Attachment A - Locomotive Specifications.pdf

ATTACHMENT A

LOCOMOTIVE OVERHAUL

• All materials to be provided by MBTA unless otherwise specified.

• Materials received from MBTA or 3rd Party are to be inspected prior to installation.

• The MBTA must be notified of any defective materials received prior to proceeding.

1.01 STANDARDS

A. The equipment, materials, and workmanship provided by the Contractor shall comply specifically with the requirements of the AAR and FRA, all applicable state and local codes in effect at the time of submission of Proposal by the Contractor, and OEM recommendations.

B. If a conflict is discovered among any of the above requirements, the following order of priority shall govern:

1. FRA – USDOT

2. Laws of the Commonwealth of Massachusetts

3. OEM recommendations

4. MBTA Standards

5. Material purchase agreement and specification

6. Recommendations of the AAR

C. In the event of such conflict, the Contractor shall notify the MBTA without delay.

D. Where references are made to the requirements of the FRA (49 CFR), recommendations of the

AAR, and specifications and instructions of the equipment manufacturer, it is the intent that they shall be the latest issue in effect at the time of proposal submittal.

E. Where not otherwise specified, all parts, materials, processes and workmanship shall conform to industry best practices or be otherwise approved by the Engineer.

1.02 GUARANTEE

A. The Contractor shall guarantee that the work done shall be free from defective workmanship and in accordance with the OEM requirements and industry best practices. All workmanship shall be first-class in all respects. All material, machinery, equipment, pieces and/or parts specified herein and installed in the locomotives shall be suitable for Railroad service for a period of one (1) year from acceptance at the MBTA.

B. The Contractor shall guarantee all material, parts, components and/or anything supplied by the contractor for a period of one (1) year from acceptance by the MBTA.

C. The MBTA will be responsible for all warranties associated with material and components provided to the Contractor for installation. The Contractor shall guarantee that the installation of this material and components is free from defective workmanship (excludes hidden damages not obvious) and installed per the OEM requirements. The installation of such material shall be guaranteed for period of one (1) year from acceptance by the MBTA.

1.03 REPLACEMENT PARTS

A. Replacement of parts or apparatus shall be made in kind, except where specified that an upgraded replacement is required.

B. Unless provided by the MBTA, the Contractor is responsible for procuring all parts materials and components, unless otherwise indicated in this technical specification.

C. To expedite the completion of work on these locomotives, when available, the Authority may free issue material to the Contractor.

PART 2.00 – STATE OF GOOD REPAIR (SGR) WORK – BASE

LOCOMOTIVES

The Contractor shall be required to inspect, repair, and remove & reinstall (R&R) major components and provide the required preventative maintenance to bring base locomotives into a service ready condition, as required by the applicable FRA and OEM standards. This shall include, but not be limited to:

2.01 FEDERALLY MANDATED MAINTENANCE

A. Contractor shall be responsible to complete all Federal Railroad Authority (FRA) required Air

Brake change-out, ATC and ACSES 92-day test and all other inspections required by FRA requirements to bring this locomotive “in date” and ready for revenue service.

B. The locomotive(s) shall be ready for revenue service, and a signed and dated “Blue Card” shall be provided for each locomotive as part of acceptance.

C. Contractor shall provide all documentation and install all labels and certifications required by

40 CFR 1033.

2.02 OVERHAUL – SHALL INCLUDE BUT NOT LIMITED TO

A. Fuel System

1. Inspect for leaks

2. Install new Paragon 7 gpm fuel pump

3. Clean strainer

4. Replace fuel filter

5. Drain Fuel Tanks and send out for complete reconditioning

a. Cleaned

b. Inspect and repair tank, baffles, pick up tube.

c. Prepare, prime and paint

B. Main Engine

1. Replace the main engine with an overhauled engine, to be provided by the Authority.

C. Cooling System

1. Radiators sent out for reconditioning

2. Check for leaks

3. Check automatic drain valve for proper function

4. Test low water shutdown

5. Test crankcase pressure detector

6. Pressure test cooling system

7. Drain, flush and refill cooling system

D. Compressed Air System

1. Compressors shall be replaced with new units to be provided by the Authority.

2. Fabricate and install all new piping for air system

a. Replace all angle cocks and ball valves associated with air system

b. Schedule 80, Copper and Poly

3. Purchase and install new Graham White model 994-500 air dryers, and upgrade and replace all associated piping required for the installation.

