EEQA923_RevB.pdf

MASSACHUSETTS BAY

TRANSPORTATION

AUTHORITY

80 Broadway Everett, MA 02149

TECHNICAL SPECIFICATION

EE&QA-923

Procurement of

Hydraulic Wheelset Assembly Press for

The Subway Main Repair Facility in Everett, MA

FIRST ISSUE: February 24, 2022

REVISIONS: Rev. A – February 28, 2023 – Updated Scope Section 1.0 to clarify features

Rev. B – May 31, 2023 – Section 1.2.1, removed bullets 2-7 and 15

- Sections 1.3 & 3.3, changed “Notice to Proceed” to

“Issuance of a Purchase Order”

- Section 2.1, added “obtain all local and state permitting required”

DocuSign Envelope ID: D5BCD16E-4916-4C07-B0FB-2AE73DEEA420

Equipment Engineering and Quality Assurance Technical Specification

Specification:

SUBJECT: Procurement of

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Date: 2/24/2022

Revised:5/31/2023

Revision: B

1.0 SCOPE

1.1 Project Objectives

The Massachusetts Bay Transportation Authority (MBTA), herein referred to as the

Authority, needs to procure a qualified vendor, herein referred to as Contractor, to furnish labor, equipment, and all material necessary to remove an old hydraulic wheel press and install a new hydraulic wheelset assembly press at the Subway Main Repair Facility

(SMRF) located in Everett, MA. This new unit and associated components will fully replace a current hydraulic wheel press in the shop. The new hydraulic wheelset assembly press shall be ready to utilize upon completion of the installation. This procurement should also be in alignment with the Authority’s commitment to a more environmentally friendly maintenance system and a smaller carbon footprint. This is a turnkey type of procurement. Everett Shops will make available all reasonable resources to ensure an efficient and effective process.

1.2 General Features

The Everett Main Subway Repair Facility is utilized by the Authority to process wheelsets from commuter rail cars as well as eleven (11) different trolley types to ensure that they are kept in a state of good repair for passenger service. The hydraulic wheelset assembly press will be used by the wheel shop to remove and install wheels and record pressing tonnages. Pressing tonnages shall be digitally recorded along with other pertinent installation data and available for recall. The dual-end pressing process should be fully automatic and should occur in a single mounting of the wheel set in the press.

The new hydraulic wheelset assembly press should also incorporate energy savings features and environmentally friendly technologies.

1.2.1 Hydraulic wheelset assembly press specifications/ features.

• The press should be designed to exert, at its minimum capacity, a force of 6000kN

• Distance between upper and lower frame should be at least 1340 mm

• Overall weight should not exceed 30000 kg

• Machine should be painted RAL 6032 (signal green)

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• Two basic inserts for pressing-on and pressing-off operations capable of withstanding a minimum force of 6000 kN

• Automatic stepwise positioning of inserts

• Interchangeable sealing elements for cylinders

• Centering device with interchangeable and tunable 90° spring-loaded centers

• Hydraulic overload protection valves

• User selectable and electronically limited maximum admissible press force setting

• Stepless press force adjustment

• Automatic pressing operations and positioning of wheelsets in press.

• Hand controls for manual operation

• Enclosed control cabinet with IP 54 protection rating.

• Emergency shut-off buttons on control desk and opposite press cylinder

• Computerized measuring and control with documenting capability

• Filter function in control software to account for surface defects

• User selectable work piece parameter sets

• Laser printer in IP 54 enclosure capable of generating force-displacement curve reports

• Measuring device with absolute encoders for both axis and hardened measuring head with capability to measure runout on wheels and brake discs

• Working area safeguards

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1.2.2 Accessories:

The following accessories shall be made available with the hydraulic wheelset assembly press.

• Foundation anchors, adjusting bolts and shims for machine installation

• Transformer capable of stepping down from 600V supply to required machine voltage

• A hands-free rotation device for assembled wheel sets during inspection.

• Pressing tools mounted on the main tool of the basic insert and on pressing cylinder

• Accommodations to press outboard mounted journal bearings off and on

• Pressing sleeves to protect axle ends

• Wheelset transport carriage with height adjustment including work piece supports, guide rails, and clamping arm

• Pumps and equipment to automate the hydraulic assist for the removal of wheels.

