SPECIFICATION NUMBER REVISION EFFECTIVE DATE PAGE SPN – 0040 1 10/11/11 Page 1 of 75
Washington Metropolitan Area Transit Authority 600 5th Street, NW Washington, DC 20001
SPECIFICATIONS PACKAGE Flashbutt Welding Prime Mover
RFP FQ12113/FRV
Part III
Table of Contents
1.0 SCOPE...... 4
1.1 GENERAL REQUIREMENTS ...... 4 2.0 APPLICABLE DOCUMENTS ...... 5
2.1 LIST OF APPLICABLE DOCUMENTS ...... 5 2.2 GENERAL ...... 5 3.0 TECHNICAL SPECIFICATIONS ...... 6
3.1 GENERAL ...... 6 3.2 OPERATING ENVIRONMENT ...... 6 3.3 TRACKWORK PARAMETERS ...... 7 3.4 GENERAL DESIGN REQUIREMENTS ...... 8 3.5 DIMENSIONS ...... 10 3.6 NOISE EXPOSURE...... 11 3.7 PERFORMANCE REQUIREMENTS ...... 12 3.8 TRUCKS ...... 12 3.9 WHEELS, AXLES, BEARINGS, FRAME, AND SUSPENSION ...... 13 3.10 TRUCK ASSEMBLY TO MAINFRAME CONNECTION ...... 15 3.11 STRESS AND FATIGUE REQUIREMENTS ...... 15 3.12 ENGINE AND POWER TRAIN ...... 15 3.13 TRANSMISSION ...... 16 3.14 EXHAUST SYSTEM ...... 17 3.15 FUEL TANK ...... 17 3.16 BRAKES ...... 18 3.17 CUTOUT COCKS ...... 20 3.18 ELECTRICAL SYSTEM ...... 20 3.19 MATERIALS ...... 23 3.20 PAINT...... 24 3.21 CLEARANCE REQUIREMENTS ...... 25 3.22 COUPLER ...... 26 3.23 OPERATOR’S CAB ...... 26 3.24 LIGHTING ...... 34 3.25 PNEUMATIC SYSTEM REQUIREMENTS ...... 35 3.26 HYDRAULIC SYSTEM REQUIREMENTS ...... 36 3.27 CRANE...... 40 3.28 OUTRIGGERS (IF APPLICABLE) ...... 41 3.29 FLASHBUTT WELDING GENSET ...... 41 3.30 PRIME MOVER WELD HEAD ...... 42 3.31 REMOTE OPERATING STATION ...... 42
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3.32 TRAVEL SPEED ...... 44 3.33 MANUALS AND DOCUMENTATION ...... 44 3.34 MAINTENANCE SPARES ...... 45 4.0 INSPECTION AND ACCEPTANCE TESTING ...... 46
4.1 INITIAL INSPECTION ...... 46 4.2 ACCEPTANCE TESTING ...... 47 5.0 SAFETY CERTIFICATION...... 48 6.0 WARRANTY ...... 48
6.1 EQUIPMENT AND COMPONENTS ...... 48 6.2 SPARES PARTS: ...... 50 7.0 TRAINING ...... 50
7.1 REQUIREMENTS/DELIVERABLES ...... 50 8.0 DELIVERY SCHEDULE...... 54
8.1 DELIVERY AND COMMISSIONING ...... 54 9.0 APPENDICES ...... 56
9.1 STANDARD CLEARANCE PACKAGE ...... 56 9.1.1 Crane Car Design Loading ...... 56 9.1.2 Rapid Transit Vehicle Design Loading ...... 57 9.1.3 Design Vehicle Dynamic Outline Diagram – Tangent Track ...... 58 9.1.4 WMATA Rapid Transit Car Clearance Envelope ...... 59 9.1.5 METRO Rapid Transit Car – Dynamic Outline, Under Floor Car Clearance ...... 60 9.2 AAR 1B WIDE FLANGE BACK TO BACK TOLERANCE ...... 61 9.3 TOW BAR DRAWING ...... 62 9.4 COMPLIANCE MATRIX ...... 63
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1.0 Scope
1.1 GENERAL REQUIREMENTS
1.1.1 This specification is for the manufacture and delivery of one (1) rail bound flash- butt welder prime mover (Hereafter referred to as the “Flashbutt Prime Mover”) to be utilized throughout the WMATA System. The Flashbutt Prime Mover shall contain a fully enclosed cab for four (4) personnel plus one (1) operator, a crane, a front mounted hydraulic tool circuit, a stand-alone diesel powered generator set, a stand-alone air compressor, a diagnostic system, and controls for the braking system of WMATA flatcars. Both ends of the Flashbutt Prime Mover shall be equipped with an AAR type (E) coupler or approved equal, tow pad eyes, an AAR angle cock valve and FS-5 coupling. Its engine shall have a rating with sufficient horsepower to meet, as a minimum, all the requirements as defined in this Technical Specification Section 3.0.
1.1.2 The Contractor shall provide spare parts in accordance with Section 3.34
1.1.3 The Contractor shall train WMATA’s staff in the operation and maintenance of the Flashbutt Prime Mover and supply training programs.
1.1.4 The Contractors shall supply full supporting documentation for training for the operation and maintenance of the Flashbutt Prime Mover.
1.1.5 As part of the bid proposal, the Contractor shall supply a list of recommended specialized and general tools, and test equipment for the diagnosis, maintenance and repair of the Flashbutt Prime Mover. The supply of specialized and general tools and test equipment shall then be as agreed between WMATA and the Contractor prior to Contract Award.
1.1.6 The Flashbutt Prime Mover shall be put into service by a factory trained representative. The Contractor shall have after sales service support with available factory trained service technicians to assist in start-up and training.
1.1.7 The Flashbutt Prime Mover shall comply and conform to all Federal, State, and Local environmental, safety, and health regulations in force, at the time of delivery.
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1.1.8 Where the Specification refers to “or approved equal” or the Contractor is submitting an alternate item for approval, the Contractor shall submit with the proposed item, a side by side comparison of the Specification required item and the proposed alternate. The proposed alternate item will then be evaluated by WMATA to determine if the performance requirements and characteristics of the proposed alternate item meet the requirements of the Specification required item.
2.0 Applicable Documents
2.1 LIST OF APPLICABLE DOCUMENTS
a) ASTM-A325 Standard
b) American Welding Society (AWS) Standards
c) 49 CFR 214.511, 49 CFR 229.121,
d) ANSI Std. B93-31-1973
e) American Association of Railroads (AAR), Wheel and Axles Manual, latest Edition
f) MIL-HDBK-1472, Human Engineering Design
g) Society of Automotive Engineers Standards: SAE J1402, SAE J10-B.
h) ASME specifications for certification
i) Flammable and Combustible Liquids Code Handbook): MFPA FCLCH 30
2.2 GENERAL
2.2.1 Where national or international standards are quoted in this Technical Specification, they shall be considered as the minimum requirement. The Contractor may propose to work to equivalent or more stringent internationally or nationally recognized standards, subject to approval by WMATA. Submissions for approval are to be supported by a copy of the proposed standards, a detailed comparison of the quoted and proposed standards and, where applicable, an English translation of the proposed standard.
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2.2.2 The version of the standard shall be the edition/revision which is in force at the date of Notice to Proceed (NTP).
2.2.3 Where quoted standards duplicate or conflict with the requirements of this Specification for a particular criterion, the more stringent requirement shall be assumed to apply. Any conflict in requirements shall be brought to the attention of WMATA for a final decision.
3.0 Technical Specifications
3.1 GENERAL
3.1.1 This specification is for the manufacture and delivery of one (1) rail bound flash- butt welder prime mover (Hereafter referred to as the “Flashbutt Prime Mover”) to be utilized throughout the WMATA System. The Flashbutt Prime Mover shall contain a fully enclosed cab for four (4) personnel plus one (1) operator, a crane, a front mounted hydraulic tool circuit, a stand-alone diesel powered generator set, a stand-alone air compressor, a diagnostic system, and controls for the braking system of WMATA flatcars. Both ends of the Flashbutt Prime Mover shall be equipped with an AAR type (E) coupler or approved equal, tow pad eyes, an AAR angle cock valve and FS-5 coupling.
3.2 OPERATING ENVIRONMENT
3.2.1 The Flashbutt Prime Mover shall be able to operate on the WMATA System, and comply with all the clearance requirements of Appendix 9.1.
3.2.2 The Flashbutt Prime Mover shall operate in the presence of airborne pollutants, such as dust, acids, and oxides; characteristic of the operating environment in the Washington DC Metropolitan Area. The Contractor shall consider the environmental conditions in the design of all aspects of the Flashbutt Prime Mover.
3.2.3 The Flashbutt Prime Mover shall be capable of being operated at the specified performance levels and stored without equipment degradation under the following environmental conditions:
a) Ambient Temperature: -5° F to 105° F
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b) Maximum Design Temperature Above Running Rail: 122° F
c) Relative Humidity: 20% to 100%, including conditions of condensation
d) Maximum Rainfall: 12 inches in 24 hours
e) Maximum Snowfall: 23 inches in 24 hours
f) Wind Speed: 80 mph (operational), 120 mph (storage)
g) Glaze or Freezing Rain: Two or three times per year
The temperatures shown only represent ambient temperature conditions.
3.2.4 The effect of increased temperatures due to solar radiation on the equipment and heat produced during operation of equipment under the environmental extremes specified above must not result in degradation of equipment performance or equipment reliability.
3.3 TRACKWORK PARAMETERS
3.3.1 The track work of the WMATA System is based on the following dimensional criteria:
a) Minimum Radius of Track Curve: 225 feet
b) Loop Restraining Rail Gap (225-300 feet radius) 1-7/8”
c) Maximum Grade on Rail: 6%
d) Turnout: AREMA No. 6 - 20
e) Maximum Superelevation: 6 inches
NOTE: Equipment must be equipped with couplers that have the capability of slewing in the most severe reverse-curve situation in which two No. 6 turnouts (of the same hand) face each others with 13.53 feet of tangent track between the points and 250-foot radius curves (in the same direction as the turnout) that continue beyond both frogs.
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3.4 GENERAL DESIGN REQUIREMENTS
3.4.1 The Flashbutt Prime Mover shall be capable of performing work functions while within the WMATA tunnel areas, without degradation of performance, for an unrestricted period of time.
3.4.2 The Flashbutt Prime Mover shall include a diagnostic system with capabilities for analysis, maintenance and service for all circuits. Diagnostic devices, such as test port connections or transducers, can be fixed or removable. Removable devices must be designed with the ability to connect provided gauges and diagnostic equipment easily and quickly under full system pressure. Diagnostic connections or transducers will be clearly identified and easily accessible for ease of use under all operational conditions. The contractor shall supply four (4) complete sets of field diagnostic equipment necessary to evaluate the overall functionality of the complete operation system of the equipment to include all OEM engine and transmission codes and remote monitoring stations. Field diagnostic equipment shall include applicable software and durable portable computers necessary to evaluate operating conditions and fault codes both in the field and shop environments. Any portable diagnostic interface equipment must be contained for proper storage and transportability. Instructions for use of all diagnostic equipment shall be included.
