision of
the purchaser’s representative. These shall be repeated on Pakistan Railways, after the
locomotive has worked for at least three months but not more than six months, in the
presence of the manufacturer’s representative

10.4 The Bidder would be required to ensure that the indicated fuel oil consumption will not
be exceeded on a locomotive fitted with supplied remanufactured diesel engine which
has completed service for three months but not more than six months. In case actual
fuel consumption during test in Pakistan is in excess of the guaranteed figure by 2%,
the purchaser shall have the right to reject the diesel engine or to call for repairs at
suppliers cost to improve the fuel consumption within acceptable limits.

11. ELECTRONIC FUEL INJECTION (EFI)


11.1 Currently, these De locomotives are equipped with old Woodward’s Governor
controlled fuel injection system. Now Pakistan Railways intends to modernize and
equip them with the OEM approved EFI system to have fuel economy. Proposed EFI
system should be OEM approved, successfully trialed out and tested on at least 200 D.E.
locomotives working satisfactorily outside the country of manufacturer with at least 50 nos.
to the countries having comparable / similar climatic conditions as mentioned in Clause-4.
The manufacturer should provide the details of exported locomotives and proof of
reliability of offered locomotives. The detailed particulars of the Railroads where such
locomotives are working (Address, Fax No., E-Mail etc.) indicating Year of Supplies, HP,
Maximum Speed, Axle Load etc. shall be supplied with the bid. The bid should be
accompanied with the performance / user Certificates issued by the foreign Railroads using
locomotives with EFI system.

12. VENTILATION AND AIR FILTRATION

12.1. In view of the severe dusty and sandy conditions in the country the existing air filtration
systems will be improved for which modification if any will be carried out in Pakistan
Railways shops as per instruction of OEM/supplier’s representative.

12.2. Details of the filtration system, filtration efficiency and technical specification of paper
used in filters should be furnished.
12.3 Modification/fabrication of Alternator Compartment should be made to improve the
existing inertia and air intake filters with modified cages to stop ingress of dust.

12.4 Indication to driver in cabin for clogged air filter should be provided

13. LOCOMOTIVE SPEED


13.1. The existing fleet is suitable for maximum speed of 150 Kmph. The rehabilitated
locomotive will be expected to be fit for the same speed.

13.2. The minimum speed at continuous tractive effort shall be indicated in the locomotive
performance curves and it should not be less than original locomotive.

14. TRACTION ALTERNATOR AND COMPANION ALTERNATOR

14.1. The existing 30 main alternator 5GMG 197B1 will be remanufactured and upgraded
for another life of 15 years by replacing worn out parts with new ones by the
OEM/suppliers on UTEX basis as per OEM standard. Furthermore, both the main /
auxiliary generators must be remanufactured to the latest GE standards with brand new
diodes, capacitors and bearings. The detail of parts to be replaced in remanufacturing
will be indicated in the technical bid
15. TRACTION MOTORS

15.1 Replacement of all GE-752 AH 24/30 traction motors (180) with remanufactured/
rehabilitated traction motors abroad on UTEX basis with new armatures, field coils,
inter poles and mechanical parts, brush holders, new C/end & p/end bearings of PR
approved manufacturers European / American country of origin as per GE standards
but if cores offered by PR do not qualify OEM standards for remanufacturing, then
bidder will supply remanufactured traction motors on outright basis with same scope
as that of UTEX motors, with guaranty/warranty as new. All the mechanical parts
shall be provided with new one along with pinion. Traction motors should be capable
of giving satisfactory performance in the climatic conditions as indicated in Article -
5. The supplier will be committed to provide technical assistance to the existing
Traction motor repair facilities in P.R workshops to improve the overhauling methods
tooling and final quality of traction motors rebuilt locally.

15.2 Provision for adequate cooling with fresh filtered air shall be made so that the traction
motors may give continuous rated output without excessive rise in temperature under
conditions in Clause-5.
15.3 The traction motor shall be provided with protection against any tendency of flash-over
within its full range of operation.
15.4 Remanufactured traction motors should be capable of giving satisfactory service of
more than 1,200,000 KMs between complete overhauls.

16. ELECTRIC CONTROL CABINET

16.1. Control cabinet and driver control stand should be replaced by the supplier with the
provision and installation of new microprocessor control system to replace the existing
one. Complete concealed rewiring of HT and LT of locomotives including driver’s
cabin and replacement of hardware items shall be ensured by the supplier. The
configuration of traction motor controller is such that it can work in series-parallel and
in case one preferably or more traction motor are cut off the remaining should work in
parallel without loss of power as for as possible
16.2 Locomotive control shall be micro processor based, which shall ensure to control the
operations/diagnostics and propulsion system of the locomotive. It should consist of
consolidated control architecture, traction motor controller, radiator fan controller,
battery charging controller, auxiliary alternator controller, traction alternator
controller, engine controlling unit and traction blower controller, air compressor motor
controller etc. The microprocessor control system does not require overhaul before 15
years of service or 3,000,000 KMs whichever is earlier.

16.3 It should have the facility to display function of control/diagnostics and parameters on
a display panel for easy operation/access and troubleshooting capabilities. It shall also
have the facility to down load and upload data via USB Port for further programming.

16.4 In the event of a traction motor failure, automatic locomotive reconfiguration should
allow continued operation of the locomotive at partial tractive effort until end of the
trip.

16.5 The Electronic cards and its components fitted in the locomotives during rehabilitation
should be robust type equipment specification to ensure working under climatic
condition as indicated in Clause -5 but maximum temperature up to 60 degree C.

16.6. The existing High Voltage Cabinet shall be replaced to improve reliability and to
ensure the supply of service parts during the next 15 years service life.

16.7 The existing panels are to be replaced with latest control gear covering the
requirements. Control gear equipment shall be housed in control cabinet in the cab. All
panels, switch gears, power contactors, etc. should be easily accessible for maintenance.
The control circuitry shall provide protection to all electric machines against overload
abnormal operating conditions and in different driving modes. The cabinet shall be air
pressurized to avoid ingress of dust.
16.8. The automatic sequence of traction motor connection or otherwise shall be furnished.

16.9. The bidder shall furnish sequence of operation through different throttle notches, engine
speeds and power output.
16.10. The Bidder shall provide a preliminary diagram showing location and functioning of
contactors, relays, reversers and interlocks
16.11 Provision shall be made to cut off individual traction motor preferably or traction
motors in pair as and when required, without incapacitating wheel slip protection..
16.12. Circuit breakers with ‘ON’ and ‘OFF’ positions shall be provided.
16.13. Improved wheel slip system for protection of motors and better adhesion is desired.
16.14 Pakistan Railways recently purchased GE locomotives ranging HP from 4300 to
2500HP. These De locomotives are equipped with BS-CCA microprocessor system. It
is therefore recommended for the bidders to propose such system to have
interchangeability for hardware and ease operation of software.

17. AIR COMPRESSOR


17.1 All air compressors 3CDC WABTEC with motors shall be replaced and upgraded with
air compressors WABTEC 3CDC BLAT having inverter based control system on
UTEX basis.
.
17.2 Rehabilitated air compressor does not require overhaul before four years of service or
800,000 Kms whichever is earlier
18. BOGIES

18.1 The existing all bogies will be reconditioned with supplied new wheel & axle
assemblies, new Journal bearings of PR approved bearing manufacturers of European
/ American country of origin, traction rods with spherical blocks, volkulan rings,
bushes, pins, bull gear, oil dampers and springs and inbound and outbound felt seals
etc. Please see relevant portion of Scope of Supply/Scope of Work given in Clause
No.40.1 (G). Gear cases shall be manufactured locally as per manufacturing drawings
provided by the OEM/supplier. All worn parts will be replaced with new one to be
supplied by the bidder.

18.2 The existing all motor suspension units (U-tube) will be supplied on UTEX basis with
new metallic components and new bearings manufactured by PR approved
manufacturers European / American country of origin.

19. EXHAUST SYSTEM


Exhaust system will be replaced by provision of new exhaust manifold along with
hardware and gaskets.
20. DATA / TECHNICAL INFORMATION
The bidder will submit with the offer the technical data relating to the rehabilitated
locomotive as well as its major new/ rehabilitated assemblies and systems.

21. BATTERIES
21.1 Storage batteries (lead acid type) must be installed for starting diesel engine, lighting
and other purposes as the design of the control of the locomotive may render
necessary and shall be amply rated not less than 426 AH capacity at eight hours rate
of discharge, assembled in eight numbers 4 cells mono block molded hard rubber
containers shall be provided. The normal expected life of the battery shall be
minimum 5 years. The maximum dimensions of each crate shall be, (Length x Width
x Height) = (720 x 285 x 450) mm with a tolerances of + 10 mm on each dimension.
Alternatively, Ni-Cd batteries with minimum service life of 6 year are also acceptable.
21.2 The cells must be capable of long period in service in the locomotives without
necessity for topping-up electrolyte level. They shall be housed in well-ventilated
boxes. Arrangements shall be provided for charging the battery from an external
source.
21.3 Low voltage control circuit must have the batteries of 64 volts DC with charging rate
72+2 volts.
Battery jog option shall be provided.

22. BRAKE EQUIPMENT


22.1. The existing brake system of locomotives would be replaced/ upgraded with NYAB CCB
II Brake system successfully tried-out by Pakistan Railways and should have (like CCL
with mechanical back up in case of electronic brake failure) with suitable additional valves
and relays in order to be able to work air brake trains equipped with brake system
conforming to UIC Specifications 540 and 541. The brake system should permit to work in
multiple unit operation and for this purpose air hosepipes with couplers should be provided
at both ends of the locomotives so that a dead locomotive can be hauled by a working unit
with the brakes of former in operative condition. It should have a provision of brake-into
safety feature. A robust, maintenance free ,air-drying system along with water separator
should also be provided.
22.2 All the latest safety features of offered air brake system shall be provided by the bidder.
22.3 All valves must be protected on atmospheric suction lines by suitable filters.
22.3.1 The existing brake tread units should be qualified as per OEM standards.
22.5 The maximum braking distance in Pakistan Railways system is 1200 meters. The
braking system should be capable to stop freight train of 2250 tonnes trailing load
equipped with air brake at a speed of 80 KM/H within the safe braking distance
prescribed above on main line track with a falling gradient of 1 in 200. It shall also be
capable to stop the maximum trailing load of 850 tonnes of passenger train at a speed of
120 KM/H within safe braking distance.
26.6 The bidder/manufacturer shall provide the calculation of braking distance for passenger
and freight trains at prescribed speed and loads.
26.7 There shall be a drop of brake pipe pressure on the locomotive while operating
air braked train in the event of:-
i. Alarm chain being pulled in the rear most compartments of 20th coaches of passenger
train. This would be equivalent to creating an air leak through 4 mm diameter choke
at a distance of about 1483 ft. (450 meters) from the locomotive. The pulling of
alarm chain in a coach would cause leakage of air through 4 mm. choke, with red
light indication in the driver’s cab, sounding of buzzer and drop in brake pipe
pressure in the locomotive ranging from 0.1 bar to 0.5 bar.
ii. ii. Guard van valve pulled in the rear most of 20 Nos. coaches of passenger train and
40 Nos. High Capacity Wagons of freight train would be equivalent to creating an air
leak through 6 mm diameter choke at a distance of full train length. The pulling of
guard van valve shall cause a pressure drop in Locomotive brake pipe pressure 0.5 to
1.5 bar with red light indication, sounding of buzzer, engine becoming No Power and
initiating of train brake application.
iii. There should be a drop of 3.8 bar (54 PSI) in brake pipe pressure on locomotive
when the last vehicles on a 40 Nos. high capacity wagons goods train or 20 Nos.
coaches passenger train getting parted (break in two) shall effect immediate engine
becomes No Power and penalty brake application.
iv. The bidder should confirm that the offered locomotives must fulfill all the
requirements of Pakistan Railways “ Advance Chapter No. XIV-A of the Air Brake
System.
26.8 The locomotive shall be provided with audio and visual indications in the cab in the
event of pulling of alarm communication chain from any carriage of a 20 coaches air
brake train of about 1483 ft (450 meters) from the locomotive. In case of freight train,
the distance of 40th vehicle is 2346 ft. from locomotive.
26.9 Parking / Hand brake with manual operation or spring applied Air-release should be
provided.
26.10 Air brake schematic diagram of all brake distributer valves be provider.

23. LUBRICATING OIL SYSTEM

23.1. Lube oil cooler elements, lube oil filter tank and by pass valve on lube oil main header
pipe shall be replaced.

23.2 The lubricating oil circuit should be provided for adequate straining and filtration to
match local operating conditions. Paper type filters will be preferred.
23.3. The lubricating oil filtration system provided shall be such type that change of
lubricating oil should not be necessary before a minimum distance of 120,000 KMs
expect for unsatisfactory lube oil test results.
23.4. The lubrication system should adequately guard against damage to engine due to
repeated cold starts. Safety devices against hot engine oil and low lubricating oil
pressure must operate when lube oil temperature and pressure reached danger limit.
23.5 Lubricating oil system should be so modified so as to ensure that temperature of lube
oil leaving pump does not exceed 104 degree C or so under PR working conditions.
Difference of temperature for in and out from lube oil cooler should not be less than 5
to 6 degree C without decreasing horse power of the engine.

24 FUEL INJECTION EQUIPMENT

24.1. The fuel injection piping system will be replaced with new ones.
24.2 Existing fuel oil pump with motor shall be replaced with new fuel oil pump with AC
motor.
24.3 Efficient filtration of fuel oil before reaching injection pumps is of vital importance.
Replaceable paper type filters are desirable.
24.4 All fuel oil pipe lines shall be so arranged and protected that any leakage of fuel from
a cracked pipe or leaking joint is prevented from falling on heated parts of engine or
close to the electric circuitry, contactors, switches, etc.

25. ENGINE WATER COOLING SYSTEM

25.1 Radiator cores along with header, radiator fan with stator and water tank including
water header pipe will be replaced with new ones.

25.2 The locomotive radiators shall be suitable to cater for high ambient temperatures (55˚
C) and improved horse power keeping in view the dusty terrain in which the
locomotives would operate. Ample radiator capacity must be provided to maintain
normal running temperature when operating for long periods at maximum output at
highest ambient temperature. The water capacity of the system should be adequate so
that make up water is not required for at least 250 hour of normal service operation,
i.e. between fortnightly schedules
25.3 The radiator capacity shall include 25% margin to take into account any reduction of
efficiency which may occur due to the coating of inner or outer surface of the radiator
elements with scale or dirt.

25.4 Due to extreme climatic conditions, special attention is required to improve the design
of existing cooling system for summer and winter seasons.

25.5 The water circulating system shall be fitted with protective devices against damage to
diesel engine due to over-heating or lack of cooling water.

25.6 The radiator elements with detachable headers should be provided for convenience of
cleaning and washing.
CABLE AND WIRING
26.1 Complete rewiring (HT/LT) of Locomotives including driver’s cabin and hardware
items will be replaced by the bidder.

26.2 All cable conductor/wire shall be of copper. The types selected shall be especially
suitable for service conditions as per GE standards or as specified in B.S. 6007 and
6500 of 1975 or corresponding ASTM Specification for the type of cables adopted and
for ultimate temperature permissible when operating under site condition. All cables
shall be suitably insulted. The layout of cables shall be such as to ensure accessibility
for inspection and replacement. The insulation of cables conductors and wires should
be flame retardant and resistant to oil, grease, salt, air moisture, sand and caustic
cleaning solutions. It should be designed to withstand electrical overload, abrasion, cut-
through-compression and crushing forces. Cables meeting ASTM B33 or ASTM B172
standards which typically has service life in excess of 15 year shall be provided.

26.3 Cables shall terminate in suitable protective place where cables interconnect relatively
with moving items such as traction motors. The flexible cables may be sheathed as far
as possible. Cables/wiring shall be concealed to avoid damage to its insulation.

26.4 Terminal lug connection of traction motor leads should be robust and of copper material
with tin plating / coating.

26.5 Jumper connections should be able to meet the most severe service requirements.
Complete information on number of wires and arrangements for inter-vehicle
connections shall be supplied by the bidder.

27. DRIVING CAB EQUIPMENT, GAUGES AND INSTRUMENTS

27.1 The driver cab will be refurbished for which all furnishing material will be supplied.
The existing size of the cab, look out glasses, sliding windows can be changed to
improve comfort. All gauges and indication lights including low lube oil indication to
be provided. The cab equipment will include: -

i. Engine throttle and automatic brake valve.


ii. Driver’s brake valve.
iii. Vigilance device.
iv. Safety device indications / warnings.
v. Public warning signal and warning bell (air operated) lever/ button on driver as
well as fireman side.
vi. Sanding button.
vii. Electrical speedometer with LOS not only indication but also no penalty
application including drive arrangement with related locomotive over speed
device adjustable for speeds of 65-122 KMPH.
viii. Headlight switch, full and dim and classification light switch.
ix. Buffer light switch, red and white aspects.
x. Cab light switch.
xi. Instrument light switch.
xii. Main air reservoir pressure gauge.
xiii. Air pressure gauge for air brake system.
xiv. Control air pressure gauge.
xv. Air brake gauge for train pipe.
xvi. Lube oil pressure gauge.
xvii. Fuel oil pressure gauge.
xviii. Turbo booster air pressure gauge.
xix. Engine water temperature gauge. (Temperatures displayed shall also on display
screen
xx. Load meter (traction generator current ammeter)
xxi. Load meter for each traction motor with color band.
xxii. Traction motor isolation switch.
xxiii. Voltmeter for battery with color band to indicate charge and discharge of
battery.
xxiv. Air horn lever on driver as well as fireman side.
xxv. Hand brake.
xxvi. Two fans.
xxvii. Wiper lever / button.
xxviii. Fire extinguishers (two in number) Dry chemical type, capacity 6 kg.
xxix. Air flow indicating device to provide indication to the driver about the train
conditions and train parting while hauling air braked stock with buzzer.
xxx. One hot plate.
xxxi. Emergency brake valve on fireman side shall be provided.
xxxii. Driver’s cabin air conditioner.
xxxiii. VHF (VHF radio set should be as per specification appendix-I) set and provision
for locomotive tracking device shall be provided.

The bidder will indicate the details of gauges and protections which will be monitored
through micro-processor or physical instruments. However, availability of above
equipment either displays through microprocessor or gauges must be ensured wherever
applicable.

27.2 Engine start and stop button be provided in drivers cab.

28. SAFETY DEVICE

28.1 The rehabilitated locomotive should be provided with safety devices (operation
through microprocessor or instruments), appropriate automatic reaction and
audio- visual warnings for the following situations: -
a. Low cooling water level.
b. Hot engine over-ride switch shall be provided to allow the engine to run, after
cutting-off power to cool it down quickly.
c. Ground in electric circuit with reset button.
d. Low lube oil pressure.
e. Wheel slip with automatic power reduction and automatic sanding.
f. Manually operated emergency engine stop device to be located out side the cab
at suitable place.
g. Failure of main air reservoir pressure.
h. High crankcase pressure.
i. Diesel engine over-speed.
j. Locomotive over-speed.
k. Indication/application of brakes through guard-van brake valve, use of
passenger alarm communication and train parting in case of air and vacuum
brake trains.
l. Clogging of engine air intake filters.

28.2 Excessive lube oil temperature safety should be provided through microprocessor
control by cutting off the power, there by racing the prime mover at 6th notch
automatically to cool down the lube oil temperature.
28.3 Radiator fan AC motor protection shall be provided i.e. suitable 3 phase circuit
breaker.

29. VIGILANCE DEVICE

29.1 A vigilance device of approved design shall be fitted. This device should be arranged
in such a manner that: -

(a) With the operation of vigilance device the power to traction motor is cut off,
the diesel engine returns to idle and locomotive and train brakes apply
automatically after suitable warning and time delay.

(b) The operation for vigilance device should preferably be cancelled by the
operation of one of the following with a time must be more than 20 second
distance of 1.5 kilometer:
(i) Cycling Device
(ii) Throttle handle
(iii) Brake automatic and independent
(iv) Push button on dash board

30. HEADLIGHT, ELECTRICAL LIGHTING, WHISTLE, ETC

30.1 The rehabilitated locomotive shall be provided with four excellent quality sealed beam
headlights at each end. The intensity and focusing of the headlights should be such that
a person standing on the track 500 meters (1640 ft) away is clearly defined. Each
headlight shall be provided with a dimmer switch.

30.2 Each end of the locomotive shall be provided with two buffer lamps with two colors,
white and red aspects.

30.3 Adequate lights be provided in the driving cab and the engine room. The
instruments/gauges are to be illuminated in such a way as not to interfere with the
visibility of the track/signals. All bulbs holders should be of screw type. Two portable
electric lamps with sufficient length of flexible cables and suitably located sockets
should be provided for inspection of running gear and engine room during the night.

30.4 The locomotive shall be provided with air operated warning whistle and warning bell
which can be operated from either side of the cab by the driver or /Assistant Driver.

30.5 Classification lights should be provided at both ends of the locomotive on each side.

31. SANDING GEAR

31.1 Sanding gear shall be provided duly rehabilitated on the wheels of both end axles of
each truck (i.e. 8 wheels). Provision should be made for both manual as well as
automatic operations, in case of wheels slipping. The sanding gear will function for
movement of the locomotive in either direction.
32. PRE SHIPMENT INSPECTION

32.1 The material/assemblies i.e. Re-manufactured Diesel Engine Units, Alternator,


Traction Motors, Turbo Superchargers, Air compressors and new Microprocessor etc
to be supplied for rehabilitation and modernization of locomotives will be subject to
inspection /tests before shipment by inspectors designated by purchaser at manufacturer
/ bidders facility as per details in Appendix-H . The supplier must comply with all
requirements in the matter of suitability of material and method of construction. All
equipment required by the inspection authority during the course of inspection and test
must be provided by the manufacture free of charge. The inspecting authority has the
right to reject any part during or after re-manufacturing, if in his opinion the quality of
material or the standard of workmanship is not up to the requisite standard. The decision
of inspection authority in this respect shall be final and all parts so rejected shall be
replaced free of charge by the manufactures. The inspection shall not absolve the
manufacturer of their responsibility regarding quality, design, material or
workmanship. The inspector has the right to inspect any remanufactured alternator,
traction motor, turbo supercharger and diesel engine with respect to crankshaft, power
assembly, camshaft, etc at assembly stage. The pre shipment inspection is subject to
mutual consent of both the parties at the time of award of contract.
32.2 All expenses of inspectors in respect of boarding, lodging, out-of-pocket expenses,
transport, round air tickets will be borne by the supplier/manufacturer for inspection.

33. ACCEPTANCE TEST OF THE POWER UNIT AND ELECTRICAL


EQUIPMENT
33.1 The material to be supplied for rehabilitation and modernization of locomotives will be
subjected to tests by the purchaser at the place of rehabilitation by an Inspecting
Authority to be designated by the Purchaser. All instruments, gauges and equipment
required shall be provided by the manufacturer free of charges.

33.2 In addition to the continuous running test, the Inspecting Authority shall have the right
to carry out overload test of any power unit which may be selected for this purpose.

33.3 The Inspecting Authority shall have the right to carry out other tests such as fuel and
lubricating oil consumption trials, etc., at his discretion. These tests shall be carried out
on at least one power unit out of the total number on order at the place of
remanufacturing.

33.4 The alternator and traction motors shall be subjected to such tests as the Inspecting
Authority may consider necessary to ensure that the temperature rise in the windings
does not exceed the maximum laid down in B.S. Specification No.173/1960 or
corresponding ASTM Specification, when the machines are working at their maximum
continuous output for a period of not less than twelve hours under conditions of the
highest ambient temperature specified, 53 degree C. The electrical resistance of the
insulation shall be tested at the end of the test runs and must be in accordance with B.S.
Specification No.173/1960 or corresponding ASTM Specification. In addition to the
measurements of resistance the insulation shall be subjected to Hi Pot tests as required
by the Inspecting Authority at the place of remanufacturing.
.

