7-09 - Exhibit H - SOW.pdf

Exhibit H - Statement of Work

Wheel Press Supply and Installation

Document Control # Workflow ID Revision #

XXXX-XXXX 3065458 0

Effective Date:

Name Title

Originator: James Vijjeswarapu Project Manager, Rail Systems & Facilities Engineering

Approver: Evelio Hernandez AVP, Rail Systems & Facilities Engineering

Revision # Description Initials Release # Date

0 Initial Release JV

DART - Engineering

XXXX-

XXXX

LRV Axle Journal Bearings Removal and Installation

Rev# 0

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1.0 General Information

This Statement of Work (SOW) describes the requirements for the new 600-Ton Double- Ended (Dual-Cylinder) Mounting/Demounting Wheel Press Machine (WPM, aka Wheel Press), that will be used for truck assembly maintenance operations for Dallas Area Rapid Transit (DART) Kinkisharyo Light Rail Vehicles (LRVs).

A. Introduction DART has a fleet of 163 Kinkisharyo LRVs that operate throughout the DART Light Rail System. DART does not have the ability to mount and demount wheelset components for maintenance operations. To improve quality control and turnaround times, DART wishes to bring the mounting/demounting operation in-house.

B. Background.

The 600-Ton Doubled-Ended Mounting/Demounting Wheel Press will be used to mount and demount wheel hubs, journal bearings, ground rings, gearboxes, brake hubs, and other axle components in support of LRV maintenance and overhaul requirements.

C. Scope The SOW identifies the requirements to provide a new computer-controlled 600- Ton Wheel Press with all components and tooling, as indicated, specifically designed to mount components onto axles to create wheelset assemblies, and to demount components from wheelset assemblies. The Contractor shall provide the software, components, and tooling required to mount and demount DARTLRV fleet wheelset assemblies. The Contractor shall train DART employees in the operation and maintenance of the Wheel Press.

1. Unless noted otherwise, references to “Contractor” within this SOW shall be understood as referring to the supplier of the Wheel Press equipment. The term “provide,” as utilized within this SOW, shall be understood to mean “design, manufacture, deliver, install, and test.”

2. The Wheel Press shall be a double-ended (dual-cylinder), horizontal-acting type, having a minimum 600-ton pressing capacity, and capable of both mounting and demounting operations.

3. The Wheel Press shall be equipped with a hydraulic assist system for wheel and gearbox mount/demount.

4. The Wheel Press shall be equipped with a pressure spiking control for wheel and bearing seating, and, if required, for gearbox seating.

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5. The Wheel Press shall be equipped with an axle positioning ram or equivalent device.

6. The Contractor shall provide all mount/demount fixtures and adapters necessary for DART’s LRV wheelsets.

7. The Wheel Press shall be equipped with a wheelset assembly support table.

8. The Wheel Press and fixtures, adapters and devices shall be specifically designed for a production rate of at least five (5) DART wheelset mount/demount operations in a seven (7) hour work shift by one operator, without assistance.

9. The Wheel Press components and controls shall be 100% non-proprietary.

10. The Wheel Press shall be designed, manufactured, and installed to provide a useful service life of at least 40 years. “Useful service life” is defined as the period during which the equipment is reliable, meaning that it performs its intended function without experiencing serious failures or requiring excessive maintenance, provided that the equipment is maintained in accordance with equipment supplier’s recommendations, and kept in operating conditions as defined herein.

“Serious failures” are defined as failures that cannot be repaired within three business days, provided that repair parts are available. “Excessive maintenance” is defined as maintenance that exceeds what is recommended in the operations and maintenance manual for the equipment.

11. Upon Contractor’s request, DART will allow the Contractor to conduct a site visit to view the installation area and working conditions.

D. Reference Standards Work shall conform to Federal and State governing rules, and regulations and ordinances including DART’s policies and procedures.

ODC Number Description

ELL-1209 LRV Illustrated Parts Catalog

ELL-1208 LRV Heavy Repair Maintenance Manual

ELL-1207 LRV Running Maintenance and Servicing Manual

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ODC Number Description

AAR Association of American Railroads, Mechanical Division, Wheel and Axle Manual, Section G, Part II.

ASTM American Society for Testing and Materials (ASTM), A551, Standard Specification for Steel Tires

AWS

American Welding Society D1.1, Structural Welding Code, Steel.

Texas Code of Regulations (TCR) Title 8 Industrial Relations, Division of Industrial Safety, including but not necessarily limited to:

a. Chapter 3.2 Texas Occupational Safety & Health Regulations (TX/OSHA);

b. Chapter 4 Division of Industrial Safety;

c. Subchapter 4 Construction Safety Orders;

d. Subchapter 5 Electrical Safety Orders.

JIC

Joint Industrial Council;

a. P-1-1975, Pneumatic Standards for Industrial

Equipment;

b. H-1-1975, Hydraulic Standards for Industrial

Equipment.

NFPA NFPA National Fire Protection Association, NFPA 70 (aka NEC - National Electric Code)

UBC Uniform Building Code Seismic Zone 4 as modified in Article 2.02.

CFR 29 CFR 1910.212 OSHA: Machinery and Machine Guarding.