4. Replace descant canister and final filter element, as required.

5. Verify that the air compressor governor shall load and unload the compressor 135 psi +/-

5 psi.

E. Trucks

1. Trucks sent out for OH per MBTA specifications

2. Clean and inspect underbody frame

3. Check bolster/ carbody bearing clearance

4. Inspect all pedestal liners, replace cracked or worn liners

5. Inspect brake rigging

6. Inspect and verify that all springs are free from defects, cracks, breaks.

7. Replace all shock absorbers.

8. Lubricate center truck castings

9. Center pins - Inspect and repair as necessary

10. Complete wheel inspection report

F. Cab

1. Replace ceiling material, material to be approved by the Authority

2. Replace Engineers and Fireman seats

3. Replace all lights, switches and buttons.

a. Replace all light boxes and bulbs and replace with LED bulbs.

4. Replace all windshield wipers and motors

5. Replace the undermount HVAC unit with a unit provided by the MBTA.

6. Replace all cab controls, circuit breakers and switches.

7. Replace windshields and frames.

8. Replace all side windows and frames.

9. Replace all cab door windows.

10. Install upgraded QES system

11. All paintable interior cab surfaces shall be repainted with suede grey.

G. Carbody

1. Inspect handrails, grab irons, steps and lights

a. Replace all light boxes and bulbs and replace with LED bulbs.

2. Replace all air filters

H. Couplers

1. Replace couplers, draft gears and yokes, record all results.

2. Coupler Pocket inspection and repair as required

I. Main Generator (AR10)

1. Perform all work to remove the main generator and install a replacement generator provided by the MBTA.

a. This work shall include any ancillary tasks to return the generator and interfaces to a service-ready condition.

J. Electrical

1. Replace AC auxiliary generator with a unit supplied by the MBTA.

2. Replace batteries with new.

3. Rewire layover cabinet, electric handbrake, HVC and ditch lights.

4. Inspect and verify that locomotive is free of high and low voltage grounds. Repair as required.

5. Replace, test and verify that all high voltage contactors and other related components are functioning as intended.

6. Replace switch gears with new OEM parts.

7. Replace all low voltage switches, relays, transducers, lamp sockets, lamps, etc.

K. Traction Motors

1. Replace traction motors with overhauled units. MBTA will provide complete combos.

L. Layover

1. Test and repair as required

M. Dynamic Brake

1. Install all new dynamic brake grids

2. Replace inertial blower motor

3. Check for grounds

4. Replace fan motors with units supplied by the MBTA

5. Test functionality

N. Head End Power (HEP)

1. Remove the HEP units and install units to be provided by the MBTA.

2. Install all new air, fuel and water piping and shall be pressure tested.

3. Electrical power and control connections shall be restored and all circuits shall be checked for grounds.

4. All circuits shall be functionally tested and reset to the OEM recommended settings.

5. Test for rated output of 600kW and record results

2.03 CLEANING

A. Contractor shall perform the following cleaning activities at the appropriate time in the sequence of work activities included in these Specifications such that the completed locomotives will have a fully cleaned appearance.

1. Interior:

a. Clean and paint main engine sump

b. Remove all trash;

c. Hand clean locomotive control stand, consoles and floor;

d. Wash and squeegee windows;

e. Remove all graffiti and unauthorized materials (stickers, gum, etc. from interior surfaces).

2. Exterior:

a. Wash locomotive exterior.

b. Drain, power wash, and pressure test retention tanks. All residual materials must be contained and disposed of per EPA standards.

c. Hand wash and squeegee windshields.

d. Inspect all decals and reflective materials and repair/replace as required.

e. Remove all graffiti and unauthorized materials (stickers, gum, etc. from exterior surfaces).