34. FINAL ROAD TESTS


34.1 A selected number of locomotives after complete rehabilitation shall be subjected to
road tests to check hauling power, maximum speed, continuous tractive efforts,
acceleration, balance speed, fuel consumption, heat balance, riding quality etc. under
climatic / operating conditions as mention in Clause-5. The time of carrying out the
tests shall be fixed by purchaser, and will normally be after a period of 3 months of
service of the rehabilitated locomotive. The supplier shall be required to appoint a
representative to witness the test and assist the purchaser in carrying out the same. Any
defect in design of material, workmanship or any failure of equipment to come up to
the standards claimed by the manufacturers in their bid, which may come up during
these tests, shall have to be corrected on all units by the supplier to the satisfaction of
Pakistan Railways. The latter shall have the right to insist on a repetition of the trials
after any modifications which may be carried out by the supplier to rectify the defects.
The tools, instruments & equipments required for above tests will be provided /
arranged by the bidder.

34.2 All power units complete with Alternator, Traction Motors, Turbo Superchargers, Air
compressors and new Microprocessor etc. shall be subjected to load test after
completing normal running in tests. These tests shall be carried out by the Inspecting
Authority in accordance with specified requirements.
34.3 The power unit shall be run at the maximum service output with the main traction
alternator voltage corresponding to that required at the traction motor terminals for
operation at the maximum safe track speed of the locomotive. This test shall be a part
of 12 hours continuous running test and the Inspecting Authority shall have the right to
select the moment at which this test shall be conducted.

35. SUPERVISION AND AFTER SALE SERVICE


35.1 Bidder shall provide necessary supervision for the entire period of rehabilitation of
locomotives at Pakistan Railways workshops so as to ensure that agreed outturn, quality
and schedule of time are met properly and to provide on the job training to purchaser’s
personnel. Man-months recommended shall be indicated but charges shall be included
in the cost of Rehabilitation of locomotives.
35.2 Bidder shall provide the services of service engineer after commissioning of
locomotives for the warranty period for watching the performance of rehabilitated
locomotives. Man-months recommended shall be indicated but charges shall be
included in the cost of Rehabilitation of locomotives.
36. TRAINING
36.1 The Bidder shall provide training to maintenance and operating staff regarding newly
introduced/developed Microprocessor, technology parts/assemblies in Pakistan
Railways premises. The bidder shall also arrange training equipment, documents,
brochures, etc for the training purpose at own expenses.

37. MACHINES AND TOOLS

37.1 Bidder should submit list along with cost of additional machine and tools required for
re-building of engine block after examining the existing facilities in Locomotives
shops, Moghalpura, Lahore. Firm should submit proposed list of machines / tools as
per requirement along with technical offer.
Bidder has to provide this list without cost separately in Technical Bid for evaluation,
prices of the same can be provided with Financial Bid.

37.2 Necessary sets of hand tools, equipment and test instruments etc essentially required
for rehabilitation and modernization of locomotives shall be supplied by the bidder. A
list of these items shall be submitted in the form of Appendix “C”.
37.3 The bidders shall be also submit a list of special electrical and mechanical tools and test
instruments required for normal repairs and major maintenance in the form of Appendix
“C-I” in technical bid and prices in financial bid.

38. SPARE PARTS


38.1 A Tentative proposed list of 3 years maintenance spares is indicated as Annexure-D,
however it is desired that Bidder/manufacturer propose a three year maintenance spares
list along with quantity as they feel deem fit for the modified/upgraded/new systems.
Bidder / manufacture are at liberty to delete or add any spar part in the proposed list as
Appendix -D. This list without pricing must be submitted with Technical Bid for
evaluation; however the same list with quoted prices should accompany the financial
bid.
38.2 A List of long life/principle assemblies is provided in Appendix-E with the required
quantities bidder should submit pricing item wise as per Appendix-E.

39. DRAWINGS AND INSTRUCTION BOOKS

39.1 All modification drawings, instructions books (operating & maintenance/service


manuals as well as parts catalogs) shall be provided both in soft and hard copies.

39.2 All documents shall be in English language.

39.3 The following maintenance manuals/literature shall be supplied for the rehabilitated
locomotives: -

i. 40 sets of operating manuals.


ii) 20 sets of maintenance instruction manuals showing sizes &
tolerances(condemning limits) of assemblies/sub assemblies and
overhauling/rebuilding procedures, pertaining to mechanical and electrical
equipment incorporating check list for individual component (Mechanical /
Electrical).
iii) 20 sets of locomotive service manuals, pertaining to mechanical and electrical
components, incorporating checking/ testing parameters and procedures.
iv) 20 sets of electrical wiring schematic, oil piping, water piping and air piping
diagrams plus 10 sets large size colored diagrams for display in sheds / training
school.

v) 40 sets of maintenance instructions for the air-cum vacuum brake system plus 10
sets of large size colored diagrams for display in sheds / training school.
(vi) 20 sets of mechanical and electrical spare parts catalog for each assembly/component
used on the locomotives.

39.4 It must be ensured that maintenance instructions and spare parts catalogue should
fully cover all proprietary items like EFI fuel injection system, turbo superchargers,
air compressors, diesel engines, microprocessors, traction motor, etc. The literature
should fully provide instruction for service and maintenance of all assemblies/
components.
40. SCOPE OF REHABILITATION AND MODERNIZATION WORK

40.1 The repair and remanufacture of the major components of the locomotives like diesel
engines, main alternator, traction motors etc as described below, will be done locally or
abroad, and the quantities are herein indicated and summarized as under ::

A. 15 nos. diesel engine units would be remanufactured and upgraded/equipped


with GE approved EFI system on UTEX basis and shall strictly conform to
standard OEM, as per scope of work attached, specifications viz 3000-3300 H.P.
Model GE 7 FDL-16 L-39. Detailed scope of work is attached as appendix-B.
The supplier will arrange suitable engine cores abroad, and rehabilitate,
modernize etc such cores to become remanufactured engines, duly tested and
guaranteed on the standards of GE/OEM but if cores do not qualify OEM
standards for remanufacturing, then bidder will supply remanufactured traction
motors on outright basis with guaranty/warranty as new (All transportation costs
will be born by bidder). Bidders, if desire, may submit their proposal for
remanufacturing of the diesel engine units as per OEM criteria detailed scope
of work for remanufacturing of the diesel engine along with offer.

B. Remaining 15 nos. diesel engine units would be remanufactured and


upgraded/equipped with GE approved EFI system with locally qualified engine
block and shall be remanufactured in Pakistan as per OEM standards as per
scope of work attached as appendix-B under the supervision of service engineer
of suppliers or representative of engine manufacturer and shall strictly confirm
the standard of OEM specifications of 3000-3300 H.P. Model 7 FDL-16 L-39. The
performance of locally remanufactured diesel engine shall be as good guaranteed
as remanufactured diesel engine supplied against this contract . Bidders, if desire,
may submit their proposal for remanufacturing of the diesel engine units as per
OEM criteria detailed scope of work for remanufacturing of the diesel engine
along with offer. The crankcase and oil pan will be remanufactured locally by
P.R staff under the supervision/guidelines of supplier / manufacturer, who under
instructions and on behalf of OEM will transfer the technology (details will be
provided in bid) to produce these works with the necessary quality. The bidders
are invited to visit engine overhauling facility at CDL workshop to work out the
requirements of plants and tooling necessarily required for the rebuilding of the
diesel engines and would arrange/supply if required. From these locally
rehabilitated crankcases and oil pans, together with the OEM parts kits to be
shipped by the supplier, 15 Nos engine units will be assembled under the
supervision of the OEM/bidder’s Service Engineer who afterwards shall test the
engines as per OEM’s standard and same warranty conditions will be enforced
as the engine unit supplied on UTEX basis. The technical characteristics of the
engines remanufactured locally will be exactly equal to those engines
remanufactured abroad.

C. All 30 Nos. Turbo Superchargers of the engines model GE7FDL-16L-39 shall


be remanufactured on UTEX basis with provision of new replaceable parts but
if cores do not qualify OEM standards for remanufacturing, then bidder will
supply remanufactured traction motors on outright basis with
guarantee/warranty as new (All transportation costs will be borne by bidder).

D. The existing 30 main alternator 5GMG 197B1 will be remanufactured and


upgraded for another life of 15 years by replacing worn out parts with new ones
by the OEM/suppliers on UTEX basis as per OEM standard but if cores do not
qualify OEM standards for remanufacturing, then bidder will supply
remanufactured traction motors on outright basis with guaranty/warranty as new
(All transportation costs will be borne by bidder). Furthermore, both the main /
auxiliary generators must be remanufactured to the latest GE standards with
brand new diodes, capacitors and bearings. The detail of parts to be replaced in
remanufacturing will be indicated in the technical bid. In order to compensate
the delay on transportation the supplier will ship 5 Nos Alternator prior to the
arrival of the used cores.

E. 180 Nos. traction motors model GE752AH24/30 shall be


remanufactured. These motors will be remanufactured abroad on UTEX basis
with used cores shipped from Pakistan but if cores do not qualify OEM
standards for remanufacturing, then bidder will supply remanufactured traction
motors on outright basis with guaranty/warranty as new (All transportation costs
will be borne by bidder). The supplier will make sure that the technical
characteristics of GE maintenance instructions will be integrally followed.
F. All air compressors 3CDC with motors shall be replaced and upgraded with
compressors WABTEC 3CDC BLAT on UTEX basis having inverter based
control system.

G. 60 (sixty) existing trucks Flexi float type GE will be rehabilitated locally with
new parts to be supplied by the bidder under the supervision of supplier (Service
Engineer) and workers of PR. The supplier will provide all necessary
parts/hardware like pins, bushes; wear plates, bolts, nuts & washers for
rehabilitation of bogies. The bidder shall provide all new items like springs,
rubber packs, traction rods with spherical blocks, vulkalan rings, oil damper,
axles, bull gears, journal boxes and journal bearings of PR approved
manufacturers of European / American country of origin etc. All gear cases will
be new and manufactured in Pakistan as per drawing provided by
supplier. Wheels Axle assembly with bearings will be brand new. The supplier
must ensure that the OEM instructions contained in M/s GE maintenance and
repair instructions No. MI-30001-016/GEK-76581 will be integrally followed
during the rehabilitation process. All worn parts shall be replaced with new
ones.

The existing all motor suspension units (U-tube) will be supplied on UTEX
basis with new metallic components and new bearings of PR approved
manufacturers of European / American country of origin.

H. 30 brand new Microprocessors BS- CCA including all necessary modules,


sensors, contactors, relay, regulators, switches traction motor switch gears,
wiring harness with other accessories etc. The Microprocessor shall ensure to
control operations / diagnostics and propulsion system of locomotive. It should
consist on consolidated control architecture, and should have the capability to
perform following:-

 Diesel engine data and parameters


 Microprocessor must have single connecter by which it can be isolated
 Have the facility to display function of control / diagnostics, and
parameters on display panels for easy operational access and
troubleshooting capabilities.
 Controls Diesel Engine speeds.
 Regulates traction alternator excitation.
 Substantial increase in locomotive adhesion through advance wheel
creep control.
 Control locomotives auxiliary loads.
 Processes feedback signals from the traction motors,
 Control and monitors tractive effort.
 Traction motor over-speed protection.
 Automatic ground relay reset.
 Regulates traction alternator excitation.
 Protects against excessive wheel slip and wheel sliding.
 Locomotive speed control system.
 Monitoring / displaying the data of safety devices.
 Local alarm bell silence-all alarms.
 Processes all commands from the Driver desk or MU train line.
 Facility to download and upload data via USB port for further
programming

The supplier shall be responsible to ensure full efficiency of the system in


operations. The Microprocessor software should have provision for storing
data regarding fault history and related status during running (trip). Software
shall be provided by the seller to buyer free of cost. The bidder should
clearly specify the service life of control system without overhauling.

I. 30 (thirty) sets of cabin components including but not limited to:


(i) Brand new control stands with all relevant accessories, all instruments,
switches, relays, resistors, lamps and A-9 & SA9 valves etc where
applicable according to new control stand configuration on the
locomotives.
(ii). Brand new electronic speedometers with speeds up to 150 KPH equipped
with alarm for over speed. The speedometers will be driven by electric
signals from compatible axle generators which will be supplied by the
bidders. Bidders would also ensure provision of GPRS based speedometer
on driver display screen.
(iii) Brand new electronic black box (event recorder) capable to register and
display whenever necessary the speeds, times, forward and reverse
motions, brake applications, brake pipe pressure and brake cylinder
pressure, and with crash memory to keep information 48 hours before any
accident. The event recorder is connected to the same axle generator that
drives the speedometer.
(iv) Brand new air conditioning unit roof top mounted with minimum of 25,000
BTU per Hour
(v) Brand new side wall mounted heater with fan for 1000 watts capacity.
(vi) Brand new hot plate.
(vii) Brand new Vigilance control system by means of foot pedal to be pressed
by the driver.

(viii) Fitment of compatible VHF radio and provision for tracking system in
driver cabin.
(ix) Provision for automatic train control unit (ATC) to be supplied by the user.
(x) Electric driven window wiper system including the wiper motors, valves,
levers etc.

J. 30 (thirty) sets for the pneumatic system included but not limited to:

i. Brand new repair kit for the automatic shutters including shutter cylinders,
valves, and levers springs etc.
ii. Brand new repair kits for the Accessory Cabinet including the instruments,
the compressor control switches, the test valves etc
iii. Brand new horn and valve.
iv. All new front and side glasses shall be fitted which should be strong enough
to withstand stone palleting.
v. Alternatively provision of all bullet proof glasses in locomotive car body be
quoted as optional.

K. 30 (twenty) cooling compartment sets including but not limited to: -

i. Brand new radiator cores and headers, piping etc


ii. Brand new complete cooling fans 9 blades (2 units per loco) with suitable
heavy duty AC motors and contactors etc.
iii. Radiator fan AC motor protection shall be provided i.e suitable 3 phase
circuit breaker.
iv. Driver control stand to be fitted new alongwith all new accessories.
v. Car body works to be carried out by purchaser at their premises with all
material supplied by the bidder.

L. 30 (twenty) sets for the air compartment including but not limited to:
i. Complete brand new dust blowers with motors.
ii. Inertia filters would be provided by PR and same would be qualified by the
bidders.
iii. 30 brand new traction motor air cooling blowers.
iv. Remanufactured HVC filter recipient with brand new paper filter
elements
v. Remanufactured engine air filter recipient with brand new paper filter
elements.
vi. Installation of air restriction sensor for protection of the engine.

M. Water Tank’s Pressure Cap and Gauge - To be Brand New.

All the 30 pressure caps and respective necks will be brand new with new water
level gauges. All water tanks will be tested and replaced if rejected.

N. Thermostatic Valves TA, TB and ETS - All Brand New.

All 30 each thermostatic switches must be replaced by brand new units.

O. Engine Instruments - To be Brand New

All instruments (water temperature, oil pressure, oil temperature etc) for the 30
DE locos will be brand new.
P. 30 (twenty) sets of brand new air brake kits of CCB-II with air dryer & water
separator be provided.

40.2. The scope of supply is broadly outlined. The bidder will indicate details with OEM Part
No. reference of Catalogue Book, Qty. per package/kit,

40.3 The bidder cannot make changes in the scope of supply/ work but can give clarification
provided that substance of bid does not change.

40.4 The bidder shall provide related documents, broachers etc of newly provided
microprocessor, parts/assemblies regarding modernization being quoted along with
purpose of reference and technical evaluation.

40.5 The total number of units mentioned against various packages are subject to adjustment
on the discretion of purchaser.

40.6. Locomotive main frame and draw gear will be reconditioned as per drawings provide
by the manufacturer/bidder to give satisfactory riding quality for a maximum speed of
150 KMPH on Pakistan Railways existing track conditions.

40.7 Modifications may be required in the superstructure of the locomotive to fit in new
control cabinet, control stand, diesel engine and other equipment and for easy access to
maintenance staff. Corroded and damaged panels of superstructure will be replaced /
repaired with the material supplied by the bidder as per OEM criteria/test i.e., rain fall
test.

40.8 The existing bogies will be qualified and reconditioned so as to give them an additional
service life of 15 years for which necessary spares, rehabilitation kit and drawings for
modification, if any, will be supplied. The bogies after rehabilitation should remain fit
for the speed mentioned earlier. The detail of components of the bogies to be replaced
shall be clearly indicated.

40.9 New look out glasses, door and window glassed with rubber packing, wind shield
wipers, sun visions, cab flooring, re-insulating roofs and replacement of driver/fireman
seats and other hardware items replacement shall be carried out with material supplied
by the bidder. The brake handle shall be located on the left hand side of the driver. An
extra folding seat shall be provided in engine cab with partition wall in rear of fireman
seat.

40.10 The rehabilitated and modernized locomotive will be painted in polyurethane according
to color scheme approved by the Pakistan Railways. For this purpose local material and
man power will be arranged by Railways. Existing procedures and facilities will be
utilized. However, the supplier may provide supervision and suggestions to improve
the quality of work.
40.11 The supply of sufficient air to traction motors shall be ensured. To keep compressor
cool, it will be preferred to separate compressor compartment from engine and radiator
compartment by providing suitable partition walls.

40.12 Drawings/instructions/equipment required for re-manufacturing of major Drawings


/instructions/equipment required for re-manufacturing of major assemblies/ systems
and assemblies and testing of these locomotives shall be provided by the bidders.
Details of all engineering re-design such as revised heat balance, re-balancing of
locomotive to minimize vibration/under stress on account of relocations of old
equipment or provision of new one shall be submitted with the offer.
40.13 New buffer assemblies are required to be provided.

41. DELIVERY PERIOD

Bidders are required to provide detail of shipment schedule along with detail of
activities with bar chart. Shortest delivery period will be preferred. Necessary drawing
for modification along with detail of local material including material specification will
be submitted in advance to carry out necessary preparatory work on locomotive’s frame
and superstructure.

42. GUARANTEE
The bidder shall guarantee the performance of the rehabilitated and modernized
locomotives and all individual components as claimed by the bidder against specific
items of performance, for a period of not less than 24 months from the date put in
service. Whereas for turbo superchargers and electrical rotating machines this warranty
will be 36 months from the date put in service. All the remanufactured parts will be
guaranteed for performance as new and will carry the same warranty as of new.

43. DESPATCH OF MATERIAL REHABILITATION AND MODERNIZATION


SCHEDULE

The successful supplier shall submit a plan for material supply, storage and inventory
control. A draft plan shall be submitted with the tender. The material shall be supplied
in kit so as to turn out rehabilitated locomotive in perfect working condition for reliable
service.
44. DEVIATIONS

Notwithstanding anything that has been said in the preceding clauses, any deviation
from specification after opening of tender is not acceptable under PPRA rules.
However, clarification about specification will be made during pre-bid conference.
APPENDIXES
APPENDIX -‘A’

MAXIMUM MOVING DIMENSIONS FOR 10’-6” (3.20 METERS) WIDE ROLLING


STOCK ACCORDING TO CME’s SKETCH NO. 1799/1
Ft. In. Meter.
1. Maximum width over all projections at 4 ins (100 mm)
above rail level, when fully loaded. 8 0 2.44

2. Maximum width over all projections at 1 ft. 0 in 10 0 3.05


(305 mm) above rail level, when fully loaded.

3. Maximum width over all projections at 3 ft. 9 ins 10 0 3.05


(1.14 meter) above rail level, when fully loaded.

4. Maximum width over all projections at 3 ft. 9 ins 10 6 3.20


(1.14 meters) above rail level, when fully loaded to
a height of 12 ft. 3 ins (3.73 meters) when empty for
bogie vehicles.

5. Maximum width over open doors .. .. 13 3 4.04

6. Maximum height above rail level for a width of 1 Ft. 14 8 4.47


0 in. (305 mm.) on either side of centre of unloaded
Vehicles.
7. Maximum height above rail level at sides of unloaded 12 3 3.73
Bogie vehicles 10 Ft. 6 ins. (3.20 meters) wide.

8. Minimum height above rail level when fully loaded 0 4 0.102


for a width of 4 Ft. 0 in. (1.22 meters) on either side of
centre of track, with the exception of wheels and
attachments thereto.

9. Minimum height above rail level when fully 1 0 0.31


loaded at 5 Ft. 0 in. (1.52 meters) from centre
of track.
10. Minimum height above rail level when fully 3 9 1.14
loaded at 5 Ft. 3 ins. (1.60 meters) from centre
of track.
11. Wheel base and length of vehicles.
(i) Minimum distance apart of bogie centre for 2/3 of length of body
bogie vehicles. of vehicles.
(ii) Maximum distance apart of bogie centres for 48 6 14.78
bogie vehicles.

(iii) Minimum distance between bogie centres .. 19 6 5.94

(iv) Minimum distance between two axles .. 4 6 1.37


Ft. In. Meter.

12. Maximum and minimum wheel gauge of distance apart 5 3 1.60


for all wheel flanges.
13. Maximum diameter measured at the tread of new wheel. 3 7 1.09

14. Minimum height above rail level for floor of fully 4 1 1.24
loaded passenger vehicles.
15. Maximum and minimum distance apart for centres 6 5 1.96
of buffers.
16. Maximum height above rail level for centres of buffers 3 7-1/2 1.10
for unloaded vehicles with side buffers.

17. Minimum height above rail level for centre of buffers 3 4-1/2 1.03
for fully loaded vehicles with side buffers.

18. The buffers must conform to the following general


dimensions:-
(i) Diameter of holes in base for attachments to 0 1-3/16 0.027
head stock.
(ii) Centers squares of 4 holes in base .. .. 0 8-1/4 0.209
(iii) Diameter of buffer head .. .. .. 1 6 0.46
(iv) Length in position from buffer face to head stock. 2 1 0.63
(v) Length of stroke .. .. .. 0 4-3/4 0.12
19. The maximum permissible length over buffers is 74’-2” (22.6 meters).
20. Minimum radius of curvature 573 ft (175 meters) equals 10 degree curves.
The minimum radius of curvature on main line is 1146 ft. (349 meters)
corresponding to 5° curve without any gauge widening. However, the
locomotives should be able to negotiate 10° curves in yards.
21. Maximum super elevation 6-1/2 inches (165 mm.).
22. The minimum permissible clearance of the locomotive when fully loaded, above rail level
for a width of 4 ft. (1.2 meter) on either side of the track is 4” (102 mm.). This dimension
shall apply to vehicle with worn tyres. With new tyres, the clearance should not be less than
5-1/2” (140 mm.). A design permitting 3-1/2” (89 mm.) wear on wheel diameter will be
preferred.

Note: - It will be noted that the maximum permissible distance apart between bogie centres
is indicated as 48 ft. 6 ins. However, this distance and the overall length of the
locomotive should not be unnecessarily long.

************
APPENDIX “A1”

PERFORMANCE FOR REHABILITATED AND MODERNIZED AGE-30


D.E LOCOMOTIVES
UTILIZATION
The locomotives shall be utilized to haul freight trains at a speed of 100 Kmph, and Mail &
Express trains at a speed of 150 Kmph under the local weather conditions as indicated in
Clause-5.

LOCOMOTIVE PERFORMANCE
The following performance curves for full and 80% load factor shall be provided (Reference
may be made to Clause 6,7&8).
1) Tractive effort speed curves from starting to maximum speed at site condition showing
maximum and continuous tractive efforts. The train resistance curve should be provided
for the following trailing loads bringing out the balanced speed.

i) Mail & Express Trains


(a) 850 tonnes on level track and 1 in 200 gradient.
(b) 750 tonnes on level track and 1 in 200 gradient.
(c) 570 tonnes on level track and 1 in 100 gradient.

ii) Freight Trains


2500 tonnes on level track and 1 in 200 gradient.
2250 tonnes on level track and 1 in 100 gradient.

2) Time speed curves when hauling following trailing load


i) Mail & Express Trains

(a) 850 tonnes on level track and 1 in 200 gradient.


