Technical Specification SOW Requirements_TS-KRC-CTC1722_Rev 2.0_7_13_18.pdf

MASSACHUSETTS

BAY

TRANSPORTATION

AUTHORITY

Railroad Operations

Technical Specification

DOCUMENT NO. TS-KRC-CTC1722

Technical Specification for Repair of

Kawasaki Commuter Rail Control Trailer Coach 1722

ISSUED: 7/13/2018

REVISION: 2.0

MASSACHUSETTS BAY TRANSPORTATION AUTHORITY

Kawasaki Commuter Rail Control Trailer Coach 1722

TS-KRC-CTC1722

Kawasaki Commuter Rail Control Trailer Coach 1722

July 13, 2018

Revision 2.0

TABLE OF CONTENTS

1 INTRODUCTION

2 DESCRIPTION OF THE DAMAGED KAWASAKI CONTROL TRAILER COACH 1722 1

3 SCOPE OF WORK

3.1 General

3.2 Transportation and Preliminary Inspections

3.3 Non-Documented Damages

3.4 Disassembly

3.6 Stepwell Assembly

3.7 Trapdoor Assembly and Heater

3.8 Pilot Bar and Support Brackets

3.9 Windows

3.10 Seat Cushions

3.11 Carbody Corner

3.12 Luggage Rack and Supports

3.13 Lighting

3.14 Ceiling Panels

3.15 Pull Box

3.16 Track Receiver Assembly and Brackets

3.17 Air Piping

3.18 Low Voltage Junction Box

3.19 Receptacles and Conduit

3.20 Sander Box and Brackets

3.21 Interior Destination Sign

4 COMMON WORK REQUIREMENTS

4.2 Non-Destructive Testing (NDT)

4.3 Welding

4.4 Straightening

4.5 Dimensional Inspection

4.6 Leak Test

4.7 Functional Test

4.8 Wiring Repairs

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4.9 Insulation Resistance Tests

4.10 Cleaning and Stripping

4.11 Corrosion Protection

4.12 Water Tightness Testing

5 QUALITY ASSURANCE AND INSPECTION

5.1 Quality Assurance Program

5.2 Inspections and Tests

5.3 Material Handling and Substitutions

6 DOCUMENTATION

6.1 Repair Records

6.2 Inspection and Test Records

6.3 Control of Quality Records

7 DRAWINGS

8 DELIVERABLES

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1 Introduction

1.1 This Specification details the requirements of the Massachusetts Bay Transportation

Authority (MBTA) for the repair of its Kawasaki Push-Pull Bi-Level Commuter Rail Control Trailer Coach 1722 which was recently damaged in a revenue service accident.

The damage was caused when a tree impacted the front, side and interior of the commuter rail coach on the No. 1 end, left side. Description of the damage is detailed in Section 2 of this Specification.

1.2 The MBTA will make available the damaged coach and equipment covered by this

Specification to be reviewed by the Contractor prior to bid and after award.

1.3 All work shall be performed at the Contractor’s facility or mutually agreed upon site. All logistics associated with transporting the damaged coach, along with any disconnected components and MBTA-supplied repair parts, between MBTA shops and the Contractor’s facility shall be the responsibility of the Contractor. All facilities used by the Contractor, including any subcontractors, shall be subject to inspection, audit, and approval by the MBTA.

1.4 The Contractor shall be required to demonstrate substantial experience in performing scheduled and heavy vehicle maintenance, and structural repair work of similar rail coaches. Please see RFP for the experience requirement.

1.4.1 For a specialized repair that cannot be performed by the Contractor, the Contractor must submit the name of the specialty Subcontractor and scope of work to the MBTA Project Manager for approval.

1.5 Any repairs or replacement beyond the scope of this Specification must be authorized by the MBTA Project Manager, refer to Section 3.3.

1.6 All references to the “MBTA” or the “MBTA Project Manager” contained in this specification shall be understood as meaning the “MBTA or a designated representative” or the “MBTA Project Manager or a designated representative”.

2 Description of the Damaged Kawasaki Control Trailer Coach 1722

2.1 Bi-Level coach 1722 was manufactured by Kawasaki between the years of 1990 to 1991 for use on the Massachusetts Bay Transportation Authority Commuter Rail, which services the suburbs of Boston, MA. A mid-life overhaul was completed by Alstom Transportation and the coach was returned to the Authority in June of 2017. Coach 1722 is designated as a control trailer coach (CTC), equipped with an operator’s station at the right side of the No. 1 end and further described in the maintenance manuals provided in Appendix 3.

2.2 During an impact with a tree in the ROW, damage was caused to coach 1722 on the left side, interior of the vehicle, and No. 1 End of the coach. An initial inspection was completed by the MBTA and found that the damage included complete removal of the pilot bar and two windows, as well as damage to the track receiver assembly, trainline

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Interior damage also occurred on the lower level, including punctures in two seatbacks, broken window panels, damage to the lower level ceiling/light fixtures, and damage to the luggage rack. No visible major carbody structural damage was seen on the coach;

however, the fringe over the carbody corners was found to be deformed. The No. 1 left trap door was removed following the incident, although it does not appear to be damaged, and must be reinstalled. All non-documented damage found by the Contractor, and not included in the bid price, will be considered Hidden Damage, as described in Section 3.3. Figure 1 depicts the location of the damage and configuration of the coach during impact.

Figure 1: Configuration and Damage Location on Coach 1722

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3 Scope of Work

3.1 General

3.1.1 The scope of this project is to ensure that Coach 1722 is repaired as required to restore complete functionality and provide performance and reliability consistent with the vehicle performance and reliability prior to the accident. The work shall consist of disassembly, cleaning, dimensional and NDT inspection, component replacement and/or repair, painting, and testing. The work shall comply with all applicable industry standards, codes, regulations, federal and state laws, OEM requirements, and the requirements of this Specification.