• Remote diagnosis system and software

• A supply of manufacturer’s recommended spare parts adequate to reasonably service the machine for one year (bulbs, buttons, fuses, relays, filters, common wear items, etc.)

1.3 General Requirements

The selected Contractor shall provide all labor, services, equipment, materials, and training required to remove the old hydraulic wheel press and install the new hydraulic wheelset assembly press, and all associated components at the designated location. All work shall be performed by the Contractor in accordance with all applicable Federal and/or State Occupational Safety and Health regulations including, but not limited to, applicable parts as specified in 29 CFR XVII, and more specifically 29 CFR 1910. The

Contractor shall also adhere to OSHA standards for fall protection guidelines and

Personal Protective Equipment (PPE) requirements in the most current versions. The selected Contractor shall have the required knowledge and properly trained personnel to perform all required tasks in an efficient, safe and acceptable manner. The Contractor shall be available to work twenty-four hours (24 hrs.) per day and seven (7) days of the

Page: 5 of 10 week if necessary to minimize obstruction of any prioritized ongoing work at the Everett

Main Repair facility. In order to streamline the work for this project, the Authority will work with the Contractor on scheduling per this specification.

The Contractor will ship the new electrical transformer (see Section 1.2.2) for the new hydraulic wheelset assembly press to the Everett Main Repair facility within one (1) month after issuance of a purchase order. Once the rest of the equipment arrives at the repair facility, the Contractor shall complete all the required work within eight (8) weeks.

The Contractor will be required to complete this project in approximately twelve (12) months after the issuance of a purchase order. The selected Contractor shall transport all tools, equipment, materials, and any other items required to perform the job with proper protocol standards to the Everett Main Repair facility. The Contractor shall maintain a safe working environment at all times. This includes, but is not limited to, ensuring that all personnel in the work area are fitted with the appropriate Personal Protective

Equipment (PPE) at all times and that spare PPE is readily available.

The removal of the old hydraulic wheel press and installation of the new hydraulic wheelset assembly press shall be performed in an efficient manner that minimizes disturbance of the daily maintenance operations at the Everett Main Repair facility. Once the installation of the new hydraulic wheelset assembly press is complete, the selected

Contractor along with facility personnel including management and/or engineering (if required) shall verify that the system is in a good working state per the manufacturer’s specifications and the facility’s requirements. Once the hydraulic wheelset assembly press’ functionality is verified, the Contractor shall install a label with the installation date. The Contractor shall then present to the foreperson or supervisor of the work area a sign-off sheet stating that the job was completed per this specification. The Contractor shall provide all relevant documentation including, but not limited to, the operations and maintenance manuals to the manager in charge of the project.

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2.0 CONTRACTOR REQUIREMENTS

2.1 Contractor Qualifications

The selected Contractor shall have a minimum of five (5) years of previous experience removing and/or installing machines in maintenance shops and/or other work areas. The

Contractor shall provide references of previous contracts if requested by the Authority.

The Contractor shall supply sufficiently detailed preliminary drawings indicating required equipment details, required electrical and mechanical services, as well as drawings and catalog cuts indicating operation, dimensions, and all features for all equipment to be supplied. These materials shall be provided by the Contractor at the time of bid submittal.

Modifications to the building or building utilities resulting from changes must be supplied with the bid and shall be the responsibility of the Contractor.

All sub-Contractors used shall also have experience removing and/or installing machines.

The Authority may require proof of this by submission of reliable data such as time work was performed and location, material information, equipment modification and maintenance records. The Contractor shall obtain all local and state permitting required and have appropriate licenses and/or certifications required for removing a hydraulic wheel press and installing a hydraulic wheelset assembly press.

2.2 Contractor Responsibilities

The Contractor selected by the Authority shall adhere to all the requirements set forth by the Authority in this Specification. Any deviations from the Authority’s requirements, as well as other proposals presented by the Contractor, must be submitted in writing for approval prior to proceeding. The Authority intends to take all suggestions regarding methods of removing the old hydraulic wheel press and installation of the new hydraulic wheelset assembly press proposed by the selected Contractor into consideration. The

Contractor shall be held responsible for any excessive damages that occur during the removal/installation process. The Authority reserves the right to assess all damages that occur and charge the Contractor accordingly.