IEEE Institute of Electrical and Electronics Engineers DART Design Criteria Manual, Volume 2

E. Definitions / Abbreviations

Abbreviations Definitions

AAR Association of American Railroads

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Abbreviations Definitions

ABMA American Bearing Manufacturers Association.

AGMA American Gear Manufacturers Association of America.

AISC American Institute of Steel Construction.

ANSI American National Standards Institute.

ASME American Society of Mechanical Engineers.

ASSY Assembly

ASTM American Society for Testing and Materials (ASTM), A551, Standard Specification for Steel Tires

AWS American Welding Society

CFR Code of Federal Regulations

DART Dallas Area Rapid Transit

HMI Human-Machine Interface

IEEE Institute of Electrical and Electronics Engineers;

LRV Light Rail Vehicle

MMS Materials Management Services

NEC National Electrical code

NEMA National Electrical Manufacturers Association

NFPA National Fire Protection Association

ODC Operations Document Control

OEM Original Equipment Manufacturer

OSHA Occupational Safety and Health Administration

PN Part Number

UBC Uniform Building Code

UL Underwriters Laboratory

F. Environment

1. The Wheel Press shall be designed to operate reliably in DART’s environment.

Contractors are to take note of the Dallas area environmental standards as they apply to equipment operation and maintenance:

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Property Description of Condition Values

Temperature Minimum ambient air, external to equipment

-7°C (20°F)

Maximum ambient air, external to equipment

46°C (115°F)

Humidity Minimum humidity 5% Maximum humidity 100%

Air Contamination Particulate 0.248 mg/m3 maximum

0.142 mg/m3 average

Ozone 0.35 ppm maximum NO2 0.44 ppm maximum SO2 0.037 ppm maximum CO 29 ppm maximum Chloride content 13.9 mg/m3 Moisture acidity pH 4.41

G. Contractor’s Responsibility

1. Furnish products in accordance with this SOW.

2. Transmit submittals and deliverables as required by this SOW.

3. Provide all Spare Parts and Special Tools and shall provide Field Service

Support.

4. Verify all dimensions, weights, and characteristics of the wheelset assembly and its components, and shall notify DART of any discrepancy before the fabrication and delivery of the Wheel Press.

5. Verify all dimensions and characteristics of the site, and shall notify DART of any constraint, potential installation issues, or potential additional work items not specified within this SOW.

6. Be responsible for the coordination and proper installation of the Wheel Press, electrical work, and the integration within the existing building.

7. Train DART personnel in the operation and maintenance of the equipment.

H. Contractor’s Qualifications

1. The Contractor shall meet the following requirements:

a) In the event that any spare part is to be discontinued, Contractor shall provide a minimum of one (1) year of advance notice to DART and supply the design drawings for the part so it can be manufactured by

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others at DART’s discretion.

b) The Contractor must be currently engaged in the business of providing hydraulic wheel presses for mounting and demounting of railroad or rail transit wheelsets, and shall demonstrate at least ten (10) years’ experience designing, manufacturing, installing, and providing product support for specialized equipment of this type.

c) Provide a list of at least five (5) wheel presses for rail transit or railroad wheelsets, supplied by the Contractor, that are currently in use. At least one location must be a double-ended wheel press of at least 400-ton capacity. The list shall indicate the location, capacity, year installed, and name and telephone number of a contact for the current operator.

d) Provide commercial literature or drawings of this equipment for illustration. This documentation shall be included by the Contractor in PDF format with the submitted bid form.

e) Employ a quality assurance program meeting the requirements of this SOW and that satisfies all safety-related quality assurance requirements imposed by applicable government regulatory agencies. The Contractor shall provide the quality assurance program to DART for review and approval.

f) The contractor requirements submitted without satisfactory evidence of meeting these requirements may be rejected by DART.

I. Technical Data I.1 General

1. Wheel Press shall be installed flush with the existing flat concrete slab foundation. Provide anchors and fasteners, washers, straps, steel shims (if required for leveling the equipment), and accessories required for complete and operable installation.

a) Fasteners shall be galvanized steel or other approved non-corrodible metal.

b) Anchor bolts shall be stainless steel. Submit current ICC/ESR Report for all anchor bolts utilized.

c) Subject to approval by DART, grout may be utilized between the Wheel

Press base plates and the floor slab. Grout shall be Five Star Self- Leveling Grout or approved equal; install with chamfered edges around the baseplate. Grout shall not be used for anchoring.

2. Pneumatic and Hydraulic installations and equipment shall be in accordance with JIC P-1-1975.

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3. All Hydraulic valves, relief valves and directional valves shall be of a common design and manufacture to facilitate interchangeability.

4. The Wheel Press shall have necessary guards to protect the operator and others from injury in accordance with state, Federal and local regulations, including but not limited to TEX/OSHA and industrial standards.

5. Power available: 480VAC 3 phase; new breaker and wiring required. New breaker shall either be of equal size to fit into existing panel or new panel and breaker shall be provided. The Contractor shall provide step-down transformer if required with line side circuit protection, 120VAC feed with circuit protection for control systems and surge protection for computer and controls.

6. Shop compressed air available: 125 psig; The Contractor shall provide filter, regulator and, if deemed necessary, separator for diester oil.

7. A corrosion-resistant identification plate clearly marked and stamped with the Contractor’s name and address, model number, serial number, date of manufacture, and all pertinent utility or operating data (or ratings) shall be attached in a prominent location to each major piece of equipment.