(b) 750 tonnes on level track and 1 in 200 gradient.
(c) 570 tonnes on level track and 1 in 100 gradient.

ii) Freight Trains


(a) 2500 tonnes on level track and 1 in 200 gradient.
(b) 2250 tonnes on level track and 1 in 100 gradient.

3) Time speed curves for passenger & freight trains at level track.
i) Tonnage of trailing load and time to achieve the speed of 120 Km /h
for passenger train.

ii) Tonnage of trailing load and time to achieve the speed of 80 & 100 Km /h
for freight train.
4) Trailing loads v/s speed charts on various grades indicated in appendices F & G for
Freight, Mail & Express trains for Rehabilitated locomotives shall be indicated by the
bidder.
APPENDIX-B

SPECIFICATIONS OF RE-MANUFACTURED DIESEL


ENGINE MODEL 7FDL16 FOR AGE-30 CLASS OF
LOCOMOTIVES.

The re manufactured Diesel Engine unit with re manufactured Engine Cylinder


block must conform to the following term & conditions and OEM specifications
.The following major Engine equipment should be used/provided/qualified for re
manufacturing of
Diesel engine as per existing DRP and under mentioned scope of work.

TAB 91000 Main Frame Assembly


TAB 92000 Forward End Cover
TAB 93000 Power Assembly
TAB 94000 Turbochargers and Intercoolers
TAB 95000 Manifolds and Exhausts
TAB 96000 Fuel Linkage System
TAB 97000 Engine Control governor (if applicable)
TAB 98000 Fuel And Lube Oil Piping
TAB 99000 Power Plant Mounting
A. Main Frame with Oil Pan and Bearing Caps.
1. Main Frame and Oil Pan assembly of latest version incorporating all design
improvements, interchangeable with our existing diesel engine models 7FDL16
shall be provided.
2. Main Frame and Oil Pan Assembly must have been qualified according to the GE
MI-91000F
3. Upper pilot bores must qualify dimensionally for cylinder bore sizes(if applicable).
4. The Diesel Engine should be qualified the following:-
(a) Tapped holes in cylinder blocks
(b) Main bearing studs.
(c) Visually check for cracks, Nicks, Burrs, Scratches, Wear, Damaged threads
and loose dowels.
5. Perform ultrasonic inspection for all critical/repaired/welded portion of engine
Main Frame and oil pan assembly to identify and correct all the cracks and
defects if exist.
6. Thoroughly inspect and qualify all oil passages in the frame and covers.
7. Lube Oil Strainer of Present Design (PB-91016-001B) to be new provided in oil
pan

B. FORWAD END COVER WITH LUBE OIL PUMP DRIVE, WATER


PUMP DRIVE, CRANKCASE BREATHER AND VIBRATION
DAMPER.

1. Forward end cover of present design (PB-92116-004F) with


provision of bottom hole on the left side to be provided.
2. Renew/Qualify Gear drive and coupling drive to Hub.
3. Gears Backlashes must be according to GE Standards.
4. Inspect all Gears and discard on the following conditions:-
● Overheating /Burning
● Scoring
● Cracking
● Galling/Wearing
● Pitting marks
5. Inspect/qualify Lube Oil gallery at the forward end, Cam shaft lubrication
holes and the bearing caps, Studs, Bolts, bearing caps and side bolts.
6. Inspect and qualify Lube oil pipes and manifolds for any defect.
7. Apply new water manifolds ,pipes and connections.
8. Inspect and qualify all fuel oil manifolds and piping.
9. Apply new hose assemblies associated with engine.10. Qualify fuel heater.
11. Qualify governor support.
12. Provide new lube oil relief valve.
13. Provide new over speed trip.
14. The following new assemblies should be provided:
● Lube Oil pump
● Water pump
● Fuel injection nozzle
● Electronic Fuel injectior (Bosch Austrai)

C. CAM DRIVE END ENGINE

1. Inspect both Camshafts Gears and Discard on following condition:


● Overheating/ burning
● Scoring
● Cracking
● Galling/Wearing
● Pitting marks
If any of above mentioned defect is noticed on any of Gears it must be replaced with
new.
2. Inspect Crankshaft split gear internal diameter and qualify for surface finish.
3. Apply new after coolers.
4. Apply new turbo charger.

D. CRANK SHAFT
1. Apply new crankshaft Nitride (required for 3600 traction horse power or
higher)
as per GE part number 119X1116-1 DRP# PB-91016-001B.
2. Qualify vibration damper.
3. All main and con rod bearings to be new provided

E. CAM SHAFT

1. Apply new camshaft segments according to GE part number applicable.


2. All camshafts bearing to be new provided

F. POWER ASSEMBLIES

1. Welded cylinder heads and liner with valves part no 121x1260-


2,cylinder jackets, Piston, Piston rings , Gasket kits, O-Rings and Bolts to be
new applied.
2. Rods assemblies (Master and Articulated) to be new applied.
3. Apply new rocker Arm shaft and push rods according to GE standards.
4. Apply new Cross guide with bearing roller & pin fuel.
G. MISCELLANEOUS COMPONENTS

1. Apply new fuel control shaft right and left with all allied parts,
bushings, springs etc.
2. Apply new cylinder test valves (Plug compression release).
3. New sump covers, power assemblies’ covers and new seals.
4. Apply new complete water discharge header with connections , jumper &
seals part no 140x1648-3 DRP PB-94616-009 and header section water inlet
with all connections and seals.
5. Apply new drain plugs, main bearing studs, Nuts and lock nuts.
6. Use all new gaskets, seals, O-Rings, Gasket kits, Bushings, Bearings
and miscellaneous hardware using edge molded seals and gasket where
possible.
7. All bolts and nuts should be new provided.
H. ENGINE ASSEMBLY

1. While assembling, all the torque values, clearances and backlashes should be
conformed to the G.E recommended values and specifications.
2. Final inspection of diesel engine to be carried out on load test with accessory
drive coupling and bringing it to full load for a period of two and half hour.
Test data showing Horsepower, RPM, Governor rack setting, Oil pressure,
Fuel Pressure, Water temperature at rear of engine to be provided.
3. The serial No. Plate to be retained and this Number to be recorded on all build
up sheets.
4. Customer to be supplied with engine builds up sheet indicating the serial No
on the following components.
● Main Frame and Oil Pan
● Crankshaft
● Turbo Charger
● Governor
● Lube Oil Pump
● Water Pump
● Pistons
● Liners
● Unitized Assembly
● Pins
● Connecting Rods
● After Coolers
● Governor Support

I. PAINTING

Complete diesel engine to be marked and painted a final coat as per GE


standards for 7FDL16.

J. SHIPPING INSTRUCTION (applicable to clause 40.1(A)


1. The Diesel engine to be shipped with complete accessories.
2. The diesel engine to be properly protected and ready to install in the
locomotive.
All the fluids to be drained and the engine protected from freezing.
Appendix-C

TOOLS, EQUIPMENT AND TEST INSTRUMENTS ESSENTIALLY REQUIRED


FOR THE REHABILITATION OF LOCOMOTIVES

Model / Quantity Price FOB/CFR


Description Maker Purpose
part No. recommended
Unit Extended
Appendix-C-I

LIST OF RUNNING MAINTENANCE TOOLS AND EQUIPMENTS.


Price FOB/CFR
S. No. Description Quantity
Unit Extended
Appendix-D
DETAIL AND DESCRIPTION OF SPARES REQUIRED
FOR THREE YEARS MAINTENANCE OF NEW/UPGRADED ASSEMBLIES/SUB
ASSEMBLIES

Price PB/CFR
S.
Description Cat No Qty
No.
Unit
Extended
DIESEL ENGINE

NB. Three years maintenance spare parts which are not applicable may be deleted
and items which are essential keeping in view the new introduced systems may
be added/ offered by the bidder.
Appendix-E

DETAILS OF PRINCIPAL AND LONG LIFE ASSEMBLIES / PARTS


Price FOB / CFR
S. Catalogue /
Description Quantity
No Part No
Unit Extended
1. Crankshaft Assembly 2 Nos.
2. Camshaft Assembly (Left & Right) 1 Loco sets.
3. EFI Fuel Injector 2 Loco Sets
4. Unitized Power assy 2 Locos Sets
5. Turbocharger 2 Nos.
6. Governor (if applicable) 1 Nos.
7. Exhaust Manifold Complete. 1 Loco Sets.
8. Lube Oil Pump 2 Loco Sets.
9. Water Pump 2 Loco Sets
10. Air Compressor 2 Nos.
11. Lube Oil Cooler 1 Nos.
12. Turbo after cooler core 2 Loco Set.
13. Compressor Intercooler 04 Nos.
14. Remanufactured Traction Alternator 02 Nos.
5GMG 197B1 on out right basis
15. Auxiliary Generator 2 Nos.
16. Blower for traction motor 1 Nos
17. Controller Mechanism 2 Loco Sets
18. Reverser 1 Loco Sets
19. Voltage Regulator (if applicable) 4 Loco Sets
21. Fuel pump with AC motor 4 Nos.
22. Radiators core 1 Loco Sets
23. Radiator fan drive assembly complete 2 Loco Sets
24. Pinion for T/Motor 24 Nos
25. Brake Tread units (all types) 04 Nos
26. Air Governors 02 Nos
27. Speedometers 2 Loco Sets
28. Re-Manufactured Traction Motor 18 Nos.
752AH24 on out right basis
29 Complete brake module on out right 02 Nos.
basis.

NB:- Principal and long life Assemblies/parts which are not applicable may be deleted and
items which are essential keeping in view the new introduced systems may be added/
offered by the bidder. Quantity is subject to change.
Appendix – F
TRAILING LOAD – SPEED – GRADE TABLE
52 TONNES LOWER A.C. COACH

SPEED 70 75 80 85 90 95 100 105 110 115 120


GRADE TRAILING LOAD – METRIC TONS
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1.10
1.20
1.30
1.40
1.50
1.60
1.70
1.80
1.90
2.00
2.10
2.20
2.30
2.40
2.50
2.60
2.70
2.80
2.90
3.00
3.10
3.20
3.30
3.40
3.50
3.60
3.70
3.80
3.90
4.00
Appendix – G
TRAILING LOAD – SPEED – GRADE TABLE
25.4 TONNES FREIGHT CARS
SPEED 40 45 50 55 60 65 70 75 80 85 90 95 100
GRADE TRAILING LOAD – METRIC TONS
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1.10
1.20
1.30
1.40
1.50
1.60
1.70
1.80
1.90
2.00
2.10
2.20
2.30
2.40
2.50
2.60
2.70
2.80
2.90
3.00
3.10
3.20
3.30
3.40
3.50
3.60
3.70
3.80
3.90
4.00
APPENDIX –‘H’

INSPECTION OF REHABILITATED / RE-MANUFACTURERED IMPORTANT


ASSEMBLIES AT MANUFACTURER’S FACILITY /MAINTENANCE LOCATIONS.

Period/
No of
No. Description. Working
personals.
days
1. Re-manufactured Engine units 03 10 days
Engine Cylinder Block 10 days
2. 02
Rebuilding
3. Alternator /T/Motor. 03 10 days
4. Turbo Supercharger. 02 10 days
5. Microprocessor 03 10 days
6. Expressor/Air Brake System 02 10 days
APPENDIX-‘I’

Technical SPECIFICATIONS of VHF RADIO having operational capability on analogue


GPS and Digital USA/Euoropean/Japan

Completely built VHF Radio set including VHF OMNI Directional Dome Type antenna
to work on electrified sections and power supply complete in all respect as per
Railway requirements.
Solid State VHF 146-174 MHz(TX & RX)
No of Channels Minimum 40 – 50
Operating temperature range Minimum 10oC to +60oC
Frequency Stability Minimum +2.55 PPM
Antenna Impedance 50Ω
Operating Volt 12/13.8V
Channel Guards/CTCSS Minimum 40 Nos.
Modulation FM
Shock & Vibration Should meet with military standard for shock,
vibration & Ruggedness
RF Output (Power) Minimum 45 Watt (Maximum power shall be
adjusted at 172.3 MHZ
Spurious & Harmon ICS Better than -65dB
Channel Spacing sec 12.5/25KHz
Sensitivity (for 12dB SINAD) Better than 0.30 uV
Squelch Programmable
Audio Response (300 – 3000 Hz) Better than +1 to -3d 3
Maintenance & Service manuals 1 with 20 radio sets
Operating Manual 1 with each set
Programming Cable 1 with 20 radio sets
Software 1 with 10 radio sets
Note: Name of manufacture originally printed on set, all accessories must be compatible
with international standard.
SPECIFICATION OF VHF OMNI DIRECTIONAL DOME TYPE ANTENNA
S. No Parameter Specification
1 Pattern Omni Directional
2 Frequency 160-174 MHz
Range
3 VSWR Less than 1
4 Output Power 100 W
5 Input Impedance 50 ohms
6 Connector PL-259 Female (So 239) (2 No. for each)
7 Accessories Antenna along with all accessories (Nuts, Bolts) Complete
in all respects
8 Nominal gain 3-6.5 db
9 Mount Type Roof mount & Mounting hardware
10 Wind Pressure 150 kmph minimum
sustainability
 Input power voltage as available in the proposed locomotives be indicated by the
bidder.
 Maintenance and faultfinding catalogues shall also be provided with locomotives.
SECTION 2
Introduction and Specifications/Scope of
work for Rehabilitation and
Up-gradation of GMU-30 Locomotives
SPECIFICATION FOR REHABILITATION AND MODERNIZATION
OF GMU-30 CLASS
DIESEL ELECTRIC LOCOMOTIVES

1) BACK GROUND:
1.1 Pakistan Railways had procured thirty six (36) GMU-30 D.E locomotives model GT-
26CW from M/s General Motors, USA (M/s EMD, USA) and put in service during
1975. These De locomotives have completed 44 years-service life and are still in use
over passenger, freight and shunting operations. At present, 35 GMU-30 locomotives
are in service. Pakistan Railways had carried out special repair of these De locomotives
during 2006-2008. These locomotives are fitted with EMD 645 series Diesel Engine,
D-77 Traction Motors, 28 LVI air and vacuum brake systems and conventional traction
control system. Pakistan Railway intends to rehabilitate and modernize 20 GMU-30
Class D.E. Locomotives with new/remanufactured diesel engines, traction alternators,
traction motors, expressers, control cabinets with microprocessor controlled traction
systems to meet the general requirements of the Railway as given in the specifications.
The rehabilitation work and performance of the rehabilitated and modernized
locomotives shall not be inferior to the new De locomotives as defined by Clauses 2 to
10; 12, 14 to 22, 23, 26, 27, 28, 29, 31, 32, 39, 40, 42. Any component or system
proposed altered or modified during the modernization which could affect locomotive
performance would be supported by analysis and documentation as defined in the
relevant Clauses. If the specification of components in a system remains the same as in
the existing GMU-30 locomotives, the requirement to carry out analysis will be waived
off. The bidders are required to examine GMU-30 locomotives fleet physically in their
interest to ascertain the scope of work involved to avoid any controversy subsequently
at the time of rehabilitation. The supplier shall submit a list of such offered
components/systems with their tender for examination & analysis. The supplier is
obliged to provide additional analysis as deemed necessary by the Pakistan Railways
on requirement. Proposed rehabilitation/modernization of GMU-30 De locomotives
would be executed at Rehabilitation shop, Moghalpura or at any other existing facility
on Pakistan Railways.
1.2 Successful bidders will be responsible for supplying the entire equipment/
assemblies/system/tools with necessary technical information, supervision and training
of Pakistan Railway personnel in the relevant fields required for the rehabilitation,
modernization and subsequent operations of these locomotives strictly according to
OEM specifications. The bidder will submit certificate that they will follow OEM
Specifications and Provide OEM parts during rehabilitation and modernization
of these DE locomotives. The scope of supply is outlined in Clause No.40.
1.3 Rehabilitation of all metallic components such as chassis, superstructure, cabin, bogies
etc will be carried out locally and inside of the Pakistan Railways facilities in
Moghalpura – Lahore. These works will be executed by PR workers under supervisors
of OEM/supplier according to OEM standard with available tooling and equipment.
There are some works related with the modernization that have never been done before
in Pakistan, and the supplier with full authorization and on behalf of the manufacturer,
has the responsibility to provide instructions, to guide, supervise and train the personnel
of PR, along with the whole scope of works, until the stage that local PR supervisors
and workers are capable to move the project efficiently forward, without any more
assistance. General mechanical handling equipment, cleaning equipment and material,
torching and welding equipment and material as well as miscellaneous material
available in locomotive handling shops will be PR responsibility. Special equipment,
tools or material specifically selected to bring in this project, and duly listed on the
supplier’s proposal will be on supplier’s responsibility.
1.4 All transportation cost for rebuilding of assemblies abroad on UTEX basis shall be
borne by the bidder.

2 LOCOMOTIVE POWER:
2.1 The horsepower for traction shall be in range of 3000 to 3300. This specified power should
be available under the climatic conditions indicated in Clause-5.
2.2 Break-up of power requirement for each of the auxiliaries at rated out put, both under site
and UIC conditions shall be provided. The supplier shall indicate the method used for
determining power requirement of each auxiliary. In case these are measured values, the
supplier shall furnish method employed for measurement of auxiliary’s horsepower.

3 PRINCIPAL DIMENSIONS:

The locomotive must conform to the Schedule of dimensions given in Appendix-‘A’ of


these ‘Technical Specifications’. The bidder shall submit fully dimensioned outline
diagram of the locomotive, superimposed on the maximum moving dimensions diagram.

4 AXLE LOAD:

The maximum axle load shall not be more than 22.50 tons (22.86 tonnes) after
modernization.

5 CLIMATIC CONDITIONS:
5.1 Temperature:
Maximum ambient temperature 55 oC
Average of maximum readings 48 oC
Average of minimum readings 17.7 oC
Minimum ambient temperature -5 oC
5.2 Relative Humidity:
Maximum 100 %
Average of maximum reading 48 %
Minimum 02 %
Average of minimum reading 21 %
5.3 The altitude between Karachi-Peshawar varies from a few meters to 705 meters above the
sea level. For purpose of general performance of rehabilitated HGMU- 30 D.E
locomotives, the altitude of the main line may be assumed as 705 meters above sea
level.
5.4 The climatic conditions over greater part of the country are very severe in respect of
heat and dust. The importance of ventilation and air filtration for supply of clean air to
engine room, traction alternator, expressor room and traction motors cannot be over
emphasized.

6 LOCOMOTIVE PERFORMANCE:

6.1 After rehabilitation, the locomotive should be a fully functional including all
standards for performance of prime mover, Alternator, traction motors, control
system, assemblies, sub assemblies, accessories, safety devices, gauges/
expresser, brake equipment as specified. The bidder should comply and provide
locomotive performance curves as indicated in Appendix A-1. The rehabilitated
Locomotive should confirm the performance, specifications indicated at appendix
A1, B & B1. The parts included as standard and optional equipment shall be listed
separately indicating item-wise price of optional parts/accessory.
6.2 The bidder shall furnish a transmission efficiency curve valid over the speed range
of 0 to 122 Kmph.
6.3 The “tractive effort-speed” & “drawbar pull-speed” curves for both freight and
passenger operation shall be submitted.

7. MAIL, EXPRESS AND PASSENGER TRAINS DATA:


7.1 The performance characteristic of the rehabilitated and modernized locomotive shall
confirm the locomotive performance as defined in Appendix A1.

8 GOODS TRAINS DATA:


8.1 The performance characteristic of the rehabilitated and modernized locomotive shall
confirm the locomotive performance as defined in Appendix A1.

9. ENGINE RATING AND PERFORMANCE:

9.1 The diesel engine should be suitable to work with high speed diesel oil specified
below:-
Specifications
S Characteristics
Test Method Winter Summer
.No
(Nov-Feb) (Mar-Oct)
1 Flash point. ASTM D 93 Min. 660C
2 Viscosity Kinematics at ASTM D 445 Min 1.5 Cst
400C. Max 6.5 Cst
3 Pour point. ASTM D 97 Max 6 0C Max 0 0C
4 Carbon residue conradson. ASTM 189/4530 % Mass Max 0.1
5 Ash. ASTM D 482 % Mass Max 0.01
6 Water. ASTM D 95 % Volume Max 0.05
Sulphur. ASTM
7 % Mass Max 0.5
D1552/2622/4294
8 Gross calorific value. - Min 19000 BTU/ Ib
9 Cetane Index. ASTM Min 45
D 4737/976
10 Corrosion copper strip3 at ASTM D 130 No. 1
1000C.
11 Density at 150C. ASTM Min 0.82 Kg/L,
D 1298/4052 Max 0.87 Kg/L
12 Distillation90% min volume ASTM D 86 Max 365 0C
recovery, 0C
13 Color ASTM ASTM D 1500 Max.2.5

14 Cloud Point 0C ASTM D 2500 Max. -1 Max 5+

15 Sediment, %. ASTM D 473 % Mass Max. 0.01

9.2 10 Diesel Engines shall be remanufactured on UTEX basis and shall strictly conform
to standard O.E.M specifications viz 3000-3300 H.P. Model EMD 16-645E3, as per
scope of work attached as appendix- B. However, if bidder proposes OEM scope of
work of UTEX engine, may be submitted for consideration.
9.3 10 Diesel Engine unites will be remanufactured in Pakistan with OEM standards under
the supervision of service engineer and shall strictly confirm the standard of OEM
specifications of 3000-3300 H.P. Model 16-645E3, as per scope of work attached as
appendix-BI. The performance of locally remanufactured diesel engine shall be as good
guaranteed as remanufactured diesel engine supplied against this contract .
9.4. Bidder shall clarify that the diesel engine offered will work satisfactorily with the types
of fuel oil mentioned in Para 9.1. Information regarding the extent of periodical
maintenance requirements between general overhauls, based on the experience on other
railroads, with similar types of fuel oil shall be given.
9.5. In case the engine is de-rated from test conditions to suit the site conditions, the derating
factor shall be specified. At the same time the formula/ curve used for derating engine
output in relation to altitude, humidity and ambient temperature shall be furnished.
9.6. The remanufactured diesel engine must be capable of running in normal service for a
distance not less than 750,000 KMs between periodical overhauls and not less than
1,500,000 KMs between major overhauls.
9.7 Low idling speed of diesel engine, maintaining full ability of powering all necessary
auxiliaries resulting in appreciable fuel saving is desirable.
The locomotives should be capable of working 2500 KMs without any maintenance.

10. FUEL CONSUMPTION:

10.1. The Bidder shall provide curves showing Brake Specific fuel Consumption of re-
manufactured diesel engine against engine speed at each throttle notch under:
(i) UIC standard conditions
(ii) At ambient temperature of 55º C and altitude of 705 meters above sea level.
10.2 The Bidder shall state the specific fuel consumption in liters per traction
horsepower/hour of re-manufactured locomotive at (a) full throttle (b) ¾ throttle, for
fuel oil specified in para 9.1.The specific fuel consumption shall be determined by
standard load testing of the locomotive. All auxiliaries shall be functioning with the
compressor unload and auxiliary generator supplying normal current for operating and
control functions including head-lights and classification lights at both ends of the
locomotive with batteries fully charged.
10.3 For supplied remanufactured engine, the fuel consumption tests may be carried out at
the manufacturer’s works and Pakistan Railways workshops under the supervision of
the purchaser’s representative. These shall be repeated on Pakistan Railways, after the
locomotive has worked for at least three months but not more than six months, in the
presence of the manufacturer’s representative
10.4 The Bidder would be required to ensure that the indicated fuel oil consumption will not
be exceeded on a locomotive fitted with supplied remanufactured diesel engine which
has completed service for three months but not more than six months. In case actual
fuel consumption during test in Pakistan is in excess of the guaranteed figure by 2%,
the purchaser shall have the right to reject the diesel engine or to call for repairs at
suppliers cost to improve the fuel consumption within acceptable limits.