2.04 ADDITIONAL WORK

A. Additional work is considered to include the replacement of missing material, repair of hidden damage, and other as-needed locomotive work that may be requested by the Authority. This may include brake system modifications to a 26L configuration and Switcher modifications.

B. Missing Parts

1. Within 7 days of receiving the NTP for the base scope of work, the Contractor shall submit to the Authority a list of missing parts, and shall identify the replacement parts with long lead times.

a. Where possible, agreements may be made for the Authority to provide those parts, inclusive of the Contractor’s obligation to provide replacement parts to the

Authority.

b. Upon Authority approval, the Contractor shall procure the remaining missing materials for installation on the locomotive(s).

2. If additional missing materials or hidden damage are identified by the Contractor at another point during the contract, the Contractor shall promptly notify the Authority

(within 1 business day).

C. Hidden Damage

1. Hidden damage shall include damaged or deteriorated parts or materials that were not visible or identifiable prior to commencement of work on the locomotive(s).

2. Contractor shall promptly notify the Authority within 1 business day when hidden damage is identified.

D. As-Needed Support

1. The Authority may also request that the Contractor provide additional, as-needed locomotive services during the term of this contract. Specific work scopes will be determined on specific locomotives at the time they are designated for work at the

Rochester facility.

a. It is anticipated that possible work may include, but not limited to repairs and unscheduled maintenance, FRA preventive maintenance, heavy maintenance of major systems, possible fleet initiatives, and cleaning.

b. The primary systems involved in these services may include, but are not limited to rotating electrical, main engines, trucks & wheels, brake system, couplers, carbody, high and low voltage systems, head end power, cab electronics, communications, etc.

2. Possible Work Assignments - The Contractor may be directed to perform a variety of work assignments on locomotives or other equipment as required, including, but not limited to:

a. FRA Inspections

b. Heavy repairs

c. Running maintenance and repairs

d. Collision repairs

e. Cleaning & graffiti removal

E. Additional Work Quotation, Completion, and Documentation

1. The Contractor shall provide a not-to-exceed quotation for labor and materials and schedule of completion for additional work within 7 days of notifying the Authority of missing materials or hidden damage, or within 7 days of receiving a request from the

MBTA for as-needed services.

a. In the case of emergency services, a not-to-exceed quotation shall be submitted within 24 hours of the request from the Authority.

b. The quotation shall be limited to the contractual hourly rates included in the

Contractor’s bid.

2. Any costs associated additional work shall be reimbursed as time & materials based on a mutually agreed upon estimate to be submitted by the selected Contractor.

3. The MBTA anticipates providing most major components for heavy maintenance programs completed as additional work, but Contractor will be responsible for procuring all materials not supplied by the Authority.

4. Contractor shall make Qualified Maintenance Personnel and other appropriate staffing resources, tools, supplies, and diagnostic equipment, available as needed to perform additional work.

5. Upon receipt of the NTP for an individual “Additional Work” task, the service provider may begin work on that task. All additional work shall be performed as directed by the

Authority, within the approved not-to-exceed quotation, to allow the complete return of locomotives to a state of good repair, and to protect the MBTA’s revenue passenger service.

6. At the completion of any additional work, Contractor shall submit to the Authority an accounting of the work completed, including a description of the work, the start and completion dates, staff who completed the work, and the final cost.

PART 3.00 – OPTIONS

The Authority shall have the right to exercise all or part of the following options at any time from

Notice to Proceed. Contractor shall provide separate, per unit pricing to perform each of the following tasks:

3.01 OPTION 1: SWITCHER MODIFICATIONS

A. All modifications for use as CFR compliant switchers.

3.02 OPTION 2: BRAKE SYSTEM UPGRADE – 26L SYSTEM

A. Contractor shall remove the CCB system and replace with a 26L system compatible with and interchangeable with the same system currently in use on the Authority’s GP40 locomotives

B. Contractor shall perform comprehensive functional test of the locomotive and trainline pneumatic brake system and updated software as recommended by the OEM and verify correct operation.