I.2 Wheelset Physical Characteristics

1. Fixtures, tools, and adapters shall be designed to accommodate the wheelsets from DART’s current fleet of Kinkisharyo LRVs. Key wheelset data is listed below. Also refer to the drawings provided in Appendices A and B. Contractor to request all necessary information.

a. Wheel diameter: 28" new, maximum; 26" fully worn.

b. Track gauge: Standard Gauge (56.5").

c. Back-to-Back dimension: 53.3125" (+0.0625”/ -0.0625”).

d. Journal Roller Bearing: TIMKEN “BEARING APPLICATION

CLASS E (6 X 11).

2. Note that the wheels for the current DART LRVs are resilient type.

3. To support future fleet procurements by DART, the Wheel Press shall be designed to mount and demount other LRV wheelsets, including for LRVs currently being supplied to U.S. transit agencies, with new wheel diameters up to 30 inches. This capability shall be achieved with the addition of different fixtures, tools, and adapters as necessary, as well as software upgrades to program the new wheelset configuration(s). The additional tooling and software would be a future purchase, and are not part of the scope in this SOW.

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1.3 Wheelset Assembly Drawings and Press Tonnage

1. Drawings of the Wheelset assembly and its components are provided as a reference in Appendix A: Drawings. The Contractor shall be responsible for requesting from DART the latest versions of these drawings.

2. The press tonnage, the bore and seat diameters, and interference fit for the axle components are provided as a reference in Appendix B: Pressing Tonnage, Diameter and Interference Fit. The Contractor shall be responsible for requesting from DART the latest versions of these drawings.

J. Wheel Press The Wheel Press shall be specifically designed, and fully equipped with fixtures, adaptors, tools, and calibration tools, for DART’s wheelsets, while not precluding the ability accommodate other LRV wheelsets in the future.

Contractor shall also include fixtures, adaptors, tools, and calibration tools to mount and demount DART’s LRV fleet wheelset assemblies.

The Wheel Press shall record mounting force (tonnage) applied versus distance and plot data on a chart in accordance with AAR requirements.

The Wheel Press shall consist of:

1. Horizontal acting hydraulic ram mounted integrally in vertical cylinder beam.

2. Horizontal tension bars connected to the vertical cylinder beam and opposed vertical outer support.

3. Resistance beam (abutment) that is supported by and attached, by means of removable pins, to the tension bars.

4. Resistance beam drive(s).

5. Hydraulic Power Unit.

6. Fixtures and adaptors necessary to enable all processes to be performed as specified herein.

7. Axle positioning device located at outer support end.

The Wheel Press and the Hydraulic Power Unit and anchor bolts shall be designed for seismic forces including but not limited to horizontal component of

0.7 times total weight of the machine or component acting and the full weight of the machine acting upward through its respective center of gravity.

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J.1 Cylinder Beams and Ram

1. The Cylinder Beams shall be made of high strength ductile iron or steel.

2. The Contractor shall provide a hydraulic ram that is a service-proven design that incorporates current industry best practices. The hydraulic ram cylinder shall provide a leak free operation under repeated high force and shock loading conditions. The hydraulic ram cylinder shall be easily repaired or replaced without removing the ram from the Wheel Press.

3. The ram shall be extended and retracted with either jackrams or double acting cylinders, and shall be prevented from rotating.

4. The ram and cylinder shall be of sufficient length so that the center of gravity of the ram is within the throat bushing throughout the entire stroke.

5. The hydraulic ram shall be provided with an automatic maximum stroke limiting device. A renewable steel cap shall protect the ram face. The ram shall advance rapidly to the press surface.

J.2 Resistance Beam

1. The resistance beam shall be of high strength ductile iron or steel or fabricated steel designed and reinforced to resist induced stress and deflection caused by the hydraulic ram.

2. The resistance beam shall be supported by anti-friction bearing mounted rollers that shall bear on lower tension bars or separate rails installed on the Wheel Press frame or foundation.

3. The resistance beam shall be easily moved from one position to another position by a motorized system that shall reposition the beam automatically to operator preset position. Locking pins shall be automatically positioned but shall provide a manual override feature whereby the pins can be inserted or removed manually.

4. A maximum of two (2) open "C" configuration or split configuration press fixtures with different sized openings shall be provided, swivel or slide mounted to the resistance beam. The resistance beam press fixtures shall be of high strength steel with machined pocket to accept insertion of wheelset component adaptors. The press fixtures shall be designed so that they can be changed by the Wheel Press operator with minimal exertion, 40 pounds force maximum, required. If the press fixtures have to be fastened in place, captive fixture bolts or clamps shall be provided to minimize set-up time.

5. Adaptors shall be provided to mount and demount wheelset components including, but not limited to: bearings, wheels, and gear housing. The

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quantity of adapters shall be the minimum required plus one spare set to effectively demount and mount all components and shall be split into two-piece elements when axle need not be removed from press to load or unload components. Adapters shall be of hardened tool steel with machined faces and designed to fit within press fixture pockets. Bolted-on axle adapters or extensions are not allowed. If bolting to wheelset components is required, the bolts shall be captive with the adaptor to minimize operator setup time.