3.4.3 Any diagnostic software subscriptions that require purchase from outside suppliers shall be for a 5 year period.
3.4.4 The Flashbutt Prime Mover shall be of the latest type in production at the time of delivery, i.e. Harsco 354C, Plasser PMC-50, or approved equal. Production parts and components shall not be obsolete, nor near the end of their planned production life. All components shall be readily available for a minimum of ten (10) years from date of delivery.
3.4.5 The Flashbutt Prime Mover design, construction, and materials used shall ensure that it will function reliably and efficiently in sustained operations under harsh and extreme conditions in adverse railway environments. When engine drive shafts are used the shafts shall have a separate protective element(s) to protect other equipment, should a drive shaft failure occur.
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3.4.6 The Flashbutt Prime Mover shall be free from defects such as incomplete welds, welds that cross welds, corrosion, loose or improper fasteners, any leaks or contamination, and any other defects that would impair or limit the operation or serviceability. All welds must comply with the associated and established American Welding Society (AWS) standards.
3.4.7 The Flashbutt Prime Mover shall incorporate a design which allows ease of access, service, replacement, and adjustment by maintenance and operational personnel including filters, fluids, and other components.
3.4.8 The Flashbutt Prime Mover shall comply and conform to all Federal, State, and Local environmental, safety, and health regulations in force, at the time of delivery.
3.4.9 The Contractor shall supply one layout-drawing (to scale) showing vehicle dimensions and component placement on the completed vehicle. The layout- drawing shall be submitted as part of the pre-selection submission package. The Contractor shall supply as-built assembly drawings along with other documentation required by Section 3.33 at time of delivery.
3.4.10 The Flashbutt Prime Mover wheel-to-wheel impedance of each wheel axle assembly shall be less than 0.2 ohms when measured with a 100 volt source over the frequency range of 1 to 10 kilohertz.
3.4.11 The Flashbutt Prime Mover shall not be insulated. The Flashbutt Prime Mover shall not be converted from an insulated design by bonding around insulating parts. If a shunt bond is used, its design must be approved by WMATA. The Flashbutt Prime Mover must give a positive indication of track occupancy under any condition of loading.
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3.4.12 Handrails or grab irons shall be installed wherever it is intended that personnel board the Flashbutt Prime Mover. The lowest step used for boarding the machine shall not be more than 12" above the top of the running rail, when measured with fully worn wheels. Any area more than 3 ft. above the top of the running rail (where persons are expected to walk or pass) shall be protected by rigid tubular handrails. The handrails shall be no less than 1-1/4" O.D. diameter, 42" high, with a secondary rail 24" high. A 3" kick board shall be provided to prevent entry into potentially hazardous areas. All floor walking areas shall be of diamond plate, or WMATA approved non-skid material. The Flashbutt Prime Mover shall have reflective tape on front, rear and sides. D.O.T. Class II certified Diamond-plated Red/White Reflective Conspicuity Tape, Reflexite # 15989 or approved equal.
3.4.13 Eight (8) inch letters specifying the equipment number shall be supplied. The numbering shall be “FB01” and be installed on each side of the equipment.
3.4.14 Equipment shall be outfitted with a directional alarm system which is compliant with 49 CFR 214.511.
3.4.15 Decking (required if any walking surfaces are on bed of vehicle)
3.4.15.1 Decking material shall be ¼” minimum steel diamond plate.
3.4.15.2 Deck plates shall be welded together where serviceability access is not required. Where serviceability access is required, plates shall be bolted for easy removing.
3.4.16 Design Life:
3.4.16.1 The Flashbutt Prime Mover shall be designed for a 20-year minimum life, operating with the duty cycle and in the environment as defined in this Specification, without requiring structural repair or replacement for any reason other than collision damage, vandalism, natural disasters, or misuse.
3.4.16.2 This requirement shall particularly apply to the mainframe structure, truck structure, and equipment cases. Other equipment may be subject to routine maintenance, overhaul or replacement as appropriate.
3.4.16.3 The Contractor shall make every effort to minimize life-cycle costs of the Flashbutt Prime Mover.
3.5 DIMENSIONS
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3.5.1 Overall height from top of running rail shall not exceed 10’ 10” during travel (reference clearance drawings in Appendix 9.1).
3.5.2 Width overall shall not exceed 10’ (reference clearance drawing in Appendix 9.1).
3.6 NOISE EXPOSURE
3.6.1 Cab interior noise:
3.6.1.1 Cab interior noise, with cab doors and windows closed and heater fan on "High" shall not exceed an eight-hour time-weighted average of 90 dBA, with a doubling rate of 5 dBA as indicated in the table below per 49 CFR 229.121.
Sound Duration Permitted (hours) Level (dBA) 12 87 8 90 6 92 4 95 2 100 1.5 102 1 105 0.5 110 0.25 or less 115
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3.6.2 Exterior Noise:
3.6.2.1 Noise shall not exceed permissible exposure for operators, assistants, and workmen for a continuous eight-hour work day. Noise sources and machine cab shall be treated to bring about total compliance of the following conditions:
a) Less than 90 dBA at 10 feet from the power plant housing; and
b) Less than 85 dBA at 50 feet from the centerline of the track; or
c) Comply with MIL-HDBOOK-1472, Human Engineering Design.
3.7 PERFORMANCE REQUIREMENTS
3.7.1 The Flashbutt Prime Mover shall be capable of pulling rolling stock of 120 tons GVW up a 6% grade. Minimum speed when loaded at 120 tons GVW and traveling up a 6% grade shall be 5 mph under dry or wet conditions. The Flashbutt Prime Mover shall be capable of pulling two (2) flat-cars of 40 tons gross vehicle weight (GVW) each over the entire transit system and maintain a minimum speed of 12 mph when traveling on grades of 2.5%.
3.7.2 The Flashbutt Prime Mover shall provide tractive effort and braking effort for a standard work train consisting of two (2) stock flats. Two (2) of each type trucking industry gladhands of "service" type and two (2) of each type trucking industry gladhands of emergency type for the Flashbutt Prime Mover shall be provided by the Contractor to allow WMATA maintenance personnel to adapt to this work train consist's brake system.
3.7.3 The Flashbutt Prime Mover shall provide tractive effort and braking effort for two (2) flat cars of 60 tons GVW each and equipped with "ABD-4" rigging type brake systems in working order.
3.8 TRUCKS
3.8.1 General:
3.8.1.1 The Flashbutt Prime Mover shall be equipped with AAR 3-piece trucks. Trucks shall conform to all applicable AAR and FRA requirements, specifications, standards and recommended practices, except as modified to provide traction drive.
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3.9 WHEELS, AXLES, BEARINGS, FRAME, AND SUSPENSION
3.9.1 Wheels and axles shall be in alignment and gauge, with the following allowable tolerances.
3.9.1.1 Wheel Contour: AAR 1B Wide Flange
a) Wheel tread Taper 1:20 (Appendix 9.2).
b) Tram: ± 1/8" Maximum Tolerance.
c) Diagonal Measurement:
1) ± 1/8" Max Tolerance for Wheel Bases up to 9 ft.
2) ± 3/16" Max Tolerance for Wheel Bases Greater Than 9 ft.
3.9.2 Wheels shall be 28" minimum diameter, not-to-exceed 30" diameter, forged to conform to AAR Section G, Specification M-107 latest edition, Class C. Wheels must be of multi-wear type. A groove, identifying wheel size condemning limits, will be machined into the face of each wheel.
3.9.3 Wheels shall be pressed on to the axles in accordance with Section G AAR, Wheel and Axles Manual, latest Edition.
3.9.4 The Flashbutt Prime Mover shall be equipped with four (4) powered axles.
3.9.5 The axles shall be suitably sprung to achieve safe travel at maximum operating conditions of FRA Class 3 track profile. The suspension system shall maintain coupler center lines within ± 0.5 inches at all times.
3.9.6 No excessive vibration, wobble, or eccentric action shall occur at any speed for which the machine is intended. Suspension shall provide for damage-free operation under maximum foreseeable operating stresses. The entire machine shall withstand a free drop of 6" to a non-resilient surface without impairing normal travel or operating functions.
3.9.7 Axles shall be of solid design and continuous in length from wheel-to-wheel, mounted on roller bearings, and of AAR Grade C or better. Axles shall be cold stamped with 1/4" markings as per AAR Wheel and Axle Manual, Latest Edition - Truck or Agricultural type axles shall not be allowed.
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3.9.8 Axles shall utilize double-row, tapered roller type axle bearings. Where pillow block bearings are used, they shall be self-aligning, double-row, non-expansion, roller type axle bearings, and shall have cast steel or ductile iron housings and their location shall be fixed to avoid movement.
3.9.9 Bearings selected for use shall have a radial load capacity of 20,000 hours, B-10 life at 50 RPM to exceed static wheel load of the machine.
3.9.10 All axle bearings shall be designed for 250,000 mile service life and shall be of sealed maintenance free design.
3.9.11 Derails guards shall be incorporated near each wheel to cover inboard and outboard rail area, so that in the event of derailment, the machine will not leave the rail. The derail guards shall be designed so as to prohibit any part of the Flashbutt Prime Mover to touch the contact rail at any time (Reference Clearance drawings in Appendix 9.1 for dimensions). The machine shall push or tow easily when not working.
3.9.12 Frame must be sufficiently flexible, or at least two (2) axles must be spring mounted, so that any wheel can drop below the plane established by the other wheels. The amount of drop in inches shall be equal to, or more than the wheelbase of the machine in feet divided by eight.
3.9.13 Frames shall be equipped with jacking pads to accept Neuero Model R05/32 located in such a manner as to distribute the dead load equally during jacking operations. Jacking Pads shall be installed in locations 26” – 28” above the ball of the rail with full/new wheel.
3.9.14 The Flashbutt Prime Mover shall be provided with a means of lifting it with a crane hook without damage to any equipment. Lifting points and balance points must be clearly marked and labeled.
3.9.15 Appurtenances and payloads shall be distributed along the Flashbutt Prime Mover such that the load on each axle falls within the range of 20% to 30% of the total dead and live load.
3.9.16 The design of members, and the assembly thereof, shall withstand all stresses imposed by continuous dead and live loads, without bending more than 1/8 inches in a span of 12 feet.
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3.9.17 A torque arm of adequate design and size for the imposed loads shall be installed on each axle.
3.9.18 All parts of the equipment, including but not limited to truck frame, journal bearings, wheel flange thicknesses, wheel back-to-backs and wheel base (axle to axle on the same truck), shall be compatible with WMATA’s existing wheel truing operations on all equipment listed below, to any wheel size diameter from new to condemned.
a) Simmons/Hegenscheidt – MFD 106T
b) Simmons/Hegenscheidt – MFD U2000
c) Simmons/Hegenscheidt – MFD U2000-400
3.10 TRUCK ASSEMBLY TO MAINFRAME CONNECTION
The connection to the mainframe shall comply with applicable AAR standards.
3.11 STRESS AND FATIGUE REQUIREMENTS
The structural of the truck shall comply with applicable AAR standards.
3.12 ENGINE AND POWER TRAIN
3.12.1 All engines offered to this purchaser shall start within 2/3 of cranking systems time rating. Engine shall incorporate high water temperature and low oil pressure shut down systems where applicable. It shall provide ample power, with clean exhaust for all equipment functions under the environmental conditions specified in Section 3.2.
