Alabama State Port Authority Construction Specifications Project Name: TASD 802 Locomotive Repower Location: Alabama State Port Authority Terminal Railway (TASD), Mobile, Alabama AFE # 2641 CN # 11-107-01 October 24, 2011 i | Page CONSTRUCTION SPECIFICATIONS INDEX SECTION 101 - GENERAL PROVISIONS ........................................................... 1 SECTION 102 - SUMMARY OF THE WORK....................................................... 2 102.01 SUMMARY ......................................................................................................... 2 102.02 WORK COVERED BY THE REQUISITION AND PROPOSAL DOCUMENTS ..... 2 102.03 WORK SEQUENCE ............................................................................................ 2 SECTION 103 - SPECIFICATIONS FOR THE WORK ........................................ 3 103.01 INTRODUCTION ................................................................................................ 3 103.02 GENERAL REQUIREMENTS ............................................................................. 3 103.03 CONFIGURATION AND STYLING...................................................................... 4 103.04 CARBODY .......................................................................................................... 5 103.05 TRUCKS SYSTEM.............................................................................................. 6 103.06 BRAKING AND AIR SYSTEMS ........................................................................... 8 103.07 ENGINE .............................................................................................................10 103.08 AUXILIARY POWER AND CONTROL SYSTEMS ..............................................12 103.09 CAB AND SHORT NOSE ...................................................................................15 103.10 SAFETY ACCESSORIES AND APPURTENANCES ..........................................18 103.11 LIGHTING SYSTEMS ........................................................................................20 103.12 MISC..................................................................................................................21
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SECTION 101 - GENERAL PROVISIONS 1 SECTION 102 - SUMMARY ... · Alabama State Port Authority Construction Specifications Project Name: TASD 802 Locomotive Repower Location: Alabama
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Alabama State Port Authority Construction Specifications
Project Name: TASD 802 Locomotive Repower
Location: Alabama State Port Authority Terminal Railway (TASD), Mobile, Alabama
AFE # 2641 CN # 11-107-01 October 24, 2011 i | P a g e
CONSTRUCTION SPECIFICATIONS
INDEX
SECTION 101 - GENERAL PROVISIONS ........................................................... 1
SECTION 102 - SUMMARY OF THE WORK ....................................................... 2
103.03.02.e Stencil “F” is located on the side sills, nearest the front end.
103.03.02.f Other Style and Paint Modifications Catwalks and short nose shall be coated with black non-skid.
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103.03.03. Identification
103.03.03.a Automatic Equipment Identification (AEI) Tags 1) Two (2) Static AEI tags - Ametech #AT5110 shall be installed
2) The AEI tags will be securely mounted directly to the side sill.
3) The tags are not to be painted.
103.03.03.b Number Boxes Front and rear number panels are of plastic construction and shall
be black on white and with the number 802.
103.03.03.c Stencil Stencil “F” is located on the side sills, nearest the front end.
103.04 CARBODY
103.04.01. Underframe 103.04.01.a Underframe shall be reconditioned, damage-free and structurally
intact. 103.04.01.b Any changes shall be upon TASD approval and change order.
103.04.02. Fuel Tank and System
103.04.02.a Fuel Tank 1) New 1,100 gallon fuel tank which meets AAR S-5506
standards shall be provided.
2) One filler pipe located on each side of tank – shall be
inspected to be structurally intact and free of defects.
3) Snyder sight shall be mounted on each side of the fuel tank.
4) Standard Manual Dial fuel gauges shall be installed.
103.04.02.b Waste Retention Tank Car body shall be sealed to route effluents to a 60 gallons holding
tank, integral to the fuel tank.
103.04.03. Anti-climbers End Walkways shall be installed. AAR S-580 compliance is NOT
required.
103.04.04. Pilot Plat 103.04.04.a Front End Arrangement - basic pilot to be repaired as necessary. 103.04.04.b Rear End Arrangement - basic pilot to be repaired as necessary.
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103.04.01. Walkways and Handrails
103.04.01.a Crossover walkways provided on both ends to facilitate crossing between locomotives in MU.
103.04.01.b Chains with breakaway links shall be installed.
103.04.02. Steps 103.04.02.a Bottom step shall comply with FRA 231.30.
103.04.03. Lifting / Jacking Devices 103.04.03.a Combination sling/jacking pads welded to the under frame side
sills, near the longitudinal bolster center - shall be inspected and/or reconditioned as necessary.
103.04.04. Couplers and Draft Gear
NOTE: Couplers and draft gears shall be shipped to the ASPA Terminal
Railway (TASD) by the selected repower contractor immediately upon
notification to proceed (NTP). Receipt of the couplers and draft gears by
the TASD must be within two (2) weeks of the NTP. TASD will install the
couplers and draft gears prior to shipment of the locomotive to the
repowering facility. The installed couplers and draft gears as specified
below will remain on the repowered locomotive.
103.04.04.a New alignment type E coupler shall be shipped to TASD and
installed by TASD.
103.04.04.b New 390 draft gear pockets shall be shipped to TASD and
installed by TASD.
103.04.04.c NC 390 with alignment control draft gears shall be shipped to
TASD and installed by TASD.
103.04.04.d Uncoupling Mechanism shall utilize the standard manual
uncoupling levers.
103.04.04.e Coupler height shall meet FRA requirement of 31.5 to 34.5 inches
from top of rail to center.