3.1.1.1 Table 1 details the full list of components identified by the MBTA as needing inspection, repair, testing, and/or replacement. Repairs of hidden damage, as described in Section 3.3, may also be required. The definitions for terminology used in Table 1 are provided below:

3.1.1.1.1 Remove: Component or assembly shall be completely removed from the vehicle. For welded brackets to be removed, the remaining weld bead shall be ground flush.

3.1.1.1.2 Fabricate: Manufacture new component to OEM drawings, specifications, and function.

3.1.1.1.3 Replace: Remove old component and install new component meeting OEM drawings, specifications, and function.

3.1.1.1.4 Repair: Bring back into accordance with OEM drawings, specifications, and function.

3.1.1.1.5 Reuse: Re-install existing component after cleaning, inspection, and passing functional testing.

3.1.1.1.6 As Needed: Contractor to determine if component meets OEM drawings, specifications, and function based on inspection and functional testing.

3.1.1.1.7 Test: Perform functional test as defined in Section 4.7.

3.1.1.1.8 Inspect: Perform dimensional and NDT inspection as defined in

Sections 4.2 and 4.5.

3.1.1.2 All components installed by the Contractor, whether repaired, replaced, or reused, shall be tested for functionality after installation. Repaired sections of the air system shall be leak tested in addition to functional tests of valves. All weld repairs shall be subject to non-destructive testing.

3.1.1.3 All components removed from the coach shall be reinstalled with new hardware in accordance with OEM requirements.

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3.1.1.4 Applicable drawings, listed under the “Drawing Provided” column in Table 1, are included in Appendix 1 or Appendix 6 and shall be used to supplement this Specification. Applicable Materials and Workmanship requirements and OEM Manuals are provided in Appendices 2 and 3 respectively.

3.1.2 MBTA will provide Coach 1722 in the condition described in Section 2. All non-damaged equipment removed by the Contractor to enable repairs shall be reinstalled in the same condition as when the car was shipped from the MBTA facility. Any equipment damaged during repairs or shipping shall be repaired by the Contractor at no cost to the MBTA.

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Table 1: List of Components Requiring Inspection, Repair, Testing, and/or Replacement

Sys.

Component

Drawing Reference

Drawing Provided

Scope

Part Supplied

Se at in g

Seat Cushion Back 1P396913 (451-001) 1P397403 (451-002)

Yes Install Yes

Seat Cushion Base Yes Install Yes 1P700275 2P700535

Seat Cushion Top Yes Install Yes 2P700552

W in d o w s

Emergency Window Assembly (1st, Left side) DE00000191933 Yes Replace Yes

Passenger Window Assembly (3rd, Left side) DE00000191936 Yes Replace Yes

Window Panel (1st, Left Side)

1P396604 (413-030) 2P397630 (413-031) 1P396148 (413-203) 1P396149 (413-204)

Yes

Replace;

Inspect insulation and replace as needed

1P700595 (413-428)

Window Panel (3rd, Left Side)

Replace;

Inspect insulation and replace as

2P700681 (413-429) 1P396781 (413-607) 1P396782 (413-608) 1P396783 (413-609)

Window Frame Damage (1st, Left side)

1P396334 (412-121) 1P396335 (412-122)

Inspect and repair as needed;

Restore surface finish

No

1P395983 (412-105)

Window Frame Damage (3rd, Left side)

Inspect and repair as needed;

1P396431 (412-123) 2P396551 (412-106) 1P396572 (412-130)

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Lo w

F lo o r

C e ili n g

Ceiling Panel

1P396813 (413-040) 1P396814 (413-041) 1P396381 (413-042) 1P396382 (413-043) 1P700443 (413-044)

Remove and replace panel;

Inspect surrounding area

Light Fixtures

1P39655 (452-010)

Yes Replace and test Yes

Light Fixtures w/ Emergency Lighting Yes Replace and test Yes

Luggage Rack 1P396236 (452-004) 1P396239 (452-005)

Remove and replace

Luggage Rack Supports 1P397943 (412-532) 1P397944 (412-533)

Remove and replace

St e p w el l a n d

T ra p D o o r Trap Door Assembly (No. 1 End, Left Side)

1P396042 (453-301) 1P396051 (453-302) 1P396052 (453-303)

Install and test

Trap Door Heater (Threshold Heater) 2P387114 (453-312) Yes Install and test Yes

Stepwell Assembly (No. 1 End, Both Sides)

1P396097 (453-207) 1P396428 (453-209) 1P396024 (453-201) 1P396473 (453-203) 1P396474 (453-204)

Inspect;

Repair as needed

M is c.

Interior Destination Sign (No. 1 End, Lower Level)

Pg. 392 IPC Vol 2 Fig 8-10

Inspect and test

Carbody Corners

1P395997 (412-302) 1P396985 (412-301) 1P396432 (412-305) 1P396838 (412-309)

Repair dents in fringe;

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U n d er c ar

Low Voltage Junction Box (No. 1 End, Both Sides)

1P396887 (575-301) 1P395962 (511-001) 2P397221 (511-002)

Inspect and repair box;

Inspect and test wiring;

Replace wiring as needed

Sander Box and Brackets (No.1 End, Right Side)

1P396140 (511-052)

Inspect and test

Brake Pipe (No. 1 End, Left Side)

1P396856 (511-031) 1P396857 (511-032) 1P396858 (511-033) 1P396859 (511-034) 1P396860 (511-035)

Test for air leaks;

Replace clamps, brackets, piping, and fittings as needed

MR Pipe (No. 1 End, Left Side)

