Annexure to tender no.

3009106088

Specification of “C3W Distributor Valve Test rack”

GENARAL NOTICE:-

Tenderers are required to give clause-wise comments on the following technical specifications, conditions
etc. confirming compliance/non-compliance with details of deviations. Offers are liable to be rejected in
case of non-compliance with these instructions.
Tenderers are required to give details of the leading parameters as per Annexure A . All the information as
per Annexure shall be submitted along with the offers

Tenderers are advised to visit the site of installation for a proper assessment of the scope of supply before
submitting their offer

1. Purpose:
Distributor valve is the most important functional component of the air brake system and
is also sometimes referred to as the heart of the air brake system. The function of the
distributor valve is to distribute compressed air received from brake pipe to auxiliary
reservoir and control reservoir. In addition to this it also senses drop and rise in brake pipe
pressure for brake application and release respectively. For the proper functioning of the Air
Brake System, it is necessary to test the Distributor Valve after overhauling. The tests are
carried out to ensure the proper functioning of Distributor valve:

2. Description:
The following tests are to be conducted on the distributor valves:

i. Pressure tightness test – (during charging, application and release test & emergency
application test).
ii. Charging time.
iii. Full service application and release.
iv. Overcharge protection test.
v. CR overcharge reduction test
vi. Emergency application.
vii. Sensitivity test.
viii. Quick service test.
ix. Insensitivity test.
x. Re-feeding test.
xi. Graduated application test.
xii. Graduated release test.
xiii. Quick release test
xiv. Control reservoir check valve reset test.
3. Scope of supply
(i) The scope of supply includes design, manufacture,supply,installation and commissioning
of a of C3W Distributor Valve Test rack with all general accessories, control and safety
equipment for proper functioning of Test rack for testing of distributor valves.
(ii) The test rake should be compact unit, housing a support bracket or equivalent to adopt
the C3W Distributor valve under test and as such fitment and removal of the distributor
valve to be very quickly.
(iii)The test rake should be incorporated with released feature as employed in the IRAB -1
and IRAB -2 brake system with selective brake volume reservoirs and as such, exact
locomotive conditions of the C3W Distributor valve besides all other test parameters
including feature with performance leakage, flow capacity etc, should be obtained from
the test rack.
(iv)The test rake should employs large number of quick opening lever type diaphragm
cocks, which eliminate leakage and also avoid delay in opening and closing of passage
for supply of air pressure to the valve/ devices. The test rake should give consistent and
dependable test results with the use of these quick opening diaphragm type cocks.
(v) The test rake should be assembled with gauges having calibration in MKS system
(vi)The Test rack shall be designed for working 7 days a week and 52 weeks per year,
minimum six hrs continuous working in a shift of eight hrs.
(vii)Accessories/ Equipment/features to be supplied/installed :-
The test bench should consists of the following components :
(a)Pressure regulator R1 - to supply air at 6 kg/cm2.
(b)Pressure Regulator R2 - to supply air at 5 kg/cm2
(c)Brake cylinders – 2 No. i.e. BC (1) and BC (2)
(d)Auxiliary reservoir AR (1) and AR (2) each having a capacity to store 100 litre of air at 6
kg/cm2.
(e)Brake pipe pressure reservoir having a capacity to store 18 litres of air at 5 kg/cm2.
(f)Control reservoir cylinder having a capacity to store 6 litres of air at 5 kg/cm2.
(g)Automatic brake valve (A9), which is used as the drivers brake valve in the locomotive
along with the C2 relay valve. This is supplied compressed air at 6 Kg/cm2. With the
help of the A9 valve, the pressure in the brake pipe can be increased or decreased.
(h)Six Pressure Gauges to indicate pressures at different locations
4. BASIC DESIGN FEATURES:
The test bench should perform following various tests

a) Pressure Tightness Test

Before conducting any other performance test to ensure the efficiency of the DV it should
be checked for the leakage from any part of the DV. For this purpose BP is charged to
regime pressure and then DBV is brought to full application, Emergency and release
positions respectively, and in each of the above positions DV is tested by soap solution to
confirm no leakage. This should be done so that every valve of DV operates at least once
and leakage from every part of the DV is checked To avoid reworking it should be always
test the DV first for leakage and once leakage free operation is assured only then other tests
should be conducted.