11. STARTING MOTORS:


Two new starting motors 64 volts along with related electrical circuit shall be replaced
for easy start of locomotive from driver cab.
12. VENTILATION AND AIR FILTRATION:
12.1 In view of the severe dusty and sandy conditions in the country the existing air filtration
systems will be improved for which modification if any will be carried out in Pakistan
Railways shops as per instruction of OEM/supplier’s representative.
12.2 Details of the filtration system, filtration efficiency and technical specification of paper
used in filters should be furnished.
12.5 Modification/fabrication of Alternator Compartment should be made to improve the
existing inertia and air intake filters with modified cages to stop ingress of dust.
12.6 Indication to driver in cabin for clogged air filter should be provided
13. LOCOMOTIVE SPEED:
13.1 The existing fleet is suitable for maximum speed of 122 Kmph. The rehabilitated
locomotive will be expected to be fit for the same speed.
13.2 The minimum speed at continuous tractive effort shall be indicated in the locomotive
performance curves and it should not be less than original locomotive.

14. TRACTION ALTERNATOR AND COMPANION ALTERNATOR:


14.1 The existing 20 main alternator AR10F1/D14 and 20 Nos. companion alternator type
D18/CA5 (OEM Standard) will be remanufactured and upgraded to AR10F1/D14 CA6
type for another life of 15 years by replacing worn out parts with new ones by the
OEM/suppliers on UTEX basis as per OEM standard.
14.2 All DC auxiliary generators 6A-7159 shall be remanufactured on UTEX basis as per
OEM standards (MI-3707).
14.3 Both the main and auxiliary generators must be remanufactured to the latest EMD
standards with brand new diodes, capacitors and bearings. The detail of parts to be
replaced in remanufacturing will be indicated in the technical bid.

15. TRACTION MOTORS:


15.1 Replacement of all D-77 traction motors (210) with remanufactured and upgraded to
traction motors D-78 abroad on UTEX basis fitted new U tube, armatures, field coils,
inter poles and mechanical parts as per EMD standards but if cores offered by PR do
not qualify OEM standards for remanufacturing, then bidder will supply
remanufactured traction motors on outright basis with same scope as that of UTEX
motors, with guaranty/warranty as new. All the mechanical parts shall be provided with
new one alongwith pinion. Traction motors should be capable of giving satisfactory
performance in the climatic conditions as indicated in Article -5.
15.2 Provision for adequate cooling with fresh filtered air shall be made so that the traction
motors may give continuous rated output without excessive rise in temperature under
conditions in Clause-5.
15.3 The traction motor shall be provided with protection against any tendency of flash-over
within its full range of operation.
15.4 Remanufactured traction motors should be capable of giving satisfactory service of
more than 1,200,000 KMs between complete overhauls.
15.5 Manually cut out switch for individual traction motor be provided in case of any fault,
without incapacitating wheel slip protection.
16. ELECTRIC CONTROL CABINET:

16.1. Control cabinet and driver control stand should be replaced by the supplier with the
provision and installation of new microprocessor control system preferably with
EM2000, to replace the existing one. Complete concealed rewiring HT/LT of
locomotives including driver’s cabin and replacement of hardware items shall be
ensured by the supplier. The configuration of traction motor controller is such that it
can work in series-parallel and in case one preferably or more traction motor are cut
off the remaining should work in parallel without loss of power as for as possible
16.2 Locomotive control shall be micro processor based, which shall ensure to control the
operations/diagnostics and propulsion system of the locomotive. It should consist of
consolidated control architecture, traction motor controller, radiator fan controller,
battery charging controller, auxiliary alternator controller, traction alternator controller,
engine controlling unit and traction blower controller, etc. The microprocessor control
system does not require overhaul before 15 years of service or 3,000,000 KMs
whichever is earlier.
16.3 It should have the facility to display function of control/diagnostics and parameters on
a display panel for easy operation/access and trouble shooting capabilities. It shall also
have the facility to down load and upload data via USB Port for further programming.
16.4 In the event of a traction motor failure, automatic locomotive reconfiguration should
allow continued operation of the locomotive at partial tractive effort until end of the
trip.
16.5 The Electronic cards and its components fitted in the locomotives during rehabilitation
should be robust type equipment specification to ensure working under climatic
condition as indicated in Clause -5 but maximum temperature up to 60 degree C.
16.6. The existing High Voltage Cabinet shall be replaced to improve reliability and to
ensure the supply of service parts during the next 15 years service life.
16.7 The existing panels are to be replaced with latest control gear covering the
requirements. Control gear equipment shall be housed in control cabinet in the cab. All
panels, switch gears, power contactors, etc. should be easily accessible for maintenance.
The control circuitry shall provide protection to all electric machines against overload
abnormal operating conditions and in different driving modes. The cabinet shall be air
pressurized to avoid ingress of dust.
16.8. The automatic sequence of traction motor connection or otherwise shall be furnished.
16.9. The bidder shall furnish sequence of operation through different throttle notches, engine
speeds and power out put.
16.10. The Bidder shall provide a preliminary diagram showing location and functioning of
contactors, relays, reversers and interlocks.
16.11 Provision shall be made to cut off individual traction motor preferably or traction
motors in pair as and when required, without incapacitating wheel slip protection..
16.12. Circuit breakers with ‘ON’ and ‘OFF’ positions shall be provided.
16.13. Improved wheel slip system for protection of motors and better adhesion is desired.

17. EXPRESSOR.

17.1 All expressers shall be replaced with remanufactured expressers on UTEX basis.
17.2 Rehabilitated expresser does not require overhaul before three years of service or
600,000 Kms whichever is earlier

18. BOGIES.

18.1 The existing bogies will be reconditioned with supplied new wheel & axle assemblies,
new Journal bearings, bushes, pins, bull gear, oil dampers and springs. Please see
relevant portion of Scope of Supply/Scope of Work given in Clause No.40.1 (H). Gear
cases shall be manufactured locally as per manufacturing drawings provided by the
OEM/supplier. All worn parts will be replaced with new one to be supplied by the
bidder.

18.2 Traction motors would be fitted on U tube suspension. Originally, these are fitted on
support bearings. U Tube bearings would be made by PR approved manufacturers.
19. EXHAUST SYSTEM.

19.1 Exhaust system will be replaced by provision of new exhaust manifold alongwith
hardware and gaskets.

20. ENGINE GOVERNOR.

20.1 Governors shall be replaced with new ones.

21. BATTERIES

21.1 All batteries lead acid shall be replaced with new one and storage batteries must be
installed for starting, lighting and other purpose to suit the design of the controls of the
locomotives as considered necessary. Lead-acid battery sets, 64 volts, consisting of 32
cells, rated at about 430 amp hours at eight hours rate of discharge, assembled in 8, 4
cells mono-block molded hard rubber containers shall be provided. The normal
expected life of the battery shall be minimum 5 years. The maximum dimensions of
each crate hall be length x width x height = 720 x 285 x 450 mm. with a tolerance of ±
10 mm. on each dimension.
21.2 The cells must be capable of rendering long service in the locomotives without
necessity for topping up electrolyte level. These shall be housed in well ventilated
boxes. Arrangements shall be provided for charging the battery from an external source.

22. BRAKE EQUIPMENT.

22.1. Locomotives shall be equipped to control all the functions offered. System should be
capable to work with the existing air brake system as the locomotive is equipped with
WABCO air-cu-vacuum brake system with suitable additional valves/relays in order to
be able to work as air braked trains equipped with air brake system to UIC specifications
540 and 541. Air hose pipes with couplers should be provided at the both ends of the
locomotives so that a dead locomotive can be hauled by a working unit with the brakes
of the former in operative conditions. It should have provision of break-in to features.
The system shall be provided with oil bath or paper type air intake filtration.
22.2. All valves must be protected on atmospheric suction lines by suitable filters and
sensors should be provided to indicate the defects in brake system. The brake system
valves and mechanism do not require overhaul before 1,200,000 KMs or 6 years.
22.3. The brake gear shall be suitable for all weather conditions in Pakistan. Re-conditioning/
overhauling work of brake gear system will be carried out in Pakistan Railways
workshops/ MGPR by using pins and bushes which shall be supplied duly hardened
and ground. Brake rigging holes shall be bushed necessary detail should be provided.
Safety straps shall be fitted with brake riggings where ever necessary. The brake
hangers should be suitable for fitting brake shoes and heads as per Pakistan Railways
Drawing No. DE-2991 (11) and DE-2977 (7). The arrangements should provide for
easy adjustment of brake shoes. The offered control system should match existing air-cum-
vacuum brake system, brake rigging system and also confirm the requirements indicated at
clause 22.5 & 22.6.
22.4. The maximum braking distance on Pakistan Railways system is 1200 meters. The
braking system should be capable to stop a freight train of 2250 tonnes trailing load
equipped with air brake at a speed of 75 km/h within the safe braking distance
prescribed above on main line track with a falling gradient of 1 in 200. It should also
be capable to stop the maximum trailing load of 850 tonnes of passenger train load at a
speed of 95 km/h within safe braking distance. In case of vacuum brake, the braking
system should be capable to stop a passenger train of 16 coaches=680 tonnes, at speed
of 80 km/h in the safe braking distance prescribed. The maximum trailing load of freight
train with vacuum brake is 2250 at speed of 65 km/h.
22.5 There shall be a drop of brake pipe pressure on the locomotive while operating air
braked train in the event of:
(i) Alarm chain being pulled in the rear most compartment of 22 coach passenger
train. This would be equivalent to creating an air leak of 4 mm at a distance of
about 1640 ft. (497 meters) from the locomotive cab.
(ii) The last vehicle on a 35 (8-wheeled) wagon goods train getting parted. There
shall be a drop in vacuum of 4 to 6 inches (100-150 mm) on the locomotive,
while operating vacuum brake train pipe in the event of:

a) Alarm chain being pulled in the rear most compartment of 22 coach


passenger train. This would be equivalent of creating an air leak of 5/8
inch (16mm) diameter at distance of about 1150 ft. (350 meters) from the
locomotive cab
b) The last vehicle on a 72 (2-axle) wagon goods train getting parted.
22.6 The locomotive shall be fitted with audio & visual indications in the cab to indicate
pulling of alarm communication chain from any carriage of a 22 coach air braked train
(length of train 497 meters). The pulling of alarm chain in a coach would cause leakage
of air through a 4 mm. choke, with red light indication in the driver’s cab, sounding of
buzzer and drop in brake pipe pressure in the locomotive ranging from 0.1 bar to 0.5
bar.
22.7 Complete overhauling of brake rigging system (replacement of worn out parts)
including brake cylinders is required. Renewal/ overhauling of air brake
valves/components (kits) including hand brakes shall be supplied by the bidder.

23. LUBRICATING OIL SYSTEM

23.1. Lube oil cooler elements, lube oil filter tank and by pass valve on lube oil main header
pipe shall be replaced.
23.2 The lubricating oil circuit should be provided for adequate straining and filtration to
match local operating conditions. Paper type filters will be preferred.
23.3. The lubricating oil filtration system provided shall be such type that change of
lubricating oil should not be necessary before a minimum distance of 120,000 KMs
expect for unsatisfactory lube oil test results.
23.4. The lubrication system should adequately guard against damage to engine due to
repeated cold starts. Safety devices against hot engine oil and low lubricating oil
pressure must operate when lube oil temperature and pressure reached danger limit.
23.5 Auto pre-lubrication oil pump with filtration shell be provided in the starting circuit of
diesel engine with necessary interlocking as well as lubrication of turbo after stopping
of diesel engine.
23.6 Lubricating oil system should be so modified so as to ensure that temperature of lube
oil leaving pump does not exceed 104 degree C or so under PR working conditions.
Difference of temperature for in and out from lube oil cooler should not be less than 5
to 6 degree C without decreasing horse power of the engine.

24 FUEL INJECTION EQUIPMENT

24.1. The fuel injection piping system will be replaced with new ones.
24.2 New fuel injectors will be provided and shall be arranged so that injection to the
corresponding cylinder can be manually cut off; if required.
24.3 Existing fuel oil pump with motor shall be replaced with new fuel oil pump with AC
motor.
24.4 Efficient filtration of fuel oil before reaching injection pumps is of vital importance.
Replaceable paper type filters are desirable.
24.5. All fuel oil pipe lines shall be so arranged and protected that any leakage of fuel from
a cracked pipe or leaking joint is prevented from falling on heated parts of engine or
close to the electric circuitry, contactors, switches, etc.

25. ENGINE WATER COOLING SYSTEM

25.1 Radiator cores along with header, radiator fan with stator and water tank including
water header pipe should be replaced with new ones.
25.2 The locomotive radiators shall be suitable to cater for high ambient temperatures (55˚
C) and improved horse power keeping in view the dusty terrain in which the
locomotives would operate. Ample radiator capacity must be provided to maintain
normal running temperature when operating for long periods at maximum out put at
highest ambient temperature. The water capacity of the system should be adequate so
that make up water is not required for at least 250 hour of normal service operation,
i.e. between fortnightly schedules
25.3 The radiator capacity shall include 25% margin to take into account any reduction of
efficiency which may occur due to the coating of inner or outer surface of the radiator
elements with scale or dirt.
25.4 Due to extreme climatic conditions, special attention is required to improve the design
of existing cooling system for summer and winter seasons.
25.5. The water circulating system shall be fitted with protective devices against damage to
diesel engine due to over-heating or lack of cooling water.
25.6 The radiator elements with detachable headers should be provided for convenience of
cleaning and washing.

26. CABLE AND WIRING

26.1. Complete rewiring (HT/LT) of Locomotives including driver’s cabin and hardware
items should be replaced by the bidder.
26.2 All cable conductor/wire shall be of copper. The types selected shall be especially
suitable for service conditions as per EMD standards or as specified in B.S. 6007 and
6500 of 1975 or corresponding ASTM Specification for the type of cables adopted and
for ultimate temperature permissible when operating under site condition. All cables
shall be suitably insulted. The layout of cables shall be such as to ensure accessibility
for inspection and replacement. The insulation of cables conductors and wires should
be flame retardant and resistant to oil, grease, salt, air moisture, sand and caustic
cleaning solutions. It should be designed to withstand electrical overload, abrasion, cut-
through-compression and crushing forces. Cables meeting ASTM B33 or ASTM B172
standards which typically has service life in excess of 20 year shall be provided.
26.3. Cables shall terminate in suitable protective place where cables interconnect relatively
with moving items such as traction motors. The flexible cables may be sheathed as far
as possible. Cables/wiring shall be concealed to avoid damage to its insulation.
26.4 Terminal lug connection of traction motor leads should be robust and of copper material
with tin plating / coating.
26.5 Jumper connections should be able to meet the most severe service requirements.
Complete information on number of wires and arrangements for inter-vehicle
connections shall be supplied by the bidder.
27. DRIVING CAB EQUIPMENT, GAUGES AND INSTRUMENTS

27.1. The driver cab will be refurbished for which all furnishing material will be supplied.
The existing size of the cab, look out glasses, sliding windows can be changed to
improve comfort. All gauges and indication lights including low lube oil indication to
be provided. The cab equipment will include: -
(a) Engine throttle and automatic brake valve.
(b) Driver’s brake valve.
(c) Vigilance device.
(d) Safety device indications / warnings.
(e) Public warning signal and warning bell (air operated) lever/ button on driver
as well as fireman side.
(f) Sanding button.
(g) Electrical speedometer with LOS not only indication but also no penalty
application including drive arrangement with related locomotive over speed
device adjustable for speeds of 65-122 KMPH.
(h) Headlight switch, full and dim and classification light switch.
(i) Buffer light switch, red and white aspects.
(j) Cab light switch.
(k) Instrument light switch.
(l) Main air reservoir pressure gauge.
(m) Air pressure gauge for air-cum-vacuum brake system.
(n) Control air pressure gauge.
(o) Vacuum and air brake gauge for train pipe.
(p) Lube oil pressure gauge.
(q) Fuel oil pressure gauge.
(r) Turbo booster air pressure gauge.
(s) Engine water temperature gauge. (Temperatures displayed shall on display
screen
(t) Load meter (traction generator current ammeter)
(u) Load meter for each traction motor with color band.
(v) Traction motor isolation switch.
(w) Voltmeter for battery with color band to indicate charge and discharge of
battery.
(x) Air horn lever on driver as well as fireman side.
(y) Hand brake.
(z) Two fans.
(aa) Wiper lever / button.
(bb) Fire extinguishers (two in number) Dry chemical type, capacity 6 kg.
(cc) Air flow indicating device to provide indication to the driver about the train
conditions and train parting while hauling air braked stock with buzzer.
(dd) One hot plate.
(ee) Emergency brake valve on fireman side shall be provided.
(ff) Driver’s cabin air conditioner.
(gg) VHF (VHF radio set should be as per specification appendix-I) set and
provision for locomotive tracking device shall be provided.
The bidder will indicate the details of gauges and protections which will be monitored
through micro-processor or physical instruments. However, availability of above
equipment either displays through microprocessor or gauges must be ensured wherever
applicable.
27.2 Engine start and stop button be provided in drivers cab.
28. SAFETY DEVICE

28.1 The rehabilitated locomotive should be provided with safety devices (operation
through microprocessor or instruments), appropriate automatic reaction and audio-
visual warnings for the following situations: -
(a) Low cooling water level.
(b) Hot engine over-ride switch shall be provided to allow the engine to run, after
cutting-off power to cool it down quickly.
(c) Ground in electric circuit with reset button.
(d) Low lube oil pressure.
(e) Wheel slip with automatic power reduction and automatic sanding.
(f) Manually operated emergency engine stop device to be located out side the cab
at suitable place.
(g) Failure of main air reservoir pressure.
(h) High crankcase pressure.
(i) Diesel engine over-speed.
(j) Locomotive over-speed.
(k) Indication/application of brakes through guard-van brake valve, use of passenger
alarm communication and train parting in case of air and vacuum brake trains.
(l) Clogging of engine air intake filters.
28.2 Excessive lube oil temperature safety should be provided through microprocessor
control by cutting off the power, there by racing the prime mover at 6th notch
automatically to cool down the lube oil temperature.
28.3 Radiator fan AC motor protection shall be provided i.e. suitable 3 phase circuit
breaker.
29. VIGILANCE DEVICE

29.1 A vigilance device of approved design shall be fitted. This device should be arranged
in such a manner that: -
a) With the operation of vigilance device the power to traction motor is cut off,
the diesel engine returns to idle and locomotive and train brakes apply
automatically after suitable warning and time delay.
b) The operation for vigilance device should preferably be cancelled by the
operation of one of the following with a time must be more than 20 second
distance of 1.5 kilometer:
i. Cycling Device
ii. Throttle handle
iii. Brake automatic and independent
iv. Push button on dash board

30. HEADLIGHT, ELECTRICAL LIGHTING, WHISTLE, ETC

30.1 The rehabilitated locomotive shall be provided with four excellent quality sealed beam
headlights at each end. The intensity and focusing of the headlights should be such that
a person standing on the track 500 meters (1640 ft) away is clearly defined. Each
headlight shall be provided with a dimmer switch.
30.2 Each end of the locomotive shall be provided with two buffer lamps with two colors,
white and red aspects.
30.3. Adequate lights be provided in the driving cab and the engine room. The
instruments/gauges are to be illuminated in such a way as not to interfere with the
visibility of the track/signals. All bulbs holders should be of screw type. Two portable
electric lamps with sufficient length of flexible cables and suitably located sockets
should be provided for inspection of running gear and engine room during the night.
30.4 The locomotive shall be provided with air operated warning whistle and warning bell
which can be operated from either side of the cab by the driver or /Assistant Driver.
30.5. Classification lights should be provided at both ends of the locomotive on each side.

31. SANDING GEAR

31.1 Sanding gear shall be provided duly rehabilitated on the wheels of both end axles of
each truck (i.e. 8 wheels). Provision should be made for both manual as well as
automatic operations, in case of wheels slipping. The sanding gear will function for
movement of the locomotive in either direction.

32. PRE SHIPMENT INSPECTION.

32.1 The material/assemblies i.e. Re-manufactured Diesel Engine Units, Alternator &
Traction Motors and new Microprocessor, to be supplied for rehabilitation and
modernization of locomotives will be subject to inspection /tests before shipment by
inspectors designated by purchaser at manufacturer / bidders facility as per details in
Appendix-H . The supplier must comply with all requirements in the matter of
suitability of material and method of construction. All equipment required by the
inspection authority during the course of inspection and test must be provided by the
manufacture free of charge. The inspecting authority has the right to reject any part
during or after re-manufacturing, if in his opinion the quality of material or the standard
of workmanship is not up to the requisite standard. The decision of inspection authority
in this respect shall be final and all parts so rejected shall be replaced free of charge by
the manufactures. The inspection shall not absolve the manufacturer of their
responsibility regarding quality, design, material or workmanship. The inspector has
the right to inspect any remanufactured alternator, traction motor, turbo supercharger
and diesel engine with respect to crankshaft, power assembly, camshaft, etc at assembly
stage. The pre shipment inspection is subject to mutual consent of both the parties at
the time of award of contract.
32.2 All expenses of inspectors in respect of boarding, lodging, out-of-pocket expenses,
transport, round air tickets will be borne by the supplier/manufacturer for inspection.

33. ACCEPTANCE TEST OF THE POWER UNIT AND ELECTRICAL


EQUIPMENT.

33.1 The material to be supplied for rehabilitation and modernization of locomotives will be
subjected to tests by the purchaser at the place of rehabilitation by an Inspecting
Authority to be designated by the Purchaser. All instruments, gauges and equipment
required shall be provided by the manufacturer free of charges.
33.2 In addition to the continuous running test, the Inspecting Authority shall have the right
to carry out overload test of any power unit which may be selected for this purpose.
33.3 The Inspecting Authority shall have the right to carry out other tests such as fuel and
lubricating oil consumption trials, etc., at his discretion. These tests shall be carried out
on at least one power unit out of the total number on order at the place of
remanufacturing.
33.4 The alternator and traction motors shall be subjected to such tests as the Inspecting
Authority may consider necessary to ensure that the temperature rise in the windings
does not exceed the maximum laid down in B.S. Specification No.173/1960 or
corresponding ASTM Specification, when the machines are working at their maximum
continuous output for a period of not less than twelve hours under conditions of the
highest ambient temperature specified, 53 degree C. The electrical resistance of the
insulation shall be tested at the end of the test runs and must be in accordance with B.S.
Specification No.173/1960 or corresponding ASTM Specification. In addition to the
measurements of resistance the insulation shall be subjected to Hi Pot tests as required
by the Inspecting Authority at the place of remanufacturing.
34. FINAL ROAD TESTS
34.1 A selected number of locomotives after complete rehabilitation shall be subjected to
road tests to check hauling power, maximum speed, continuous tractive efforts,
acceleration, balance speed, fuel consumption, heat balance, riding quality etc. under
climatic / operating conditions as mention in Clause-5. The time of carrying out the
tests shall be fixed by purchaser, and will normally be after a period of 3 months of
service of the rehabilitated locomotive. The supplier shall be required to appoint a
representative to witness the test and assist the purchaser in carrying out the same. Any
defect in design of material, workmanship or any failure of equipment to come up to
the standards claimed by the manufacturers in their bid, which may come up during
these tests, shall have to be corrected on all units by the supplier to the satisfaction of
Pakistan Railways. The latter shall have the right to insist on a repetition of the trials
after any modifications which may be carried out by the supplier to rectify the defects.
The tools, instruments & equipments required for above tests will be provided /
arranged by the bidder.
34.2 All power units complete with Alternator, Traction Motors, Turbo Superchargers,
Expressors and new Microprocessor etc. shall be subjected to load test after completing
normal running in tests. These tests shall be carried out by the Inspecting Authority in
accordance with specified requirements.
34.3 The power unit shall be run at the maximum service output with the main traction
alternator voltage corresponding to that required at the traction motor terminals for
operation at the maximum safe track speed of the locomotive. This test shall be a part
of 12 hours continuous running test and the Inspecting Authority shall have the right to
select the moment at which this test shall be conducted.