Test for air leaks;

Replace clamps, brackets, piping, and fittings as needed

Pilot Bar (Snow plow) 1P396373 (453-501) 1P396374 (453-502)

Test Fit-Up

Pilot Bar Support Brackets

1P396662 (453-503)

Inspect brackets and repair/replace as needed Inspect surrounding structure;

Paint

Low Voltage Receptacles and Cables (No. 1 End, Left Side)

1P396603 (511-003) 1P396545 (578-001)

DE00000198158(J01)

Remove and replace receptacles;

Inspect brackets and repair/replace as needed;

Inspect wiring and repair as

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High Voltage Receptacles and Cables (No. 1 End, Left Side)

1P396603 (511-003) 1P396545 (578-001)

Remove and replace receptacles;

Inspect brackets and repair/replace as needed;

Electrical Conduit

1P396869 (551-046) 1P396870 (551-047) 1P396871 (551-048) 1P396872 (551-049)

Inspect and replace as needed;

Replace clamps and brackets as

Ethernet Trainline Connector

AMPHENOL-RJFTV12N

Remove and replace receptacle;

Inspect brackets and repair/replace as needed;

Pull Box (No. 1 End, Left Side)

1P397571 (551-015) 2P397019 (551-016) 2P397020 (551-017)

Fabricate and replace box;

Inspect surrounding structure;

Inspect and test wiring;

Repair wiring as needed;

Track Receiver Assembly Brackets

Fabricate and replace;

Inspect surrounding structure;

Paint

Track Receiver Assembly 1P397082 (511-083) Yes Test Fit-Up Yes

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3.1.3 The Contractor shall provide a detailed plan of all work to be performed, as described in Section 3.5.1 to the MBTA Project Manager for approval prior to commencing the work and shall perform the work in accordance with the approved plan.

3.1.4 Should conflicts exist or an item or feature be deemed by the Contractor not to be adequately described in this Specification, the Contractor shall formally apply for further written clarification, as may be necessary, and shall adhere to the written clarification provided by the MBTA Project Manager.

3.1.5 The Contractor’s quality control system shall ensure that all operations performed are properly documented, verified, and approved by a qualified quality control person at the time the operation is completed.

3.1.6 MBTA will provide to the Contractor all parts identified in the “Part Supplied” column in

Table 1. The Contractor is responsible to supply all other parts and materials required to complete the specified repairs.

3.2 Transportation and Preliminary Inspections

3.2.1 The damaged coach shall be shipped from and returned to the MBTA’s Commuter Rail

Maintenance Facility, formerly known as the Boston Engine Terminal, 70 (rear) 3rd Ave | Somerville, MA 02143. All costs associated with shipping and packaging of the Coach and any additional parts shall be the responsibility of the Contractor. If shipping is required to another facility for special work, all costs and packaging shall be the responsibility of the Contractor.

3.2.2 The MBTA will perform an outbound inspection, described in Section 5.2.2, noting the condition of the coach and any missing or damaged items. An outbound inspection report will be generated and transmitted by the MBTA to the Contractor.

3.2.3 After receipt by the Contractor, a receiving inspection, as described in Section 5.2.3, shall be conducted immediately to determine if any damage may have occurred during shipment. The Contractor shall generate a Receiving Inspection Report equivalent to the MBTA’s outbound inspection report noting any discrepancies between the two reports.

3.3 Non-Documented Damages

3.3.1 The MBTA understands that, over the course of the repair process, non-documented damage may become apparent, necessitating repairs beyond the level identified in this Specification. Such items will be referred to within this Specification as “Hidden Damage”.

3.3.2 Upon identifying any Hidden Damage, the Contractor shall notify the MBTA Project

Manager of the damage and provide photographic evidence, inspection reports, and a corrective action plan, including labor hours and material costs, for review and approval.

The Contractor shall only proceed with the proposed corrective actions upon receipt of written approval from the MBTA Project Manager.

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3.3.3 The Contractor shall submit an invoice for all approved Hidden Damage repairs to the MBTA Project Manager after the repaired Coach has been received by MBTA and a signed Notice of Approval has been provided by MBTA.

3.4 Disassembly

3.4.1 The Coach shall be disassembled sufficiently to complete a thorough inspection and repair of the damaged areas. Any part removed, not intended to be scrapped, shall be identified by shop order or traveler number and kept together with the coach through a tracking system as the part is cleaned, repaired, assembled, and tested. Where applicable, the serial numbers of replaced, repaired, or reused parts shall be recorded on the shop order or traveler.

3.4.2 A hold point inspection shall be performed, as defined by Section 5.2.4, following disassembly and prior to beginning repairs. The purpose of this hold point inspection is to ensure that the damaged areas of the Coach have been completely inspected, the condition documented, and any Hidden Damage identified.

3.5 Execution

3.5.1 The Contractor shall provide a detailed Repair Plan for MBTA review and approval, expanding on this Specification and the items listed in Table 1. The Repair Plan shall include: work to be performed, processes to be utilized, designated hold point and in-process inspection points, inspection requirements, components to be replaced, repaired, or reused, assembly instructions, functional tests, tooling and inspection gages, and materials. [CDRL 3.5.1]

3.5.1.1 The Contractor shall be responsible for developing and maintaining all tools and test equipment necessary to ensure the requirements of this Specification are met.

3.5.1.2 The Contractor shall not permit the destruction of any tool, such as drill jigs, welding fixtures, assembly fixtures, or test racks without first offering the MBTA the opportunity to acquire the same.

3.5.1.3 All measuring and testing equipment shall be properly identified and tabulated by serial number and calibration date.

