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Tender for air dryer and filter for 3000/3100 series railcars.

Exerpts from tender - for official tender information refer to the SA tenders website and search for provider "TransAdelaide". Otherwise for personal copies download this unofficial copy.

1. SCOPE

This specification is for the design, supply and installation of a compressed air dryer and filter system to 10 (ten) 3000/3100 class railcars. The specification covers the technical requirements for a membrane type compressed air dryer and filter system but also includes brackets, other non proprietary items and documentation required to ensure that when fitted the system is complete and only requires ongoing system checks and preventative maintenance.

2. OPERATIONAL CONDITIONS

Air Compressor: Knorr Bremse VV 110/200-1
4 cylinder, 2stage, reciprocating type with 3 low compression cylinders and 1 high compression cylinder.
Air Flow Rate: 560 Litres per minute @ 800 kPa
Delivery Pressure: 700 to 800 kPa (normal cycling)
Compressor Cycle Time (Typical Service): 1 minute on, 5 minutes off
(Emergency) 2 minutes on, 5 minutes off
(Initial Start Up): 8 minutes
Control Voltage: 24 Volts d.c. (nominal)
Shade Air Temperatures: 0 to 45 degrees C
Aftercooler Exit Temperature: Assumed 10 degrees C above ambient

3 PERFORMANCE REQUIREMENTS

3.1 The drier shall reduce the pressure dew point in the main reservoir to at least 15T degrees C below the current ambient air temperature for the full shade air temperature range, given in clause 2 above, during charging of the main reservoirs from zero pressure and on all subsequent normal cycling.

3.2 The percentage purge flow must be adequate to maintain drier performance indefinitely, even in emergency working conditions. This must be demonstrated by testing on the first fitted railcar. The purge flow setting must be tamper proof.

3.3 Pre-filtration is required prior to the compressed air passing into the membrane drier. A minimum of 2 stage filtration is required, stage 1 providing liquid water removal and stage 2 oil removal. The filter bodies should be of sufficient size to ensure that at least a 12 month element life is achieved.

3.4 Whilst the first pre-filter shall remove all of the water condensed by the after-cooler the second filter must be capable of removing oil and particulate down to 0.01 microns.

3.5 A third pre-filter may be provided but would be required to be capable of removing oil vapour from the compressed air system.

3.6 Pre-filters are to be easily serviceable, in-situ element change time (removal and replacement) is to be less than 5 minutes.

3.7 The first and second stage filtration are to have well functioning and easily serviceable demand operated auto drains.

3.8 The coalescing pre-filters are to have Pressure Drop indicators fitted.

4 INSTALLED ENVIRONMENT

4.1 The pre filters and membrane drier are to be mounted on the railcar under-frame and therefore subject to occasional ballast strikes dust and other general atmospheric conditions. The filters, dryers, pipe or hoses shall be of robust construction sufficient to withstand a ballast strike of a 0.2 kg weight stone at a velocity of 100 km/hr without rupture or they must be protected by stone guards.

4.2 The system is to be located in the compressed air system between the compressor after cooler and the main reservoir check valve.

4.3 The weight of the equipment and mounting brackets is to be documented in the design submitted with the tender. The mounting shall withstand vertical accelerations of 5 g upwards and 1.5 g downwards and 4 g laterally and longitudinally.

4.4 Should any electrical wiring be required for operation control purposes then it shall be shielded within flexible conduit.

5. WARRANTY - (removed. 12 months)

6. SCHEDULE FOR THE WORK

The successful contractor or contractors will provide a schedule for the work to be undertaken. It is expected that work should commence during February 2002 and be completed before the end of June 2002.
The schedule will detail the length of time required to complete fitting of all air drier components on each railcar and be based on no more than two railcars being provided at any one time.

7. LOCATION OF THE WORK SITE

The successful contractor or contractors are required to nominate the work site where they expect the work will be carried out. If at the Adelaide Maintenance Centre the contractor will have to negotiate with Goninan for a suitable location to do the work and for the use of any facilities or utilities required. If not at the Adelaide Maintenance Centre contractors are reminded that they will require a facility with Broad Gauge rail access to the Adelaide metropolitan broad gauge rail network.

8. RAILCAR AVAILABILITY

As mentioned above in clause 6 no more than 2 railcars will be provided at any one time for the work and release of the railcar will require negotiation with Goninan at the Adelaide Maintenance Centre. Due to the limited availability of railcars it may be necessary for the contractor to share the railcar with other contractors undertaking other work or modifications at the same time. This will be negotiated with the successful contractor or contractors at the time on a railcar by railcar basis.

9. PAYMENT (removed. Paid on successful trials, 5% retained until end of warranty)

10. MAINTENANCE, OPERATIONAL MANUALS AND TRAINING

10.1 Three copies of all documentation shall be provided and maintenance check lists are to be integrated into the current maintenance schedule cycles of 6, 12, 24, 48 and 96 weeks and a 15 year component change out period. The level of inspection and preventative maintenance increasing with each increased cycle period.

The documentation shall cover the following:

The documentation shall be clear, concise and suitable for the use by maintenance staff. The 3 copies of the documentation is to be provided within one week after the acceptance of the first system fitted.

One copy of each 'as built' drawing, schematic or wiring diagram shall be provided on plastic film suitable for reproduction as well as in DXF format on 3.5 inch 1.44 Mb floppy disk. (ed: they haven't specified the logical disk format, most likely Microsoft's File Allocation Table (FAT) format)

10.2 The successful tenderer shall provide training for up to 5 of the maintenance provider's staff.

11. MAINTENANCE EQUIPMENT/TOOLS

The requirement for and the cost of any special equipment or tools, needed to maintain the items supplied in good condition, must be stated in the submission of this tender bid.

12. CONTRACTOR'S RESPONSIBILITIES (removed)

13. SPECIAL REQUIREMENTS

The successful tenderer (the contractor(s)) engaged from this tender call is required to demonstrate they have the adequate expertise and experience to undertake this work. Preference will be given to those contractors that can demonstrate that they have their product installed on other railcars or public transport vehicles.


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