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JI. ~ ,,~=-Specification Of Electronic Toe Load Measuring Device

(Specification No.TM/SMlETLMD/218)(Second reprint incorporated revision upto 13.09.2012)

1.0 Scope:

This specifications covers the material, functional and technical requirements, inspectionand testing procedure of the Electronic Toe Load Measuring Device (ETLMD) which isuseful for measuring & recording the toe-load of elastic rail clips in-situ on railway track.

2.0 Reference: Following codes/documents have been referred to in this specification. Theupdated copy of latest version with correction slip/amendments shall be followed andavailable at the firm's works.

i) IS: 104-1979(Re-affirmed Specification for Ready mixed paint, brushing,2004) zinc chrome, priming

ii) IS:2074-1992 (Re-affirmed Ready mixed paint, air drying, red oxide, zinc2002) chrome, priming-Specification

iii) IS: 1632-1993(Re-affirmed Optical Instruments-Bubbles-Specification.1998)

iv) IS:2932-2003 Enamel, Synthetic, Exterior: (a) Undercoating(b) Finishing - Specification

v) RDSO drawing no. ETLMD and its part detailsTM/9909 (A It-3),TM/9909/1 (Alt-3) andTM/9910

3.0 Materials, Processing And Workmanship:

3.1 The quality of materials of all the component parts of device shall conform to theirrespective specifications indicated in the drawing or mentioned in this specification.

3.2 All components used in the device shall be free from manufacturing defects. All metalsurfaces shall be properly finished and rough and sharp edges shall be removed. All thecomponents used in Load Measurement and Display unit such as load cell, LCDindicator etc. shall be of good quality and of reputed make.

3.3 All the working parts and the parts subject to wear shall be accurately machined asspecified in the drawing.

3.4 The responsibility for obtaining the raw materials as specified in drawing required for themanufacture shall rest entirely with the supplier.

3.5 Heat Treatment:

3.5.1 The tong shall be suitably heat treated to withstand a repetitive load cycle of 1400 kgwithout any sign of deformation/breakage.

3.5.2 The link hanger and rotation handle shall be heat treated as specified in drawing. Afterheat treatment, the hardness shall be in the range of210-240 HB.

3.5.3 Steel Link shall be as specified in the drawing referred earlier.01

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3.6

4.04.1

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4.24.2.1

4.2.2

4.2.3

4.2.4

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All surfaces of the device shall be painted with one coat of zinc chromate primer to IS:104-1979 followed by one coat of red oxidelzinc chromate primer to IS:2074-1992 andtwo coats of synthetic enamel to IS:2932-2003 or other approved painting system. Thefinished surface of the load indicator shall be dark black-blue and base plate shall be ofyellow colour. Longer leg of the tong of tong set shall be painted red. For proper use ofETLMD in field red painted tong (longer one) shall be kept outside and this shallinvariably be mentioned by the manufacturer in the user manual. Rotating handle shall bepainted navy blue and legs, link hanger, tong, nuts & bolts shall be black.

Functional Requirements:

Electronic Load Measuring And Display Unit, Power Source, Gap Sensing Unit Etc:

Electronic Load Measuring and Display Unit shall be compact, rugged, shock, dust andwaterproof, electrically shielded and capable of functioning reliably in the severe fieldconditions normally encountered in Indian Railway system including on electrifiedsection. Overall external dimension of unit should not be more than indicated in thedrawing. Unit should contain compression type load cell for load measurement with allalphanumeric LCD type load display indicator with facility of low battery and over loadindication, rechargeable battery pack of reputed make for its operation, sockets forconnecting gap sensing device to activate peak hold facility etc, integrated with suitableand reliable electronic circuitry. It should also contain Non-volatile memory which shallbe capable of storing minimum 1000 Nos of Toe load readings with date time andlocation stamp. The unit shall also be provided with two sprit levels rigidly placed at thebase plate as shown in the drawing.

Load Cell and LCD Display Unit:

The load cell shall be compressive type of stainless steel/corrosive resistant materialconforming to relevant IS Specification for stainless steel for manufacture of load cell.Load cell and LCD display unit shall have the features mentioned in 5.0.The static load testing of Electronic Load Measurement and Display unit shall be carriedout in any Govt. approved NABL accredited laboratory or in Track Laboratory of TMMDirectorate, RDSO, Lucknow. In each case, before carrying out the static load tests, theload cell shall be compressed and released three times in quick succession upto 2000 kgload. If then it is compressed further, there shall be no further zero drifting.Each individual Electronic Load Measurement and Display Unit shall be pre-calibratedby the firm and verified by authorized representative nominated by the consignee forspecified measurement accuracy. The verification facility shall be provided by any Govt.approved NABL accredited laboratory or by Track Laboratory of TMM Directorate,RDSO, Lucknow. If verification facility is provided by Track Laboratory of TMMDirectorate, the payment in advance shall be made through demand draft payable toExecutive DirectorlFinance, RDSO, Lucknow. Each unit will be checked for itsmeasurement accuracy as here under:"Complete Load Measurement and Display Unit will be subjected to predeterminedcompressive loads in stages in UTM machinelProving ring at specified Load interval upto maximum 2000 kg load. Load indicated in the display unit will be compared withactual applied load as indicated in UTM machine/Proving ring and in no case loaddisplayed by the unit should show variation more than the specified accuracy i.e. (:t)0.5% of the rated capacity of load cell i.e. (:t) 10 kg. In case variation is more thanspecified accuracy, supplier will be informed accordingly for taking necessary correctiveaction".