b) Charging Time Test

Charging time for initially charging the control
reservoir and auxiliary reservoir up to desired pressure is specified. Operation of the DV
should be such that time required to charge the CR and AR should neither be more nor less
than the specified limits. It should be necessary because if the DV of different wagons/
coaches operate with different timings, then brakes will be applied and released in different
wagons/coaches with different timings, and this will create problems.

c) Full Service Application and Release Test.

For efficient operation of brakes, it is necessary that after operating
the DBV for applying the brakes, brake cylinder pressure should rise to the desired level,
very quickly (i.e. from 0 to 3.6 kg/cm2 in 18 to 30 seconds). Therefore all the distributor
Valves should be tested for the time required to raise the brake cylinder pressure. This time
should neither be more nor less than the specified limits. In this test it is also checked that
brake should release quickly and it means that brake cylinder pressure should be released
within specified time period, and hence the DV is tested for release timings also.
d) Overcharge Protection Test
Sometimes driver overcharges the brake pipe for short duration so that
brake pipe is completely charged till last wagon and brakes in every wagon are released
quickly.
But this overcharging of brake pipe should not result in overcharging of control
reservoir and auxiliary reservoir, because the pressure of control reservoir works as
reference pressure for the DV and if the control reservoir is overcharged then it may result in
malfunctioning of the DV. And hence the DV should be such that it should avoid
overcharging of CR and AR even if brake pipe is slightly overcharged (In this test, brake
pipe is charged up to 6 kg/cm2 for 25 seconds and it is assured that CR and AR should not
get overcharged by 0.1 kg/cm2.)

e) CR Overcharge Reduction Test

Some times when locomotive connected with a rake is
changed, in that case there may be problems due to different regime pressures of locomotive
and rake. In these type of cases control reservoir should be overcharged for short duration
for adjustments, but control reservoir pressure should come back to brake pipe pressure
when release valve handle of the distributor valve is pulled for 3 seconds.

f) Emergency Application Test

The purpose of this test is similar to that of full application and
release test i.e. in this test time taken to raise the brake cylinder pressure during emergency
application is measured. It should also seen that maximum rise in the brake cylinder
pressure should be within limits.

g) Sensitivity Test
Sensitivity test is conducted on DV for checking the fastness of response of
DV. In this test it is expected that DV should respond to apply brakes when BP pressure is
reduced by 0.6 kg/cm2 in 6 seconds.

h) Quick Service Test

This test is conducted to ensure proper functioning of quick service valve of
C3W .

i) Insensitivity Test
DV should be insensitive enough so that it does not operate due to small drop
in pressure in brake pipe due to leakage. And hence insensitivity test is conducted On DV
and it is assured that it should not operate if brake pipe pressure is reducing @ of 0.3 kg/cm2
in 60 seconds.
j) Re-feeding Test
The DV should be designed in such a way that it continues to supply air to the
brake cylinder so that the brake cylinder pressure is maintained at desired level, even when it
is leaking. The re-feeding test assures the proper functioning of main valve in C3W type
DV.
k) Graduated Application Test
This test should be done to ensure response of the distributor valve when
brake pipe pressure is gradually reduced i.e. brake cylinder pressure should increase
accordingly when brake pipe pressure is reduced gradually.

l) Graduated Release Test

Air brake system should be such that brakes should be released
gradually or slowly. To ensure this in this test, brake pipe pressure is increased in steps and
it is seen that brake cylinder pressure should reduce accordingly.