J.3 Tension Bars

1. The Cylinder Beam, Resistance Beam and Outer Support shall be tied together by heavy, rolled steel Tension Bars.

2. The Tension Bars shall be proportioned to limit elastic elongation to

.006" per foot when subjected to maximum tonnage.

3. For resistance beam positioning, slots or round pin holes shall be provided in the Tension Bars at locations appropriate to accommodate the range of work on the wheelsets to be handled. The resistance beam and cylinder shall be joined by forged steel keys or high carbon alloy round steel pins placed in the slots or round holes in the Tension Bars.

The keys shall be designed to provide maximum cross-section at the slot location for greatest strength.

4. The Tension Bars shall be rigidly fastened to the two ends of the Wheel Press. There shall be a minimum of two Tension Bars provided and the bottom bar or bars may be a part of the Wheel Press frame.

J.4 Wheelset Support Table

1. A Wheelset Support Table shall be provided. The table shall be hydraulic powered and shall be designed to support the complete wheelset, partially assembled wheelset, and applicable components (e.g., gearbox) during all loading, unloading, mounting and demounting operations.

2. The Wheelset Support Table shall be designed to do the following:

a. Allow safe operation and assembly/disassembly of wheelsets.

b. Be capable of being moved longitudinally (left/right), transverse to the frame (in/out), and up/down to position a wheelset, partially-assembled wheelset, or component in all necessary positions.

c. Move outward through the Wheel Press in transverse direction beyond Wheel Press frame (i.e., from front of press (control side) to non-control side) to allow repositioning of Resistance Beam for mount and demount operations.

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3. The Wheelset Support Table shall be equipped with axle support arms, cradle, and clamp.

4. The Wheelset Support Table shall be designed and suitably ballasted to prevent overturning while:

a. Supporting a partially-mounted wheelset; and

b. During transverse movement of a partially-mounted wheelset.

5. The Wheelset Support Table shall be equipped with a gearbox support device designed to hold the tail end of the gearbox during all mount and demount operations with axle in either gearbox end or non-gearbox end position.

J.5 Hydraulic Power Unit

1. The Hydraulic Power Unit shall be self-contained so that all component parts are mounted on a single base and shall have a properly sized fluid reservoir.

2. The Hydraulic Power Unit shall provide self-bleeding capabilities to the Cylinder(s), and shall include appropriate interconnecting piping.

3. The Hydraulic Power Unit shall be manufactured to JIC and NFPA standards.

4. The Hydraulic Power Unit shall include a motor; a high-volume, low-pressure vane pump; a piston pump for low volume, high pressure;

system pressure and flow controls; system filtration; indicating gauges, and a JIC reservoir. The capacity of the reservoir shall be sufficient to prevent excessive component temperatures and avoid early deterioration of sealing.

5. During operation, the Hydraulic Power Unit, together with rest of the Wheel Press, shall not exceed noise limitations stipulated within this

SOW.

6. The Wheel Press controller shall monitor the press mode and automatically determine the required pressure. The press controller shall monitor and adjust the hydraulic system (pumps, motors, valves, pressure, etc.) to ensure that the required pressure is provided.

7. The controls shall be arranged to provide a rapid approach speed that automatically changes to an accurately controlled slower pressing speed when reaching a preset tonnage figure during normal pressing operation.

8. The pump shall be normally unloaded to conserve power.

9. An across-the-line type combination starter with fusible disconnect and

"On", "Off" push button station shall be located at the pump stand.

10. There shall be an automatic safety stop at the preset maximum allowable

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stroke to protect the Wheel Press from damage due to over stroking of the main ram.

11. The return line filtration system with a filter and automatic clog indicator shall be provided to eliminate contaminates in the fluid.

12. Oil level and temperature shall be automatically monitored and displayed on the control panel. In addition, a visual oil and temperature gauge shall be provided.

13. In the event of low level, high temperature, or a filter clog, a red light shall be illuminated on the control panel indicating a hydraulic problem.

14. The Hydraulic Unit Support stand shall be designed, braced and anchored to withstand seismic forces.

15. All key hydraulic components, including but not limited to, pump, reservoir, valves, and actuators shall be identified with a permanent label or hanging stamped metal tag, with the component name and an identification number that matches the part number on the hydraulic diagrams. All piping shall have flow direction labels as applicable.

J.6 High Pressure Injection System

1. A High-Pressure Injection System (Hydraulic Assist) shall be provided for the removal of wheels and gearbox units.

2. The system shall be designed to deliver lubricant at variable flows and pressures, delivering up to 6 cubic inches of lubricant at pressures up to 30,000 psi, and shall be fully equipped with all required special tooling and fittings. The unit shall be self-contained.

a. The system’s layout and location shall be reviewed and approved by

DART.

b. An oil containment system shall be provided to catch and hold the oil as components are pressed off.

c. The Wheel Press shall have an automatic hydraulic release function which shall automatically provide hydraulic fluid/pressure for ease of wheel demount and automatically shut down after a preset distance displacement of the wheel.

3. The system shall be able to connect to the two fittings located on the LRV gearbox. The operation of the injection of lubricant is dictated by distance, in accordance with the OEM manuals.