Unit should calibrate itself at zero position automatically and at each measuring timeLCD should show 'Zero' reading quickly. No zero setting knob/screw or any manual

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4.2.5

4.34.3.1

4.3.2

4.4

4.4.1

operation is required at the time of calibration of the load cell.

Unit should not show the variation in load reading due to reduced strength of the batteryconsequent to its use. However, discharged/weak battery condition, leading to operationof unit and thus requiring recharging of battery, should be indicated by Low BatteryIndication in display unit.

Power Source:

Load measuring and display unit should be battery operated. There should be a provisionof easily available compact rechargeable battery pack of reputed make provided insidethe unit. Suitable charger should be provided to charge the battery pack provided insidethe unit.

Electronic circuitry and operative voltage should be so designed so as to give acontinuous working of minimum sixteen hours with fully charged battery pack. This willbe tested in TM Directorate of RDSO at the time of initial approval (for type test). However,this test, at the time of supply, will be carried out by the consignee or his authorizedrepresentative alongwith acceptance tests as per Inspection Clause 7.1. For testing, LoadMeasurement and Display Unit with fully charged battery pack will be kept in loadedcondition and it should not show low battery indication before 16 hrs. The battery lifeshall not be less than two years.

Gap Sensing Device and Peak Hold Facility:

Gap sensing device.as indicated in the drawing or of any other suitable design with feelerstrip of 0.05/0.10 mm. thickness to sense the incipient lifting of the toe of clip should beprovided with the device. At the point of lifting of toe, this device should activate thepeak hold facility of Load Measurement and Display Unit and freeze the toe load readingin display panel and record the same in its memory.

4.4.2 The device should be of such design so as to facilitate the easy replacement ofunserviceable feeler strip and easy to hold.

4.4.3 The thrust bearing, shown in the drawing shall be fitted within the rotation handle.

4.4.4 Manufacturer shall use only verified and tested Load Measuring and Display Unitapproved by RDSO.

4.5 Sprit Level:

4.5.1 Dimensions and other details of sprit levels shall conform to RDSO, Drawings No.TMl9909 (Alt-3) and TMl990911 (Alt-3).

4.5.1 The bubble used in the sprit levels shall be capable to retain its length, (length of AirBubble) at an elevated temperature upto 70°C.

4.5.2 The bubble and its construction including material shall conform to IS 1632-1993.

4.6 Data Transfer Module

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This module is used for transferring data from Display Unit to Personal Computer (PC)through USB Port of PC. Data transferred in Computer should create a file in ASCII

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I, form-..t cornpLltiblc to TMS "vnvyar~ as glvcu belOw:-

1. Location record format: I,RRRR,DDDD,SSSS,SSSS where I is 1 for this type ofrecord, RRRR is name of Railway, DDDD is name of Division and SSSS,SSSS is nameof the two stations in between toe load measuring is being done.

2. Kilometer record format: I,KKKK where I is 2 for this type of record, KKKK iskilometer post reading where toe load measuring is being done.

3. Toe reading record format: I,DDIMMNY,HH:MM,TTTT,LLLLL,TP,TP whereI is 3 for this type of record, DDIMMlYY is date, month and year, HH:MM is time,TTTT is toe load in Kilogram, LLLLL is the name of line and TP TP is name of thetwo Telephone poles in between toe load measuring is being done.

Thus file generated on PC will be in following format :-

1,RRRR,DDDD,SSSS,SSSS2bKKKK3,06/10/10,16:26,0835,LLLLL,TP,TP(, stands for blank space)This data can also be further accessed in EXCEL files. The supplier shall provide asoftware on CD (compact disc) for both the functions. This module shall be designed insuch a way that it can be fitted easily in Display Unit and does not contain any powersource or battery. Dimensions of this module should be maximum 7.0 cm X 6.0 em X 2.6cm.

4.7 Real Time Clock:

High stability real time clock with date is to be provided. Clock shouldeven after the battery is removed for a month howeverarrangement to set this clock is also to be provided.

functionsuitable

4.8 The Device shall have menu based and user friendly man machine dialogue byusing in-built/detachable key board which enables:

• Setting of date and time.• Setting of name of Railway, Division, from Station to Station upto 4 alphabets

maximum.• Setting of Kilometer upto 4 numeric maximum.• Setting of Line name upto 5 alphanumeric maximum.• Setting of 'from TP to TP' upto 2 numeric maximum each.