m) Quick Release Test

Automatic exhausting of brake cylinder to release the brakes a
manual handle is provided on the DV. When this handle is pulled, it results in complete
draining of AR and CR and brake cylinder, and in other words, the brakes are released.
But at the same time on pulling this lever when brakes
are in released position (i.e. when brake pipe is in charged condition) it should not result in
releasing of CR & AR. Similarly when brakes are in applied condition and if some one pulls
the release lever even then ideally brake cylinder pressure should not exhaust. But DV
design is such that in this condition brake cylinder pressure exhausts to some extent but it
should not exhaust beyond 1 kg/cm2 i.e. even after pulling release lever when brakes are in
applied position, the brake cylinder pressure should not fall below 1 kg/cm2.

This test ensures proper functioning of the DV when release lever is pulled.

n) CR Check Valve Reset Test

This test is also known as “automatic repositioning of quick release
system”. If brake pipe pressure is again increased in the above test (CR is in discharged
condition) by pulling the release lever in emergency operation or detached wagon condition
( i.e. when brake pipe pressure is zero), double release valve (which is responsible for
discharging the control reservoir) should close automatically so that CR is again charged

5. Technical Literature.
One copy of the printed illustrative catalogue showing feature of test bench and its elements
must be provided. The catalogue should consist of maintenance schedule & details of
different components of test bench along with part list number of each components with
exploded views and assembly drawing & operational manual along with all electrical circuit
diagram to the consignee directly with equipment.
6. Spares (optional)
List of recommended perishable & non perishable spares for normal
maintenance to cover complete range of mechanical & electrical equipments including
control & safety items should be furnished & quoted separately. Self life should be indicated
with the quotation of spares.

7. Special features
Special features incorporated into the test bench it any shall be indicated
separately clearly indicating the advantages of features.

8. Deviations :
Offer should fully meet the specification provided in various design features
incorporated in test bench to fulfill different technical performance required & shall be fully
explained in offer. However minor deviation which does not affect the basis need of test
bench to test C3W valve or in any way interfere with the stipulated performance standard or
would result in improved safety/ reliability or would reduce maintenance/ operating cost of
plant can be accepted.
8. Training:
Training shall be given for operation and maintenance of the plant. The training to be
imparted shall cover all mechanical, electrical and electronic equipments. This training
shall be provided to operation and maintenance staff nominated by the consignee during
commissioning of the plant. The training shall be minimum 21 (twenty one) man days free
of cost.

9. Erection & commissioning:

Erection & commissioning of the equipments will be done under firm’s supervision.