J.7 Wheel Press Lubrication

1. The Wheel Press shall be equipped with an automatic lubrication system, and shall alert the operator when servicing is required by means of a

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flashing yellow light mounted on the control panel with appropriately-labeled reset button.. Provide fittings to facilitate lubrication of moving parts, bearings, and ways, except where self-lubricating, low-friction materials, or sealed bearings are used.

J.8 Control Stations

1. Provide two control stations for all mounting and demounting operations-

- one fixed and one portable unit. The portable control station unit shall be equipped with a spring-loaded cable reel with cable of sufficient length, or pendant mounted on a davit arm, to permit the operator to operate the machine in an ergonomically correct position and allow the operator to safely view all Wheel Press operations while operating the Wheel Press controls. The portable control unit shall be designed to be hung at or be rotated towards (if arm-mounted), the cylinder beam when not in use and to replicate all control functions of the fixed unit. The control stations shall be identical and provide the same full functionality.

Both control stations shall be interlocked so that only one can be in use at a time, to avoid the possibility of conflicting commands.

2. No controls shall be permitted to be mounted directly on the resistance beam.

3. The control stations shall have a red mushroom type ‘Emergency Stop” pushbutton with pull-out reset “power on”

4. The control stations shall be designed to provide complete isolation from damaging vibration that may occur during Wheel Press operation.

5. The fixed control stations shall have a display suitable for DART’s shop environment. The display shall indicate visually (in graphic/pictorial representation) the status of the Wheel Press configuration for mounting or demounting (e.g., bearings, wheels), and diagnostic capabilities. Final design shall be approved by DART.

6. Press ram motions shall be controlled by pushbuttons and selector switches. The ram motions shall be FORWARD and REVERSE. Under FORWARD motion control the ram shall move rapidly to the work.

When contact is made with the work, resistance will increase, and the ram shall automatically slow to pressing speed. The control shall feature a quick-acting pressure release that causes the ram to be stopped instantaneously by releasing the FORWARD control button. The press ram positioning system shall automatically stop the ram when the component reaches its location on the axle. Under REVERSE control, the ram shall rapidly move the work towards the starting point.

7. Electrical control panels shall include necessary "deadman" type pushbutton switches, indicating lights, and remote mounted ram movement momentary alarm klaxon, and strobe light. The momentary

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ram movement alarm shall sound when ram movement begins and shall remain "ON" for an adjustable period of 10 to 30 seconds and then automatically be silenced until the start of the next ram motion. The flashing strobe light shall be amber in color and shall remain "ON" whenever the hydraulic ram is actuated. The alarm shall sound whenever the ram is started in motion (forward or reverse travel) and the strobe shall flash whenever the ram is set in motion and continue flashing until the ram stops.

8. The ram travel shall be controlled by means of spring return momentary contact ("deadman" type) push buttons, so that the operator can stop the ram and hold its position at any position of the ram stroke by releasing one or the other push button.

9. A "bearing mount" control switch and program shall be provided. When the Wheel Press control is set for "bearing mount", either locally or remote, the press tonnage shall be accurately controlled to a preset, adjustable limit so that when the bearing contacts the shoulder of the larger diameter wheel seat and the pressure rises rapidly, the ram advance shall be immediately terminated.

10. The Wheel Press shall be equipped with a spiking control bearing and wheel mounting which, when turned "on" by the operator during any mount operation, shall monitor electronically, and control, the component fit forces. When the start of a spike (a sudden rise in pressing force) is detected, the spike shall be analyzed and when the spike reaches an adjustable preset limit, the ram advance shall be immediately terminated.

11. A control station for the Axle Positioning Device shall be provided, mounted near the Device and designed to control all functions independently. In addition, controls shall be provided to cause the Axle Positioning Device to move horizontally at the same rate as the main hydraulic ram so that the wheelset is held by the two while being repositioned. The accomplishment of this horizontal wheelset motion shall be automatic when the control switch for this purpose is engaged.

12. An automatic ram positioning control system for gearbox mounting shall be provided to immediately stop ram advance when the gearbox reaches pre-set gauge distance as indicated on the Reference Drawings. The gearbox gauged distance shall be accurately maintained within tolerances indicated, and the accuracy shall be intrinsic in the design of the ram positioning control system. The design of the device shall be submitted to DART for review and approval. The gauge distance shall be measured during pre- shipment and on-site tests. The automatic ram positioning control system shall be complete with selector switch identified "gearbox", and shall be disengaged until operator actuates switch, and shall automatically shut system off and reset switch when ram advance for gearbox mounting has come to the controlled stop. Alternatively, the Contractor may position the gearbox on the gauge for mounting position

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by using a spike tooling and spike on the end of the axle tooling.

J.9 Pressure Gauges and Recording Devices

1. The Wheel Press shall be equipped with a dual reading, 6-inch minimum diameter pressure gauge calibrated in pounds per square inch and tons exerted by the ram. The gauge shall be mounted on the cylinder beam in clear view of the operator. A red mark shall be provided to indicate the maximum rated tonnage of the ram. A spare Pressure Gauge shall be provided.

2. The Wheel Press shall be equipped with a wheel-mounted recording gauge or computerized graph generator that shall provide an AAR approved pressure versus distance record of wheel and component fits.

Means shall be provided to isolate the system when not required. The gauge shall be activated only in the mounting mode.