3.5.2 If plasma or flame cutting will be used, the Contractor shall submit a Plasma/Flame Cutting Plan for MBTA review and approval, detailing the type of cutting performed, machine settings, temperature limits, and temperature measurement equipment for each combination of material and thickness being cut.

3.5.3 If hot forming or straightening will be used, the Contractor shall submit a Hot Forming

Plan for MBTA review and approval, detailing the heating equipment used, temperature measurement devices, temperature limits for each combination of material and thickness, force application equipment, and inspection requirements following forming or straightening.

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3.5.4 The Contractor shall submit a Welding Plan for MBTA review and approval, containing at a minimum: [CDRL 3.5.4]

3.5.4.1 A copy of all weld procedure specifications (WPS) and procedure qualification records (PQR) used for the Project.

3.5.4.2 A list of all welders who will be working on the project and the WPSs for which each welder is qualified.

3.5.4.3 A Weld Map showing the location of each weld, the WPS to be used, and the inspection requirements.

3.5.4.4 Specifications for the purchase of welding consumables.

3.5.5 The Contractor shall submit an NDT Inspection Plan for MBTA review and approval, containing at a minimum: [CDRL 3.5.5]

3.5.5.1 Procedures for each type of NDT inspection used for the Project, at a minimum visual inspection (VT), magnetic particle inspection (MT), and dye penetrant inspection (PT).

3.5.5.2 Equipment to perform each type of NDT inspection used for the Project.

3.5.5.3 Calibration control for all inspection equipment.

3.5.5.4 A list of NDT Inspectors who will be working on the project and each inspector’s certification levels.

3.5.6 The Contractor shall submit a Cleaning and Stripping Plan for MBTA review and approval, containing at a minimum: [CDRL 3.5.6]

3.5.6.1 Method of protecting surfaces that do not require cleaning or stripping.

3.5.6.2 Process to be used for cleaning or stripping each type of base material.

3.5.6.3 Equipment used for each cleaning or stripping process.

3.5.6.4 Consumables used for each cleaning or stripping process (i.e. solvent type/concentration, grit type/size, blast media type/size).

3.5.7 The Contractor shall submit a Corrosion Protection Plan for MBTA review and approval, containing at a minimum: [CDRL 3.5.7]

3.5.7.1 Method of protecting surfaces that are not being treated.

3.5.7.2 Type of primer, paint, or passivation used for each base material.

3.5.7.3 Sealant Map showing the application locations and types of sealant used.

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3.5.7.4 Technical data sheets for all primers, paints, acids, and sealants used for the Project.

3.5.7.5 Surface preparation requirements for each process.

3.5.7.6 Temperature and humidity requirements for each process.

3.5.7.7 Coating thickness and drying time requirements for each process.

3.5.7.8 Coating adhesion test results.

3.5.7.9 The surface finish on all parts shall match the OEM configuration, except with written approval from the MBTA Project Manager.

3.5.8 The Contractor shall submit a Material Accountability Plan for MBTA review and approval, containing at a minimum: [CDRL 3.5.8]

3.5.8.1 Control of materials to be removed and reused.

3.5.8.2 Control of materials supplied by MBTA.

3.5.8.3 Control of materials purchased by the Contractor, including quarantine and receiving inspection requirements.

3.5.8.4 Control of materials fabricated by the Contractor, including material traceability.

3.5.8.5 A list of all materials purchased or fabricated by the Contractor, including description, drawing/part number, material, supplier, quantity, and lead time.

3.5.9 The Contractor shall submit a Wiring Control Plan for MBTA review and approval, containing at a minimum: [CDRL 3.5.9]

3.5.9.1 Wire type and insulation.

3.5.9.2 Electrical connectors.

3.5.9.3 Conduit, supports, cable cleats.

3.5.9.4 Installation hardware.

3.5.9.5 Wire markings, including colors and labeling as required.

3.5.9.6 The wiring configuration shall match the OEM configuration, except with

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3.5.10 The Contractor shall submit a Pneumatic Piping Control Plan for MBTA review and approval, containing at a minimum: [CDRL 3.5.10]

3.5.10.1 Piping material, size, and lengths used.

3.5.10.2 Quantity, type, size, part number, and supplier of fittings, joints, and valves.

3.5.10.3 The piping configuration shall match the OEM configuration, except with

3.5.11 The Contractor shall submit a Hardware Control Plan for MBTA review and approval, containing at a minimum: [CDRL 3.5.11]

3.5.11.1 Material and grade of all hardware used for the project.

3.5.11.2 Controls for preventing the use of hardware with incorrect material or grade.

3.5.11.3 Torque value for each combination of material, grade, size, thread pitch, and installation condition (dry, lubricated, etc.).

3.5.11.4 Controls to ensure that all fasteners are properly torqued, verified, and marked with inspector’s sealant (torque stripe) after verification.

3.5.12 The Contractor shall submit an Inspection and Test Plan for MBTA review and approval, containing at a minimum: [CDRL 3.5.12]

3.5.12.1 Functional Tests Required.

3.5.12.2 Final Inspections Required.

3.5.12.3 Air System Leak Test.

3.5.12.4 Insulation Resistance Test.

3.5.12.5 Pass/Fail Criteria for each inspection and test.

3.5.12.6 Record sheets for each inspection and test.

3.5.13 The Contractor shall provide a Repair Checklist to record if each component was either replaced, repaired, or reused. The checklist shall be signed by the person who performed the inspection. [CDRL 3.5.13]

3.5.14 All results of inspection and testing shall be documented and records maintained by the

Contractor. All non-conforming material and repairs shall be documented and the records maintained by the Contractor. A copy of all such records shall be submitted to the MBTA Project Manager as part of the Pre-shipment Inspection Report described in Section 5.2.5.