35. SUPERVISION AND AFTER SALE SERVICE


35.1 Bidder shall provide necessary supervision for the entire period of rehabilitation of
locomotives at Pakistan Railways workshops so as to ensure that agreed outturn, quality
and schedule of time are met properly and to provide on the job training to purchaser’s
personnel. Man-months recommended shall be indicated but charges shall be included
in the cost of Rehabilitation of locomotives.
35.2 Bidder shall provide the services of service engineer after commissioning of
locomotives for the warranty period for watching the performance of rehabilitated
locomotives. Man-months recommended shall be indicated but charges shall be
included in the cost of Rehabilitation of locomotives.
36. TRAINING
36.1 The Bidder shall provide training to maintenance and operating staff regarding newly
introduced/developed Microprocessor, technology parts/assemblies in Pakistan
Railways premises. The bidder shall also arrange training equipment, documents,
brochures, etc for the training purpose at own expenses.

37. MACHINES AND TOOLS


37.1 Bidder should submit list along with cost of additional machine and tools required for
re-building of engine block after examining the existing facilities in Locomotives
shops, Moghalpura, Lahore (if any required). A tentative proposed list of machines /
tools is attached as Appendix-B2 which is subject to change by purchaser.
Bidder has to provide this list without cost separately in Technical Bid for evaluation,
prices of the same can be provided with Financial Bid.

37.2 Necessary sets of hand tools, equipment and test instruments etc essentially required
for rehabilitation and modernization of locomotives shall be supplied by the bidder. A
list of these items shall be submitted in the form of Appendix “C”.
37.3 The bidders shall be also submit a list of special electrical and mechanical tools and test
instruments required for normal repairs and major maintenance in the form of Appendix
“C-I” in technical bid and prices in financial bid.
38. SPARE PARTS
38.1 A Tentative proposed list of 3 years maintenance spares is indicated as Annexure-D,
however it is desired that Bidder/manufacturer propose a three year maintenance spares
list along with quantity as they feel deem fit. Bidder / manufacture are at liberty to
delete or add any spar part in the proposed list as Appendix -D. This list without pricing
must be submitted with Technical Bid for evaluation; however the same list with quoted
prices should accompany the financial bid.
38.2 A List of long life/principle assemblies is provided in Appendix-E with the
required quantities bidder should submit pricing item wise as per Appendix-E.

39. DRAWINGS AND INSTRUCTION BOOKS

39.1. All modification drawings, instructions books (operating & maintenance/service


manuals as well as parts catalogs) shall be provided both in soft and hard copies.
39.2 All documents shall be in English language.
39.3. The following maintenance manuals/literature shall be supplied for the rehabilitated
locomotives: -
i. 40 sets of operating manuals.
ii. 20 sets of maintenance instruction manuals, pertaining to mechanical and electrical
equipment incorporating check list for individual component (Mechanical /
Electrical).
iii. 20 sets of locomotive service manuals, pertaining to mechanical and electrical
components, incorporating checking/ testing parameters and procedures.
iv. 20 sets of electrical wiring schematic, oil piping, water piping and air piping
diagrams plus 10 sets large size colored diagrams for display in sheds / training
school.
v. 40 sets of maintenance instructions for the air-cum vacuum brake system plus 10
sets of large size colored diagrams for display in sheds / training school.
vi. 20 sets of mechanical and electrical spare parts catalog for each
assembly/component used on the locomotives.
39.4 It must be ensured that maintenance instructions and spare parts catalogue should
fully cover all proprietary items like governor, expressors, traction motor, etc. The
literature should fully provide instruction for service and maintenance of all
assemblies/ components.
40. SCOPE OF REHABILITATION AND MODERNIZATION WORK

40.1 The repair and remanufacture of the major components of the locomotives like diesel
engines, main alternator, traction motors etc as described below, will be done locally or
abroad, and the quantities are herein indicated and summarized as under :

A. 10 Diesel Engines shall be remanufactured abroad on UTEX basis by replacing


with OEM parts. The supplier will arrange suitable engine cores abroad, and
rehabilitate, modernize etc such cores to become remanufactured engines, duly
tested and guaranteed on the standards of EMD/OEM. Bidder would submit
detail criteria of OEM remanufacturing and parts to be changed along with the
bid for deciding the parts to be replaced.

B. 10 nos. Diesel Engines shall be remanufactured locally, with new OEM part kits
as per OEM standard criteria for remanufacturing. Bidder would submit detail
criteria of OEM remanufacturing and proposed parts to be replaced along with
the bid for deciding the parts to be replaced. However, the crankcase and oil pan
will be remanufactured locally by P.R staff under the supervision/guidelines of
supplier / manufacturer, who under instructions and on behalf of EMD will
transfer the technology (details will be provided in bid) to produce these works
with the necessary quality. In addition plant & machinery, tooling and special
Jig/fixtures as per Appendix-B2 will be necessary to supply for the
refurbishment of the Engine Block Repair facilities in Lahore (if necessary).
The bidders are invited to visit this facility and supply the items necessary to
comply with this requirement. From these locally rehabilitated crankcases and
oil pans, together with the OEM parts kits to be shipped by the supplier, 10 nos.
diesel engine units will be assembled under the supervision of the OEM/bidder’s
Service Engineer who afterwards shall test the engines as per OEM’s standard
and same warranty conditions will be enforced as the engine unit supplied on
UTEX basis. The technical characteristics of the engines remanufactured locally
will be exactly equal to those engines remanufactured abroad.

C. All 20 nos. turbo superchargers shall be remanufactured on UTEX basis with


provision of new replaceable parts.

D. 20 (twenty) Main Alternators AR 10F1/D14 shall be remanufactured and


upgraded as AR 10 – CA 6 abroad on U-TEX basis with used cores shipped
from Pakistan to the bidder/manufactures works (All transportation costs will
be born by bidder) under technical characteristics covered by MI-3317 and MI-
3332 but if cores do not qualify OEM standards for remanufacturing, then
bidder will supply remanufactured traction motors on outright basis with
guaranty/warranty as new (All transportation costs will be borne by bidder).

E. 120 Nos. traction motors model D77 shall be remanufactured and upgraded to
D 78 traction motors with larger axle caps as per clause15. These motors will
be remanufactured abroad on UTEX basis with used cores shipped from
Pakistan but if cores do not qualify OEM standards for remanufacturing, then
bidder will supply remanufactured traction motors on outright basis with
guaranty/warranty as new (All transportation costs will be born by bidder). The
supplier will make sure that the technical characteristics and the EMD
instructions through the MI-3900 and 3950-3 will be integrally followed. In
order to compensate the delay for transportation the supplier will ship 20
traction motors prior to receive the used cores. All the traction motors will be
fitted on new wheel axle assemblies with U tube suspension.

F. Bidder will carry out remanufacturing / rehabilitation 20 DC auxiliary


generators 6A-7159 capacity brushless type, through EMD instructions
contained on the MI-3707. Bidder should also ensure that the Microprocessor
and these AC auxiliary generators are compatible with each other.
G. 20 Expressers ADJV of existing capacities shall be remanufactured on UTEX
basis with all new replacement parts as per OEM standards.

H. 40 (forty) existing trucks Rigid type EMD 9087197 (MI 1506) will be
rehabilitated locally with new parts to be supplied by the bidder under the
supervision of supplier (Service Engineer) and workers of PR. The supplier will
provide all necessary parts/hardware like pins, bushes; wear plates, bolts, nuts
& washers for rehabilitation of bogies. The bidder shall provide all new items
like springs, rubber packs, oil damper, axles, support bearing, bull gears, journal
boxes, journal bearings (PR approved manufacturers of European/USA),
inbound and outbound felt seals for gear cases etc with new ones. All gear cases
will be new and manufactured in Pakistan as per drawing provided by
supplier. Wheels Axle assembly with bearings will be brand new. The supplier
must ensure that the OEM instructions contained in M/s GM/EMD maintenance
and repair instructions No. MI-1508 Rev. A will be integrally followed during
the rehabilitation process. All worn parts shall be replaced with new one.

I. 20 (twenty) brand new Microprocessors EM 2000 including all necessary


modules, sensors, contactors, relay, regulators, switches traction motor switch
gears, wiring harness with other accessories etc. The Microprocessor shall
ensure to control operations / diagnostics and propulsion system of locomotive.
It should consist on consolidated control architecture, and should have the
capability to perform following:-

a. Diesel engine data and parameters

b. Microprocessor must have single connecter by which it can be isolated

 Have the facility to display function of control / diagnostics, and


parameters on display panels for easy operational access and
troubleshooting capabilities.
 Controls Diesel Engine speeds.
 Regulates traction alternator excitation.
 Substantial increase in locomotive adhesion through advance wheel
creep control.
 Control locomotives auxiliary loads.
 Processes feedback signals from the traction motors,
 Control and monitors tractive effort.
 Traction motor over-speed protection.
 Automatic ground relay reset.
 Regulates traction alternator excitation.
 Protects against excessive wheel slip and wheel sliding.
 Locomotive speed control system.
 Monitoring / displaying the data of safety devices.
 Local alarm bell silence-all alarms.
 Processes all commands from the Driver desk or MU train line.
 Facility to download and upload data via USB port for further
programming

The supplier shall be responsible to ensure full efficiency of the system in operations.
The Microprocessor software should have provision for storing data regarding fault
history and related status during running (trip). Software shall be provided by the
seller to buyer free of cost. The bidder should clearly specify the service life of
control system without overhauling.

J. 20 (twenty) sets of repair kits for the existing air brake system 28LV1 Air cum
Vacuum system Westinghouse, USA, shall be provided. The individual kits
must be sufficient to repair all main and auxiliary valves of the system so that
the brake system complies with the braking requirements of Pakistan Railways.
K. 20 (twenty) sets of cabin components including but not limited to:
(i) Brand new control stands with all relevant accessories, all instruments,
switches, relays, resistors, lamps and A-9 & SA9 valves etc where
applicable according to new control stand configuration on the
locomotives.
(ii). Brand new electronic speedometers with speeds up to 140 KPH
equipped with alarm for over speed. The speedometers will be driven
by electric signals from compatible axle generators also necessary to
supply in brand new condition.
(iii) Brand new electronic black box (event recorder) capable to register and
display whenever necessary the speeds, times, forward and reverse
motions, brake applications, brake pipe pressure and brake cylinder
pressure, and with crash memory to keep information 48 hours before
any accident. The event recorder is connected to the same axle
generator that drives the speedometer.
(iv) Brand new air conditioning unit roof top mounted with minimum of
25,000 BTU per Hour
(v) Brand new side wall mounted heater with fan for 1000 watts
capacity.
(vi) Brand new hot plate.
(vii) Brand new Vigilance control system by means of foot pedal to be
pressed by the driver.
(viii) Fitment of compatible VHF radio and provision for tracking system
in driver cabin.
(ix) Provision for automatic train control unit (ATC) to be supplied by the
user.
(x) Brand new (upgraded) electrical driven window wiper system
including the wiper motors, valves, levers, etc.
L. 20 (twenty) sets for the pneumatic system included but not limited to:

i. Brand new repair kit for the automatic shutters including shutter cylinders,
valves, and levers springs etc.
ii. Brand new repair kits for the Accessory Cabinet including the instruments,
the compressor control switches, the test valves etc
iii. Brand new horn and valve.
iv. All new front and side glasses shall be fitted which should be strong enough
to withstand stone palleting.
v. Alternatively provision of all bullet proof glasses in locomotive car body
be quoted as optional.
M. 20 (twenty) cooling compartment sets including but not limited to: -
i. Brand new radiator cores and headers, piping etc
ii. Brand new complete cooling fans 9 blades (2 units per loco) with suitable
heavy duty AC motors and contactors etc.
iii. Radiator fan AC motor protection shall be provided i.e suitable 3 phase
circuit breaker.
iv. Driver control stand to be fitted new along with all new accessories
v. Car body works to be carried out by purchaser at their premises with all
material supplied by the bidder.
N. 20 (twenty) sets for the air compartment including but not limited to:
i. Complete brand new dust blowers with motors.
ii. 40 brand new inertia filters set to be provided.
iii. 10 brand new air cooling blowers and 10 complete blower kits with
bearings should be provided for rehabilitation of remaining air cooling
blowers.
iv. Remanufactured HVC filter recipient with brand new paper filter
elements
v. Remanufactured engine air filter recipient with brand new paper filter
elements.
vi. Installation of air restriction sensor for protection of the engine.

O. Water Tank’s Pressure Cap and Gauge - To be Brand New.


All the 20 pressure caps and respective necks will be brand new with new water
level gauges. All water tanks will be tested and replaced if rejected.
P. Thermostatic Valves TA, TB and ETS - All Brand New.
All 20 each thermostatic switches must be replaced by brand new units.
Q. Engine Instruments - To be Brand New
All instruments (water temperature, oil pressure, oil temperature etc) for the 20
DE locos will be brand new.

R. All 20 sets of flexible couplings for Expressor and AC auxiliary generator shall
be replaced with new one.

40.2. The scope of supply is broadly outlined. The bidder will indicate details with OEM Part
No. reference of Catalogue Book, Qty. per package/kit,
40.3 The bidder cannot make changes in the scope of supply/ work but can give clarification
provided that substance of bid does not change.
40.4 The bidder shall provide related documents, broachers etc of newly provided
microprocessor, parts/assemblies regarding modernization being quoted along with
purpose of reference and technical evaluation.
40.5 The total number of units mentioned against various packages are subject to adjustment
on the discretion of purchaser.
40.6. Locomotive main frame and draw gear will be reconditioned as per drawings provide
by the manufacturer/bidder to give satisfactory riding quality for a maximum speed of
122 KMPH on Pakistan Railways existing track conditions.
40.7 Modifications may be required in the superstructure of the locomotive to fit in new
control cabinet, control stand, diesel engine and other equipment and for easy access to
maintenance staff. Corroded and damaged panels of superstructure will be replaced /
repaired with the material supplied by the bidder.
40.8 The existing bogies will be qualified and reconditioned so as to give them an additional
service life of 15 years for which necessary spares, rehabilitation kit and drawings for
modification, if any, will be supplied. The bogies after rehabilitation should remain fit
for the speed mentioned earlier. The detail of components of the bogies to be replaced
shall be clearly indicated.
40.9 New look out glasses, door and window glassed with rubber packing, wind shield
wipers, sun visions, cab flooring, re-insulating roofs and replacement of driver/fireman
seats and other hardware items replacement shall be carried out with material supplied
by the bidder. The brake handle shall be located on the left hand side of the driver. An
extra folding seat shall be provided in engine cab with partition wall in rear of fireman
seat.
40.10 The rehabilitated and modernized locomotive will be painted in polyurethane according
to colour scheme approved by the Pakistan Railways. For this purpose local material
and man power will be arranged by Railways. Existing procedures and facilities will be
utilized. However, the supplier may provide supervision and suggestions to improve
the quality of work.
40.11 The supply of sufficient air to traction motors shall be ensured. To keep compressor
cool it will be preferred to separate compressor compartment from engine and radiator
compartment by providing suitable partition walls.
40.12 Drawings/instructions/equipment required for re-manufacturing of major Drawings
/instructions/equipment required for re-manufacturing of major assemblies/ systems
and assemblies and testing of these locomotives shall be provided by the bidders.
Details of all engineering re-design such as revised heat balance, re-balancing of
locomotive to minimize vibration/under stress on account of relocations of old
equipment or provision of new one shall be submitted with the offer.

41. DELIVERY PERIOD

Bidders are required to provide detail of shipment schedule along with detail of
activities with bar chart. Shortest delivery period will be preferred. Necessary drawing
for modification along with detail of local material including material specification will
be submitted in advance to carry out necessary preparatory work on locomotive’s frame
and superstructure.

42. DATA / TECHNICAL INFORMATION

42.1 The bidder will submit with the offer the technical data relating to the rehabilitated
locomotive as well as its major new/ rehabilitated assemblies and systems.

43. GUARANTEE

43.1 The bidder shall guarantee the performance of the rehabilitated and modernized
locomotives and all individual components as claimed by the bidder against specific
items of performance, for a period of not less than 24 months from the date put in
service. Whereas for turbo superchargers and electrical rotating machines this warranty
will be 36 months from the date put in service. All the remanufactured parts will be
guaranteed for performance as new and will carry the same warranty as of new.

44. DESPATCH OF MATERIAL REHABILITATION AND MODERNIZATION


SCHEDULE.

44.1 The successful supplier shall submit a plan for material supply, storage and inventory
control. A draft plan shall be submitted with the tender. The material shall be supplied
in kit so as to turn out rehabilitated locomotive in perfect working condition for reliable
service.

45. DEVIATIONS

45.1 Notwithstanding anything that has been said in the preceding clauses, any deviation
from specification after opening of tender is not acceptable under PPRA rules.
However, clarification about specification will be made during pre-bid conference.
APPENDIXES
APPENDIX -‘A’

MAXIMUM MOVING DIMENSIONS FOR 10’-6” (3.20 METERS) WIDE ROLLING


STOCK ACCORDING TO CME’s SKETCH NO. 1799/1
Ft. In. Meter.
1. Maximum width over all projections at 4 ins (100 mm)
above rail level, when fully loaded. 8 0 2.44
2. Maximum width over all projections at 1 ft. 0 in 10 0 3.05
(305 mm) above rail level, when fully loaded.
3. Maximum width over all projections at 3 ft. 9 ins 10 0 3.05
(1.14 meter) above rail level, when fully loaded.
4. Maximum width over all projections at 3 ft. 9 ins 10 6 3.20
(1.14 meters) above rail level, when fully loaded to
a height of 12 ft. 3 ins (3.73 meters) when empty for
bogie vehicles.
5. Maximum width over open doors .. .. 13 3 4.04
6. Maximum height above rail level for a width of 1 Ft. 14 8 4.47
0 in. (305 mm.) on either side of centre of unloaded
Vehicles.
7. Maximum height above rail level at sides of unloaded 12 3 3.73
Bogie vehicles 10 Ft. 6 ins. (3.20 meters) wide.
8. Minimum height above rail level when fully loaded 0 4 0.102
for a width of 4 Ft. 0 in. (1.22 meters) on either side of
centre of track, with the exception of wheels and
attachments thereto.
9. Minimum height above rail level when fully 1 0 0.31
loaded at 5 Ft. 0 in. (1.52 meters) from centre
of track.
10. Minimum height above rail level when fully 3 9 1.14
loaded at 5 Ft. 3 ins. (1.60 meters) from centre
of track.
11. Wheel base and length of vehicles.
(i) Minimum distance apart of bogie centre for 2/3 of length of body
bogie vehicles. of vehicles.
(ii) Maximum distance apart of bogie centres for 48 6 14.78
bogie vehicles.
(iii) Minimum distance between bogie centres .. 19 6 5.94
(iv) Minimum distance between two axles .. 4 6 1.37
Ft. In. Meter.
12. Maximum and minimum wheel gauge of distance apart 5 3 1.60
for all wheel flanges.
13. Maximum diameter measured at the tread of new wheel. 3 7 1.09
14. Minimum height above rail level for floor of fully 4 1 1.24
loaded passenger vehicles.
15. Maximum and minimum distance apart for centres 6 5 1.96
of buffers.
16. Maximum height above rail level for centres of buffers 3 7-1/2 1.10
for unloaded vehicles with side buffers.
17. Minimum height above rail level for centre of buffers 3 4-1/2 1.03
for fully loaded vehicles with side buffers.
18. The buffers must conform to the following general
dimensions:-
(i) Diameter of holes in base for attachments to 0 1-3/16 0.027
head stock.
(ii) Centers squares of 4 holes in base .. .. 0 8-1/4 0.209
(iii) Diameter of buffer head .. .. .. 1 6 0.46
(iv) Length in position from buffer face to head stock. 2 1 0.63
(v) Length of stroke .. .. .. 0 4-3/4 0.12
19. The maximum permissible length over buffers is 74’-2” (22.6 meters).
20. Minimum radius of curvature 573 ft (175 meters) equals 10 degree curves.
The minimum radius of curvature on main line is 1146 ft. (349 meters)
corresponding to 5° curve without any gauge widening. However, the
locomotives should be able to negotiate 10° curves in yards.
21. Maximum super elevation 6-1/2 inches (165 mm.).
22. The minimum permissible clearance of the locomotive when fully loaded, above rail level
for a width of 4 ft. (1.2 meter) on either side of the track is 4” (102 mm.). This dimension
shall apply to vehicle with worn tyres. With new tyres, the clearance should not be less than
5-1/2” (140 mm.). A design permitting 3-1/2” (89 mm.) wear on wheel diameter will be
preferred.
Note: - It will be noted that the maximum permissible distance apart between bogie centres
is indicated as 48 ft. 6 ins. However, this distance and the overall length of the
locomotive should not be unnecessarily long.
************
APPENDIX “A1”

PERFORMANCE FOR REHABILITATED AND MODERNIZED GMU-30


D.E LOCOMOTIVES
UTILIZATION
The locomotives shall be utilized to haul freight trains at a speed of 100 Kmph, and Mail &
Express trains at a speed of 120 Kmph under the local weather conditions as indicated in
Clause-5.

LOCOMOTIVE PERFORMANCE
The following performance curves for full and 80% load factor shall be provided (Reference
may be made to Clause 6,7&8).
1) Tractive effort speed curves from starting to maximum speed at site condition showing
maximum and continuous tractive efforts. The train resistance curve should be provided
for the following trailing loads bringing out the balanced speed.

i) Mail & Express Trains


(a) 850 tonnes on level track and 1 in 200 gradient.
(b) 750 tonnes on level track and 1 in 200 gradient.
(c) 570 tonnes on level track and 1 in 100 gradient.

ii) Freight Trains


2500 tonnes on level track and 1 in 200 gradient.
2250 tonnes on level track and 1 in 100 gradient.

2) Time speed curves when hauling following trailing load


i) Mail & Express Trains

(a) 850 tonnes on level track and 1 in 200 gradient.


(b) 750 tonnes on level track and 1 in 200 gradient.
(c) 570 tonnes on level track and 1 in 100 gradient.

ii) Freight Trains


(a) 2500 tonnes on level track and 1 in 200 gradient.
(b) 2250 tonnes on level track and 1 in 100 gradient.

3) Time speed curves for passenger & freight trains at level track.
i) Tonnage of trailing load and time to achieve the speed of 120 Km /h
for passenger train.

ii) Tonnage of trailing load and time to achieve the speed of 80 & 100 Km /h
for freight train.
4) Trailing loads v/s speed charts on various grades indicated in appendices F & G for
Freight, Mail & Express trains for Rehabilitated locomotives shall be indicated by the
bidder.
Appendix – B

SPECIFICATION OF 15 NOS. RE-MANUFACTURED DIESEL ENGINE MODEL


16-645E3C TO BE SUPPLIED ON UTEX BASIS

The remanufactured diesel engine units must conform to the following terms and
conditions set out in the specification as per following details:-

A. CRANKCASE AND OIL PAN.

i. Crank case and oil pan assembly with serial number should be indicated which
should be interchangeable with our existing diesel engines model 16-645E3C.
ii. Crank case and oil pan assembly must have been qualified according to the
EMD/GM’s M.I.100 Rev.
iii. Provide new upper and lower liner pilot bore sleeves and qualify dimensionally
for cylinder bore sizes.
iv. Qualify the following: -
a. Tapped holes in cylinder blocks
b. Main bearing studs
c. Crab bolts

v. Perform ultrasonic inspection of all critical/repaired/welded portion of engine


crank case and oil pan assembly to identify and correct any cracks if already
existed without compromising performance.
vi. Exhaust chamber base plate flanges must be flat to be within 0.010
vii. New turbo screen shall be provided.
viii. The bidder will furnish a certificate that the crankcase and oil pan assembly is
exactly interchangeable with existing crankcase and oil pan assemblies and would
not require any modification or alteration in the assemblies or any of the allied
equipment.