C. Passenger/Freight Mode - The system shall be capable of switching between operation at 110 psi or at 90 psi brake pipe pressure without modification to the hardware or software. It shall be possible to switch between the following modes with a mode selector switch, or other similar arrangement that does not require modifications to the hardware or software:

D. Contractor shall perform comprehensive test of the pneumatic brake system and software as recommended by the OEM.

3.03 OPTION 3: BRAKE SYSTEM UPGRADE – FASTBRAKE SYSTEM

A. Contractor shall provide separate pricing in their bid for replacement of the current CCB system on up to six (6) GP40 locomotives with a FastBrake system, as follows:

1. Contractor shall remove the CCB system and replace with a FastBrake system compatible with and interchangeable with the same system currently in use on the Authority’s HSP46 locomotives, Hyundai-Rotem control cars and overhauled Kawasaki control cars.

2. Contractor shall perform comprehensive functional test of the locomotive and trainline pneumatic brake system and updated software as recommended by the OEM and verify correct operation.

B. Passenger/Freight Mode - The system shall be capable of switching between operation at 110 psi or at 90 psi brake pipe pressure without modification to the hardware or software. It shall be possible to switch between the following modes with a mode selector switch, or other similar arrangement that does not require modifications to the hardware or software:

1. Passenger Mode: Movement of the mode selection switch to this mode shall provide the same features and operation as currently provided when the system is operated in the IN position (per current configuration) when locomotive is the lead vehicle in a consist. In this mode, the air brake pipe pressure is set at 110 psi.

2. Freight Mode: Movement of the mode selection switch to this mode shall automatically set the brake system to operate in freight service.

3. TRL (Trail): Used when the locomotive is a trailing locomotive in a consist led by another locomotive.

4. Cut Out: Used when the locomotive is pushing a train from the rear while controlled by a cab car at the front of the train. Also used when hauling the locomotive “dead” in a train.

C. Contractor shall perform comprehensive test of the pneumatic brake system and software as recommended by the OEM.

PART 4.00 – SWITCHER MODIFICATIONS (OPTION 1)

4.01 INTENT

A. The following specifications detail the requirements for Option 1: Switcher Modifications, listed in Section 3.01 modification of the MBTA’s GP40MC road locomotives to make them suitable for CFR compliant switching service. The locomotives will retain all of their capabilities to be used in passenger road service.

1. The modifications will not change the locomotive interface to the wayside, other vehicles, trainline connections, or in any way alter the geometry or functional interface to the MBTA System.

a. All trainline connections, jumper cables, pneumatic hoses, etc. currently used by the

MBTA shall operate without kinking, binding, dragging, rubbing, or stretching anywhere in the MBTA System when connecting the modified locomotives to any of the existing MBTA rolling stock.

b. The passenger car buffing plates shall remain effective in buffing the between-car-diaphragm mounted to passenger coaches.

2. Work performed, and materials applied shall conform to the applicable sections of Error! R eference source not found., Materials and Workmanship.

4.02 SCOPE OF WORK

A. Corner Stairway Modifications - The Contractor shall carry out the following modifications of the locomotive corner stairways:

1. Reconfigure both rear stairways by relocating the existing ladders, incorporating a switching step, and creating dimensions and clearances meeting the requirements of 49

CFR 231.30.

2. Reconfigure both front stairways to create dimensions and clearances meeting the requirements of 49 CFR 231.30.

3. Remove, modify, or replace (if necessary), and reapply the vertical handholds at all four stairways to meet the requirements of 49 CFR 231.30.

4. Remove, modify, or replace (if necessary), and reapply the uncoupling levers at all four stairways to meet the requirements of 49 CFR 231.30.