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3.5.15 The Contractor shall submit weekly Status Reports to the MBTA Project Manager and weekly Progress Meetings shall be held between the Contractor and MBTA to review document approvals, inspection/test schedules, and repair progress.

3.6 Stepwell Assembly

3.6.1 The existing Stepwell Assemblies on the No. 1 Left and Right Sides shall be visually and dimensionally inspected and repaired according to OEM requirements. Refer to Table 1 for OEM drawing numbers.

3.6.2 Inspection

3.6.2.1 The repaired Stepwell Assemblies shall be inspected for quality of workmanship. All hardware shall be properly torqued and torque-striped.

3.6.2.2 The conductor’s buzzer button shall be tested for functionality.

3.6.2.3 Stepwells shall be tested for water tightness in accordance with Section 4.12.

3.7 Trapdoor Assembly and Heater

3.7.1 The trap door assembly and heater supplied by the MBTA shall be installed on the No.

1 End, Left Side of the car. The new trap door and heater shall be installed according to OEM requirements, refer to Table 1.

3.7.1.1 The trap door hinge and latch shall be completely sealed to prevent water intrusion.

3.7.2 Inspection

3.7.2.1 The Trap Door installation shall be inspected for quality of workmanship. All hardware shall be torqued and torque-striped and all components shall be properly aligned.

3.7.2.2 Trap Doors shall be tested for water tightness in accordance with Section

4.12

3.7.2.3 All Trap Door latches, hinges, and springs shall be tested to confirm their functionality.

3.7.2.4 The exterior release shall be tested to confirm its functionality.

3.7.2.5 The heater shall be tested to confirm its functionality.

3.7.2.6 The proximity sensor shall be tested to confirm its functionality.

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3.8 Pilot Bar and Support Brackets

3.8.1 The Pilot Bar Support Brackets shall be NDT and dimensionally inspected and repaired per OEM requirements or replaced with new brackets fabricated according to OEM requirements as needed. Refer to Table 1 for OEM drawing numbers.

3.8.1.1 The underframe structure surrounding the Pilot Bar Support Brackets shall be dimensionally and NDT inspected. If the brackets are removed, inspection shall be performed after removal of the brackets.

3.8.1.2 The Pilot Bar Support Brackets and surrounding portion of the underframe structure shall be painted according to OEM requirements after installation of any new brackets.

3.8.2 Inspection

3.8.2.1 The welds between the Pilot Bar Support Brackets and underframe shall be

NDT inspected to confirm that they are free from weld defects. The bracket position shall be dimensionally inspected in accordance with OEM requirements.

3.8.2.2 A new Pilot Bar provided by MBTA shall be installed to demonstrate proper fit-up. The Pilot Bar shall be removed prior to shipping and returned to MBTA separately.

3.9 Windows

3.9.1 The remaining damaged glazing and damaged window panels at the first and third windows on the left side of the car shall be removed. New windows and window panels provided by MBTA shall be installed according to OEM requirements, refer to Table 1 for OEM drawing numbers. Molding may be reused, unless damaged.

3.9.1.1 The side sheathing and framing surrounding the window shall be visually and dimensionally inspected and repaired as necessary.

3.9.1.2 The surface finish of the side sheathing shall be restored and repainted as necessary.

3.9.1.3 All insulation and sound deadening materials shall be inspected for damage and replaced as necessary with materials meeting OEM requirements.

3.9.2 Inspection

3.9.2.1 The window installations shall be inspected for quality of workmanship. All hardware shall be properly torqued and torque-striped and all components shall be properly aligned.

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3.9.2.2 Gaskets shall be inspected for pinching, gaps and cracking. The window assemblies shall be tested to verify that a watertight seal is achieved. Refer to Section 4.12 for water tightness test requirements.

3.10 Seat Cushions

3.10.1 All damaged or missing seat cushions shall be replaced with new units supplied by the

MBTA according to the OEM drawings, reference Table 1.

3.10.2 Inspection

3.10.2.1 The seat cushion installation shall be inspected for quality of workmanship.

Cushions shall be installed in the proper orientation and all hardware shall be properly torqued.

3.11 Carbody Corner

3.11.1 The exterior surface of both carbody corners on the No. 1 end shall be visually inspected. The fringe shall be repaired to remove dents. The surface finish of the fringe shall be restored to meet OEM requirements.

3.11.1.1 If cracks are identified, the fringe shall be removed and replaced as Hidden

Damage.

3.11.2 Inspection

3.11.2.1 The repaired carbody corners shall be visually inspected to ensure quality of workmanship.

3.12 Luggage Rack and Supports

3.12.1 The luggage rack and associated supports near the first damaged window shall be removed and replaced with new components provided by MBTA according to OEM requirements, refer to Table 1.

3.12.1.1 The surrounding luggage racks, supports, and walls near the damaged items shall be visually inspected.

3.12.2 Inspection

3.12.2.1 The luggage rack and supports shall be inspected for quality of workmanship. All hardware shall be properly torqued and all components shall be properly aligned.

3.13 Lighting

3.13.1 Three damaged light fixtures, one of which includes emergency lighting, shall be removed and replaced with new components supplied by the MBTA. Refer to Table 1 for OEM drawing numbers.

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3.13.2 Inspection

3.13.2.1 The lighting installation shall be inspected for quality of workmanship. All hardware shall be properly torqued and all components shall be properly aligned.

3.13.2.2 The lighting and emergency lighting shall be tested for functionality following installation.

3.14 Ceiling Panels

3.14.1 The damaged ceiling panel near the damaged windows shall be replaced with a new panel provided by MBTA in accordance with OEM requirements. Refer to Table 1 for OEM drawing numbers.

3.14.1.1 All equipment and structure in the area surrounding and above the ceiling panel shall be visually inspected once the ceiling panel has been removed.