B- ACCESSORY END OF ENGINE

i. To qualify accessory drive housing.


ii. Renew damper assembly, gear as per OEM standard.
iii. To modify crankcase for over speed trip housing, internal drain as per OEM
standard.
iv. Renew lube oil strainer.
v. Renew/qualify governor drive gear.
vi. Qualify gear backlash to be according to OEM’s standards in gear box.
vii. Governor drive gear shaft to be re-qualified.
viii. Qualify dowel accessory drive housing in place.
ix. Inspect lube and water manifold for any defect and qualify.
x. Over speed trip and fuel injection pump control linkage to be qualified and replace
all associated pump control linkage bearing with new ones.
xi. Inspect and qualify all fuel oil manifolds with new piping.
xii. Apply new spin-on-elements.
xiii. Apply new engine protection devices.
xiv. Apply new hose assemblies associated with engine.
xv. Qualify and renew lube oil relief valve.
xvi. Qualify and renew over speed trip and cam counter weights.
xvii. Replace following assemblies with new ones.

a. Lube oil pressure pumps


b. Lube oil scavenging pump
c. Water pumps

xviii. Replacement of Governors and fuel Injectors with new one..


xix. Qualify accessory drive coupling and replace center bonded joint
xx. Renew hot oil detector thermostatic valve.
xxi. Replace load control rheostat (LCR) with new one.

C- CAM DRIVE END ENGINE

i. Replace all gears related to cam drive end engine with new one.
ii. Replace idler gear I.D and qualify for surface finish
iii. Replace idler gear bushing with new ones.
iv. Spring drive to be reconditioned incorporating latest design.
v. Qualify double idler stub shaft.
vi. Recondition auxiliary generator drive assembly.
vii. Provision of all new after cooler.
viii. Provision of turbo supercharger on UTEX basis with replacement of new parts.
ix. Replace existing soak back motor assembly to AC brush less motor assembly with
new one.
x. Replace lube oil separator with new one.
xi. Replace ring gear and coupling disc with new one

D- LUBE OIL SYSTEM

i. Replace turbo filter element.


ii. Replace soak back filter element

E- CRANKSHAFT

i. Apply new crankshaft according to OEM part number applicable,


ii. All main and con rod bearings to be replaced with new ones.

F- CAM SHAFT

i. Apply all new camshaft segments according to OEM part number applicable.
ii. Apply new camshaft bearings.

G- POWER ASSEMBLIES

i. New pistons, valves (inconel), piston rings (compatible with chrome plated
liners), gasket kits, insert bearings, thrust washer and bolts to be applied with
OEM brand new cylinder heads.
ii. New OEM cylinder liners (chrome plated) to be applied.
iii. Provision of new rod assemblies (Fork and Blade) to be applied.
iv. Provide new injectors, fuel rack actuator, release spring and racks, etc.
v. Provision of new valve bridge assembly and lash adjusters.
vi. Apply new rocker arm shaft and rocker arms with new crowned type roller
according to OEM standards.
vii. Apply new lower liner inserts and tubes oil piston cooling.
viii. Apply new/qualified plate crab and neck down crabs bolt according to OEM
standard.

H- MISCELLANEOUS COMPONENTS.

i. Apply complete new exhaust manifold alongwith hardware and Gaskets


ii. Apply new cylinder test valves with CRV seals.
iii. Qualify hand holes covers and apply new seals.
iv. Apply new water manifolds and jumper lines.
v. Apply new after coolers.
vi. Apply new piston cooling tubes.
vii. Apply new fuel jumper lines.
viii. Apply new starting motors.
ix. Inspect/qualify and apply new drain plugs, crabs stands (apply neck down type)
main bearing stud, plates and covers.
x. Assemble diesel engine using all new gaskets, seals, O-rings, gasket kits,
bushings, bearings and miscellaneous hardware. Use edge molded seals and
gasket where possible.
xi. Apply new governor plug/protector kit.
xii. All bolts and nuts are applied as new and female threading reconditioned.

I- ENGINE ASSEMBLY
i. Assemble diesel engine using OEM recommended torque specifications,
clearances and gear backlash.
ii. Starting motor bracket to be aligned and doweled according to OEM standards.
iii. Final inspection of the diesel engine to be carried out on load test with accessory
drive coupling and ring gear installed, bringing it to full load over a period of two
hours, and a half hours. Test data showing horsepower, RPM governor rack
setting, oil pressure, fuel pressure and water temperature at rear of engine to be
provided.
iv. The serial No. plate to be retained and this number to be recorded on all build up
sheets.
v. Customer to be supplied with engine build-up sheet along with test bed result
when they become available indicating the serial No. of the following
components: -
a. Crank case and oil pan
b. Crankshaft
c. Turbo super charger
d. Governor
e. Main lube oil pump
f. Scavenging oil pump
g. Pistons
h. Pins
i. Carriers
j. Connecting rods
k. Liners
l. Oil pans

PAINTING.
Complete diesel engine to be marked and painted a final coat of “SUEDE GRAY” paint.
SHIPPING INSTRUCTION.
1. The Diesel engine to be shipped complete with engine governors, turbochargers, all
accessories, including starting motors, fly wheel and accessory drive coupling etc.
2. The diesel engine to be properly protected and ready to install in the locomotive car body.
All the fluids to be drained and the engine protected from freezing
APPENDIX-B1

SPECIFICATION OF 12 NOS. RE-MANUFACTURED DIESEL ENGINE MODEL


16-645E3C TO BE REMANUFACTURED IN PAKISTAN.

The 16-645E3C engine is a 16 cylinder, turbocharged, after cooled engine of two stroke
cycle design. The engine characteristics, dimensions, tools, torques, weights etc are
described in the EMM (Engine Maintenance Manual) which must be followed step by
step during the remanufacturing process. The standards to be followed and the factory
criteria are bellow summarized for guidance of the bidders who are allowed to inspect
available engines in the Pakistan Railways facilities. Additional instructions must be
provided by the supplier under the form of technical assistance and transfer of
technology from persons who can demonstrate written credentials from EMD/supplier
of their involvement in similar scope of works.1–Engine Crankcase and Oil Pan- to be
remanufactured locally.

1. Engine Crankcase and Oil Pan- to be remanufactured locally.

Instructions contained on EMD documents as follows which must be exhibited by the


suppliers during the works, EMM: MI-100; MI-315; MI- 316; MI- 317; MI-318. The
supplier must visit the existing facilities in Lahore and suggest a list of tools, plant and
machinery, jig and fixtures and equipments not yet available in the facilities but found
necessary for the complete rehabilitation of these major engine parts. The supplier
must also indicate the list of all works to be performed during the remanufacturing
process, the quality standards to use and the time that it takes to complete the whole
amount of tasks.

2. Crankshaft - To be supplied OEM brand new .

The supplier should fit all crankshafts to be brand new.

3. Connecting Rods (Fork and Blade Types) To be OEM brand new.

The supplier must consider for supply of new connecting rods (fork and blade type)
conforming EMD specifications.

4. Cylinder Heads, Crab System and Cylinder Test Valves - To be OEM Brand
New

The cylinder heads and their parts like exhaust valves, exhaust valve springs etc. shall
be supplied brand new, conforming to the instructions of the EMM or the EMD
specification. All cylinder test valves (CRV) will be replaced by brand new units. All
exhaust valves; springs etc will be replaced by brand new units. All of the cast iron head
frames will be brand new. In order to improve the clamping force on the cylinder heads,
all engines will be contemplated by the brand new clamping system that includes plate
type crabs and brand new studs and nuts.

5. Cylinder Liners - All OEM Brand New.

All cylinder liners chrome plated will be supplied in brand new.


6. Pistons, Carriers, Rings and Piston Pins -All OEM Brand New.

All sets of compatible pistons, rings, carriers and piston pins will be supplied in brand
new.

7. Injectors & Injector Linkages - To be OEM brand new.

All injectors, injection pumps and associated linkage like fuel rack actuators, release
springs etc must be brand new.

8. Fuel Pump - To be OEM Brand New.

All brand new fuel pumps with AC motor shall be supplied. This item makes part of
the modernization package.

9. Flywheel Rings and Couplings - To be OEM Brand New.

The bidder shall supply all sets of couplings, flywheel ring gears as brand new.

10. Damper Assembly, gear - To be OEM Brand New.

The engine damper assembly “gear type” brand new.

11. Gear Trains ( Front and Rear) and Stub Shafts - To be OEM Brand New

All stubs shafts must be brand new, with brand new bearings. All spring drive gears
must be brand new. All accessory drive gears must be brand new and with brand new
internal components. All crankshaft drive gears will be brand new with new governor
drive gears. All idler gears shall be brand new. All scavenging pump gears will be brand
new. All main lube pump gears must be brand new. All water pump drive gears must
be brand new. All camshaft drive gears must be brand new.

12. Camshafts - to be supplied OEM Brand New.

The bidder shall supply all camshaft segments brand new.

13. Top Deck Components - To be OEM Brand New

Each engine of 16 cylinders contains the following parts that shall be replaced with
new one.

a) 16 injector rocker arms


b) 32 valves rocker arms
c) 32 valve bridges
d) 32 valve bridge springs
e) 16 rocker arm shaft
f) 32 support arm shafts
g) 16 oil lines assembly
h) 16 injector control link and bracket
i) 16 lever sets for injector control
j) 2 injector control rods
k) 16 over speed trip assemblies.
All the top deck must be supplied in brand new.
14. Over Speed Trip Housing and Mechanism - To be OEM Brand New.

All the aluminum housings for the over speed device should be modernized with the
relocation of the drain hole for the oil. The mechanism parts sets shall brand new.

15. Oil Pump ( Scavenging ) - To be OEM Brand New.

All pumps will be brand new.

16. Oil Pump (Main and Cooling) - To be OEM Brand New.

All pumps to be brand new.

17. Lube Oil Coolers and By-Pass Valve - To be OEM Brand New.

All oil cooler cores will be brand new with headers, valves, piping etc.

18. Oil Pressure Regulating Valve - To be OEM Brand New.

All oil pressure and regulating valve shall be brand new.

19. Engine Protector and Hot Oil Valve - To be OEM Brand New.

All brand new units.

20. Water Pump - To be OEM Brand New.

All water pumps shall be supplied in brand new.

21. Engine Governor - To be OEM Brand New.

All new engine governors shall be supplied brand new.

21(a) Replace load control rheostat (LCR) with OEM new one.

22. Turbo super chargers.

All 12 Nos. turbo superchargers shall be remanufactured on UTEX basis.

23. After Coolers - To be supplied OEM Brand New.

All after coolers to be brand new.

24. Turbo Pump ( Soak Back Pump ) and Valves - To be OEM Brand New

All the existing turbo soak bag pumps shall be replaced with AC brush less motor
alongwith by pass valves brand new.
25. Exhaust manifold alongwith hardware & Gaskets- To be OEM Brand New .

New exhaust manifold alongwith hardware & Gaskets to be provided.

All sets of rubber elements according to the MI-1753 will be replaced by brand new
ones.

26. Engine Final assembly

All gaskets, seals, bearings, washers, responsible bolts and nuts etc will be replaced by
brand new units during the final assembly of the engine. The methods used during the
final assembly should be as per OEM standard and followed by the workers and
supervisors of PR transmitted by the authorized EMD/supplies inspectors who are under
the responsibility of the supplier. Same is applicable to tooling and fixtures that the
supplier must bring to the project in case it is missing. Suppliers are invited to analyze
in detail what are the items necessary to bring to the project and make the necessary
proposal for its acquisition.
Annexure-B2

TOOLS /EQUIPMENT NEEDED FOR UP-GRADATION


OF BLOCK SHOP MOGHALPURA
1. Equipments:

S.
Description Cat No. Qty Price FOB/CFR
No.
Unit Extended

2. Jig and Tools:

S.
Description Cat No. Qty Price FOB/CFR
No.
Unit Extended
Appendix-C

TOOLS, EQUIPMENT AND TEST INSTRUMENTS ESSENTIALLY REQUIRED


FOR THE REHABILITATION OF LOCOMOTIVES

Model / Price FOB/CFR


Description Maker Purpose Quantity recommended
part No.
Unit Extended
Appendix-C-I

LIST OF RUNNING MAINTENANCE TOOLS AND EQUIPMENTS.


Price FOB/CFR
S. No. Description Quantity
Unit Extended
Appendix-D
DETAIL AND DESCRIPTION OF SPARES REQUIRED
FOR THREE YEARS MAINTENANCE

S. Price PB/CFR
Description Cat No Qty
No.
Unit Extended
DIESEL ENGINE
1 Gasket Kit Cylinder Head
Gasket Kit Power Assembly
2
Installation
3 Con Rod Bearing Upper
4 Con Rod Bearing Lower
5 Test Cock Valve Assembly
6 Liner
7 Cylinder Head Assembly
8 Ring Set
9 Valve Exhaust
10 Adjuster Assembly
11 Washer Hardened
12 Thrust Washer
13 Bearing Insert
14 Screw Elbow Head
15 Nut (Basket) (8487883)
16 Washer (Special) Basket
17 Tube Water Inlet (8347340)
18 Gasket Chamber to Adopter
19 Gasket Adopter Expansion
20 Turbo Gasket kit
Gasket kit Piston Cooling and
21
Pressure Pump
Gasket kit lube Oil Scanvenging
22
Pump
23 Water Pump Gasket
24 Gasket kit Lube Oil Hosing
25 Seal Air Box hand hole cover
26 Fuel Bowl
27 Water system Coupling Assembly 1"
28 Coupling Assembly 1-1/2''
29 Line Assembly [Fuel]
30 Line Assembly [Lube Oil]
31 Link Assembly (Standard)
32 Gauge Glass
33 Body Cock Lower
34 Body Cock Upper
35 Lube Oil drain Pipe
36 Coupling 3'' (Radiator)
37 Coupling 3'' (Lube Oil Cooler)
38 Rubber Seal 1''
39 Rubber Seal 4''
40 Rubber Seal 3''
41 Injector
42 Injector Repair Kit
43 Turbo Lube Oil Filter (L)
44 Turbo Lube Oil Filter (S)
45 Fuel Strainer
46 Fuel Element Filter
47 Paper Air Filter
48 Lube Oil Filter
49 Water Pump Inlet Pipe Left side
50 Water Pump Inlet Pipe Right side
51 Cap Assy. Water Tank
52 Bolt Fly Wheel
53 Bolt Gen. Foundation
54 Unit Foundation
55 Water Drain Cock
56 Elbow Assy.
57 Coupling Assembly 1/2''
58 Rubber Seal 1/12"
59 Gasket Fuel Oil Bowel
TURBO SECTION
60 Clutch Assembly
61 Support Assy
62 Seal Ring Carrier
63 Carrier Seal Ring
64 Seal Assembly Compressor
65 Thrust Washer
66 Seal Assembly Impeller
68 Bearing Compressor
69 Seal Spritalic
70 Bolt Deffuser Exhaust
71 Ball Bearing
72 Balancing Assembly
73 Varrier Shaft
74 Roller Bearing
75 Seal O Ring
76 Support Assy
77 Roller, Cam Plate
78 Cup, Spring
79 Spring
80 Seal "O" Ring
81 Gasket Impeller
82 Gasket Compressor Seal
83 Gasket Turbine Seal
84 Gasket Support
85 Gasket Clutch

GOVERNOR
86 Oil Seal
87 Oil Filter
88 Connector
89 Diaphragm
90 Switch
91 Seal Oil
92 Seal
93 Seal
94 Seal O Ring
95 Seal
96 Gasket
97 Gasket
98 Gasket
99 Gasket
100 Gasket
101 By Pass Valve
102 Triangular Plate
TRACTION MOTOR AND BOGIE TRUCK
103 Pinion
104 Nut Pinion
105 Air Duct [Traction Motor] Large
106 Air Duct [Traction Motor] Small
107 Carbon Brush Traction motor
108 Bull Gear
109 Axle Finished
111 Spacer
112 Roller Bearing
113 Roller Bearing
114 Axle Lining (Pair)
115 Shock Absorber Horizontal
116 Shock Absorber
117 Shock Absorber Vertical
118 Big Coil Spring
119 Piston Packing Cup
120 Labrinth Ring
121 Central Coil Spring (Outer)
122 Central Coil Spring (Inner)
Hex Head Bolt M12x40 (Axle Cap /
123
Lock Plate)
124 Hex Head Bolt M16x40
125 Spacer Ring
126 Dust Guard
127 Clamp Dust Guard
128 Wickpad
129 Turn Buckle
130 Link Bolt (Large)
131 Link Bolt (Small)
132 Stop Buffer [645-169-02-01]
133 Fuel Glo Rod
134 Fish Plate
135 Brake Hanger
136 Brake Pull Rod
137 Pin
138 Pin
139 Line Clear (Rail Guard)
140 Bush Fish Plate (Large)
141 Bush Fish Plate (Small)
142 Split Pin
143 Cotter Pin
144 Shock absorber vertical Bolt
145 Shock absorber horizontal Bolt
146 Shock absorber Bolt with nut (Axle)
147 Brake Shoe
ELECTRICAL
148 Pressure Switch
149 Starting Motor 64 V DC
150 AC-1 & 2 Contactor
151 Fuel Pump with Motor AC
152 FPC
Hub Assy. Included Rotter Fabricated
153
Fan
154 Conduit Assembly Blower Motor
155 STA(U008482180)
156 Stator Assembly Radiator Fan
157 Magnetic Valve [MV-01-ZG]
158 Buffer Lights
159 Axle Generator
160 Battery Set (8X8V=64V)
161 Circuit Breaker Auxiliary Generator
162 Water Temp Switch 174F
163 Water Temp Switch 190F
164 Water Temp Switch 208F
165 Cab Light Switch
166 Headlight Sealed Beam
167 Radiator Fan Fuse [200amp]
168 355 Amp Battery Charging Fuse
169 Auxiliary Shaft Coupler
170 No Power Switch [Cam Switch]
171 Number Lights With Holder [E27]
172 63 AMP Fuse
173 Volt Meter
174 Load Meter
175 Wire No. 16 ADP (Mtrs)
176 Push Button
177 Head Light Resister RE-708
178 Water Temperature Sensor
179 Fuel Pressure Sensor
180 Lube Oil Pressure Gauge Sensor
Magnetic Switch assy. (RVR)
181
complete
182 Micro Switch
183 Magnetic Power contactor complete
LCR complete with (Reheostate to
184 part
No. 6150011850)
185 Cable Wire 35mm (Mtrs)
AIR COMPRESSOR(9523465NS) / AIR BRAKE SYSTEM
186 Discharge Valve HP
187 Inlet Valve HP
188 Bearing Shell
189 Dial Gauge
190 Crank Shaft
191 Kit Crank-case Detector
192 Cylinder HP
193 Cylinder LP
194 Cylinder Twin
195 Spring Valve
196 Oil Separator
197 Oil Bath Filter
198 Con Rod
199 Ring Set LP + Exhauster
200 Ring Set HP
201 Copper Gasket HP
202 Copper Gasket HP
203 Copper Gasket LP(Exh)
SA-9 Brake Handle (Independent
204
Brake Valve)
A-9 & Air Brake Kit (Automatic
205
Brake Valve)
206 Air Break Cylinder Bellow
207 Cup Diaphram
All Vaccum Hose Pipes with Clip and
208
Clamp
209 Brake Cylinder Coupling Pipe
210 Dummy Coupling Bracket
Air Brake Pipe (70 lbs) (Hose
211
Coupling)
212 Distributive Valve
213 Air Flow Indicator
214 Drain Cock with Adoptor
215 Oil Seal
216 Safety Valve
217 Air Compressor Filter
218 Pressure Reduce Valve (3.2 bar)
219 Pressure Reduce Valve (3.5 bar)
220 Roller Bearing
Oil Pump Strainer Pipe with Elbow
221
Complete)
222 Complete Air Horn
223 Snap Ring
224 Sealing Ring
225 K.K Ring
226 Sealing Ring
227 Packing Seal
228 Valve Element
229 Check Valve with damping 1 1/4"
230 Check Valve
231 Spring
DRIVER CAB
232 Pressure Guage (0-10 Bar)
233 Pressure Guage (0-4 Bar)
234 Water Temp Guage (0-120 C)
235 Ammeter (0-1500 amp)
236 Ammeter (0-250 amp)
237 Volt Meter (0-100 V)
238 Push Button Ground Reset
239 Padle Switch
240 Fireman Side Door Lookout Glass
241 Cab Lights
242 Headlight Switch
Driver & Fireman Side Window
243
Glasses
244 Driver & Fireman Side Weather strip
245 Cab Door Lock
246 Cut off Valve
247 Fuel Prime Engine Start Switch
248 Start Run Switch (Cam Switch}
249 Master Controller
250 Buffer Light Switch
251 Horn Push Button [yellow]
252 RE-3
253 ST Contactor
254 GFC Contactor
255 GFD Contactor
256 Bus Bar-13
257 Bus Bar-11
MISCELLANEOUS
258 Thermostat Pipe
259 Water Coupling Assembly
260 Water Tank Filling Cap
261 Water Tank to Water Pump Coupling

NB. Three years maintenance spare parts which are not applicable may be deleted
and items which are essential keeping in view the new introduced systems may
be added/ offered by the bidder.
Appendix-E

DETAILS OF PRINCIPAL AND LONG LIFE ASSEMBLIES / PARTS


Price FOB / CFR
S. Catalogue /
Description Quantity
No Part No
Unit Extended
1. Crankshaft Assembly 2 Nos.
2. Camshaft Assembly (Left & Right) 1 Loco sets.
3. Fuel Injector 2 Loco Sets
4. Power Pack fork & blade 2 Locos Sets
5. Turbocharger 2 Nos.
6. Governor 1 Nos.
7. Exhaust Manifold Complete. 1 Loco Sets.
8. Lube Oil Pump 2 Loco Sets.
9. Water Pump 2 Loco Sets
10. Air Compressor/Exhauster (WXOV) 2 Nos.
11. Lube Oil Cooler 1 Nos.
12. Turbo after cooler core 2 Loco Set.
13. Compressor Intercooler 04 Nos.
14. Remanufacture Traction Alternator 03 Nos.
AR 10 CA 6 on out right basis
15. Auxiliary Generator 2 Nos.
16. Blower for traction motor 1 Nos
17. Controller Mechanism 2 Loco Sets
18. Reverser 1 Loco Sets
19. Voltage Regulator 4 Loco Sets
21. Fuel booster pump with AC motor 4 Nos.
22. Radiators core 1 Loco Sets
23. Radiator fan drive assembly complete 2 Loco Sets
24. Pinion for T/Motor 24 Nos
25. Air Brake cylinders 04 Nos
26. Air Governors 02 Nos
27. Speedometers 2 Loco Sets
28. Re-Manufacturer Traction Motor D-78 36 Nos.
on out right basis
29 Complete brake module on out right 02 Nos.
basis.