5. The Contractor is advised that in the course of performing the stairway modifications, some and possibly all of the following items may need to be removed, modified, replaced and/or reinstalled and tested.

a. Portions of the walkway deck plate

b. Step lights, junction boxes and associated conduit and wiring

c. MU air piping and cut-out cocks

d. Sand delivery pipes

e. MU and Communications receptacles, junction boxes, wiring, and associated end plate mounting area

f. End plate braces

g. Platform handrails

h. Buffing plates

6. All corner stairway modifications must remain within the MBTA clearance envelope.

7. The corner stairways and all related parts of the locomotive affected by the modification work shall be primed and painted with polyurethane paint to original MBTA colors, as approved by the MBTA.

8. Any required changes to wiring shall be consistent with this modification.

a. The Authority will make any available information regarding the wiring of these locomotives available to the selected Bidder.

B. ATC Modifications - The Contractor shall make the following modifications to the locomotive’s Microcab (US&S) ATC System:

1. Install a supporting cross member and a pair of compatible receiver bars under the rear and front end of the locomotive.

2. Install interlocking relay(s) so that the receiver bars are activated in the locomotive leading direction and are isolated in the trailing direction based upon the reverser lever position.

a. When the locomotive is operating in regular passenger service, the Microcab ATC

System / receiver bar operation shall operate normally (i.e. the same as before modification).

3. The capability to operate the ACSES system for operation in reverse shall be either verified or provided by the Contractor.

C. Ditch Light Integration - The Contractor shall install ditch lights on the R-end of the locomotive meeting the requirements of 49CFR229.125.

1. Interlocking relay(s) shall activate the ditch lights in the locomotive leading direction and de-activate them in the trailing direction based upon the reverser lever position.

The control and functioning of the rear ditch lights shall be the same as the existing front ditch lights.

PART 5.00 – TESTING

5.01 IN-PROCESS TESTS

Prior to completion of the locomotives, Contractor shall perform the following tests on each locomotive:

A. In-process repairs, inspections and tests shall be witnessed by the MBTA or its representatives.

B. Testing and inspections shall be done at the Rochester facility before State of Good Repair

(SGR) work, during the SGR and after all work is completed.

1. Contractor shall provide an independent third party to perform QA/QC inspections.

2. Testing/Inspection before SGR work shall be done to determine the condition of existing equipment and the SGR work to be accomplished.

3. Testing/Inspection during the SGR process shall be done to ensure the quality of workmanship and the correctness of their installation.

4. Final testing after all SGR work is completed shall be done to ensure that the locomotive and all its interrelated systems are operating correctly and efficiently, and that the locomotive is ready for revenue service.

C. Other Functional Tests

1. The Contractor shall demonstrate that all systems and subsystems function as intended.

2. Tests to be performed shall be as jointly agreed upon by the Contractor and the Authority.

5.02 SWITCHER MODIFICATION TESTING (OPTION 1)

For any locomotives on which the switcher modifications in Option 1 have been implemented, Contractor shall complete the following tests and verifications with an MBTA witness.

A. Switcher Stairs:

1. Verification that each corner stairway is in conformance with the specified requirements

(i.e. meeting the requirements of 49 CFR 231.30)

2. All significant dimensions relative to 49 CFR 231.30 shall be included.

3. Significant clearance dimensions.

B. Air Piping:

1. A test to verify that all air piping affected by the modification work is leak-tight and free of restrictions, demonstrating that:

a. All MU connections on both sides of the locomotive permit full air flow.

b. Leakage of the locomotive air system is within FRA limits.

c. All valves and cut-out cocks perform their original functions as before the modification.

C. Brake System:

1. Comprehensive test of locomotive and trainline pneumatic brake functionality.

D. Wiring:

1. Insulation integrity, continuity, and functional tests of all step light and wiring affected by the modification work.

E. Trainlines:

1. Complete trainline testing of all trainlines to ensure trainlines are performing to the original design requirements.

F. Watertightness:

1. Watertightness test of all trainline junction boxes affected by the modification work.

G. ATC System:

1. Insulation integrity and continuity tests of ATC wiring installed by the Contractor and static functional test of the ATC system in both forward and reverse settings.

2. Complete box and loop test shall be completed in both the forward and reverse directions, the cab signal paperwork shall be completed and signed.