3.14.2 Inspection

3.14.2.1 The ceiling panel installation shall be inspected for quality of workmanship.

All hardware shall be properly torqued and all components shall be properly aligned.

3.15 Pull Box

3.15.1 The No. 1 end, left side pull box and cover shall be removed and replaced with a new box fabricated and painted to the OEM requirements.

3.15.1.1 The underframe structure and brackets surrounding the pull box shall be NDT and dimensionally inspected after removing the boxes.

3.15.2 The internal wiring shall be visually inspected and the proper connection of all wires through the box shall be tested. All damaged wiring shall be repaired per OEM requirements. Refer to Table 1 for OEM drawing numbers.

3.15.3 Inspection

3.15.3.1 The pull box installation shall be inspected for quality of workmanship. All hardware shall be properly torqued and torque-striped. All wires shall be clearly labeled in accordance with the OEM drawings. Loose hardware, cut or worn cable insulation, burning, and corrosion shall not be permitted. All welds shall be NDT inspected to ensure that they are free from weld defects per the applicable AWS code.

3.15.3.2 The pull box shall be tested to verify a water tight seal is achieved. Refer to

Section 4.12 for water tightness test requirements.

3.15.3.3 The wiring shall be functionally tested per Section 4.7.

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3.16 Track Receiver Assembly and Brackets

3.16.1 Any remaining portions of the existing Track Receiver Assembly shall be removed and returned to the MBTA.

3.16.2 The Track Receiver Assembly Brackets shall be removed and replaced with new brackets fabricated to the OEM requirements. Refer to Table 1 for OEM drawing numbers.

3.16.2.1 The underframe structure surrounding the Track Receiver Assembly

Brackets shall be dimensionally and NDT inspected once the brackets have been removed.

3.16.2.2 After installation, the new Track Receiver Assembly Brackets and surrounding portion of the underframe shall be painted according to OEM

3.16.3 Inspection

3.16.3.1 The welds between the Track Receiver Assembly Brackets and underframe shall be NDT inspected to ensure that they are free from weld defects per the applicable AWS code. The bracket position shall be dimensionally inspected in accordance with OEM requirements.

3.16.3.2 A new Track Receiver Assembly provided by MBTA shall be installed to demonstrate proper fit-up. The Track Receiver Assembly shall be removed prior to shipping and returned to MBTA separately.

3.16.3.3 The Track Receiver Assembly function will be tested by MBTA following return shipment of coach 1722.

3.17 Air Piping

3.17.1 Air piping and fittings for the Main Reservoir (MR) and Brake Pipe (BP) on the No. 1 End, Left Side shall be visually inspected and leak tested. All damaged or leaking piping and fittings shall be replaced with new components meeting OEM requirements.

Reference Table 1 for OEM drawing numbers.

3.17.1.1 All damaged clamps and brackets for the air piping shall be removed and replaced with new components in accordance with the OEM drawing configuration.

3.17.2 Inspection

3.17.2.1 The installation of the air piping, fittings, clamps, and brackets shall be inspected for quality of workmanship. The piping shall be supported securely and there shall be no loose hardware.

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3.17.2.2 All repaired air piping and fittings shall be leak tested to verify that the system is completely sealed. Any leaks identified shall be repaired and the entire leak test repeated.

3.18 Low Voltage Junction Box

3.18.1 The low voltage junction boxes on both sides of the No. 1 End shall be visually and dimensionally inspected and repaired in accordance with the OEM drawing configuration. Reference Table 1 for OEM drawing numbers.

3.18.2 Internal wiring shall be visually inspected and the proper connection of all wires through the junction box shall be tested. All damaged wiring shall be replaced.

3.18.3 Inspection

3.18.3.1 The low voltage junction box installation shall be inspected for quality of workmanship. All hardware shall be properly torqued and torque-striped.

All wires shall be clearly labeled in accordance with the OEM drawings.

Loose hardware, cut or worn cable insulation, burning, and corrosion shall not be permitted. All new welds shall be NDT inspected to ensure that they are free from weld defects per the applicable AWS code.

3.18.3.2 The low voltage junction box shall be tested to verify a water tight seal is achieved. Refer to Section 4.12 for water tightness test requirements.

3.18.3.3 The wiring shall be functionally tested per Section 4.7.

3.19 Receptacles and Conduit

3.19.1 The following receptacles shall be removed and replaced with new components provided by MBTA according to the OEM requirements. Reference Table 1 for OEM drawing numbers.

3.19.1.1 480V Receptacle Assembly (No. 1 End, Left Side)

3.19.1.2 Low Voltage Receptacles (No. 1 End, Left Side)

3.19.1.3 Ethernet Receptacle (No. 1 End, Left Side)

3.19.2 The brackets used to mount the receptacles shall be dimensionally and NDT inspected once the receptacles are fully removed. All damaged brackets shall be repaired or replaced in accordance with the OEM requirements.

3.19.3 Conduit and wiring leading to the receptacles shall be visually inspected. All damaged conduit and wiring shall be repaired or replaced in accordance with the OEM

3.19.3.1 Clamps and brackets for the conduit and wiring shall be replaced as needed with new components meeting the OEM requirements.

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3.19.4 Inspection

3.19.4.1 All repairs performed shall be inspected for quality of workmanship. All wires shall be clearly labeled in accordance with the OEM drawings. Loose hardware, cut or worn cable insulation, burning, and corrosion shall not be permitted. All hardware shall be properly torqued and torque-striped.

3.19.4.2 Receptacle covers shall be tested to verify that the spring functions properly and that a water tight seal is achieved in the closed position.

Refer to Section 4.12 for water tightness test requirements.