NB:- Principal and long life Assemblies/parts which are not applicable may be deleted and
items which are essential keeping in view the new introduced systems may be added/
offered by the bidder. Quantity is subject to change.
Appendix – F
TRAILING LOAD – SPEED – GRADE TABLE
52 TONNES LOWER A.C. COACH

SPEED 70 75 80 85 90 95 100 105 110 115 120


GRADE TRAILING LOAD – METRIC TONS
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1.10
1.20
1.30
1.40
1.50
1.60
1.70
1.80
1.90
2.00
2.10
2.20
2.30
2.40
2.50
2.60
2.70
2.80
2.90
3.00
3.10
3.20
3.30
3.40
3.50
3.60
3.70
3.80
3.90
4.00
Appendix – G
TRAILING LOAD – SPEED – GRADE TABLE
25.4 TONNES FREIGHT CARS
SPEED 40 45 50 55 60 65 70 75 80 85 90 95 100
GRADE TRAILING LOAD – METRIC TONS
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1.10
1.20
1.30
1.40
1.50
1.60
1.70
1.80
1.90
2.00
2.10
2.20
2.30
2.40
2.50
2.60
2.70
2.80
2.90
3.00
3.10
3.20
3.30
3.40
3.50
3.60
3.70
3.80
3.90
4.00
APPENDIX –‘H’
INSPECTION OF REHABILITATED / RE-MANUFACTURERED IMPORTANT
ASSEMBLIES AT MANUFACTURER’S FACILITY /MAINTENANCE LOCATIONS.
Period/
No of
No. Description. Working
personals.
days
1. Re-manufactured Engine units 03 10 days
Engine Cylinder Block 10 days
2. 02
Rebuilding
3. Alternator /T/Motor. 03 10 days
4. Turbo Supercharger. 02 10 days
5. Microprocessor 03 10 days
6. Expressor/Air Brake System 02 10 days
APPENDIX-‘I’
TECHNICAL SPECIFICATIONS OF VHF RADIO ANALOGUE GPS AND DIGITAL
USA/EUOROPEAN/JAPAN

Completely built VHF Radio set including VHF OMNI Directional Dome Type antenna to
work on electrified sections and power supply complete in all respect as per Railway
requirements.
Solid State VHF 146-174 MHz(TX & RX)
No of Channels Minimum 40 – 50
Operating temperature range Minimum 10oC to +60oC
Frequency Stability Minimum +2.55 PPM
Antenna Impedance 50Ω
Operating Volt 12/13.8V
Channel Guards/CTCSS Minimum 40 Nos.
Modulation FM
Shock & Vibration Should meet with military standard for shock,
vibration & Ruggedness
RF Output (Power) Minimum 45 Watt (Maximum power shall be
adjusted at 172.3 MHZ
Spurious & Harmon ICS Better than -65dB
Channel Spacing 12.5/25KHz
Sensitivity (for 12dB SINAD) Better than 0.30 uV
Squelch Programmable
Audio Response (300 – 3000 Hz) Better than +1 to -3d 3
Maintenance & Service manuals 1 with 20 radio sets
Operating Manual 1 with each set
Programming Cable 1 with 20 radio sets
Software 1 with 10 radio sets
Note: Name of manufacture originally printed on set, all accessories must be compatible
with International Standard.
SPECIFICATION OF VHF OMNI DIRECTIONAL DOME TYPE ANTENNA
S. No Parameter Specification
1 Pattern Omni Directional
2 Frequency Range 160-174 MHz
3 VSWR Less than 1
4 Output Power 100 W
5 Input Impedance 50 ohms
6 Connector PL-259 Female (So 239) (2 No. for each)
7 Accessories Antenna along with all accessories (Nuts,
Bolts) Complete in all respects
8 Nominal gain 3-6.5 db
9 Mount Type Roof mount & Mounting hardware
10 Wind Pressure 150 kmph minimum
sustainability
 Input power voltage as available in the proposed locomotives be indicated by the
bidder.
 Maintenance and faultfinding catalogues shall also be provided with locomotives.
SECTION 3

Introduction & Specifications/Scope of work for


Proposal for Rehabilitation &
Up-gradation of DPU-30/20 Locomotives
SPECIFICATION FOR REHABILITATION AND MODERNIZATION
OF DPU-30/20 CLASS DIESEL ELECTRIC LOCOMOTIVES
1. Back Ground
1.1 PR had procured 69 De locomotives (DPU-20/ 2000 H.P) and DPU-30 /3000 H.P) were
from M/s Dong Fong, Dalian, China and were put into services during the years 2003
to 2008. These locomotives were based at Karachi and Rawalpindi sheds. During start
of operation of these locomotives, a large number of technical problems surfaced,
however these defects were rectified by the manufacturer under the contractual
obligation but not to the satisfactory level. During and after expiry of the warranty
period, the problems continued pouring in and no permanent solution could be
implemented. In addition, the repair/maintenance and operational cost was also high
but availability and reliability of these locomotives remained on lower side. PR initiated
different special repair projects of these De locomotives but futile. At present, all 69
DPU 20/30 De locomotives are temporarily ground at Diesel Workshop Karachi and
Rawalpindi.
1.2 Details of major troubles experienced on DPU-20/30 class of locomotives by PR
detailed as below;
1.2.1 Premature failure of Turbo Superchargers
Originally DPU-20/30 D.E. locomotives were fitted with ABB (Switzerland) turbo
supercharger Model VTC-214 and VTC-254 respectively. The common problem was excessive
leakage and accumulation of oil inside the turbo super charger that resulted into carbonization
between seal cover and turbine disc.
1.2.2 Poor performance of Power Assemblies.
The Chinese origin engine (Model 240) could not perform well in Pakistan environment. There
was frequent replacement of piston assemblies, water jackets, liners, cylinder heads because
life of these parts was very less. The major defects in the power assemblies were as under:
i). The water passage of cylinder head was observed as badly eroded.
ii). Pin holes observed in cylinder liners.
iii). Poor circulation of water around cylinder liners and difficult to maintain the
temperature during summer season.
1.2.3 Premature failure of Auxiliary Transmission System (TGB)
The performance of auxiliary transmission gear boxes was not satisfactory due to breakage of
plastic cage “Ball Bearings” fitted in the transmission gear boxes, other problems related to
TGB were as under:
i. Difficult to remove flange of the drive coupling during maintenance.
ii. Difficult to dismantle/replace various gears of (TGB).
1.2.4 Poor performance of ACU/MCU & Inverter cards (electronic cards)
The quality of ACU/MCU & inverter cards (Electronic Cards) was unsatisfactory as frequent
voltage fluctuations noticed thereby stopping either radiator fan motor or air compressor motor
resulting into failure of the locomotive. The frequent burning of cards was also noticed.
1.2.5 Poor performance of Radiator fan Motors.
Frequent troubles experienced in AC radiator fan motor due to its substandard insulation and
under rated ball bearings.
1.2.6 Poor performance of AC Auxiliary Generators.
The performance of the AC Auxiliary Generator was unsatisfactory due to overheating of its
rotor on account of substandard quality of insulation and frequent failures of bearings.
1.2.7 Substandard insulation of high voltage and control cables/wires.
The insulation of high voltage wires was swelling up with the passage of time due to poor
insulation material. Leakage of current was increased between locomotive body & high/low
voltage circuit, resulting in short circuiting and malfunctioning of electronic circuits. Frequent
ground troubles were also experienced resulting into number of fire cases and frequent “No
Power Troubles”.
1.2.8 Valve mechanism of Cylinder Heads.

1. Premature breakages of valves at root.


2. Inlet/exhaust valve seats failure.
3. Excessive carbon deposits were observed at exhaust valves.

Specifications and scope of work as detailed below are applicable equally for both classes
of DE locomotives except where specified.

2. LOCOMOTIVE POWER:
a. The horsepower for traction shall be in range of 3000-3300 for DPU-30 and
2200-2500 for DPU-20. This specified power should be available under the
climatic conditions indicated in Clause-5.
b. Break-up of power requirement for each of the auxiliaries at rated out put, both
under site and UIC conditions shall be provided. The supplier shall indicate the
method used for determining power requirement of each auxiliary. In case these
are measured values, the supplier shall furnish method employed for
measurement of auxiliary’s horsepower.
3. PRINCIPAL DIMENSIONS:
The locomotive must conform to the Schedule of dimensions given in Appendix-‘A’
of these ‘Technical Specifications’. The bidder shall submit fully dimensioned outline
diagram of the locomotive, superimposed on the maximum moving dimensions
diagram.
4. AXLE LOAD:
The maximum axle load shall not be more than 22.50 tons (22.86 tonnes) after
modernization for DPU-30 and 17.50 tonnes for DPU-20 respectively.
5. CLIMATIC CONDITIONS:
a. Temperature:
Maximum ambient temperature 55 oC
Average of maximum readings 48 oC
Average of minimum readings 17.7 oC
Minimum ambient temperature -5 oC
b. Relative Humidity:
Maximum 100 %
Average of maximum reading 48 %
Minimum 02 %
Average of minimum reading 21 %
c. The altitude between Karachi-Peshawar varies from a few meters to 705 meters
above the sea level.
d. The climatic conditions over greater part of the country are very severe in
respect of heat and dust. The importance of ventilation and air filtration for
supply of clean air to engine room, traction alternator, expresser room and
traction motors cannot be over emphasized.
6. LOCOMOTIVE PERFORMANCE:
6.1 After rehabilitation, the locomotive should be a fully functional including all
standard for performance of prime mover, Alternator, traction motors, control
system, assemblies, sub assemblies, accessories, safety devices, gauges/
expresser, brake equipment as specified. The bidder should comply and provide
locomotive performance curves as indicated in Appendix A-1. The rehabilitated
Locomotive should confirm the performance, specifications indicated at
appendix A1. The parts included as standard and optional equipment shall be
listed separately indicating item-wise price of optional parts/accessory.
6.2 The bidder shall furnish a transmission efficiency curve valid over the speed
range of 0 to 125 Kmph.
6.3 The “tractive effort-speed” & “drawbar pull-speed” curves for both freight and
passenger operation shall be submitted.

7. MAIL, EXPRESS AND PASSENGER TRAINS DATA:

7.1 The performance characteristic of the rehabilitated and modernized locomotive


shall confirm the loco performance as defined in Appendix A1.

8. GOODS TRAINS DATA:

8.1 The performance characteristic of the rehabilitated and modernized locomotive


shall confirm the locomotive performance as defined in Appendix A1.

9. ENGINE RATING AND PERFORMANCE:

9.1 The diesel engine should be suitable to work with high speed diesel oil specified
below:-

Specifications
S
Characteristics Test Method Winter Summer
.No
(Nov-Feb) (Mar-Oct)
1 Flash point. ASTM D 93 Min. 660C
2 Viscosity Kinematics at ASTM D 445 Min 1.5 Cst
400C. Max 6.5 Cst

3 Pour point. ASTM D 97 Max 6 0C Max 0 0C


4 Carbon residue ASTM 189/4530 % Mass Max 0.1
conradson.
5 Ash. ASTM D 482 % Mass Max 0.01
6 Water. ASTM D 95 % Volume Max 0.05
ASTM
7 Sulphur. D1552/2622/4294 % Mass Max 0.5
8 Gross calorific value. - Min 19000 BTU/ Ib
9 Cetane Index. ASTM Min 45
D 4737/976
10 Corrosion copper strip3 ASTM D 130 No. 1
at 1000C.
11 Density at 150C. ASTM Min 0.82 Kg/L,
D 1298/4052 Max 0.87 Kg/L
12 Distillation90% min ASTM D 86 Max 365 0C
volume recovery, 0C
13 Color ASTM ASTM D 1500 Max.2.5
0
14 Cloud Point C ASTM D 2500 Max. -1 Max 5+
15 Sediment, %. ASTM D 473 % Mass Max. 0.01

9.2 The Bidder shall provide curves showing Brake Specific fuel Consumption of re-
manufactured diesel engine against engine speed at each throttle notch under:
(i) UIC standard conditions
(ii) At ambient temperature of 55º C and altitude of 705 meters above sea level.
9.3 The Bidder shall state the specific fuel consumption in liters per traction
horsepower/hour of re-manufactured locomotive at (a) full throttle (b) ¾ throttle, for
fuel oil specified in para 9.1.The specific fuel consumption shall be determined by
standard load testing of the locomotive. All auxiliaries shall be functioning with the
compressor unload and auxiliary generator supplying normal current for operating and
control functions including head-lights and classification lights at both ends of the
locomotive with batteries fully charged.
9.4 For supplied remanufactured engine, the fuel consumption tests may be carried out at
the manufacturer’s works and Pakistan Railways workshops under the supervision of
the purchaser’s representative. These shall be repeated on Pakistan Railways, after the
locomotive has worked for at least three months but not more than six months, in the
presence of the manufacturer’s representative
9.5 The Bidder would be required to ensure that the indicated fuel oil consumption will not
be exceeded on a locomotive fitted with supplied remanufactured diesel engine which
has completed service for three months but not more than six months. In case actual
fuel consumption during test in Pakistan is in excess of the guaranteed figure by 2%,
the purchaser shall have the right to reject the diesel engine or to call for repairs at
suppliers cost to improve the fuel consumption within acceptable limits.
10. The existing fleet is suitable for maximum speed of 125 Kmph. The rehabilitated
locomotive will be expected to be fit for the same speed.
10.1 The minimum speed at continuous tractive effort shall be indicated in the
locomotive performance curves and it should not be less than original locomotive.

11. PRE SHIPMENT INSPECTION.

11.1 The material/assemblies i.e. Diesel Engine Units, Alternator & Traction Motors and
new Microprocessor, to be supplied for rehabilitation and modernization of
locomotives will be subject to inspection /tests before shipment by inspectors
designated by purchaser at manufacturer / bidders facility as per details in Appendix-H
. The supplier must comply with all requirements in the matter of suitability of material
and method of construction. All equipment required by the inspection authority during
the course of inspection and test must be provided by the manufacture free of charge.
The inspecting authority has the right to reject any part during or after re-
manufacturing, if in his opinion the quality of material or the standard of workmanship
is not up to the requisite standard. The decision of inspection authority in this respect
shall be final and all parts so rejected shall be replaced free of charge by the
manufactures. The inspection shall not absolve the manufacturer of their responsibility
regarding quality, design, material or workmanship. The inspector has the right to
inspect any remanufactured alternator, traction motor, turbo supercharger and diesel
engine with respect to crankshaft, power assembly, camshaft, etc at assembly stage.
The pre shipment inspection is subject to mutual consent of both the parties at the time
of award of contract.
11.2 All expenses of inspectors in respect of boarding, lodging, out-of-pocket expenses,
transport, round air tickets will be borne by the supplier/manufacturer for inspection.
12. ACCEPTANCE TEST OF THE POWER UNIT AND ELECTRICAL
EQUIPMENT.

12.1 The material to be supplied for rehabilitation and modernization of locomotives will be
subjected to tests by the purchaser at the place of rehabilitation by an Inspecting
Authority to be designated by the Purchaser. All instruments, gauges and equipment
required shall be provided by the manufacturer free of charges.
12.2 In addition to the continuous running test, the Inspecting Authority shall have the right
to carry out overload test of any power unit which may be selected for this purpose.
12.3 The Inspecting Authority shall have the right to carry out other tests such as fuel and
lubricating oil consumption trials, etc., at his discretion. These tests shall be carried out
on at least one power unit out of the total number on order at the place of
remanufacturing.
12.4 The alternator and traction motors shall be subjected to such tests as the Inspecting
Authority may consider necessary to ensure that the temperature rise in the windings
does not exceed the maximum laid down in B.S. Specification No.173/1960 or
corresponding ASTM Specification, when the machines are working at their maximum
continuous output for a period of not less than twelve hours under conditions of the
highest ambient temperature specified, 55 degree C. The electrical resistance of the
insulation shall be tested at the end of the test runs and must be in accordance with B.S.
Specification No.173/1960 or corresponding ASTM Specification. In addition to the
measurements of resistance the insulation shall be subjected to Hi Pot tests as required
by the Inspecting Authority at the place of remanufacturing.

13. FINAL ROAD TESTS

13.1 A selected number of locomotives after complete rehabilitation shall be subjected to


road tests to check hauling power, maximum speed, continuous tractive efforts,
acceleration, balance speed, fuel consumption, heat balance, riding quality etc. under
climatic / operating conditions as mention in Clause-5. The time of carrying out the
tests shall be fixed by purchaser, and will normally be after a period of 3 months of
service of the rehabilitated locomotive. The supplier shall be required to appoint a
representative to witness the test and assist the purchaser in carrying out the same. Any
defect in design of material, workmanship or any failure of equipment to come up to
the standards claimed by the manufacturers in their bid, which may come up during
these tests, shall have to be corrected on all units by the supplier to the satisfaction of
Pakistan Railways. The latter shall have the right to insist on a repetition of the trials
after any modifications which may be carried out by the supplier to rectify the defects.
The tools, instruments & equipments required for above tests will be provided /
arranged by the bidder.
13.2 All power units complete with Alternator, Traction Motors, Turbo Superchargers,
Expressors and new Microprocessor etc. shall be subjected to load test after completing
normal running in tests. These tests shall be carried out by the Inspecting Authority in
accordance with specified requirements.
13.3 The power unit shall be run at the maximum service output with the main traction
alternator voltage corresponding to that required at the traction motor terminals for
operation at the maximum safe track speed of the locomotive. This test shall be a part
of 12 hours continuous running test and the Inspecting Authority shall have the right to
select the moment at which this test shall be conducted.
14. SUPERVISION AND AFTER SALE SERVICE

14.1 Bidder shall provide necessary supervision for the entire period of rehabilitation of
locomotives at Pakistan Railways workshops so as to ensure that agreed outturn, quality
and schedule of time are met properly and to provide on the job training to purchaser’s
personnel. Man-months recommended shall be indicated but charges shall be included
in the cost of Rehabilitation of locomotives.
14.2 Bidder shall provide the services of service engineer after commissioning of
locomotives for the warranty period for watching the performance of rehabilitated
locomotives. Man-months recommended shall be indicated but charges shall be
included in the cost of Rehabilitation of locomotives.
15 TRAINING

15.1 The Bidder shall provide training to maintenance and operating staff regarding newly
introduced/developed Microprocessor, technology parts/assemblies in Pakistan
Railways premises. The bidder shall also arrange training equipment, documents,
brochures, etc for the training purpose at own expenses.

16 MACHINES AND TOOLS

16.1 Necessary sets of hand tools, equipment and test instruments etc essentially required
for rehabilitation and modernization of locomotives shall be supplied by the bidder. A
list of these items shall be submitted in the form of Appendix “C”.
16.2 The bidders shall be also submit a list of special electrical and mechanical tools and test
instruments required for normal repairs and major maintenance in the form of Appendix
“C-I” in technical bid and prices in financial bid.

17. SPARE PARTS

17.1 A Tentative proposed list of 3 years maintenance spares is indicated as Annexure-D,


however it is desired that Bidder/manufacturer propose a three year maintenance spares
list along with quantity as they feel deem fit. Bidder / manufacture are at liberty to
delete or add any spar part in the proposed list as Appendix -D. This list without pricing
must be submitted with Technical Bid for evaluation; however the same list with quoted
prices should accompany the financial bid.
17.2 A List of long life/principle assemblies is provided in Appendix-E with the
required quantities bidder should submit pricing item wise as per Appendix-E.

18. DRAWINGS AND INSTRUCTION BOOKS

18.1. All modification drawings, instructions books (operating & maintenance/service


manuals as well as parts catalogs) shall be provided both in soft and hard copies.
18.2 All documents shall be in English language.
18.3. The following maintenance manuals/literature shall be supplied for the rehabilitated
locomotives: -
i. 40 sets of operating manuals.
ii. 20 sets of maintenance instruction manuals, pertaining to mechanical and electrical
equipment incorporating check list for individual component (Mechanical /
Electrical).
iii. 20 sets of locomotive service manuals, pertaining to mechanical and electrical
components, incorporating checking/ testing parameters and procedures.
iv. 20 sets of electrical wiring schematic, oil piping, water piping and air piping
diagrams plus 10 sets large size colored diagrams for display in sheds / training
school.
v. 40 sets of maintenance instructions for the air-cum vacuum brake system plus 10
sets of large size colored diagrams for display in sheds / training school.
vi. 20 sets of mechanical and electrical spare parts catalog for each
assembly/component used on the locomotives.
18.4 It must be ensured that maintenance instructions and spare parts catalogue should fully
cover all proprietary items like governor, expressors, traction motor, etc. The literature
should fully provide instruction for service and maintenance of all assemblies/
components.
18.5 Modifications may be required in the superstructure of the locomotive to fit in new
control cabinet, control stand, diesel engine and other equipment and for easy access to
maintenance staff. Corroded and damaged panels of superstructure will be replaced /
repaired with the material supplied by the bidder.
18.6 The existing bogies will be qualified and reconditioned so as to give them an additional
service life of 15 years for which necessary spares, rehabilitation kit and drawings for
modification, if any, will be supplied. The bogies after rehabilitation should remain fit
for the speed mentioned earlier. The detail of components of the bogies to be replaced
shall be clearly indicated.
18.7 New look out glasses, door and window glassed with rubber packing, wind shield
wipers, sun visions, cab flooring, re-insulating roofs and replacement of driver/fireman
seats and other hardware items replacement shall be carried out with material supplied
by the bidder. The brake handle shall be located on the left hand side of the driver. An
extra folding seat shall be provided in engine cab with partition wall in rear of fireman
seat.
18.8 The rehabilitated and modernized locomotive will be painted in polyurethane according
to colour scheme approved by the Pakistan Railways. For this purpose local material
and man power will be arranged by Railways. Existing procedures and facilities will be
utilized. However, the supplier may provide supervision and suggestions to improve
the quality of work.
18.9 The supply of sufficient air to traction motors shall be ensured. To keep compressor
cool it will be preferred to separate compressor compartment from engine and radiator
compartment by providing suitable partition walls.
18.10 Drawings/instructions/equipment required for re-manufacturing of major Drawings
/instructions/equipment required for re-manufacturing of major assemblies/ systems and
assemblies and testing of these locomotives shall be provided by the bidders. Details of all
engineering re-design such as revised heat balance, re-balancing of locomotive to
minimize vibration/under stress on account of relocations of old equipment or provision
of new one shall be submitted with the offer.

19. DELIVERY PERIOD

19.1Bidders are required to provide detail of shipment schedule along with detail of
activities with bar chart. Shortest delivery period will be preferred. Necessary drawing
for modification along with detail of local material including material specification
will be submitted in advance to carry out necessary preparatory work on locomotive’s
frame and superstructure.

20. DATA / TECHNICAL INFORMATION


The bidder will submit with the offer the technical data relating to the rehabilitated
locomotive as well as its major new/ rehabilitated assemblies and systems.

21 GUARANTEE
The bidder shall guarantee the performance of the rehabilitated and modernized
locomotives and all individual components as claimed by the bidder against specific
items of performance, for a period of not less than 24 months from the date put in
service. Whereas for turbo superchargers and electrical rotating machines this
warranty will be 36 months from the date put in service. All the remanufactured parts
will be guaranteed for performance as new and will carry the same warranty as of new.
22 DESPATCH OF MATERIAL REHABILITATION AND MODERNIZATION
SCHEDULE
The successful supplier shall submit a plan for material supply, storage and inventory
control. A draft plan shall be submitted with the tender. The material shall be supplied
in kit so as to turn out rehabilitated locomotive in perfect working condition for reliable
service.
23 DEVIATIONS

Notwithstanding anything that has been said in the preceding clauses, any deviation
from specification after opening of tender is not acceptable under PPRA rules.
However, clarification about specification will be made during pre-bid conference.
24 SUPPLY RECORD.