H. Ditch Lights:

1. Insulation integrity and continuity tests of rear ditch light wiring and functional tests of ditch light operation in both forward and reverse settings, and when coupled to a passenger coach and cab car.

2. The contractor shall demonstrate that the rear ditch alignment meet all FRA requirements

5.03 TEST PROCEDURES

A. The Contractor shall perform MBTA test procedure for each test.

B. Each test procedure shall include all information necessary to ensure the successful, accurate and safe performance of the described test. At a minimum, each test procedure shall include:

1. Safety Precautions

2. Identification of the specification section(s) that is verified by the test

3. Scope of test (what is being tested and how many)

4. Test equipment required (by model number) and latest calibration information.

5. Personnel required

6. Any special conditions required, including condition of the equipment under test

7. Reference drawings, schematics, or documents

8. Clearly understood step-by-step instructions for performing the test, and set-up of test equipment.

9. Clear pass/fail criteria, including applicable tolerances, nonconformance correction, retest provisions

10. Data sheets to record test results, including confirmation of test equipment certification

11. Sample test report format

5.04 WRITTEN REPORTS

A. No test shall be considered complete until a formal test report has been received and approved by the MBTA.

B. Written reports of all tests performed on the vehicles and their components shall be submitted within five (5) calendar days of test performance to the MBTA for acceptance.

PART 6.00 – QUALITY ASSURANCE / QUALITY CONTROL

6.01 QUALITY ASSURANCE PLAN

A. The Contractor shall have in place a Quality Assurance (QA) Plan as a part of his Quality

Management System. This plan shall also cover Contractor’s subcontractors and suppliers as applicable.

B. The QA Plan shall include provisions for material and procedure review.

C. Minimum Contents

1. The QA Plan shall consist of the documented procedures, policies, plans and organization activities of the Contractor, subcontractors, manufacturers, and suppliers, which shall assure all work, materials, test, and documentation conform to the requirements of the contract and specifications. The quality assurance plan shall be supported by detailed project work instructions.

2. Within ten (10) days after award of the Contract, the Contractor shall submit to the

Authority, for acceptance, a written QA Plan consisting of, but not limited to:

a. Contractor quality assurance and quality control procedures

b. Calibration Controls to control all gauging, measuring, and test equipment, and ensure that it is maintained in serviceable condition and accurate calibration

c. Inspection plan identifying each inspection required by the Contract, and good quality practices, and the point in time or manufacturing sequence at which it will be performed

d. Copies of current AWS and pipe welding certifications for all welders that will be participating in the modifications

6.02 DOCUMENTATION AND DESIGN CONTROL (CONFIGURATION CONTROL)

A. The Contractor shall have an established procedure to control drawings, design modifications and change orders to ensure that specification requirements are correctly translated into the drawings and specifications that are in use for existing procurement, fabrication, manufacturing, or testing. This procedure shall ensure that all drawings and documents used are at the latest approved revision level. This shall be conditional on the MBTA drawings provided.

6.03 MBTA INSPECTIONS

A. The Authority shall have the right to audit and verify compliance throughout the Contract.

This right shall in no way reduce the responsibility of the Contractor to comply with all

Quality Assurance requirements of this section.

B. The Authority will witness modification work and all test procedures deemed necessary, and monitor the work on a daily basis.

C. The Authority shall retain the right to reject items found to be in noncompliance with the

Contract specifications, industry practices, procedures, and documentation as applicable to

Contractor, subcontractors, manufacturers, and suppliers during the course of the Contract.

D. as-needed basis to support modification design.

6.04 FORMS

A. Contractor shall complete all FRA and any other forms required by the MBTA for return of the locomotives to service:

2. Replace all air filters

2. If additional missing materials or hidden damage are identified by the Contractor at another point during the contract, the Contractor shall promptly notify the Authority (within 1 business day).

C. Contractor shall perform comprehensive test of the pneumatic brake system and software as recommended by the OEM.

2. Work performed, and materials applied shall conform to the applicable sections of Error! Reference source not found., Materials and Workmanship.

3. The capability to operate the ACSES system for operation in reverse shall be either verified or provided by the Contractor.