3.12.2 The engine of the Flashbutt Prime Mover shall be the most current production version of the Caterpiller C-9 diesel engine or WMATA approved equal. The engine of shall have adequate horsepower to operate when subjected to the conditions of Section 3.7, while operating the compressor listed in Section 3.25, at 110 psi and shall not have a rating of less than 400 brake horsepower at 2,300 RPM and 890 ft-lbs of torque at 1,400 RPM.
3.12.3 The engine of the Flashbutt Prime Mover shall be water cooled, diesel fueled, four (4) cycle in operation, turbo charged, and of proven design.
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3.12.4 The air filter for the engine shall be of adequate size of recommended by the engine manufacturer and be equipped with a highly visible air filter restriction indicator. The air filter shall be positioned to be readily accessible and shall operate with unrestricted fresh, outside air.
3.12.5 The Engine shall be equipped with remote oil drains routed below deck to underside of main frame and accessible from the side of the equipment. The drains shall be equipped with ball valves and JIC caps.
3.12.6 The engine shall be supplied with a coolant overflow/recovery tank.
3.13 TRANSMISSION
3.13.1 The transmission shall be of an engine drive torque converter and fully automatic / manual four (4) speed transmission, and governor or speed sensor controlled, not to allow engine over speed conditions. The torque convertor must be a fluid driven design. The transmission shall include a feathering valve to permit precise, controlled movement from the remote operating station (see Section 3.31). The transmission shall shift automatically in the automatic mode and the operator will select each gear only in the manual mode. The transmission shall be of a long loop drop design (18-5/8") to facilitate connection to the front and rear drive shafts. The transmission shall contain an internal fault logic system equipped with a single point connector for diagnostic testing. Diagnostic test equipment to aid in isolating transmission faults shall be provided. For towing purposes, a manual mechanism shall be provided to permit easy disengagement of the transmission.
3.13.2 The transmission shall be configured to permit remote simple selection of full- time 4 wheel drive or 8 wheel drive from inside the operator’s cab.
3.13.3 The transmission/drivetrain shall provide at least one (1) power take-off port (PTO), SAE "C" mount or larger to allow the Contractor to mount hydraulic pumps, air compressor, alternators, etc. The Power Take-Off (PTO) ports must facilitate disconnection of the attached device from the system.
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3.13.4 Hydraulic powered traction power drive systems may be bid as an option. However, if this option is chosen by the Contractor, proven full functional compliance must be proven by the Contractor, prior to the authorization of this option by the Authority. In addition, if a hydraulic powered traction drive system is bid, this system shall contain a failsafe safety circuit to shut off hydraulic tank flow in the event of catastrophic failure, i.e. hose rupture.
3.14 EXHAUST SYSTEM
3.14.1 The exhaust system shall be so located that it will cause no adverse temperature rise in any other part of the equipment and so that a minimum of heat and exhaust gas can reach the operator.
3.14.2 Machines equipped with enclosed cab or cab top shall have the exhaust discharge at least 12" above the top or as Tunnel Restrictions apply. (see Appendix 9.1).
3.14.3 An exhaust muffler, located as close as possible to the engine shall be provided. Noise level shall be limited to 85 dB when measured at a distance of 50 ft. from the operating unit.
3.14.4 Stainless steel shall be used for all exhaust components. Not more than 36" of flexible metal exhaust pipe may be used, where necessary to reduce transmission or vibration. All exhaust piping shall be properly braced to eliminate shocks at all junctions, and at the interfaces between the manifold and muffler. Vibration dampeners may be used if necessary. The system shall provide for expansion, contraction, vibration, and stress produced by operation of the machine. The system shall at a minimum comply with the latest EPA Tier 4 interim emission standards.
3.14.5 When utilizing exhaust tubing in the vertical position, the end shall be bent or a rain cap incorporated to eliminate moisture entry into the exhaust system.
3.15 FUEL TANK
3.15.1 Capacity of fuel tank shall provide for continuous operation of the machine for a period of no-less-than 24 hours of operation at 50% of the rated output.
3.15.2 Filler opening shall have a minimum diameter of 1-1/2", a removable strainer (accomplished only with the use of common hand tools), and a hinged or chained filler cap.
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3.15.3 The filler opening shall be located so as to make it impossible for a fuel can or nozzle to contact electrically energized parts. Tanks shall be located to eliminate fire hazard from spill, overflow, or drain of fuel.
3.15.4 The tank shall be located on the Flashbutt Prime Mover, in a position that will provide protection against rupture due to collision or derailment.
3.15.5 The tank shall incorporate a top loading port vented cap, a sight gauge for fuel levels, a remote fuel gauge (cab-console); and a 3/4" drain valve with a pipe plug and provisions for a padlock.
3.16 BRAKES
3.16.1 The Flashbutt Prime Mover shall be equipped with fail-safe spring applied, pneumatic released brakes on all wheels. Service brakes shall be progressive in force application and capable of reducing the speed of the Flashbutt Prime Mover at a rate equal to, or greater than three (3) mph per second at maximum travel speed.
3.16.2 Hydraulic-dynamic type braking will not be accepted as service brakes.
3.16.3 Brake application shall not result in bending of axles, support structure, or vehicle frame. A single shoe at the top of the wheel may apply downward pressure along a line passing through the wheel center within 15" of vertical. Double shoes applying equal opposing forces may be used in any position.
3.16.4 Brake shoes shall be of a composition type (Cobra or equivalent).
3.16.5 Air brake systems must utilize SAE J1402 Table A (formerly Type E), DOT #EMV-SS 106-74 Type A1 air brake hose with reusable fittings. Brake systems must have independent pressure regulators, pressure gauges, and standard truck type reservoirs. The brake systems must be activated by standard truck type hand operated, control valves, and one (1) truck type quick release valve for each two (2) wheels.
3.16.6 Reservoirs must conform to SAE J10-B specifications. Manufacturers/Contractors shall also be able to provide reservoirs which meet ASME specifications for certification when requested as an option. The reservoir(s) shall be at least 30 gallons in capacity.
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3.16.7 Air brake systems must maintain operating pressure above 90 psi but not more than 110 psi. An audible low pressure alarm shall be furnished and installed in the operator's cab, and shall be activated at 70 psi or less.
3.16.8 The Flashbutt Prime Mover shall provide a friction braking system capable of providing all braking effort required for the Flashbutt Prime Mover and two (2) flat-cars of 60 tons GVW each (total 120 tons) of conventional two (2) axle, four (4) wheel trucks with "ABD-4" rigging air brake systems.
3.16.9 Main brake power shall be supplied by an in-line engine mounted gear driven compressor with a minimum of 28 CFM @ 2,100 rpm. The compressor shall be capable of operation at normal engine speeds and shall be lubricated by the engine oil sump. The compressor must be mounted in such a manner as to limit vibration during normal operations.
3.16.10 A fail safe spring-applied parking brake shall be furnished. The parking brake shall be capable of holding the Flashbutt Prime Mover on a 6% grade.
3.16.11 The brake line connections for flat-cars / rail train shall terminate with standard trucking industry gladhands keyed and labeled on the "service" and "emergency" and attached to their respective air lines on both the front and rear of the Flashbutt Prime Mover. The air lines shall be of trucking industry type, 6 foot long and attached to the Flashbutt Prime Mover on the right-side of the center line of the frame and facing the frame in a convenient location allowing hookup to the front or rear of a flat-car and provide operation of the flat-car brakes in either position. All brake lines shall be protected from chafing, binding, or other damage by being enclosed in metal conduit, channel, or tubing.
3.16.12 The brake system for the "ABD-4" flat car rigging brake shall consist of an independent A-9 control valve, or WMATA approved equal, from the Flashbutt Prime Mover brake system, and shall allow the operator complete control (release and apply capabilities) of the "ABD-4" rigging brake system. All air lines from the reservoir to the angle cock shall be of 1-1/4" schedule 40 pipe, hose construction, or WMATA approved design. The train line brake system shall terminate with an AAR approved 1-1/4" angle cock, a 1-1/8" x 22" long hose with attached FS-5 coupling. The angle cock shall be mounted to ensure the FS-5 coupling will be located at the extreme far end, and on centerline (CL) of the AAR coupler (knuckle) and 8" below the bottom of the coupler.
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3.16.13 To allow for emergency rescue of the prime mover, an FM 3103 1/4" NPT male quick disconnect emergency rescue port will be provided at the front and rear of the prime mover to allow charging and full release of the Flashbutt Prime Mover brake system from a compatible external source. Total failure of on-board electrical and engine systems shall have no affect on operation of the brake system during the emergency rescue mode. While in the emergency rescue mode, override and bypass components in the brake system will be isolated to avoid accidental or inadvertent venting of the charged brake system. Location of emergency rescue ports will be clearly identified on the prime mover. A step by step instruction placard for towing operations shall be installed inside the cab.
3.16.14 In the event of total failure of the onboard air storage system, a single point FM 3103 1/4" quick disconnect, located on the right side of the prime mover and easily accessible from the track bed, will be provided to allow a compatible external air source which provides air directly to the brake chambers of each wheel to release the parking brakes for recovery/rescue. After removal of external air source any air trapped in the system must be vented for normal operations. A 60 foot 1/4" hose, equipped with compatible male connectors will be provided, and clearly marked and stowed in the operators cab. The location of the emergency brake release port will be clearly identified on the prime mover.
3.16.15 The tank shall comply with MFPA FCLCH 30 (Flammable and Combustible Liquids Code Handbook).
3.17 CUTOUT COCKS
3.17.1 Cutout cocks shall be provided for all pneumatic components and subsystems. All handles shall be of the locking type, except for multiple access cutouts, and shall be arranged so that in the open position, they are parallel to the flow of the air and in the closed position, perpendicular (crosswise) to the flow of the air.
3.17.2 All cutout cocks shall be permanently marked to indicate the direction of flow. As a minimum, cutout cocks shall be provided for the brake cylinders, trainline isolation, and test fittings.
3.18 ELECTRICAL SYSTEM
3.18.1 Electrical Systems shall conform to the regulations of the American National Standards Institution (ANSI) and the International Standards Organization (ISO) where applicable.
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3.18.2 Upon completion of manufacture and before any operation shall begin, all parts shall be clean and free from scale, rust, water, and/or any contamination. All materials and workmanship must be of good quality for the intended use.
3.18.3 Sequence of operation and electrical, physical, and schematic drawings showing the exact circuit(s) in use on the machine and large enough to be easily followed during trouble-shooting shall be furnished. Subsequent changes shall be covered by new drawings furnished to the customer.
3.18.4 Whenever practical, components shall be interchangeable.
3.18.5 Cable shall be routed to prevent exposure to damage. Square tube shall be used as conduit to help prevent cable damage.
3.18.6 DC Systems, when grounded must have negative ground.
3.18.7 Battery charging alternators must have a rated capacity to handle all equipment and accessories with a 50% reserve.
3.18.8 The DC Electrical System shall be 24 volts.
3.18.9 Circuit breakers shall be utilized for overload protection as required. All wiring with potential difference of 50 volts or more must be separated by a clearance of 1½".
3.18.10 The battery box shall be constructed of stainless steel material and shall incorporate adequate drain holes and provide proper ventilation when lead acid batteries are used. The battery shall be provided with a disconnect switch and shall have a cover.
3.18.11 The Flashbutt Prime Mover shall be equipped with four (4) 8D batteries, connected as follows:
a) Two banks, two batteries each, with a marine type selector switch for electrical connection selection of each bank separately or both banks in parallel.