5.0 Technical Features:

(i) Capacity of load cell(ii) Display Resolution(iii) Display(iv) Operating Rail temperature(v) Measurement Accuracy(vi) Humidity Effect(vii) Zero (Sensitivity)

6.0 Tests:

: 2000 kg: 1 kg: 8 to 16 character alphanumeric display: (-)SoC to 70°C: (±) 0.5% of rated capacity ofload cell: Nil: Fast return to zeroe.

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6.1 Tests at the time of initial approval (Type Tests): Following tests shall be carried outat the time of initial approval. The manufacturer/supplier shall produce two proto typesofETLMD for carrying out following tests:

Dimensional Check: Each part of the device shall conform to the stipulated dimensionsof the drawing.

6.1.1

6.1.2 Application Test: Each proto type ETLMD shall be subjected to application test in astandard assembly. Specified load will be given to load cell 20 times. The assemblyincluding load cell shall withstand the load without any deformation.

Performance Test: During test the tong shall withstand a load of 1400 kg for 20 cycleswithout any sign of deformation/breakage.

6.1.3

6.1.4 Link hanger and rotating handle: The threaded portion of the link hanger and rotatinghandle should not show any deformation after conducting application and performancetest.

6.1.5 The aspects mentioned in clause 4.6 &4.8 shall also be checked.

6.1.6 If necessary, inspecting official may ask for dismantling of the device for checking itsparts.

6.1.7 RDSO will be at liberty to carry out all or some of the type tests on any of the devicesupplied to a consignee by the manufacturer on receipt of a complain or for quality checkon its own. The facilities necessary for such tests shall be provided by the manufacturer.

6.2 Tests at the time of supply (Acceptance Test): Tests as per 6.1.1 to 6.1.5 shall becarried out at the time of supply to railways:

7.0 Inspection:7.1 The inspection of Electronic Toe Load Measuring Device against zonal railways

P.O.shall be carried out at the premises of manufacturer by the consignee or hisauthorized representative. Minimum level of the inspecting official shall be SE (SectionEngineer). 05% or min. 2 nos. of the device per 10tIPO (randomly selected) shall besubjected to dimensional check, application test, performance test and tests for checkingthe aspects of clause 4.6 & 4.8 for which necessary facilities shall be provided by themanufacturer. If necessary, inspecting official can ask for dismantling of device forchecking of its parts.

7.2 Prior to giving a call to the inspecting authority for inspection and testing of device,the tenderer/manufacturer shall ensure that all the ETLMD are ready in all respect andin assembled condition after testing by manufacturer themselves.

7.3 In the event of the tests/inspection not being carried through to the completion due tooffer of incomplete ETLMD or other reasons attributable to tenderer/manufacturer andit is required for the representative of the inspecting authority to go again or morenumber of times to the works of the tenderer/manufacturer for continuing and/orcompleting inspection of already offered incomplete ETLMD, thetenderer/manufacturer shall reimburse to the purchaser the costs of representative(inspection team's) visit to the works for the inspection.

8.0 Warranty & AMC:8.1 The supplier shall warranty the material covered by the specification to be free from

defects under normal use and service. His obligation under this warranty shall be limitedto repair the device and replace free of cost those parts which shall be found defective

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within one year for manufacturing and two years for material defects from the date ofreceipt by the consignee.

8.2 During procurement of the device railways should go post-warranty AMC with thesupplier for a pre-determined period as decided by the purchaser railway. This shall beincorporated in the tender document as a condition of contract/Tender/Supply ..

9.0 Service Facility and Spare Parts (including tools):

9.1 Each device shall be supplied with 3 sets of tong & 1 set of steel link as spares completewith steel link grip nuts and bolts and three feeler gauge strips of the gap sensing deviceas per specification and drawings.

9.2 The manufacturer/supplier shall have a good service network throughout the country forquick and easy access to the users. A prompt response to the call of the customer isexpected in case of any problem experienced in field.

10.0 Documentations:

10.1 Detailed operating manual, maintenance and service manual shall be specially preparedand two copies each of the same shall be supplied with each ETLMD.

10.2 Copies of the maker's certificate guaranteeing the performance of the ETLMD should besupplied in duplicate along with the delivery of each ETLMD.

11.0 Training and Commissioning:

11.1 The service engineer shall guide the operating and maintenance staff duringcommissioning ofETLMD for proper handling and operation.

11.2 Adequate training for operation and maintenance of the ETLMD shall beimparted at consignee end during supply which shall be treated as part ofcommissioning.

12.0 Marking And Packing:

12.1 Each ETLMD shall be legibly and indelibly marked with the following details:(i) Name and trade marklbrand of the manufacturer.(ii) Capacity.(iii) Month & year of supply.

12.2 The device shall be packed in an Iron sheet box of 20 Gauge (1.0 mm thick) providedwith proper locking arrangement and carrying handle.

12.3 The device shall be supplied packed according to best trade practice.(£.

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