3.19.4.3 The proper connection of all wires shall be tested by verifying the continuity of all pins according to Section 4.7.

3.20 Sander Box and Brackets

3.20.1 The sander box and brackets on the No. 1 End, Right Side shall be functionally tested and visually and dimensionally inspected according to OEM requirements. Reference Table 1 for OEM drawing numbers. All damaged items shall be considered Hidden Damage.

3.21 Interior Destination Sign

3.21.1 The interior destination sign on the No. 1 End, Lower Section shall be functionally tested and visually inspected according to OEM requirements. Reference Table 1 for OEM drawing numbers. All damaged items shall be considered Hidden Damage.

4 Common Work Requirements

4.1 The requirements of this section supplement the individual requirements described in

Section 3 and apply to all repairs performed by the Contractor. Additionally, where not specified within this specification, the Materials and Workmanship document in Appendix 2 shall apply.

4.2 Non-Destructive Testing (NDT)

4.2.1 All production welds shall receive NDT inspection in accordance with Section 4.2. Other

NDT inspection needs are defined in Section 3.

4.2.2 Visual Inspection (VT)

4.2.2.1 At a minimum, visual inspections shall check for wear, damage, deformation, section loss due to corrosion, and weld defects.

4.2.3 Dye Penetrant Inspection (PT)

4.2.3.1 PT inspections shall be performed in accordance with the latest revision of

ASTM E165.

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4.2.3.2 PT inspection acceptance/rejection criteria shall be as follows:

4.2.3.2.1 Welds: Acceptance criteria per applicable AWS code.

4.2.3.2.2 Non-cast base materials: Indications with a major axis longer than 1/8” shall be rejected.

4.2.3.3 The inspector performing the inspection shall be certified to perform the PT inspection and evaluate the results.

4.2.4 Magnetic Particle Inspection (MT)

4.2.4.1 Magnetic particle inspections, as required for each individual part, shall be conducted according to ASTM E709, by personnel certified to ASNT-TC-1A or approved alternate.

4.2.4.1.1 Half wave-rectified alternating current shall be used, sufficient to detect surface and sub-surface defects.

4.2.4.1.2 Adequate magnetic field strength shall be verified by the use of a “pie gage” (Field Strength Indicator).

4.2.4.1.3 The affected area shall be demagnetized to not more than 5 gauss upon completion of all magnetic particle testing.

4.2.4.2 MT inspection acceptance/rejection criteria shall be as follows:

4.2.4.2.1 Non-cast base materials: Indications with a major axis longer than 1/8” shall be rejected.

4.2.4.2.2 Welds: Acceptance criteria per applicable AWS code.

4.3 Welding

4.3.1 The Contractor shall be responsible for the quality of all welding performed by the

Contractor and any Subcontractors in accordance with this Specification.

4.3.2 All arc welding between stainless steel and carbon steel, HSLA, or stainless steel shall be performed in accordance with AWS D1.6 using an appropriate austenitic stainless steel filler metal, 309L or equivalent.

4.3.3 All arc welding between HSLA and carbon steel or HSLA shall be performed in accordance with AWS D1.1 or D1.3 using an appropriate HSLA filler metal with minimum tensile strength equal to or greater than the minimum tensile strength of the weaker base metal.

4.3.3.1 AWS D1.1 shall apply to steel of 1/8-inch and greater thickness.

4.3.3.2 AWS D1.3 shall apply to steel of less than 1/8-inch thickness.

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4.3.4 All resistance spot welding shall be performed in accordance with AWS D17.2/D17.2M, using requirements for Class B welds.

4.3.4.1 Surface burn and discoloration shall be removed by chemical cleaning, or an approved equal method, and sanding or polishing to match the surrounding surface.

4.3.5 Weld Qualification

4.3.5.1 Weld Procedure Specifications (WPS) shall be prepared for all welds in accordance with the applicable AWS code.

4.3.5.2 All WPS shall be fully qualified by welding tests that are documented on a Procedure Qualification Record (PQR). A separate PQR shall be prepared for each welded sample and associated set of tests. One PQR may support multiple WPS’s,

4.3.5.2.1 Weld qualifications shall include impact toughness testing performed using Charpy V-Notch specimens. Impact toughness in the weld heat affected zone (HAZ) shall be greater than 15 ft-lbs at -20°F.

4.3.5.3 All WPS shall be qualified by the Contractor or Subcontractor who will be performing the welds. Qualification samples shall be welded at the Contractor or Subcontractor’s facility using the procedures, consumables, backing (if applicable), and welding equipment that will be used for all production welds.

4.3.5.3.1 The use of WPS purchased from an external organization or the use of pre-qualified welds shall be prohibited.

4.3.6 Welder Qualification

4.3.6.1 Welders shall make only those welds for which they have been qualified according to the requirements of the applicable AWS standard.

4.3.6.2 Written welder qualification test records (WQTR) shall be made available for review at the MBTA’s request.

4.3.7 Documentation

4.3.7.1 All WPS and PQR shall be submitted for MBTA review and approval as part of the Welding Plan defined in Section 3.5.4.

4.3.7.2 Specifications for the purchase of welding consumables (i.e. electrodes, welding wires, and cover gases) shall be submitted for MBTA review and approval as part of the Welding Plan defined in Section 3.5.4.

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4.3.8 Production Welds

4.3.8.1 All production welds performed by the Contractor shall be 100% inspected in accordance with Section 4.2. Weld quality shall be in accordance the applicable AWS code.

4.3.8.1.1 All welds shall be inspected using Visual Inspection (VT).

4.3.8.1.2 Welds performed using austenitic stainless steel or other non-ferromagnetic filler metal shall be inspected using Dye Penetrant Inspection (PT) in addition to VT.