Firm/contractor/partner of JV must have manufactured at least 200 proposed engine


units and out of 200, 50 supply out of country in similar climatic condition if offered
other than given in clause 25.2 . Firm would supply record of proposed remanufactured
or latest diesel engines to various customers be submitted indicating order No., year of
supply, and name of customer, address and fax No. of customer, Engine model,
Quantity supplied and performance certificate by the customer (if any). The bidder will
attach the undertaking with the bid that they will follow the certified OEM
specifications throughout the remanufacturing process and will also render certificate
to this fact at the time of inspection.
25 SCOPE OF WORK
25.1 PR intends to bidders to examine these 69 De locomotives (25 DPU-20 & 44 DPU-
30) and propose a most workable, economical plan keeping in view the inherited
design issues, pre mature failure of various assemblies etc and usability of car body
main frame, Bogies, Traction Motors, Traction Generators etc as given below
(clauses 25.2 to 26.8) to PR for up gradation, modernization & re commission these
69 De locomotives for another life of 15-20years. Bidder would examine the issues
explained above besides physical examination of the assemblies and will submit
offer for revival of 69 DE locos by ensuring that these would meet with PR
standards given in the documents in light of scope of work given below.
25.2 Replacement of existing diesel engines preferably with GE 7 FDL/EMD 710/G
EVO/EMD 645 series with use of rebuilt/re-manufactured assemblies including
turbo superchargers. Bidder may propose some equivalent diesel engine but must
have manufactured 200 no. Out of 200, 50 units must be serving out of country
having similar climatic conditions. Bidder would furnish details of address, fax, and
performance certificate from operator.
25.3 Replacement of High voltage and low voltage wiring.
25.4 Strengthen / requalification of main frame.
25.5 Replacement of TGB / AC Auxiliary / DC Auxiliary with suitable system or
upgraded TGB on UTEX basis
25.6 Replacement of radiator / lube oil cooler and its accessories being corroded badly
25.7 Replacement & compatibility of Traction Control system with proposed prime
mover.
25.8 Replacement of Traction motors, alternators, auxiliary and starting generators,
expressers, dust blower motors, radiator fan motors, expressers with upgraded
versions on UTEX basis
25.7 Improved cooling system and other support system suitable for PR working
environment.
25.8 Improved (4 stage) air filtration system.
25.9 Replacement of existing inverter system with upgraded versions. The invertors
must be made by worldwide renowned manufacturers/ companies and country of
origin / manufacturing like:

 M/s Siemens, Germany


 M/s ABB, Switzerland
 M/s Bombardier, Germany
 M/s General Electric USA
 M/s Schneider Electric, Germany
 M/s Mitsubishi, Japan
 M/s Eaton, USA
 M/s EMD, USA

25.10 Relocation/redesigning of battery place besides to re-qualify the fuel tank etc
25.11 Improved software system including micro-processor

26 Locomotives shall be equipped to control all the functions offered. System should be
capable to work with the existing air brake system as the locomotive is equipped with
Knorr Bremse air-cu-vacuum brake system with suitable additional valves/relays in
order to be able to work as air braked trains equipped with air brake system to UIC
specifications 540 and 541. Air hose pipes with couplers should be provided at the both
ends of the locomotives so that a dead locomotive can be hauled by a working unit with
the brakes of the former in operative conditions. It should have provision of break-in to
features. The system shall be provided with oil bath or paper type air intake filtration.
26.2. All valves must be protected on atmospheric suction lines by suitable filters
and sensors should be provided to indicate the defects in brake system. The
brake system valves and mechanism do not require overhaul before 1,200,000
KMs or 6 years.
26.3. The brake gear shall be suitable for all weather conditions in Pakistan. Re-
conditioning/ overhauling work of brake gear system will be carried out in
Pakistan Railways workshops/ MGPR by using pins and bushes which shall be
supplied duly hardened and ground. Brake rigging holes shall be bushed
necessary detail should be provided. Safety straps shall be fitted with brake
riggings where ever necessary. The brake hangers should be suitable for
fitting brake shoes and heads as per Pakistan Railways Drawing No. DE-2991
(11) and DE-2977 (7). The arrangements should provide for easy adjustment of
brake shoes. The offered control system should match existing air-cum-vacuum
brake system, brake rigging system and also confirm the requirements indicated
at clause 22.5 & 22.6.
26.4 The maximum braking distance on Pakistan Railways system is 1200 meters.
The braking system should be capable to stop a freight train of 2250 tonnes
trailing load equipped with air brake at a speed of 75 km/h within the safe
braking distance prescribed above on main line track with a falling gradient of
1 in 200. It should also be capable to stop the maximum trailing load of 850
tonnes of passenger train load at a speed of 95 km/h within safe braking
distance. In case of vacuum brake, the braking system should be capable to stop
a passenger train of 16 coaches=680 tonnes, at speed of 80 km/h in the safe
braking distance prescribed. The maximum trailing load of freight train with
vacuum brake is 2250 at speed of 65 km/h.
26.5 There shall be a drop of brake pipe pressure on the locomotive while operating
air braked train in the event of:
(i) Alarm chain being pulled in the rear most compartment of 22 coach passenger
train. This would be equivalent to creating an air leak of 4 mm at a distance of
about 1640 ft. (497 meters) from the locomotive cab.
(ii) The last vehicle on a 35 (8-wheeled) wagon goods train getting parted. There
shall be a drop in vacuum of 4 to 6 inches (100-150 mm) on the locomotive,
while operating vacuum brake train pipe in the event of:

a) Alarm chain being pulled in the rear most compartment of 22 coach


passenger train. This would be equivalent of creating an air leak of 5/8
inch (16mm) diameter at distance of about 1150 ft. (350 meters) from the
locomotive cab
b) The last vehicle on a 72 (2-axle) wagon goods train getting parted.
26.7 The locomotive shall be fitted with audio & visual indications in the cab to
indicate pulling of alarm communication chain from any carriage of a 22 coach
air braked train (length of train 497 meters). The pulling of alarm chain in a
coach would cause leakage of air through a 4 mm. choke, with red light
indication in the driver’s cab, sounding of buzzer and drop in brake pipe
pressure in the locomotive ranging from 0.1 bar to 0.5 bar.
27 Complete overhauling of brake rigging system (replacement of worn out parts)
including brake cylinders is required. Renewal/ overhauling of air brake
valves/components (kits) including hand brakes shall be supplied by the bidder.
28 All bogies/under trucks will be rehabilitated locally with new parts to be supplied by the
bidder under the supervision of supplier (Service Engineer) and workers of PR. The
supplier will provide all necessary parts/hardware like pins, bushes; wear plates, bolts, nuts
& washers for rehabilitation of bogies. The bidder shall provide all new items like springs,
rubber packs, oil damper, axles, bull gears, journal boxes, bearings (PR approved
manufacturers of European/USA), inbound and outbound felt seals for gear cases etc with
new ones. All gear cases will be new and manufactured in Pakistan as per drawing
provided by supplier. Wheels Axle assembly with bearings will be brand new. The supplier
must ensure that the OEM will be integrally followed during the rehabilitation process. All
worn parts shall be replaced with new one.
29 All fuel/water/lube oil/air pipe lines would be replaced with new as per best practices over
the world.
30 Provision of roof mounted air condition unit having 25000BTU.
APPENDIXES
APPENDIX -‘A’

MAXIMUM MOVING DIMENSIONS FOR 10’-6” (3.20 METERS) WIDE ROLLING


STOCK ACCORDING TO CME’s SKETCH NO. 1799/1
Ft. In. Meter.
1. Maximum width over all projections at 4 ins (100 mm)
above rail level, when fully loaded. 8 0 2.44

2. Maximum width over all projections at 1 ft. 0 in 10 0 3.05


(305 mm) above rail level, when fully loaded.

3. Maximum width over all projections at 3 ft. 9 ins 10 0 3.05


(1.14 meter) above rail level, when fully loaded.

4. Maximum width over all projections at 3 ft. 9 ins 10 6 3.20


(1.14 meters) above rail level, when fully loaded to
a height of 12 ft. 3 ins (3.73 meters) when empty for
bogie vehicles.

4. Maximum width ov
5. er open doors .. .. 13 3 4.04

6. Maximum height above rail level for a width of 1 Ft. 14 8 4.47


0 in. (305 mm.) on either side of centre of unloaded
Vehicles.
7. Maximum height above rail level at sides of unloaded 12 3 3.73
Bogie vehicles 10 Ft. 6 ins. (3.20 meters) wide.
8. Minimum height above rail level when fully loaded 0 4 0.102
for a width of 4 Ft. 0 in. (1.22 meters) on either side of
centre of track, with the exception of wheels and
attachments thereto.

9. Minimum height above rail level when fully 1 0 0.31


loaded at 5 Ft. 0 in. (1.52 meters) from centre
of track.
10. Minimum height above rail level when fully 3 9 1.14
loaded at 5 Ft. 3 ins. (1.60 meters) from centre
of track.
11. Wheel base and length of vehicles.
(i) Minimum distance apart of bogie centre for 2/3 of length of body
bogie vehicles. of vehicles.
(ii) Maximum distance apart of bogie centres for 48 6 14.78
bogie vehicles.

(iii) Minimum distance between bogie centres .. 19 6 5.94

(iv) Minimum distance between two axles .. 4 6 1.37


Ft. In. Meter.

12. Maximum and minimum wheel gauge of distance apart 5 3 1.60


for all wheel flanges.

13. Maximum diameter measured at the tread of new wheel. 3 7 1.09


14. Minimum height above rail level for floor of fully 4 1 1.24
loaded passenger vehicles.
15. Maximum and minimum distance apart for centres 6 5 1.96
of buffers.
16. Maximum height above rail level for centres of buffers 3 7-1/2 1.10
for unloaded vehicles with side buffers.

17. Minimum height above rail level for centre of buffers 3 4-1/2 1.03
for fully loaded vehicles with side buffers.

18. The buffers must conform to the following general


dimensions:-
(i) Diameter of holes in base for attachments to 0 1-3/16 0.027
head stock.
(ii) Centers squares of 4 holes in base .. .. 0 8-1/4 0.209
(iii) Diameter of buffer head .. .. .. 1 6 0.46
(iv) Length in position from buffer face to head stock. 2 1 0.63
(v) Length of stroke .. .. .. 0 4-3/4 0.12
19. The maximum permissible length over buffers is 74’-2” (22.6 meters).
20. Minimum radius of curvature 573 ft (175 meters) equals 10 degree curves.
The minimum radius of curvature on main line is 1146 ft. (349 meters)
corresponding to 5° curve without any gauge widening. However, the
locomotives should be able to negotiate 10° curves in yards.
21. Maximum super elevation 6-1/2 inches (165 mm.).
22. The minimum permissible clearance of the locomotive when fully loaded, above rail level
for a width of 4 ft. (1.2 meter) on either side of the track is 4” (102 mm.). This dimension
shall apply to vehicle with worn tyres. With new tyres, the clearance should not be less than
5-1/2” (140 mm.). A design permitting 3-1/2” (89 mm.) wear on wheel diameter will be
preferred.

Note: - It will be noted that the maximum permissible distance apart between bogie centres
is indicated as 48 ft. 6 ins. However, this distance and the overall length of the
locomotive should not be unnecessarily long.

************
APPENDIX “A1”

PERFORMANCE FOR REHABILITATED AND MODERNIZED AGE-30


D.E LOCOMOTIVES
UTILIZATION
The locomotives shall be utilized to haul freight trains at a speed of 100 Kmph, and Mail &
Express trains at a speed of 150 Kmph under the local weather conditions as indicated in
Clause-5.

LOCOMOTIVE PERFORMANCE
The following performance curves for full and 80% load factor shall be provided (Reference
may be made to Clause 6,7&8).
1) Tractive effort speed curves from starting to maximum speed at site condition showing
maximum and continuous tractive efforts. The train resistance curve should be provided
for the following trailing loads bringing out the balanced speed.

i) Mail & Express Trains


(a) 850 tonnes on level track and 1 in 200 gradient.
(b) 750 tonnes on level track and 1 in 200 gradient.
(c) 570 tonnes on level track and 1 in 100 gradient.

ii) Freight Trains


2500 tonnes on level track and 1 in 200 gradient.
2250 tonnes on level track and 1 in 100 gradient.

2) Time speed curves when hauling following trailing load


i) Mail & Express Trains

(a) 850 tonnes on level track and 1 in 200 gradient.


(b) 750 tonnes on level track and 1 in 200 gradient.
(c) 570 tonnes on level track and 1 in 100 gradient.

ii) Freight Trains


(a) 2500 tonnes on level track and 1 in 200 gradient.
(b) 2250 tonnes on level track and 1 in 100 gradient.

3) Time speed curves for passenger & freight trains at level track.
i) Tonnage of trailing load and time to achieve the speed of 120 Km /h
for passenger train.

ii) Tonnage of trailing load and time to achieve the speed of 80 & 100 Km /h
for freight train.
4) Trailing loads v/s speed charts on various grades indicated in appendices F & G for
Freight, Mail & Express trains for Rehabilitated locomotives shall be indicated by the
bidder.
Appendix-C

TOOLS, EQUIPMENT AND TEST INSTRUMENTS ESSENTIALLY REQUIRED


FOR THE REHABILITATION OF LOCOMOTIVES

Model / Quantity Price FOB/CFR


Description Maker Purpose
part No. recommended
Unit Extended
Appendix-C-I

LIST OF RUNNING MAINTENANCE TOOLS AND EQUIPMENTS.


Price FOB/CFR
S. No. Description Quantity
Unit Extended
Appendix-D
DETAIL AND DESCRIPTION OF SPARES REQUIRED
FOR THREE YEARS MAINTENANCE OF NEW/UPGRADED ASSEMBLIES/SUB
ASSEMBLIES

Price PB/CFR
S.
Description Cat No Qty
No.
Unit
Extended
DIESEL ENGINE

NB. Three years maintenance spare parts which are not applicable may be deleted
and items which are essential keeping in view the new introduced systems may
be added/ offered by the bidder.
Appendix-E

DETAILS OF PRINCIPAL AND LONG LIFE ASSEMBLIES / PARTS


Price FOB / CFR
S. Catalogue /
Description Quantity
No Part No
Unit Extended
1. Crankshaft Assembly 2 Nos.
2. Camshaft Assembly (Left & Right) 1 Loco sets.
3. EFI Fuel Injector 2 Loco Sets
4. Unitized Power assy 2 Locos Sets
5. Turbocharger 2 Nos.
6. Governor (if applicable) 1 Nos.
7. Exhaust Manifold Complete. 1 Loco Sets.
8. Lube Oil Pump 2 Loco Sets.
9. Water Pump 2 Loco Sets
10. Air Compressor 2 Nos.
11. Lube Oil Cooler 1 Nos.
12. Turbo after cooler core 2 Loco Set.
13. Compressor Intercooler 04 Nos.
14. Remanufactured Traction Alternator 02 Nos.
5GMG 197B1 on out right basis
15. Auxiliary Generator 2 Nos.
16. Blower for traction motor 1 Nos
17. Controller Mechanism 2 Loco Sets
18. Reverser 1 Loco Sets
19. Voltage Regulator (if applicable) 4 Loco Sets
21. Fuel pump with AC motor 4 Nos.
22. Radiators core 1 Loco Sets
23. Radiator fan drive assembly complete 2 Loco Sets
24. Pinion for T/Motor 24 Nos
25. Brake Tread units (all types) 04 Nos
26. Air Governors 02 Nos
27. Speedometers 2 Loco Sets
28. Re-Manufactured Traction Motor 18 Nos.
752AH24 on out right basis
29 Complete brake module on out right 02 Nos.
basis.

NB:- Principal and long life Assemblies/parts which are not applicable may be deleted and
items which are essential keeping in view the new introduced systems may be added/
offered by the bidder. Quantity is subject to change.
Appendix – F
TRAILING LOAD – SPEED – GRADE TABLE
52 TONNES LOWER A.C. COACH

SPEED 70 75 80 85 90 95 100 105 110 115 120


GRADE TRAILING LOAD – METRIC TONS
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1.10
1.20
1.30
1.40
1.50
1.60
1.70
1.80
1.90
2.00
2.10
2.20
2.30
2.40
2.50
2.60
2.70
2.80
2.90
3.00
3.10
3.20
3.30
3.40
3.50
3.60
3.70
3.80
3.90
4.00
Appendix – G
TRAILING LOAD – SPEED – GRADE TABLE
25.4 TONNES FREIGHT CARS
SPEED 40 45 50 55 60 65 70 75 80 85 90 95 100
GRADE TRAILING LOAD – METRIC TONS
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1.10
1.20
1.30
1.40
1.50
1.60
1.70
1.80
1.90
2.00
2.10
2.20
2.30
2.40
2.50
2.60
2.70
2.80
2.90
3.00
3.10
3.20
3.30
3.40
3.50
3.60
3.70
3.80
3.90
4.00
APPENDIX –‘H’

INSPECTION OF REHABILITATED / RE-MANUFACTURERED IMPORTANT


ASSEMBLIES AT MANUFACTURER’S FACILITY /MAINTENANCE LOCATIONS.

Period/
No of
No. Description. Working
personals.
days
1. Re-manufactured Engine units 03 10 days
Engine Cylinder Block 10 days
2. 02
Rebuilding
3. Alternator /T/Motor. 03 10 days
4. Turbo Supercharger. 02 10 days
5. Microprocessor 03 10 days
6. Expressor/Air Brake System 02 10 days
APPENDIX-‘I’

TECHNICAL SPECIFICATIONS OF VHF RADIO ANALOGUE GPS AND DIGITAL


USA/EUOROPEAN/JAPAN

Completely built VHF Radio set including VHF OMNI Directional Dome Type antenna to
work on electrified sections and power supply complete in all respect as per Railway
requirements.
Solid State VHF 146-174 MHz(TX & RX)
No of Channels Minimum 40 – 50
Operating temperature range Minimum 10oC to +60oC
Frequency Stability Minimum +2.55 PPM
Antenna Impedance 50Ω
Operating Volt 12/13.8V
Channel Guards/CTCSS Minimum 40 Nos.
Modulation FM
Shock & Vibration Should meet with military standard for shock,
vibration & Ruggedness
RF Output (Power) Minimum 45 Watt (Maximum power shall be
adjusted at 172.3 MHZ
Spurious & Harmon ICS Better than -65dB
Channel Spacing 12.5/25KHz
Sensitivity (for 12dB SINAD) Better than 0.30 uV
Squelch Programmable
Audio Response (300 – 3000 Hz) Better than +1 to -3d 3
Maintenance & Service manuals 1 with 20 radio sets
Operating Manual 1 with each set
Programming Cable 1 with 20 radio sets
Software 1 with 10 radio sets
Note: Name of manufacture originally printed on set, all accessories must be compatible
with International Standard.
SPECIFICATION OF VHF OMNI DIRECTIONAL DOME TYPE ANTENNA
S. No Parameter Specification
1 Pattern Omni Directional
2 Frequency Range 160-174 MHz
3 VSWR Less than 1
4 Output Power 100 W
5 Input Impedance 50 ohms
6 Connector PL-259 Female (So 239) (2 No. for each)
7 Accessories Antenna along with all accessories (Nuts,
Bolts) Complete in all respects
8 Nominal gain 3-6.5 db
9 Mount Type Roof mount & Mounting hardware
10 Wind Pressure 150 kmph minimum
sustainability
 Input power voltage as available in the proposed locomotives be indicated by the
bidder.
 Maintenance and faultfinding catalogues shall also be provided with locomotives.
SECTION 4
Evaluation Criteria of AGE-30
TECHNICAL EVALUATION FOR REHABILITATION OF 30 AGE-30 D.E
LOCOMOTIVES

Max Marks
Article Parameters Remarks
Marks Obtained
1 Back Ground 100
2 Locomotive Power 100
Principle Dimensions & Axle
3&4 100
Load
5 Climatic Conditions 100
6 Locomotive Performance 800
7&8 Goods & Passenger Train Data 200
The remarks given
9 Engine Rating & Performance 1000 against Clause 9.2 may
also be considered.
10 Fuel Consumption 600
The remarks given
11 Electronic Fuel Injection (EFI) 200 against Clause 11.1 may
also be considered.
12 Ventilation & Air Filtration 400
13 Locomotive Speed 100
The remarks given
Traction Alternator & Companion
14 1000 against Clause 14.1 may
Alternator
also be considered.
The remarks given
15 Traction Motors 1000 against Clause 15.1 may
also be considered.
16 Electronic Control Cabinet 1200
17 Air Compressor 500
18 Bogies 500
19 Exhaust System 200
20 Data and Technical Information 100
21 Batteries 100
22 Brake Equipment 600
23 Lube Oil System 600
24 Fuel Injection Equipment 300
25 Engine Water Cooling System 800
26 Cables & Wiring 400
Driver Cab Equipment, Gauges &
27 700
Instruments
28 Safety Devices 400
29 Vigilance Device 200
Head Light, Electric Lighting,
30 200
Whistle etc.
31 Sanding Gear 100
The remarks given
32 Inspection 500 against Clause 32.1 may
also be considered.
The remarks given
33 Acceptance Test 300 against Clause 33 may
also be considered.
The remarks given
34 Final Road Test 300 against Clause 34 may
also be considered.
35 Supervision & After Sale Service 200
36 Training 100
37 Machine & Tools 300
38 Three Years Maintenance Spare 200
39 Drawings and Instruction Books 100
Scope of Rehabilitation and
40 2500
Modernization work
The remarks given
41 Delivery/Completion Period 200 against Clause 41 may
also be considered.
42 Data/ Technical Information 100
43 Guarantee 200
Dispatch of Material,
44 Rehabilitation & Modernization 100
Schedule
45 Supply of record. 300
TOTAL 18000
SECTION 5
Evaluation criteria of GMU-30
TECHNICAL EVALUATION FOR REHABILITATION OF 20 GMU-30 D.E
LOCOMOTIVES

Max Marks
Article Parameters Remarks
Marks Obtained
1 Back Ground 100
2 Locomotive Power 100
Principle Dimensions & Axle
3&4 100
Load
5 Climatic Conditions 100
6 Locomotive Performance 800
7&8 Goods & Passenger Train Data 200
The remarks given
9 Engine Rating & Performance 1000 against Clause 9.2 may
also be considered.
10 Fuel Consumption 600
11 Starting Motors 100
12 Ventilation & Air Filtration 400
13 Locomotive Speed 100
The remarks given
Traction Alternator & Companion
14 1000 against Clause 14.1 may
Alternator
also be considered.
The remarks given
15 Traction Motors 1000 against Clause 15.1 may
also be considered.
16 Electronic Control Cabinet 1200
17 Expressor 500
18 Bogies 500
19 Exhaust System 200
20 Governor 200
21 Batteries 100
22 Brake Equipment 600
23 Lube Oil System 600
24 Fuel Injection Equipment 300
25 Engine Water Cooling System 800
26 Cables & Wiring 400
Driver Cab Equipment, Gauges &
27 700
Instruments
28 Safety Devices 400
29 Vigilance Device 200
Head Light, Electric Lighting,
30 200
Whistle etc.
31 Sanding Gear 100
The remarks given
32 Inspection 500 against Clause 32.1 may
also be considered.
The remarks given
33 Acceptance Test 300 against Clause 33 may
also be considered.
The remarks given
34 Final Road Test 300 against Clause 34 may
also be considered.
35 Supervision & After Sale Service 200
36 Training 100
37 Machine & Tools 300
38 Three Years Maintenance Spare 200
39 Drawings and Instruction Books 100
Scope of Rehabilitation and
40 2500
Modernization work
The remarks given
41 Delivery/Completion Period 200 against Clause 41 may
also be considered.
42 Data/ Technical Information 100
43 Guarantee 200
Dispatch of Material,
44 Rehabilitation & Modernization 100
Schedule
45 Supply of record. 300
TOTAL 18000
SECTION 6
Evaluation criteria of DPU- 20/30
TECHNICAL EVALUATION FOR REHABILITATION OF 69DPU-30/20 D.E
LOCOMOTIVES

Max Marks
Article Parameters Remarks
Marks Obtained
1 Back Ground 100
2 Locomotive Power 100
Principle Dimensions & Axle
3&4 100
Load
5 Climatic Conditions 100
6 Locomotive Performance 800
7&8 Goods & Passenger Train Data 200
9 Engine Rating & Performance 1000
10 Fuel Consumption 600
11 Diesel Engine 5000
12 Ventilation & Air Filtration 400
13 Locomotive Speed 100
Traction Alternator & Companion
14 500
Alternator
15 Traction Motors 500
16 Electronic Control Cabinet 1200
17 Expressor 300
18 Bogies 500
19 Exhaust System 200
20 Governor 200
21 Batteries 100
22 Brake Equipment 600
23 Lube Oil System 600
24 Fuel Injection Equipment 300
25 Engine Water Cooling System 2000
26 Cables & Wiring 2000
Driver Cab Equipment, Gauges &
27 500
Instruments
28 Safety Devices 400
29 Vigilance Device 200
Head Light, Electric Lighting,
30 200
Whistle etc.
31 Inverter 2000

The remarks given


32 Inspection 300 against Clause 32.1 may
also be considered.
The remarks given
33 Acceptance Test 300 against Clause 33 may
also be considered.
The remarks given
34 Final Road Test 300 against Clause 34 may
also be considered.
35 Supervision & After Sale Service 1000
36 Training 100
37 Machine & Tools 300
38 Three Years Maintenance Spare 1000
39 Drawings and Instruction Books 100
Scope of Rehabilitation and
40 2500
Modernization work
The remarks given
41 Delivery/Completion Period 200 against Clause 41 may
also be considered.
42 Data/ Technical Information 100
43 Guarantee 200
Dispatch of Material,
44 Rehabilitation & Modernization 100
Schedule
45 Supply of record. 1000
TOTAL 28300