3.18.12 The batteries shall be connected to the alternator through a battery isolator to prevent discharge of both battery sets.
3.18.13 Standard, industrial grade, readily available components shall be used.
3.18.14 Electrical Apparatus Cabinets:
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3.18.14.1 Cabinets shall be of steel construction. Clearance between walls and bare "live" parts shall not be less than 1-1/2", unless affected interior surfaces utilize isolative plastic or fiber sheeting, where a potential in excess of 50 volts exists. Cabinets must be weatherproof.
3.18.14.2 Panels must be readily removable and parts easily accessible.
3.18.14.3 Adequate lighting shall be provided in cabinets.
3.18.14.4 Electrical cabinets shall not contain adhesive type tie downs or wiring mounts.
3.18.14.5 Interior metal surface walls must be painted with electrical insulating paint or covered with other approved electrical insulating material.
3.18.14.6 Nominal voltages used must be plainly shown on outside of cabinet.
3.18.14.7 All parts and groups of parts shall be identified by function and clear, simple, exact reference to service diagram and parts list. Integral units such as circuit board, should be considered as one part, if intended to be replaced as a unit. Complete parts identification shall be shown where practical, in order to minimize errors and time consuming reference to drawings or lists.
3.18.14.8 Wires must be equipped with good quality ring lug, push-on or pin and screw type terminals and identified with permanent numbered markers, color coded when practical, and terminal posts must be plainly marked. Once used, a number or color code must not be reused for a different circuit. All wires must be neatly dressed and clamped.
3.18.14.9 Housing containing heat producing elements must be properly ventilated.
3.18.15 A recessed 120 Volt AC weather-proof receptacle shall be installed at the each corner of the Flashbutt Prime Mover for a total of 4 receptacles. These shall be wired to the control panel of the generator. Each receptacle shall be controlled by a 20 amp circuit breaker.
3.18.16 The electrical system shall have a New Mar 32-12-15 DC-DC Converter or a WMATA approved equivalent to power the 12 VDC radio communication system and crane system.
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3.19 MATERIALS
3.19.1 Materials used in the construction of the vehicle shall not constitute a health hazard for passengers, staff or the public. Prohibited materials shall include but shall not be limited to the following:
a) PVC;
b) Asbestos;
c) Polychlorinated Biphenyls;
d) Mercury (excluding fluorescent light bulbs);
e) Lead based pigment paints, and lead in brake shoes (if applicable);
f) Halogens (excluding thin walled cross linked polyolefin cable);
g) Silica;
h) Urethane foam;
i) Chlorinated fluorocarbons that may cause environmental problems;
j) Materials that emit toxic gases or irritants in their normal state; and
k) Known carcinogenic materials.
3.19.2 All steel plates, shapes, bars, and sheets shall be of a quality that has good weldability, high impact resistance and meets IZOD impact toughness at low temperatures (0 to 40 deg. Fahrenheit). Steel items shall be of alloys and grades normally used for maintenance of way equipment and railway rolling stock. Design of structural members subject to normal working loads shall have a minimum design safety factor of 2 to 1. Structural members shall be designed to withstand impact stresses with a minimum safety factor of 3 to 1. It is generally recognized that this is only a minimum recommended guideline and greater design safety factors may be required as necessary.
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3.19.3 All fasteners shall meet requirements of ASTM-A-325 for structural components and grade USS/SAE 5 or 8 for assembly hardware as a minimum. Manufacturer or Contractor shall use certified fasteners. Manufacturer or Contractor shall be aware of the high possibility of counterfeit fasteners available. All fasteners shall be plated or anodized to avoid corrosion or galvanic reaction to the mating surfaces.
3.19.4 All bolt applications shall have at least two (2) full threads protruding beyond the nut after the fastener has been torqued and no more than six (6) threads protruding beyond the nut.
3.19.5 All fastener certifications shall be maintained by the builder for inspection by WMATA until all warranty/reliability periods have expired.
3.19.6 All non-ferrous metals shall be of alloys having strength and corrosion resistance suitable for the service and operating environment intended.
3.20 PAINT
3.20.1 Contractor shall use paints which meet OSHA regulations and standards, and do not have any known history of biological hazards due to long term exposure. Passive respirators and eye protection shall be the only safety or health equipment necessary to protect workers making repairs.
3.20.2 All surfaces shall be shop blast prepared prior to application of primer coats. Two-part epoxy primer compatible to the surface finish shall be used. The surface coat shall be U-tech, chrome yellow, high solids, catalyzed or two-stage urethane, or approved equivalent. The surface finish shall have a glossy, high quality, durable finish, which resists dulling, fading, cracking, or chalking when maintained with suitable cleaning compounds.
3.20.3 The paint used on any part of the units shall be lead-free. If the requested color is not available, the Contractor shall provide the brightest or most easily identifiable colors available, as approved by the Authority.
3.20.4 Exposed parts of each machine shall be painted U-Tech (Chrome Yellow), # UTCB9355-MX/GL, Urethane except as follows:
a) Diesel Fuel Tank GREEN
b) Hydraulic Reservoir BLUE
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c) Coolant Tank GRAY
d) Wheels and Handrails: BLACK
e) Lifting Lugs: BLACK
f) Safety Locks: RED
g) Jacking Points or Pads: BLACK
h) Engine and Other Parts: Manufacturer’s Option
3.20.5 The name of fluid and the words “CHECK DAILY” shall be stenciled on each tank in 1” letters. Total machine weight with all tanks filled shall be plainly marked on both sides of the machine in 1 ½” letters: WEIGHT ______Lbs. (Manufacturer/Contractor to fill in the blank.)
3.20.6 All equipment shall be protected by finishes suitable to the environment. Moving parts shall be self-lubricated or shall contain provisions for full application of all lubricants.
3.20.7 Exteriors exposed to the elements shall be finished by a minimum three (3) coat process. The base coat shall contain a rust inhibitor phosphatized coating and be thoroughly bonded to base metals.
3.21 CLEARANCE REQUIREMENTS
3.21.1 Clearance of fixed system points: The Flashbutt Prime Mover and appurtenances must successfully operate and negotiate within the constraints of the dynamic characteristic of the WMATA system.
3.21.2 Major dimensions of the Flashbutt Prime Mover shall be governed by the Dynamic Envelope Drawings found in Appendix 9.1.
3.21.3 Dynamic motions, while in travel mode, of the Flashbutt Prime Mover and its components shall not project any part of the vehicle beyond the Contractor declared clearance requirement, which must fit within the WMATA structure gauge.
3.21.4 The Contractor shall submit for approval by WMATA, design configuration drawings showing the static and dynamic car outline, on tangent track, and the swept path for the Flashbutt Prime Mover indicating compliance with these requirements.
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3.21.5 Components which may encroach upon track, signal, crossing, or other structures on, or within the WMATA System must have a positive mechanical lock to secure these components into a safe position for travel.
3.21.6 No component shall be less than 3” above the plane extending from the ball of one (1) rail to the ball of the other rail.
3.21.7 All components which may present a hazard to the operator or bystanders shall be protected with a shield or safety device.
3.22 COUPLER
3.22.1 Each end of the Flashbutt Prime Mover shall be provided with AAR type “E” coupler, adjusted to 34 1/2" on knuckle centerline above the rails.
3.22.1.1 Slew Capability: must be able to negotiate a reversed back to back #6 turnout with a distance of 13.28 ft between the points of switches.
3.22.1.2 The tow eye on the front of the Flashbutt Prime Mover shall be incorporated into the snowplow mount.
3.22.1.3 The tow eye shall be 14", ± ½”, from the top of rail to centerline of tow eye as measured with new wheels and shall include 2-1/8” hole to accept tow bar pins (refer to Appendix 9.3 for a drawing of the tow bar).
3.22.1.4 The machine shall incorporate, in the operator’s cab, where possible, a metal etched placard designating the towing procedure.
3.22.2 One (1) Tow Bar with 2" pins of a strength equal to 150% of the Draw Bar force required by the maximum load coupled to the Flashbutt Prime Mover of minimum six (6) ft. length shall be provided and stowed in an accessible area of the Flashbutt Prime Mover.
3.23 OPERATOR’S CAB
3.23.1 General:
3.23.1.1 An Operator’s Cab shall be provided at one end of the Flashbutt Prime Mover.
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3.23.1.2 The Operator Cab shall provide seating space for the operator and four (4) passengers. A 360 horizontal viewing angle shall be possible. From the operator's position, a vertical viewing angle of ± 45 to the front and near-side shall be possible. The rear of the cab shall contain windows and wipers in both door and side panel to allow maximum viewing of deck area and ladder ways. The cab shall be weather tight. The glazing material shall be 1/4" laminated safety glass. Cab side windows shall be divided into two (2) halves. The rear half shall be fixed. The front half shall be a sliding track window with a closed latched position. The windshield wiper(s) shall clear 75% of the front and rear glazing, and shall maintain full blade contact with the glazing while the Flashbutt Prime Mover is traveling at maximum speed. The wiper shall be of the 2-speed type with controls within easy reach of the operator.
3.23.1.3 When rechargeable wet type batteries are located inside the body or cab, the top of battery shall be vented to outside air.
3.23.1.4 The cab door must be equipped with lock hasps which incorporate a 3/8" minimum inner diameter Hasp Ring, and to be in addition to any other type door locks. A door shall be placed at the rear bulkhead of the cab, and allow egress/access by way of the Flashbutt Prime Mover equipment area. The door shall be located to allow the operator a clear and unobstructed view when traveling in reverse, and shall be equipped with a wiper which clears 75% of the door glazing.
3.23.1.5 The cab shall be equipped with an HVAC system. A hydraulically driven, Visionaire, self-contained environmental control unit, or approved equivalent, shall be used. Fluid power for the unit shall be provided by main power unit. Fresh air intakes shall assure a minimum of three (3) changes of air volume per hour. Interior temperatures shall be thermostatically controlled through operator adjustment, such that at maximum heating conditions, a temperature of 68 F can be sustained and at maximum cooling conditions, a temperature of 85 F can be sustained.
3.23.1.6 The cab shall contain a metal locker for storage of drawings and similar materials. The minimum interior dimensions shall be 12" high, 20" wide, and 15" deep. This door shall be key locked.
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3.23.1.7 The cab floor shall have hinged access doors for components located under the cab for ease of maintenance and service.
3.23.1.8 All switches, valves, levers, controls, and adjustments used to start, stop, or operate the machine shall be clearly labeled with weather and wear resistant plates permanently affixed to the machine or component. Controls used in continuous operation of the machine shall be within easy reach of the operator and shall not interfere with his view of the work. Instruments and gauges not inside a closed, lockable cab, shall be protected from vandalism.
3.23.1.9 The following safety items shall be included:
a) A fire extinguisher and first aid kit mounted inside the cab.
b) Bi-directional dual tone electric or air horns shall be mounted on the exterior of the unit.
c) Outside rear view mirror on both sides of cab.
3.23.2 Interior Arrangement:
3.23.2.1 The general arrangement of the cab controls and indications shall enable all normal driving functions to be performed while the operator is seated.
3.23.2.2 All controls and work look-ups shall be accessible from the operator’s seated position.
3.23.3 Visibility Requirements:
3.23.3.1 The cab design shall minimize “blind spots” caused by pillars or other obstacles which may block sections of viewable area from the operator. It is acceptable to require the operator to lean forward in their seat to achieve this view requirement.