3. Real time operation of the Wheel Press shall be capable of being monitored via the DART IT network. All Wheel Press storage drives shall be viewed using “Chart Manager” or equal as approved by DART.

J.10 Computer System

1. The Computer System shall be configured as follows:

a) Monitor and control Wheel Press operations;

b) The operator interface via a touch screen shall provide visual real-time plotted graph of the force (tonnage) versus distance, shown on a real-time plot of the recorded data;

c) Print as a minimum by means of inkjet or LaserJet printer a graph chart of mounting forces versus distance for each wheelset with serial number, date, time recorded and all other wheelset pertinent data;

d) Computer Operating System used shall be Window’s compliant and shall be minimum MS Windows 11 Pro for Workstations. If more recent versions of Windows are available, these shall be presented to DART for consideration and approval. Software shall be delivered to DART to allow hard copy printout of force graphs at any DART computer printout workstation.

2. The computer shall meet the following requirements:

a) Current state of the art technology, which for the processor is defined as “high end” current generation desktop CPU and compatible chip set from Intel or AMD. CPU shall have hybrid core architecture and minimum 4.0 GHz base processor speed.

Chip set shall feature PCIe 5.0 for graphics and storage, DDR5

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memory support, and current generation connectivity features (WiFi 7 and a minimum of five USB-A ports and five USB-C ports). Submit proposed hardware specifications at time of bid.

b) Hard drive of adequate capacity to store information on 20,000 wheelsets.

c) Provide online 2-hour battery backup (i.e., UPS), power filter, and surge protection.

d) The Wheel Press shall have the capability to connect through the internet for remote support by using secure gateways and VPNs (internet connection to be provided by others).

e) Computer system shall be designed for a rail maintenance shop environment, and equipped with sufficient cooling fan capacity.

J.11 Data Storage System

1. The data storage system shall record the following:

a. Date and time of all components press mount; Operator identification code;

b. Mount side of axle (left/right);

c. All pertinent process parameters, including, but not limited to, maximum force (tonnage); pressure, distance, time, and temperature;

d. Wheelset Assembly serial number; Axle serial number;

e. Wheel serial number, manufacturer, and size and axle end;

f. Bearing serial number, manufacturer, and axle end;

g. Gearbox serial number;

h. Brake Disc serial number, manufacturer and side.

J.12 Wheel Press Alarm/Fault Testing

1. Provide a current generation PLC Controller that is optimal for Wheel

Press control and monitoring functions. Submit proposed hardware specifications at time of bid.

2. Provide software for recording Input/Output Alarms and Troubleshooting Input/Outputs of the Wheel Press Control (utilizing the computer used for the Wheel Press Recording System of this SOW). The Software shall:

a. Automatically record and display all alarms and errors;

b. Allow the operator to test and record manual intervention from

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sensors and switches;

c. Permit the operator to determine if the I/O is bad or if the sensor or switch is bad;

d. Provide MMI/PLC Ladder Logic Fault/Alarm I/O programming for

Wheel Press;

e. Provide Spare Parts List for the PLC hardware.

3. Provide a fully documented, final version of the control software in electronic format. A hardcopy of the control software shall also be included in the Operation & Maintenance Manual.

J.13 Hardware and Accessories

1. Wheel Press Recorder Stand:

a. The stand shall be of type NEMA 12 enclosure or equal and be freestanding in order to ensure complete isolation from damaging vibration that may occur during the mounting/demounting process;

b. The stand shall provide interconnecting wire to the pressure and displacement transducers.

2. Pressure Transducer:

a. Pressure Transducer shall be provided for the main ram hydraulic pressure line;

b. The pressure transducers shall be located as close as possible to the pressure port of the main ram;

c. The pressure transducers shall be properly calibrated to convert hydraulic pressure to electrical current scaled in the computer to force or tonnage;

d. The Contractor shall provide procedures for the re-calibration of the pressure transducers.

3. Lighting:

a. High-intensity LED work area lighting mounted above the yoke opening and swivel mounted for positioning.

b. LED light level shall be minimum 50 foot-candles and minimum color temperature 6000K.

4. Camera:

a. A CCTV camera, as approved by DART, shall be provided and mounted on the resistance beam and connected to the computer control monitor screen with an icon function to toggle the CCTV on-off. The camera shall allow the operator to stay at the control stand

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and monitor the wheelset installation/alignment rather than moving around or needing assistance from other to guide the installation.

The camera shall be black and white, stationary (not TPZ), with minimum 2K resolution, hardwired for power and video data. Video data to be stored for up to 72 hours. It shall turn on whenever the Wheel Press is turned on.

J.14 Electrical

1. All Electrical equipment shall be in accordance with the National Electric

Code (NFPA 70) and appropriate NEMA and ANSI standards.

2. All motors shall be totally enclosed, heavy duty type, equipped with sealed ball bearing and thermal overload protection. Enclosures shall be steel or cast iron only. Aluminum end bells are permitted.

3. Motors shall be high efficiency, each bearing the UL label and constructed to a minimum standard of NEMA and IEEE.

4. Installation instructions shall have details regarding correct rotation and alignment of motor shafts. Motors shall include identification of the correct direction of rotation.

5. Circuit overload protection shall be provided for motors to permit operation within their rating under all design load conditions.