4.3.8.1.3 Welds performed using carbon steel, HSLA, or other ferromagnetic filler metal shall be inspected using Magnetic Particle Inspection (MT) in addition to VT.

4.3.8.1.4 Volumetric NDT inspection of production welds is not required by this

Specification, but may be requested at the discretion of the MBTA Project Manager in the event that weld defects are experienced by the Contractor or any Subcontractors.

4.3.8.2 Exterior production welds shall be finished to provide a flush surface, consistent with the visual appearance of surrounding areas on the Coach.

4.4 Straightening

4.4.1 Where possible, straightening shall be used to correct dimensional nonconformities.

The Contractor shall be responsible for determining the applicability of cold or hot straightening and ensuring that straightening operations do not cause cracking, tearing, or other defects in the part being straightened.

4.4.1.1 Cold straightening shall be used to correct minor dimensional nonconformities only.

4.4.1.2 Hot straightening shall be used to correct larger dimensional nonconformities.

4.4.2 The following requirements apply to hot straightening:

4.4.2.1 The Contractor shall set maximum limits for straightening temperature for each material that will be hot straightened. The temperature limits shall be based on industry standards, testing performed by the Contractor, or requirements elsewhere in this Specification. The maximum straightening temperature shall not cause residual changes to the mechanical properties of the material being straightened. For quench and tempered materials, the straightening temperature shall not exceed the tempering temperature.

4.4.2.2 Temperature measurements shall be performed by means of contact or non-contact thermometers. If non-contact thermometers are used, Kawasaki Commuter Rail Control Trailer Coach 1722

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4.4.2.3 If heating is applied using a torch, nozzles and heating technique shall be such that temperature gradients are limited and heating is distributed across the part being straightened. Localized melting of the material surface shall not be permitted.

4.4.2.4 If heating is applied using a torch, the torch shall be adjusted for a neutral flame. Carburizing flames shall not be permitted.

4.4.2.5 All parts shall be cooled in still air following hot straightening. Forced cooling shall not be used.

4.4.3 After cold or hot straightening, the entire straightened part shall be visually inspected.

Additionally, MT or PT shall be performed surrounding the locations of force application, mechanical fixation, and heat application, if used. All NDT inspection shall be performed in accordance with Section 4.2.

4.5 Dimensional Inspection

4.5.1 All mounting holes, including threaded holes, shall be inspected using calibrated gages.

4.5.2 Flatness and roughness of all mounting surfaces shall be verified per the OEM drawings.

4.5.3 Straightness and position of all brackets shall be verified per the OEM drawings.

4.5.4 All components installed by the Contractors shall be checked for proper position and alignment per the OEM drawings following installation.

4.6 Leak Test

4.6.1 Following installation, all piping systems shall be cleaned to remove dirt, metal chips, oily contamination, and moisture.

4.6.2 Prior to performing the leak test, the air system being tested shall be charged to the peak operating pressure provided in the Running Maintenance Manual.

4.6.3 Soap solution shall be applied to all fittings, valves, and other components. Bubbling of the soap solution indicates a leak. All leaks, regardless of severity, shall be repaired.

4.6.4 After making repairs, the entire leak test shall be repeated to verify that repair work did not cause any additional leaks.

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4.7 Functional Test

4.7.1 Functional tests shall be performed in accordance with the Running Maintenance Manual or Heavy Maintenance Manual, as applicable, for the MBTA Bi-Level Commuter Coaches manufactured by Kawasaki.

4.8 Wiring Repairs

4.8.1 Except as specified below, all damaged electrical wiring and connections shall be removed and replaced with new wiring and connections in accordance with OEM drawings and specifications, including but not limited to material, plating, wire gauge, insulation and jacket, markings and color, and connector configuration.

4.8.1.1 The Contractor may propose, for review and approval by the MBTA Project

Manager, a plan to run new wires while leaving the existing damaged wire(s) in place but inactive. The proposed plan must demonstrate that significant cost savings or lead time reductions would result without negatively impacting the vehicle’s long-term safety, reliability, or maintainability.

4.8.1.2 In limited cases, where completely replacing a damaged wire would require significant disassembly of the carbody, flooring, or interior fittings, the Contractor may propose, for review and approval by the MBTA Project Manager, a plan to modify the OEM configuration to allow for partial replacement of the wire. The proposed plan must demonstrate that significant cost savings or lead time reductions would result without negatively impacting the vehicle’s long-term safety, reliability, or maintainability.

4.8.1.2.1 All modifications shall comply with the Materials and Workmanship requirements provided in Appendix 2.

4.8.1.2.2 Any additional terminals or connectors shall be mechanically supported and environmentally protected.

4.8.1.2.3 Splices shall not be permitted.

4.8.2 Damaged conduits, cable trays, brackets, cleats, or other wire supports shall be replaced with new components per OEM drawings and specifications.

4.8.3 Insulation tests shall be performed in accordance with Section 4.9 on all electrical wiring and connections repaired by the Contractor.

4.8.4 Electrical Wiring and Connections

4.8.4.1 All wiring shall be performed by qualified, experienced wiring personnel using appropriate tools for stripping insulation, cutting, tinning, soldering, harness making, attaching terminals, and other wire fabrication tasks.

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4.8.4.2 Wire shall be protected from damage during all phases of equipment manufacture.

4.8.4.2.1 Wire shall not be walked on, dragged across sharp or abrasive objects, kinked or twisted, or otherwise mishandled.

4.8.4.2.2 The ends of wire shall not be permitted to lay on wet floors or other damp areas where moisture may be absorbed into the conductors.

4.8.4.3 There shall be no nicks in the insulation of any wire or cable.

4.8.4.3.1 Wire and cable with nicked or otherwise damaged insulation shall…