3.23.4 Operator’s Seat:
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3.23.4.1 Each seat shall be constructed of durable non-toxic materials. The operator seat position shall be equipped with a cushioned seat and back, employing natural or man-made leather, over 3" low smoke foam cushion (Chestnut Ridge 200) or WMATA approved equal. The operator seat position shall be adjustable to accommodate operators ranging in height from 5'2" to 6'4".
3.23.4.2 The operator seat shall be capable of 90 rotation, left to right from center locking position facing the main console and be capable of being secured in the front or rear facing position by means of a latch.
3.23.4.3 The seat shall be placed in the cab to allow an unrestricted view along the left-side of the boom crane when the seat is positioned in the rear facing position.
3.23.4.4 The operator’s seat shall be equipped with a safety belt.
3.23.5 Main Console:
3.23.5.1 The operator main console shall be located on the left cab wall near the front. The operator seat shall face the main console.
3.23.5.2 The surfaces of the main console shall be wear-resistant, reflection-free, thermally insulated, abuse-resistant and without any sharp edges. Console switches shall be heavy-duty, transit service-proven pushbutton, rocker or rotary switches.
3.23.5.3 All cab facilities shall be properly marked with extremely durable labels or markings in English and shall have pictograms where necessary to improve clarity.
3.23.5.4 Control stand and panels shall be neat in appearance, with all equipment, indicators, devices and controls arranged in an orderly manner. The control stand and panels shall have a flat, black, no-glare finish that does not cause reflections in the operator’s windshield. Light indicators shall be arranged so they do not cause reflections in the operator’s windshield.
3.23.6 Camera System
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3.23.6.1 The Flashbutt Prime Mover shall be equipped with an HD camera system to minimize blind spots and to view the work area. Cameras shall also be installed in all areas with obstructions and for rear viewing.
3.23.6.2 The cab shall be equipped with monitors for easy operator viewing. The monitor shall be the largest size available without obstructing the operator.
3.23.6.3 The arrangement of the camera system, equipment selection, and installation shall be submitted to WMATA for review and approval.
3.23.7 Controls:
3.23.7.1 A red emergency shutdown control shall be quickly accessible to the operator. The shut down control must stop the engine and apply prime mover brakes at a reduced pressure to prevent locking of wheels.
3.23.7.2 An emergency shutdown shall also be installed in all operating stations and at each outside corner of the Flashbutt Prime Mover.
3.23.7.3 An emergency shutdown indicator system shall be installed on the operator’s console, red LED type that will indicate which shut down is activated.
3.23.7.4 The engine must not start with controls in travel position.
3.23.7.5 The operator's seat shall contain the readily accessible controls to allow operation when the seat is latched in the forward position or rearward facing position.
a) These contained controls shall include:
1) Train line Braking
2) Service Braking
3) Engine Throttle Control
4) Gear Selection.
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3.23.7.6 The operator's console shall contain all other instruments and controls necessary to operate the forward and reverse motion of the work train in a safe manner. Controls for exterior lights, windshield wipers, and horns shall be readily accessible to the operator. All exterior switches shall be weather proof. The controls shall consist of:
a) Switches:
1) Windshield Wiper - Front
2) Windshield Wiper - Rear
3) Defroster Fan - Front
4) Defroster Fan - Rear
5) Headlights - Front/Rear
6) Interior Lights - On/Off
7) Exterior Work Lights - Front/Rear
b) Gauges: (All Gauges shall be the back lighted type and in American Standard.)
1) Oil Pressure Engine psi
2) Water Temperature Fahrenheit
3) Volts - Battery Set #1
4) Volts - Battery Set #2
5) Air Pressure – Main psi
6) Air Pressure - System Brakes psi
7) Air Pressure - Brake Pipe (Train line) psi
8) Oil Pressure – Transmission psi
9) Oil Temperature – Transmission Fahrenheit
10) Fuel Level
11) Speedometer - MPH
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12) Tachometer - RPM
c) Controls:
1) Throttle
2) Main Brakes
3) "ABD-4" Brakes
4) Forward / Reverse
5) Gear Select
6) Air Horn (Overhead pull cable type)
7) Electric Horn (pushbutton – low decibel)
8) Tools - On/Off
9) Parking Brake
10) Cab-Remote
11) Engine Kill - Mushroom Button
d) Indicators:
1) Tools - On
2) Remote - On
3) Engine alarm
4) Audible/Visible Low Air Alarm
5) Engine shut down by location
6) Outrigger up in stowed position by location (reference Section 3.28)
e) Console:
1) Shall have soft exterior lighting
f) Circuit Breakers:
1) Required
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g) Key Switches:
1) Ignition
2) Battery
3.23.8 Radio
3.23.8.1 Provisions shall be made within the cab for mounting, by the Contractor, a transit vehicle radio with separate speaker and separate microphone and an exterior antenna. The Contractor shall furnish a source of 12 VDC power as described in Section 3.18.16, through a circuit breaker rated at 3 AMPS for the control circuit and 40 AMPS for the transmitter.
3.23.8.2 The Contractor shall provide the following for the radio system:
a) Astro XTL 5000 Digital Mobile Radio
b) Mobile Astro XTL 5000 W5 482-512 MHZ 20-40 Watts 128 Channel (120W)
c) ENH: Software Astro Digital Common Air Interface Operation (G806)
d) ENH: Software Smartnet System (G50)
e) ENH: DigitallD Display (G114)
f) ALT: Remote Mount W4, W5, or W7 with 17 foot Cable (W496)
g) Antenna with cables.
h) Programming: Talkgroup template, etc.
i) Installation within vehicle.
j) Varilator: DB Spectra UHF Varilator, Model #ACV2501JIMO
3.23.9 Cab Windows:
3.23.9.1 The cab shall maximize the use of glazing to allow a high degree of visibility for the operator. The cab side windows shall be tinted to minimize glare and solar heat gain during daytime operations, but shall not restrict visibility during night time operations.
3.23.9.2 All windows shall be sealed around the entire window perimeter to resist water penetration under all operating conditions.
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3.23.9.3 All windows shall be replaceable from outside of the cab.
3.23.10 Cab Windshields:
3.23.10.1 Visible glare or reflections on the windshield, including reflections from interior lighting during night operation shall be minimized.
3.23.10.2 Windshield wipers shall be provided on both the travel and work viewing glass locations.
3.23.11 Sun Visor:
3.23.11.1 A tinted, adjustable, heavy duty sun visor shall be provided in the cab. The sun visor shall have the capability of pivoting to shade either side window or a separate provision can be made to accomplish this.
3.24 LIGHTING
3.24.1 Cab Lighting
3.24.1.1 A lighting fixture shall be suitably placed on the ceiling of the Operator’s Cab. An on/off switch and dimmer control shall be provided on the operator’s console to control this fixture.
3.24.2 Exterior Lighting
3.24.2.1 Both ends of the Flashbutt Prime Mover shall be equipped with the following Exterior Lights:
a) Two (2) – 4 inch Minimum Red Marker Lights, LED Type
b) Two (2) – Headlights, U.S. Reflector Xenon X-4500 Broad Beam
3.24.2.2 The operation of these lights shall be as follows, and automatically switchable as the vehicle direction is selected:
CAB-END LEADING FORWARD REVERSE RED Marker Light OFF ON Head Lights ON OFF REAR-END LEADING RED Marker Light OFF ON Head Lights ON OFF
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3.24.3 Work Lights
3.24.3.1 The work deck shall be illuminated by U.S. Reflector Xenon X-4500 Wide Flood as required by deck layout with a minimum two (2) lights illuminating the deck from rear of cab and two (2) lights illuminating the welding operation and storage area.
3.25 PNEUMATIC SYSTEM REQUIREMENTS
3.25.1 A Sullair Air Compressor, Model Sullscrew, or WMATA approved equal shall be provided by the Contractor. The compressor shall be rated at 185 CFM, 90 psi, and be of the single stage oil flooded rotary screw type design. The Air Compressor shall be driven by an independent diesel engine, protected by over temperature and lubrication failure sensors. Fuel shall be supplied from the main fuel tank. Air tool connections located at each end of the car shall be plumbed to this compressor. As a back-up to the machine air system, this compressor shall be plumbed into the machine air system tank using a 1 ¼” pipe and check valve. The engine and compressor shall be equipped with remote oil drains routed below deck to underside of main frame and accessible from the side of the equipment. The drains shall be equipped with ball valves and JIC caps.
3.25.2 System must contain an air pressure gauge in easy view of operator.
3.25.3 Standard air brake hose SAE-J402 Table Al will be the only hose used anywhere in the system. Use of push-on barb type fittings are banned, except for control circuits where space is critical, and where working pressure and abrasion is not severe and braking is not involved.
3.25.4 The system shall have:
3.25.4.1 An air compressor Discharge Line constructed of heat resistant, teflon, flexible tubing utilizing an outer layer of stainless steel wire braid.
3.25.4.2 An engine air compressor intake supply commonly connected to the Engine Air Inlet System.
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3.25.4.3 The air reservoir shall be equipped with a Bendix automatic dump valve, Model V-2 or equivalent, to exhaust accumulated moisture. The dump valve shall blow down periodically during operation, and shall be equipped with a 24 V heater mechanism to prevent cold weather freezing. The reservoir shall also be equipped with an easily operated manual drain valve.
3.25.4.4 An easily accessible in line filter/dryer (Turbo 2000) or approved equivalent, with heater, and an automatic blowdown/spit valve will be installed in the air system to trap and vent accumulated moisture. The spit valve will momentarily operate when the electrical system is keyed down.
3.25.4.5 An inline air lubricator/water filter shall be installed in the main air system. The filter shall be conveniently located for compliance with scheduled maintenance.
3.26 HYDRAULIC SYSTEM REQUIREMENTS
3.26.1 The hydraulic system shall conform to the recommendation of the National Fluid Power Association (NFPA), American National Standards Institute (ANSI), and the International Standards Organization (ISO).
3.26.2 Upon completion of manufacture and before any operation, all parts of the system shall be cleaned and free from contaminants. Threads, holes, cuts, flares and machining must be deburred and cleaned.
3.26.3 Manufacturers must pre-filter all oil through a ten (10) micron or finer filtering system.
3.26.4 All reservoirs shall be designed and constructed to prevent entry of foreign matter, including water, and sized to protect the hydraulic system against excessive heat or thermal conditions. Reservoir shall be of 100-gallons size or larger, and shall include:
a) Baffles to separate intake and return lines to facilitate the separation of air and foreign matter from the hydraulic fluid, separate pump inlet from the settling portion of the tank, and shall direct flow toward tank walls for maximum heat dissipation.