6. Motor insulation shall be Class "F": Temperature rating of motors shall not exceed that permitted by Class B insulation.

7. Each individual motor circuit shall be provided with branch circuit over current protection in three phases via circuit breakers.

8. Motor starters shall be provided with overload elements of the bimetal thermal type on each phase.

9. Each motor shall be connected to the emergency safety stop control circuit.

10. The motor control cabinet shall be constructed to NEMA 12 standards.

The cabinet shall include all overload breakers, starters, circuit breakers, main and individual motor disconnect switches and control transformers.

Control panels shall be serviced by 110V or less. Controls shall be well-illuminated, visible from 10 feet away from location, and located close to the operator’s normal working position, readily accessible in an emergency, and not obstructing the operator’s movements.

11. The electrical control panels shall be totally wired by the Contractor up to and including the main circuit breaker.

12. Wiring, including conductors and conduit, shall be furnished and installed.

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13. Provide interlock systems which will ensure safe operation of the Wheel Press. The system shall inhibit Wheel Press operation in programmed instances of possible collision of components and control the operating pressure of the Hydraulic Power Unit based upon operator settings and the current demands of the press.

14. The Wheel Press shall be provided with a single master disconnect switch from which power shall be distributed to all press components requiring power, providing the ability to terminate power to all Wheel Press components from a single location. The Master disconnect switch shall be fused with current limiting fuses or circuit breaker.

15. Permanently label all equipment items including but not limited to switches, starters, controllers, and start-stop stations with engraved PVC labels with minimum 0.5-inch-high lettering to identify corresponding equipment items.

16. Wiring shall be identified by a wire tag with a number corresponding to the wiring diagram.

17. The Contractor shall provide a disconnect switch for each equipment item requiring electric power. Disconnect switch shall meet the requirements of the respective equipment item manufacturer.

18. The Contractor shall permanently label each disconnect switch to identify corresponding equipment item.

19. Equipment Grounding: The Wheel Press shall be electrically connected to the common grounding grid of the shop building, in accordance with DART Design Criteria Manual, Volume 2, Chapter 8.

J.15 Hydraulic Piping, Tubing and Fittings

1. Piping shall be selected according to ASTM A53.

2. Hydraulic pipe fittings and unions shall be selected according to ASTM

A181 or A234.

3. Hydraulic and force feed lubricant tubing shall be 18.8 stainless steel, fully annealed, seamless, or electric resistant welded suitable for bending and flaring. The tubing wall thickness shall be determined based on Joint Industry Conference for Hydraulic Equipment (J.I.C.) Standards for H-1- 1975 Paragraph H4.1.62 "Class B" (considerable hydraulic shock and mechanical strain) service at working pressure indicated with safety factor of 6 applied.

4. Hydraulic and force feed lubricant fittings shall be selected according to ASTM A234. DART approved flareless type ASTM A234 forged stainless steel alloy fittings may be used if Contractor can demonstrate that joints will not leak at 5000 psig test pressure held for two (2) hours.

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If flareless type fittings are used, the ferrule shall be specifically designed for heavy stainless steel tube wall and shall bite into tube wall and wedge against tube and fitting body to form a positive seal.

J.16 Fasteners

1. Anchor Bolts, Nuts and Washers

a. Bolts, studs, threaded rods, nuts, and washers shall each conform to ASTM A307, Grade A and ASTM A449, F1554, Grade 36, A563, and F436, respectively as applicable. Bolts and studs, nuts, and washers shall be hot-dip galvanized in accordance with ASTM A153.

Contractor shall select an appropriate post installed adhesive or undercut anchor for the installation of the new WPM. Substantiating calculations shall be submitted in compliance with the selected anchor’s Evaluation Service Report. The calculations shall be signed and sealed by a qualified Texas licensed design professional.

2. Fasteners and Accessories:

a. Provide anchors and fasteners, washers, straps, steel shims, if required for leveling, and accessories required for a complete and finished installation. Fasteners shall be galvanized steel or other DART approved non-corrodible metal.

J.17 Vibration Isolation

1. Vibration isolation pads shall be provided by the Contractor. The vibration isolation pad type and size shall be shown on the installation plans. New pads shall be specifically designed for the weight, and vibration characteristics of the Wheel Press. The pads shall provide proper distribution of weight to avoid distortion of the bedplates.

J.18 Painting in Factory

1. Non-moving parts of the Wheel Press shall be painted with dark grey color per Federal Standard 26008, gloss finish. Moving parts of the Wheel Press shall be painted OSHA safety yellow per Federal Standard 13591, gloss finish.

2. Non-sliding or rotating steel surfaces shall be given a primer coat of factory-applied rust-inhibiting paint to a dry film. Paint thickness shall be determined by the Contractor to prevent peeling and/or paint cracks for at least 20 years.

3. Surfaces shall be free of rust, scale, dirt, grease, and oil before painting.

Matching touch- up paint shall be provided in the minimum amount of

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one quart of each color used to permit retouching. Final touchups shall be performed by the Contractor.

J.19 Noise Limitations

1. Noise shall not exceed 85 dbA under peak operating load conditions when measured five feet from source, excluding alarms and warning devices.