(i) The supplier or his agent would be required to carry out a joint check at the
consignee’s and along with the consignee, before unpacking is done to avoid
subsequent complaints regarding short shipment/ transit damages. It is necessary that
this joint inspection be done immediately on receipt of the plant by consignee to avoid
commissioning delays due to shortages/transit damages.
(ii) Commissioning of the plant would be done, under the supervision/direction of
firm’s Engineers.
(iii) The supplier shall arrange commissioning of the plant at Rly. Premises on receiving
a call from the consignee within 30 days.Adequate number of teams of technical
experts will be made available so that the commissioning delays are eliminated.
(iv) The test bench per performance shall be demonstrated by supplier or his agent after
successful commissioning at consignee’s works for a period of five 8 hrs. shifts .
Thereafter the test bench performance shall be watched by the consignee for a period
of one month before the final test certificate is issued.
10.0 PERFORMANCE/CREDENTIAL
10.1 The tenderer shall furnish satisfactory evidence acceptable to the purchaser show that
he is a manufacturer and has adequate plants and manufacturing capacity and has a
“Quality Assurance Program”. He shall furnish a statement giving a list of C3W
Distributor Valve Test rack as per his offer or similar supplied/commissioned by
him during the last 3 years, along with the purchaser’s names and addresses, order
number, date and quantity supplied and their performance and whether the supplies
were made within the delivery period.
10.2 In case of imported supply quoted through Indian authorized representative, the firm
shall furnish a statement giving a list of items as per his offer and/or similar items
supplied and commissioned by him during the last three years in the railway or other
Govt. semi Govt. sector.
The Indian authorized representative should have current valid authorization letter
from foreign OEM and must have adequate infrastructure and technical know how
to provide after sales service support. The Indian authorized representative must also
furnish documentary evidence of above.
10.3 In case of indigenous supply quoted through their authorized representative, the firm
shall furnish a statement giving a list of items as per is offer and/or similar
items supplied and commissioned by him during the last three years in the railway or
other Govt. semi Govt. sector.The authorized representative should have current valid
authorization letter from OEM and must have adequate infrastructure and technical
know how to provide after sales service support. The authorized representative must
also funish documentary evidence of above.
10.4 Tenderers who are OEM, must give undertaking for supply of spare parts for a period
of expected life of the machine/equipment. Other tenderers must submit undertaking
from OEM for supply of spare parts for a period of codal life of the
machine/equipment as prescribed by Indian Railway.
10.5 Authorization letter from OEM after opening of tender is not acceptable.
10.6 The tenderer should provide complete drawing of the C3W Distributor Valve
Test rack .Inabsence of the above information, the tender is liable to be rejected.
11. PACKING AND TRANSPORATION :
Packing of item shall be done properly to avoid any damage during
transportation. Items/ components will be sent to Diesel Shed/SPJ at suppliers risk &
responsibility.

12. WARRANTY
12.1 Twenty four month from date of commissioning (The other penalty conditionof should
be confirmed to latest norms, rules & guideline for M&P procurement)

12.2 The suppliers will clearly spell out in the offer the facilities available to provide
adequate after sales services in India during warranty period. Replacement or repair of
defects arising out of faulty materials will be done by suppliers within warranty
period.

12.3 After the warranty period ,OEM should agree to provide service support for trouble
shooting and obtain spare parts. OEM must give undertaking for supply of spare parts
for a period of expected life of the machine/ equipment. Other must submit
undertaking from OEM for supply of spare parts for a period of expected life of
machine /equipment.
12.4 In absence of the above information, the tender is liable to be rejected.

13. OTHERS TERMS AND CONDITION:-

(i)Prices,taxes other charges etc should be made clear in the offer of tender/bidder.
Nothing should be hidden.
(ii) Price should be quoted FOR destination.
(iii) PAYMENT : 80 % will be made on proof of consignee’s receipt in good condition of
complete set of machine and inspection note. Balance 20% payment will be made on
furnishing a Bank Guarantee (Nationalised Indian Bank) for an amount equal to 10% of
contract value after successful completion of commissioning/proving test. (The condition
of payments should be confirmed to latest norms, rules & guideline for M&P
procurement)
(iv) Inspection: As per latest rules & guideline for M&P item .

(v)Delivery :Delivery & commissioning should be within 10 weeks from date of acceptance
from technically and commercially clear.
 Annexure”A”

Leading Technical parameters of Specification of “C3W Distributor Valve

Test rack”

S.N Description Unit

1 Pressure regulator R1 to supply air at 6 kg/cm2.
2 Pressure Regulator R2 to supply air at 5 kg/cm2
3 Brake cylinders 2 No. i.e. BC (1) and BC (2)
4 Auxiliary reservoir AR (1) and AR to store 100 litre of air at 6
(2) kg/cm2.

5 Brake pipe pressure reservoir to store 18 litres of air at 5 kg/cm2.

having a capacity
6 Control reservoir cylinder having a to store 6 litres of air at 5 kg/cm2.
capacity
7 Automatic brake valve (A9), which This is supplied compressed air at 6
is used as the drivers brake valve in Kg/cm2. With the help of the A9
the locomotive along with the C2 valve, the pressure in the brake pipe
relay valve. can be increased or decreased
8 Six Pressure Gauges to indicate pressures at different
locations