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b) Access panels large enough for complete cleaning, inspection, maintenance, and servicing of sump filters with an accessible means to empty the reservoir in the event the fluid is to be retained. The reservoir shall be equipped with remote oil drains routed below deck to underside of main frame and accessible from the side of the equipment. The drains shall be equipped with ball valves and JIC caps.
c) An air inlet breather which is of sufficient capacity to maintain approximately atmospheric pressure at maximum demands on the hydraulic system and to assure vacuum at pump inlet(s) shall not exceed 60% of pump manufacturers’ recommendations. Air breather system shall be equipped with a 25 micron or finer filter, either cartridge or spin-on type.
d) An exception to the filter requirement in this section shall be a sealed and pressurized system.
e) A thermometer, in plain view, protected from damage, as near the intake line as possible, at the add point fluid level.
f) A static fluid level gauge to show fall and add points protected from damage.
g) A non-integral reservoir (not part of the frame) shall be utilized. This reservoir shall be mounted in accordance with the section relating to the fuel tank (Section 3.15).
h) Both the intake and return tubes shall be located below the minimum working fluid level so as not to cause cavitations’ or aeration.
i) Hydraulic system shall contain a failsafe safety circuit to shut off hydraulic tank flow in the event of catastrophic failure, i.e. hose rupture.
3.26.5 Fluid temperature in the reservoirs shall not exceed 180 F at the reservoir outlet(s) while operating in a 100 F ambient. The minimum fluid temperature after 5 minutes, warm up to or operation shall be at least 60 F with a 20 F ambient.
3.26.6 Where failure of the power plant or pump can immobilize components, in a position which would prevent moving of the Flashbutt Prime Mover, a battery operated emergency pump shall be provided in the circuit to allow normalization of all equipment components for movement of the Flashbutt Prime Mover to a proper location.
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3.26.7 Fluid Filtration
3.26.7.1 The total pressure line and/or return line flow shall pass through filters rated at 20 microns or finer and minimum beta 10 rating of 10 per ANSI Std. B93-31-1973, equipped with a condition indicator. Filtration shall not be less than recommended by manufacturers of the hydraulic system components.
3.26.7.2 In closed loop systems, filtration as recommended by the pump manufacturer will apply.
3.26.7.3 A magnetic particle attraction feature shall be provided in the pump intake line and/or in the filters and/or in the reservoir.
3.26.8 Fluid Conductors
3.26.8.1 Maximum use of rigid tubing is preferred. Tubing will be equipped with 370 fittings for interfacing with flexible hose used when needed. Fluid conductors utilized in circuits operating at or under 3000 psi must use high pressure hose; SAE 100 R2 Type A Plus, Hi-Impulse type with the following qualification requirements:
a) Constructed with a corrosion resistant, 2-wire braid reinforcement.
b) Have a bursting pressure safety factor of 4:1.
c) Tested to 300,000 impulse cycles at 250 F.
d) Have an operating temperature range of - 30 F to + 250 F
e) Use with non-skive type, crimp fittings.
3.26.8.2 All fluid conductors utilized in circuits operating over 3000 psi or in hydrostatic drive systems should use extra high pressure hose; SAE 100 R12 plus type when utilizing hose sized up to 1 in., which have the following qualification requirements:
a) Constructed with 4-spiral plies of steel reinforcement.
b) Have a bursting pressure safety factor of 4:1.
c) Tested to 1,000,000 impulse cycles at 250 F
d) Have an operating temperature range of - 50 F to + 250 F SPN-0040 FLASHBUTT WELDING PRIME MOVER Rev. 0 - 9/20/2011 Page 38 of 75
e) Use with permanent, crimp type fittings, for added reliability.
3.26.8.3 Maximum use of rigid tubing is preferred. Tubing will be equipped with 370 fittings for interfacing with flexible hose used where needed. All fluid circuits and hydrostatic drive systems operating at pressures exceeding 3000 psi shall use ultra-high pressure, heavy duty, hi-impulse tubing and hoses. SAE 100 R13 type hoses 1" diameter and larger shall meet the following requirements:
a) Constructed with 6-spiral plies of steel reinforcement.
b) Have a bursting pressure safety factor of 4:1.
c) Tested to 1,000,000 impulse cycles at 250 F
d) Have an operating temperature range of - 40 to + 250 F
e) Use with permanent, crimp type fittings, for added reliability.
3.26.8.4 Pump supply hoses must meet the requirement of SAE 100R4, with reusable or crimped fittings
3.26.8.5 Hose shall not be:
a) Flexed to less than their rated minimum bend radius.
b) Installed or routed to expose them to temperatures above or below their rated operating temperature ranges.
c) Subjected to any twisting, pulling, kinking, crushing, or abrasion.
d) Routed in a manner which would expose the hose to damage under normal conditions.
e) Painted
3.26.8.6 Hoses shall be installed routed, and isolated where possible for proper support through clamping and/or brackets to avoid all of the above conditions, especially abrasion. If necessary, hoses subjected to excessive abrasion should be wrapped with an abrasion resistant wrapping or sleeve.
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3.26.8.7 Tubing and piping shall be mounted to minimize vibration. Tubing shall have only gentle bends to change direction or compensate for thermal expansion. Bend radii shall not be less than three (3) times the inner diameter.
3.26.8.8 Pipe threads are not recommended but not prohibited. If they are used, they must be NPTF dry seal type.
3.26.8.9 When practical, valves shall be manifold mounted.
3.26.8.10 Galvanized or brass tube, pipe, or fittings shall not be used.
3.26.8.11 Two (2) hose reels shall be supplied to provide power for various hydraulic tools at the front of the machine only. The hydraulic hose reels shall meet the following provisions:
1) Two (2) retractable reels, each equipped with 60 ft. of Twin Parker Parflex 518C-8 nonconductive SAE 1000R7 ½" ID hose each, and FD 49 Aeroquip (or Parker equivalent) quick connect fittings and dust plugs shall be supplied. A 10 gpm non-adjustable flow control and separate selector valve shall be installed for each reel. The selector valve shall be located within close proximity to the hose reel. The two (2) reels shall be installed on the frame at the front of the Flashbutt Prime Mover, as approved by WMATA. Any of the hose reels must be simultaneously usable.
2) The selector valves shall be of closed port, open center design to allow the pressure trapped in the tool and hose to be relieved back to the tank. A valve shall be installed at each hose reel to prevent leakage of fluid from the return side in the event of hose failure; this valve will allow hose change out with the engine running.
3.26.8.12 All reels shall have spring rewind, and locking pawls. Fairleads shall be equipped on the reels to permit pulling and retracting hoses without interfering with other components or chaffing. Hoses shall be equipped with the proper size stop ball to prevent complete retracting into the reel, and dust caps. Hose reels shall be positioned to eliminate interference with coupling to all other equipment, and during any movement of the equipment. Hoses shall not protrude forward of the reels.
3.27 CRANE
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3.27.1 A hydraulic crane shall be provided on the non cab end of the Flashbutt Prime Mover. The performance requirements shall include:
a) Crane Capacity: 12,000 lbs
b) Weight: 6,785 lbs
c) Operating Power: Hydraulic
d) Maximum Boom Extension: 140” from fully closed
e) Boom Extension Mechanism: Rack and Pinion
f) Maximum Rotation: 16° either side of center
g) Boom Rotation Mechanism: Hydraulic cylinder
h) Load Lifting Type: Dual rope and sheaves
i) Rope Breaking Strength: 84,400 lbs (dual rope)
j) Rope Certified Working Strength: 16,480 lbs
k) Maximum Rope Lift: 72 inches
l) Load Lifting Mechanism: Hydraulic
m) Crane Maximum Operating Pressure: 2,000 psi
n) An emergency pump shall be provided (refer to Section 3.26.6)
3.27.2 The crane shall incorporate a design which allows ease of access, service, replacement, and adjustment by maintenance and operational personnel including control levers, gauges, switches, overload and indicator lights, adjustment valves, and regulators for all crane functions.
3.28 OUTRIGGERS (IF APPLICABLE)
3.28.1 Outriggers shall be supplied if necessary to meet required crane loading and vehicle stability. The proposed arrangement shall be submitted to WMATA for review and approval before incorporating into equipment design.
3.29 FLASHBUTT WELDING GENSET
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3.29.1 Power for the Flashbutt welder shall be provided by an electric generator, Newage model HCI 534E, or WMATA approved equal, capable of meeting the following performance requirements:
a) 460V, 60 Hz, 3 Phase at 1800 RPM
b) Rated current (50% load) – 540 A
c) Rated power (50% load) – 210 KVA
d) Engine rated power – 375 kW
e) Generator rated capacity – 375 KVA
3.30 PRIME MOVER WELD HEAD
3.30.1 Prime Mover must have the capability to accept a Mobile Flash Butt Welding System. (Note: Mobile Flash Butt Welding System to be supplied by separate contract.)
3.30.2 Warning signs and labels (“STAND CLEAR”; “DANGER”, etc) shall be installed where applicable in the welder work area.
3.31 REMOTE OPERATING STATION
3.31.1 The Contractor shall provide a Remote Operating Station (ROS) at the crane-end with a rearward facing seat that will allow full operation of trainline and service brakes. Full throttle operation, and control of forward and reverse in conjunction with the transmission feathering valve shall be provided. The ROS shall be equipped with a visual indicator that shall indicate when controls have been switched to the ROS and indicate forward or reverse modes of operation. The ROS shall also provide operation of the crane from a seated or standing position. The brake control for the service side of the fail safe brakes must be of a foot pedal operated type. A control in the cabin operator station must be provided and must allow for full ROS lockout. No function will operate except for crane when selected (NOTE: A red mushroom engine "kill" button shall be included at the ROS). During switching from main console to ROS or ROS to main console there shall be no delay in the braking system that would allow roll back on a 6% grade.
3.31.2 Seat construction and material shall be of adequate design to withstand adverse environmental conditions for a period of five (5) years.
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3.31.3 A permanent mounting location on the deck for an oxygen and acetylene cylinder, with clamps and bottom rings to prevent the cylinder from tipping or falling shall be provided. They shall be located so as to provide for easy cylinder replacement.
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3.32 TRAVEL SPEED
3.32.1 Each axle of the Flashbutt Prime-Mover shall be powered and permit operation at maximum torque speed, in both directions of travel. The power plant shall permit operation under full design load at speeds of not less than 25 mph, on level tangent track, but shall be governed to prohibit operation above 40 mph under minimum load conditions. The accuracy of speed regulation shall be within the following ranges:
SPEED LOAD ACCURACY < 1 mph – 5 mph Full +/- 0.5 mph > 5 mph – 35 mph Minimum Load: +/- 2.0 mph Maximum Load: +/- 0.5 mph
3.33 MANUALS AND DOCUMENTATION
3.33.1 Scope
3.33.1.1 The Contractor shall provide Operation & Maintenance (O&M) Manuals in sufficient detail to enable WMATA to operate, test, maintain, overhaul, and repair and restore the Flashbutt Prime Mover to its original vehicle- acceptance condition that meets the specified performance requirements.
3.33.1.2 The O&M manuals set shall contain the complete operation, parts, maintenance and overall procedure manuals for all major components.
3.33.1.3 One (1) set of these manuals shall accompany the Flashbutt Prime Mover in a waterproof container permanently affixed to the body of the machine. Manuals will be for the major components.
3.33.1.4 Twelve (12) additional complete sets of manuals referenced in this section shall be submitted as hard copies and on twelve (12) writable CD’s in Portable Document Format (PDF) upon delivery of the Flashbutt Prime Mover (390 days from NTP). Section 8.1.4 outlines the delivery schedule and delivery address for the manuals.
3.33.2 General Requirements for O&M Manuals
3.33.2.1 The O&M Manual shall fully describe the operation, testing, maintenance and repair of all systems, subsystems, equipment and components.