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The Contractor shall perform all the required electrical wiring necessary to install the new equipment in the designated location. This includes, but is not limited to, furnishing the required materials and labor necessary to perform the electrical wiring and/or piping from a desired location within the facility to the new equipment. The Contractor shall install the wiring to from the new hydraulic wheelset assembly press to the machine’s new transformer (see Section 1.2.2). The Contractor shall install additional conduit system if required for the control cabling.

The Contractor shall secure all the required state and/or local permits necessary in order to be compliant when performing its tasks and to complete this project in a safe manner.

The Contractor shall adhere to these terms when the contract is awarded.

2.3 Authority Responsibilities

The Authority will be responsible for the removal of as many equipment units and/or vehicles as reasonably possible from the work area that may obstruct/prevent the

Contractor from working in an efficient manner. Working with the Contractor, the

Authority will ensure that all the agreed upon recommendations and tasks are completed before the removal of the old hydraulic wheel press and installation of the new hydraulic wheelset assembly press at the Everett Main Repair Facility. The Authority’s in-house electricians will perform installation of the new machine’s new electrical transformer (see

Section 1.2.2). Additionally, the Authority will make available personnel at EMR readily available to assist the contractor as required in order to make this process proceed as seamlessly as possible.

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3.0 TRAINING, TOOLING, MANUALS, SHIPPING and WARRANTY

3.1 Training

The Contractor shall provide training for the appropriate operation and maintenance of the new hydraulic wheelset assembly press. Training is to be provide to at least ten (10) individuals selected by the Authority. The on-site training is to include start-up, commission, and machine operation. The selected Contractor shall provide hands-on training to personnel at the Everett Main Repair shop and any other shop deemed appropriate by the Authority pertaining to the repair/maintenance of the new hydraulic wheelset assembly press.

3.2 Tooling

At the time of installation, the Contractor shall provide complete parts manuals as well as operating and maintenance manuals covering any major new accessories, components, or systems. Manuals shall include but not be limited to the following:

• Description of system and/or each component

• Schematic diagrams

• Printed listing of periodic preventive maintenance items and recommended frequency required to validate warranties. Provide services to perform these items/tasks for a period of 24 months

• List of original manufacturer's parts, including supplier's part numbers and cut-sheets, recommended spare stockage quantity, and local parts and service source

• Provide three (3) copies of each manual, appropriately labeled in a three (3) ring binder. The manuals should also be provided in electronic format

• Diagnosis Software with access to future updates

• Portable Test Unit (If one is required)

• Apparatus required for the installation/removal of all components

If the Contractor cannot provide all the necessary tools to perform the repairs, it is the responsibility of the Contractor to provide the Authority with all the necessary information required (i.e. drawings, materials list, specifications, etc.) to obtain or manufacture them.

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3.3 Shipping

The Contractor, as part of their proposal, is to include the cost of shipping all the new equipment from their facility to the Authority’s Everett Main Repair facility. All rigging cost, including the removal and disposal of the existing hydraulic wheel press as well as any rigging cost related to the installation of the new hydraulic wheelset assembly press shall be the responsibility of the Contractor.

Equipment and components shall be suitably crated to prevent damage in transit or during handling. Items shall be carefully stored at the site as required in a manner to avoid misalignment or distortion, and shall be adequately protected against damage by weather or other cause. Special precautions shall be taken to prevent damage to the electrical components such as motors, controls and conductors.

The new electrical transformer (see Section 1.2.2) for the new hydraulic wheelset assembly press is to be shipped to the Everett Main Repair facility within one (1) month of the issuance of a Purchase Order.

3.4 Warranty

The Contractor shall provide and honor the following warranty upon the installation completion. These warranties include:

1. One (1) year warranty on hydraulic wheelset assembly press and optional components covered under normal work conditions

2. One (1) year warranty including all service and labor

3. One (1) year warranty on all external electrical components installed. This includes, disconnects, conduit, transformer, etc.

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4.0 APPROVALS

Prepared By:

Date:

Theodore Cooke - Engineer

Equipment Engineering & Quality Assurance

Approved By:

James Brienzo – Supervisor

Everett Main Repair Facility – Subway Operations

Steve Golbranson – Supervisor

Everett Main Repair Facility – Subway Operations

Edward J. Belanger – Superintendent, Everett

Main Repair Facility – Subway Operations

Kimberly Woollard – Director, Everett Main

Repair Facility

Michael F. Walsh – Director, Rail Maintenance

Steven Hicks – Chief Mechanical Officer

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