K. Site Dimensional Limitations

1. The Wheel Press shall be located within the area indicated on the floor plan in the Appendix C drawings.

2. Horizontal centerline of hydraulic ram of Wheel Press measured above existing finished floor or working platform shall be between 2'-6" minimum and 3'-6" maximum.

3. Location and mounting height of control panels and displays shall take into account ergonomic considerations. Provide tilting or vertical travel mechanism to allow operator to optimize panel orientation for lighting conditions and operator height.

L. Submittals and Deliverables L.1. Submittals at the Proposal time

1. Submit six hardcopy sets, and one electronic set as searchable PDF files on a USB flash memory device, of the preliminary general arrangement drawings and mount/demount sequence diagrams for DART’s review of the Wheel Press basic design.

2. Detailed technical specifications by the Contractor may not yet be available at the proposal stage; however, expected selection of the major components shall be identified and technical catalog data / cut-sheets shall be supplied:

a. Hydraulic pump including performance curves; hydraulic control valves, valves, filters and gauges; hydraulic fluid cooling coil/fan unit;

b. Hydraulic fluid specification sheet and Safety Data Sheet

(SDS);

c. Computer, power supplies, monitor display and keyboard.

d. All motors;

e. Electrical starters, breakers and panels.

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3. Proposed Schedule - As part of the bid package, submit to DART a proposed schedule of activities including, but not limited to:

a. Conceptual design review;

b. Pre-production design review;

c. Production design review;

d. Submittals and deliverables;

e. Wheel Press fabrication milestones;

f. Factory inspection and testing;

g. Wheel Press Installation; Inspections;

h. Acceptance Testing;

i. Commissioning

j. Training.

4. Submit, as part of the proposal, a draft Quality Assurance (QA) Plan.

L.2. Supporting Documentation and Information

1. Language of the text for all manuals and other documents shall be English, and all dimensions shall be displayed in English units.

2. Fabrication drawings, including bill of materials and material specifications.

Detail drawings of assemblies and components.

3. Operation drawings showing the tooling used for the mounting and demounting of the wheelset.

4. Installation drawings, narrative and schedule.

5. Utility connection plan.

6. Electrical control diagram/schematic and hardcopy of control software.

Electrical wiring diagram.

7. Hydraulic system schematic diagram and calculations demonstrating adequacy of hydraulic system design.

8. Product data, manufacturers, literature including catalog cuts, equipment specification, performance and test data, on the following, but not limited to Wheel Press components shall be submitted:

9. Hydraulic pump including performance curves; Hydraulic control valves, valves, filters and gauges; Hydraulic fluid cooling coil/fan unit;

10. Hydraulic fluid specification sheet and Material Safety Data Sheet;

Computer, power supplies, monitor display, and keyboard;

11. All motors;

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12. Electrical starters, breakers and panels;

13. Transducers and sensors.

14. Equipment installation instructions and installation drawings.

15. Provide to DART for review and approval all specifications and Safety Data

Sheets (SDS) of all chemical materials, substances, and compounds that will be used on the project.

16. Complete description of hydraulic fluid, including, but not limited to, trade name, chemical composition, physical properties including viscosity and Safety Data Sheet (SDS).

17. Provide a document that indicates conformance with or deviation from specification requirements on a line-by-line basis. All items identified as a deviation must be provided with an explanation of the deviation, benefit to DART and showing DART approval of the deviation.

18. Final documentation (manuals, as-built drawings, diagrams, commissioning data, control software, etc.) and supplied spare parts shall be supplied no later than 20 days after satisfactory completion of equipment installation and testing.

19. Provide the Final As-Built drawings as follows:

a. All changes made during installation, testing and checkout.

b. All assembly drawings, exploded views of assemblies, operation drawings, electrical drawings, wiring diagrams and layouts, electrical schematics, control diagrams, and I/O drawings necessary for long-term operation and maintenance of the equipment.

c. As-built drawings shall be hardcopy sets (11X17, Qty 2) and also be supplied on two identical USB flash memory devices in non-editable, searchable PDF electronic file format and editable AutoCAD electronic file format compatible with DART’s Documentation Control system.

L.3. Manuals

1. The manuals shall be in accordance with DART’s manual format and shall contain all of the necessary safety precautions to operate and maintain the Wheel Press.

2. Electronic copy of all manuals shall be provided in searchable PDF file and MS Word file. The Contractor shall provide the following manuals:

a. Operation Manual – Detailing proper operation and basic troubleshooting of the supplied equipment. This shall include

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operating instructions, including step-by-step preparation for starting, operating, shutdown and emergency requirements.

b. Maintenance Manual – Detailing both corrective and scheduled preventive maintenance of the supplied equipment. This manual shall provide in depth troubling shooting, system functional description, theory of operation and detailed illustrated parts catalog.

The preventive maintenance information shall include recommended service replacement intervals for all maintainable components up to system replacement.

c. Overhaul Manual – Detailing all of the necessary information to replace and upgrade all key components.

3. Manuals shall contain the following, but not limited to, as approved by

DART:

a. Title page: Include the name and function of the equipment, manufacturer’s identification number, and Contract Specifications Section number and title. List contact information for service and parts support from equipment supplier and local factory-authorized representative.

b. Table of Contents: Provide in numerical order listing each section and subsection title of the manuals with reference to the page on which each starts and a list of diagrams and drawings.

c.…