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3.33.2.2 The Contractor shall provide an illustrated parts catalog within the manuals for the Flashbutt Prime Mover. The illustrated parts catalog shall consist of combinations of parts lists and illustrations covering all equipment on the Flashbutt Prime Mover starting from the top of the equipment hierarchy down to the smallest replaceable component.
3.33.2.3 Layout drawings of the equipment shall be included in the O&M Manual.
3.33.3 The machine shall incorporate, in the operator’s cab, where possible, a metal etched placard designating lubrication point, indicating types of lubricant, location on machine, and frequency of checking or changing lubricants. These placards must be designed by part number for the appropriate machine. The O&M Manual shall also contain the comprehensive lubrication chart for the appropriate type machine.
3.34 MAINTENANCE SPARES
3.34.1 Equipment shall be delivered with a full complement of all parts necessary to ensure successful start-up and total operational capability for a minimum of one (1) year which includes 3 PMI cycles.
3.34.2 Additionally, as soon as the equipment designs become finalized, the Contractor shall provide a list of recommended Maintenance Spares that should be held by WMATA for the ongoing maintenance of the Flashbutt Prime Mover inclusive of current prices. The Maintenance Spares shall include consumables, casualty replacements, and a maintenance float. The list shall be based on industry standard reliability failure predictions, and availability Mean Time Between Failures (MTBF) reliability data. As a minimum, the following information shall be furnished for each item on the Maintenance Spares list:
a) A supplier part number;
b) Description;
c) Recommended quantity;
d) Estimated annual consumption (for consumable spares);
e) Shelf life;
f) Unit price and extended price by vehicle; and
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g) Lead time for ordering.
3.34.3 The lead time for each item on the Maintenance Spares list shall take into consideration the following classifications:
a) Wear – Parts that may be expected to require regular replacement under normal maintenance schedules, such as mechanical parts subject to continuous operation.
b) Consumables – Parts, including fluids, with an expected life of less than five (5) years.
c) One Shot – Parts that normally require replacement after performing their function one time, such as fuses.
d) Long Lead – Parts that are not readily available from distributors or the manufacturer.
e) Exchange Assemblies – Assemblies that will be exchanged with failed units (or units that are not responding as specified) on the supplied equipment and that must be inventoried as complete assemblies.
3.34.4 The OEM part numbers shall be supplied to WMATA for all commercially available standard parts and components purchased by the offeror from external sources. OEM parts modified by the offeror to meet the needs of this procurement will be clearly identified by a unique number in the parts manual.
4.0 Inspection and Acceptance Testing
4.1 INITIAL INSPECTION
4.1.1 WMATA representatives may inspect the equipment at the manufacturing facility at any time during the manufacturing period. In addition, WMATA representatives shall perform onsite testing and acceptance testing at the manufacturing facility at key milestones of the manufacturing process and before delivery to WMATA.
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4.1.2 The machine shall be inspected upon delivery. The machine shall be completely lubricated and serviced with all equipment installed for immediate operation, except for fuel. Water cooled engines are to be protected from freeze up by a 50/50 solution of ethylene glycol base anti-freeze (rust inhibitive type) unless otherwise specified, and the radiator marked or tagged to show the manufacturer and type of coolant used and actual protection afforded.
4.2 ACCEPTANCE TESTING
4.2.1 Upon equipment delivery, the Contractor shall perform on-rail acceptance testing at WMATA. Acceptance test plans shall be submitted by the Contractor ten (10) working days prior to performing the test and approved by WMATA, prior to testing. As a minimum acceptance tests shall include:
a) Tow Capacity Verification
b) Air Compressor Capacity Verification
c) Hydraulic System Performance Check
d) System Clearance Checks (within the WMATA System);
e) AC Generator Capacity Verification
f) Crane Operation & Load Capacity Verification
g) Full-functions performance testing;
h) Radio Frequency & Power Test
i) Coupling Test
j) Braking Capability Verification;
k) Vehicle Lighting Test;
l) Heating & Cooling Test;
m) Noise Level Measurements.
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4.2.2 On site WMATA acceptance testing start date: 390 days after contract award.
WMATA Attn: Lee Hall 3101 Eisenhower Avenue Alexandria, VA 22314
4.2.3 A Contractor's Representative shall place equipment in service and instruct WMATA’s operators, mechanics, and supervisors at a location, to be specified by WMATA (not necessarily at the machine delivery point).
4.2.4 The maintenance training course shall not be concurrent with the equipment start-up assistance and training.
5.0 Safety Certification
5.1.1 The Contractor shall comply with the U.S. Department of Labor’s Occupational Safety and Health Administration (OSHA) standards.
5.1.2 The Contractor shall conduct a safety program, which ensures to the greatest extent possible, that the equipment delivered to WMATA are operationally safe and secure for passengers, employees, emergency responders, and the general public.
6.0 Warranty
6.1 EQUIPMENT AND COMPONENTS
6.1.1 All components, parts, and equipment furnished under this Contract shall carry a minimum 12 month (1 year) warranty for parts and labor. Warranty coverage shall be activated upon acceptance of the Flashbutt Prime Mover at WMATA.
6.1.2 Pre-Manufactured items installed on the Flashbutt Prime Mover will be covered by the OEM manufacturers’ warranties unless the warranty is less than one (1) year. The Contractor shall cover all Pre-Manufactured items not covered by OEM manufacturers’ warranties up to the one (1) year requirement.
(SEE SPECIAL PROVISION #14 FOR ADDITIONAL WARRANTY PROVISIONS.)
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6.2 SPARES PARTS:
6.2.1 The Contractor shall maintain an adequate stock of Warranty Spare Parts to replace failed components during the warranty period of one (1) year without cost to WMATA.
6.2.2 Delivery of Warranty Spare Parts to WMATA shall take no longer than 24 hours from notification by WMATA of a failed component.
7.0 Training
7.1 REQUIREMENTS/DELIVERABLES
7.1.1 The Contractor is responsible for providing:
7.1.1.1 Training in the maintenance and operation of the contracted item(s).
7.1.1.2 Training materials sufficient to support continued in-house WMATA training.
7.1.1.3 Updated training and training materials when, in the scope of the Contract, changes or modifications are made that affect the operation or maintenance of the equipment contracted for.
7.1.2 Scope of work: Training for the Flashbutt Prime Mover will require a minimum of two (2) weeks at forty (40) hours per week shifts to be designated by WMATA with no premium rates and two (2) class sessions that consist of forty (40) hours each for maintenance per unit delivered.
7.1.3 All training, as described below, shall take place by the Contractor prior to acceptance of equipment or materials by WMATA. The number of WMATA employees to be trained will be specified on a contract-by-contract basis. However, the minimum number shall be ten (10) for operation training and forty (40) for operations and maintenance of equipment or materials by WMATA. Those persons shall be identified by WMATA.
7.1.3.1 Operations training: Will be tailored specifically to WMATA equipment, and designed to teach the day to day operations of all equipment. The training will be sufficient to bring personnel to a level of operating proficiency such that routine Contractor support is not needed.
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7.1.3.2 Maintenance training: Will be subdivided into two major levels:
a) System Level Maintenance Training covering:
1) Theory of operation of the system and its major components.
2) System configuration.
3) Preventative maintenance, consisting of written procedures and schedules for the periodic maintenance of all equipment.
4) Written and validated inspection procedures and a system - level troubleshooting guide (to the lowest field - replaceable unit).
b) Shop Level Maintenance Training covering:
1) Detailed theory of operation to module, board, and /or device level;
2) Component level troubleshooting and component replacement;
3) Testing and alignment procedures of repaired units.
7.1.4 Deliverables: WMATA’s Department of Technical Training and Document Control (TTDC) requires the following non-copyrighted course materials to be delivered by the Contractor, according to the following specifications:
a) Training Plan containing the data necessary to begin scheduling instruction. The plan must be submitted to TTDC ten (10) days after NTP. The plan must address, for approval, a proposed time line that ensures that all deliverables are approved and training is presented before the equipment is placed into service.
b) A list of courses and their duration.
c) Recommended class size.
d) Student Qualifications / Prerequisites: For the purpose of course development and presentation, Contractors should assume all WMATA students are high school graduates (or equivalent), and that maintenance personnel will possess the ability to use basic hand tools and electronic test equipment.
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e) Instructor Qualifications: A description of instructor qualifications, a resume, Curriculum Vitae or other description of instructional qualifications must be submitted to TTDC as part of the Training Plan. The description should document a thorough knowledge of the subject equipment, an understanding of the adult learning process and demonstrated experience in vocational instruction.
f) Instructor’s Guide containing all the information and direction necessary for the instructor to make an effective presentation. It shall include adequate guidelines to conduct a comprehensive training program. Individual lessons within the course will be organized as separate blocks (or modules) which may be taught as a unit. In some instances, the same standard operating procedures could be used for train operators, transportation supervisors, and central control supervisors. The Instructor Guide should contain, at a minimum:
1) Program Overview;
2) A statement of overall program goals;
3) Lesson plans (a session by session outline containing the following):
A- Student learning objectives, stated in measurable terms;
B- Overview of each lesson;
C- Suggested instructional methods/learning activities;
D- Required equipment and /or resources;
E- Required time for each topic, lesson and course.
g) Evaluation device (s) (written and /or practical tests) designed to measure the extent to which a student has met the learning objectives, with an answer key for each of the tests developed. Tests should use a multiple choice format, and have been validated in a pilot course or by some other means agreed to by TTDC. Whenever possible, a practical hands-on test shall be developed to demonstrate the transference of skills.
h) Student Manual, to include all materials for the student to interact in the learning situation. It shall contain, at a minimum:
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1) Program overview/introduction.
2) Statement of overall program goals.
3) Learning objectives, stated in measurable terms, which specifically describe desired knowledge to be gained.
4) Prose treatment (not outline format) fully developed content presentation, developed in the same modular format as the Instructor’s Guide.
5) Illustrations, charts, graphics, and duplication of each visual aid used during course presentation in order to enhance content presentation and provide a course reference.
6) Problems/questions related to lesson content, as appropriate.
7) Audio-visual aids (handouts, transparencies, slides, films, and computer presentations). Visual aids are required for each circuit or wiring diagram and all activities not demonstrable in the classroom.
8) Supplemental materials: A functional mock-up, or a functional representation, is required of any equipment which requires theoretical discussion. This may be in the form of an animated schematic, a model of the equipment, an actual device, an interactive video training device, or a TTDC - approved substitute. All mock-ups become the property of WMATA.
7.1.5 Number of Copies: The Contractor shall deliver final copies to WMATA as follows:
a) One (1) complete set of training materials that is in a specified electronic format or camera ready copy.
b) Five (5) copies of all student and instructor materials, to be used for archival purpose in the TTDC and Document Center (TDC).
c) A set of complete student materials for each participant enrolled in training classes.
7.1.6 Delivery of Instruction: All instruction will be presented in accordance with approved training materials as specified under deliverables.
a) All operator training will be coordinated through WMATA Track & Structure/System (TSSM) Training.
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b) All maintenance training will be coordinated through Car Maintenance (CMNT/ CTEM).
c) All courses will be attended and monitored by TTDC. Unsatisfactory performance may result in the suspension of the training until such time as the specified discrepancies are corrected.
d) Operator training shall be performed between 7:00 AM to 3:00 PM for daytime training and 10:00 PM to 6:00 AM for night time training.
e) Training shall cover safe operation of all systems.
f) All training shall be performed at the location specified by WMATA TSSM and CMNT.
g) The Trainer must have a minimum of five (5) years of experience on the specified equipment.
h) All operators shall receive a “Certificate of Completion” on the satisfactory completion of the training.
8.0 Delivery Schedule
8.1 DELIVERY AND COMMISSIONING
8.1.1 Equipment shall be constructed, prepared, and loaded so that it will withstand, without damage, handling likely to be encountered during delivery. Valuable and easily pilfered parts such as batteries, tools, and loose small items shall be shipped in such a manner as to resist pilferage.
8.1.2 Delivery of the equipment to WMATA’s Alexandria Yard shall take place 390 days after Notice to Proceed (NTP), at the following address:
WMATA Attn: Lee Hall 3101 Eisenhower Avenue Alexandria, VA 22314
8.1.3 Contractor shall be responsible for unloading the Flashbutt Prime Mover onto the track designated by WMATA.
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8.1.4 Complete operations and maintenance manuals (see Section 3.33) shall be delivered as outlined by the following:
a) 180 days after NTP - two (2) sets of preliminary manuals will be delivered for review. These preliminary manuals shall not be counted against the thirteen (13) operation and maintenance manuals specified in Section 3.33.
b) 390 days after NTP - one (1) complete set of manuals will accompany the Flashbutt Prime Mover delivered as the result of this Contract. Manuals will be packaged in a container permanently affixed in the cab of the machine.
c) The remaining twelve (12) sets of manuals shall be provided in hardcopy and on twelve (12) writeable CD’s in Portable Document Format (PDF) and shall be delivered not later than 390 days after NTP to Lee Hall.
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9.0 Appendices
9.1 STANDARD CLEARANCE PACKAGE
9.1.1 Crane Car Design Loading
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9.1.2 Rapid Transit Vehicle Design Loading
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9.1.3 Design Vehicle Dynamic Outline Diagram – Tangent Track
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9.1.4 WMATA Rapid Transit Car Clearance Envelope
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9.1.5 METRO Rapid Transit Car – Dynamic Outline, Under Floor Car Clearance
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9.2 AAR 1B WIDE FLANGE BACK TO BACK TOLERANCE
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9.3 TOW BAR DRAWING
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9.4 COMPLIANCE MATRIX
The offeror shall submit the Compliance Matrix with the Technical Proposal. The offeror shall check the 'C' Compliant, 'NC' Not Compliant, or 'NA' Not Applicable box for each section or sub-section listed. If a box is checked 'NC' or 'NA', then the offeror must provide comments as to why the functional or technical requirement cannot be met (or is not applicable) and propose alternatives, if any, which are equivalent or better for WMATA's consideration.
Compliant Spec Section Notes Yes No N/A 1.0 Scope 1.1 General Requirements 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 2.0 Applicable Documents 2.1 List of Applicable Documents 2.2 General 2.2.1 2.2.2 2.2.3 3.0 Technical Specifications 3.1 General 3.1.1 3.2 Operating Environment 3.2.1 3.2.2 3.2.3 SPN-0040 FLASHBUTT WELDING PRIME MOVER Rev. 0 - 9/20/2011 Page 63 of 75
Compliant Spec Section Notes Yes No N/A 3.2.4 3.3 Trackwork Parameters 3.1.1 3.4 General Design Requirements 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8 3.4.9 3.4.10 3.4.11 3.4.12 3.4.13 3.4.14 3.4.15 Decking (if required) 3.4.15.1 3.4.15.2 3.4.16 Design Life 3.4.16.1 3.4.16.2 3.4.16.3 3.5 Dimensions 3.5.1 3.5.2 3.6 Noise Exposure 3.6.1 Cab Interior Noise 3.6.1.1 SPN-0040 FLASHBUTT WELDING PRIME MOVER Rev. 0 - 9/20/2011 Page 64 of 75
Compliant Spec Section Notes Yes No N/A 3.6.2 Exterior Noise 3.6.2.1 3.7 Performance Requirements 3.7.1 3.7.2 3.7.3 3.8 Trucks 3.8.1 General 3.8.1.1 3.9 Wheels, Axles, Bearings, Frame, and Suspension 3.9.1 3.9.1.1 3.9.2 3.9.3 3.9.4 3.9.5 3.9.6 3.9.7 3.9.8 3.9.9 3.9.10 3.9.11 3.9.12 3.9.13 3.9.14 3.9.15 3.9.16 3.9.17 3.9.18 3.10 Truck Assembly to Mainframe SPN-0040 FLASHBUTT WELDING PRIME MOVER Rev. 0 - 9/20/2011 Page 65 of 75
Compliant Spec Section Notes Yes No N/A Connection 3.11 Stress and Fatigue Requirements 3.12 Engine and Power Train 3.12.1 3.12.2 3.12.3 3.12.4 3.12.5 3.12.6 3.13 Transmission 3.13.1 3.13.2 3.13.3 3.13.4 3.14 Exhaust System 3.14.1 3.14.2 3.14.3 3.14.4 3.14.5 3.15 Fuel Tank 3.15.1 3.15.2 3.15.3 3.15.4 3.15.5 3.16 Brakes 3.16.1 3.16.2 3.16.3 3.16.4 SPN-0040 FLASHBUTT WELDING PRIME MOVER Rev. 0 - 9/20/2011 Page 66 of 75
Compliant Spec Section Notes Yes No N/A 3.16.5 3.16.6 3.16.7 3.16.8 3.16.9 3.16.10 3.16.11 3.16.12 3.16.13 3.16.14 3.16.15 3.17 Cutout Cocks 3.17.1 3.17.2 3.18 Electrical System 3.18.1 3.18.2 3.18.3 3.18.4 3.18.5 3.18.6 3.18.7 3.18.8 3.18.9 3.18.10 3.18.11 3.18.12 3.18.13 3.18.14 (Electrical Apparatus Cabinets) 3.18.14.1 3.18.14.2 SPN-0040 FLASHBUTT WELDING PRIME MOVER Rev. 0 - 9/20/2011 Page 67 of 75
Compliant Spec Section Notes Yes No N/A 3.18.14.3 3.18.14.4 3.18.14.5 3.18.14.6 3.18.14.7 3.18.14.8 3.18.14.9 3.18.15 3.18.16 3.19 Materials 3.19.1 3.19.2 3.19.3 3.19.4 3.19.5 3.19.6 3.20 Paint 3.20.1 3.20.2 3.20.3 3.20.4 3.20.5 3.20.6 3.20.7 3.21 Clearance Requirements 3.21.1 3.21.2 3.21.3 3.21.4 3.21.5 3.21.6 SPN-0040 FLASHBUTT WELDING PRIME MOVER Rev. 0 - 9/20/2011 Page 68 of 75
Compliant Spec Section Notes Yes No N/A 3.21.7 3.22 Coupler 3.22.1 3.22.1.1 3.22.1.2 3.22.1.3 3.22.1.4 3.22.2 3.23 Operator’s Cab 3.23.1 General 3.23.1.1 3.23.1.2 3.23.1.3 3.23.1.4 3.23.1.5 3.23.1.6 3.23.1.7 3.23.1.8 3.23.1.9 3.23.2 Interior Arrangement 3.23.2.1 3.23.2.2 3.23.3 Visibility Requirements 3.23.3.1 3.23.4 Operator’s Seat 3.23.4.1 3.23.4.2 3.23.4.3 3.23.4.4 3.23.5 Main Console 3.23.5.1 SPN-0040 FLASHBUTT WELDING PRIME MOVER Rev. 0 - 9/20/2011 Page 69 of 75
Compliant Spec Section Notes Yes No N/A 3.23.5.2 3.23.5.3 3.23.5.4 3.23.6 Camera System 3.23.6.1 3.23.6.2 3.23.6.3 3.23.7 Controls 3.23.7.1 3.23.7.2 3.23.7.3 3.23.7.4 3.23.7.5 3.23.7.6 3.23.8 Radio 3.23.8.1 3.23.8.2 3.23.8.3 3.23.9 Cab Windows 3.23.9.1 3.23.9.2 3.23.9.3 3.23.10 Cab Windshields 3.23.10.1 3.23.10.2 3.23.10.3 3.23.11 Sun Visor 3.23.11.1 3.24 Lighting 3.24.1 Remote Operating Cab Light 3.24.1.1 SPN-0040 FLASHBUTT WELDING PRIME MOVER Rev. 0 - 9/20/2011 Page 70 of 75
Compliant Spec Section Notes Yes No N/A 3.24.2 Exterior Lighting 3.24.2.1 3.24.2.2 3.24.3 Work Lights 3.24.3.1 3.25 Pneumatic System Requirements 3.25.1 3.25.2 3.25.3 3.25.4 3.25.4.1 3.25.4.2 3.25.4.3 3.25.4.4 3.25.4.5 3.26 Hydraulic System Requirements 3.26.1 3.26.2 3.26.3 3.26.4 3.26.5 3.26.6 3.26.7 Fluid Filtration 3.26.7.1 3.26.7.2 3.26.7.3 3.26.8 Fluid Conductors 3.26.8.1 3.26.8.2 3.26.8.3 3.26.8.4 SPN-0040 FLASHBUTT WELDING PRIME MOVER Rev. 0 - 9/20/2011 Page 71 of 75
Compliant Spec Section Notes Yes No N/A 3.26.8.5 3.26.8.6 3.26.8.7 3.26.8.8 3.26.8.9 3.26.8.10 3.26.8.11 3.26.8.12 3.27 Crane 3.27.1 3.27.2 3.28 Outriggers 3.28.1 3.29 Flashbutt Welding Genset 3.29.1 3.30 Prime Mover Weld Head 3.30.1 3.30.2 3.31 Remote Operating Station 3.31.1 3.31.2 3.31.3 3.32 Travel Speed 3.32.1 3.33 Manuals and Documentation 3.33.1 Scope 3.33.1.1 3.33.1.2 3.33.1.3 3.33.1.4 3.33.2 General Requirements SPN-0040 FLASHBUTT WELDING PRIME MOVER Rev. 0 - 9/20/2011 Page 72 of 75
Compliant Spec Section Notes Yes No N/A 3.33.2.1 3.33.2.2 3.33.2.3 3.33.3 3.34 Maintenance Spares 3.34.1 3.34.2 3.34.3 3.34.4 4.0 Inspection and Acceptance Testing 4.1 Initial Inspection 4.1.1 4.1.2 4.2 Acceptance Testing 4.2.1 4.2.2 4.2.3 4.2.4 5.0 Safety Certification 5.1.1 5.1.2 6.0 Warranty 6.1 Equipment and Components 6.1.1 6.1.2 6.2 Spare Parts 6.2.1 6.2.2 7.0 Training 7.1 Requirements / Deliverables 7.1.1 SPN-0040 FLASHBUTT WELDING PRIME MOVER Rev. 0 - 9/20/2011 Page 73 of 75
Compliant Spec Section Notes Yes No N/A 7.1.1.1 7.1.1.2 7.1.1.3 7.1.2 7.1.3 7.1.3.1 7.1.3.2 7.1.4 7.1.5 7.1.6 8.0 Delivery Schedule 8.1 Delivery and Commissioning 8.1.1 8.1.2 8.1.3 8.1.4
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