103.05 TRUCKS SYSTEM
103.05.01. Trucks 103.05.01.a Two 2-axle truck assemblies with DC traction motors shall be
reconditioned, damage-free and structurally intact.
103.05.01.b Any changes shall be upon TASD approval and change order.
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103.05.02. Traction Motors
103.05.02.a Traction Motors shall be controlled by NRE Electronics NFORCE Traction Control System or equivalent system that produces the same or greater tractive effort.
103.05.02.b Traction Motor Mounting 1) Four (4) D77/ D78 traction motors -basic rebuilt- shall be
installed.
2) Motor connection to carbody cable shall be made using
standard solder terminals.
3) Each traction motor shall be grounded to the carbody by a
cable no less than #6 AWG size.
4) New traction motor bearing rings – with dual seal support –
shall be installed.
5) Individual traction motor ISOLATION/ CUT-OUT switches
shall be provided on engine control panel.
6) New plastic pedestal liners shall be installed.
7) Traction motor nose pads shall be qualified, repaired, or
replaced as necessary.
103.05.02.c Traction Motor Cooling The Equipment Blower Assembly shall be driven by a 3-Phase 240 VAC motor – with ducting to provide cooling air to the traction motors and motor controllers.
be inspected, qualified and replaced as necessary.
103.05.04. Suspension System 103.05.04.a All springs shall be qualified and replaced as necessary.
103.05.05. Wheel / Axle / Gear 103.05.05.a Wheels shall be re-used – same size as received. 103.05.05.b Gears, with a ratio of 62:15, shall be re-used. 103.05.05.c Traction motor gear cases - with crater filled - shall reconditioned,
damage-free and structurally intact. 103.05.05.d Gear case halves shall be shall reconditioned, damage-free and
structurally intact. 103.05.05.e Axles shall be qualified repaired and/or replaced as necessary (via
Change Order).
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103.05.06. Journal Bearings and Housings
103.05.06.a Rebuilt Hyatt journal boxes/ bearings shall be reconditioned, and/ or repaired as per joint inspection with TASD and work order change request.
103.05.06.b “3-in1” journal box wear plates shall be reconditioned, and/ or repaired as per joint inspection with TASD and work order change request.
103.06 BRAKING AND AIR SYSTEMS
103.06.01. Air Brake System
103.06.01.a The Air Brake system shall be NYAB - CCB 26 or equivalent.
103.06.01.b All air piping shall be reconditioned, and/ or repaired as per joint inspection with TASD and work order change request.
103.06.01.c Air Brake Connections 1) Duplex air end connection with ball type c/o cocks shall be
applied and vented.
2) Main reservoir cock shall be vented when closed and direct
air away from operator.
3) EBV brake shall be vented to a position below the cab
floor.
4) Brake pipe shall be located on both sides of coupler when
facing the end plates.
103.06.01.d Emergency Brake Emergency brake valve in cab shall be provided.
103.06.01.e Pneumatic Control 1) Instantaneous PC knockdown to idle and brake pipe
charging cutoff in the event of an Engineer Induced
Emergency or a Fireman Induced Emergency.
2) Six (6) seconds delay PC knockdown for train initiated
emergency (break-in-two) – including while in Motoring.
3) Six (6) seconds delay on penalty brake application
(overspeed, etc).
4) Independent brake valve control pressure shall be set for
45 PSI.
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103.06.02. Air Compressor
103.06.02.a New GAR37 variable speed 240 VAC 3-Phase electric motor driven rotary screw air compressor or equivalent.
103.06.02.b Air Compressor Protection - short and open circuit protection shall be provided.
103.06.02.c Air compressor MU synchronization shall be provided.
103.06.02.d Air compressor set to load at 130 PSI and unload at 140 PSI.
103.06.02.e Air compressor shall provide a minimum displacement of 140 CFM at maximum operating rpm.
103.06.03. Main Reservoir
103.06.03.a Main Reservoir
Main Reservoirs shall be cleaned, inspected, and re-applied.
103.06.03.b Safety Valve Setting Main reservoir safety valve shall be set at 150 PSI.
103.06.03.c Air Filters 1) The main reservoir and auxiliary reservoir air system shall
be equipped with two (2) final filters.
2) The filters shall be equipped with two (2) air actuated drain
valve.
103.06.03.d Air Dryer 1) Air Dryer - 975-101 Normal Volume or equivalent shall be
installed.
2) Air dryer circuitry shall be protected by the utility circuit
breaker.
103.06.03.e Drain Valves & Actuation 1) Two main reservoir combination automatic/manual drain
valves shall be installed on the main reservoirs.
2) Exhausted air shall be piped into 1" pipe mounted flushed
with the bottom (not below) of the fuel tank. Air shall be
deflected in a manner as not to blow holes in ballast.
3) Actuation of automatic blow down valves shall be cycled by
the loading and unloading of the air compressor.
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103.06.04. Sanding System
103.06.04.a Sanding Control 1) Sanding - Intermediate Inboard/Outboard Sanders
reconditioned, and/ or repaired as per joint inspection with
TASD and work order change request.
2) Automatic and Manual sanding for wheel adhesion
enhancement in direction of travel shall be provided.
3) Electrical control of emergency, lead truck, and manual
sand to disable sanding at 0 MPH. At 0 MPH (testing)
Emergency Sand will only applied if manual sand is also
selected and will only be applied for 10 seconds or after
release of manual sand switch.
103.06.04.b Sand Traps and Related Devices 1) A total of eight sand traps shall be reconditioned, and/ or
repaired as per joint inspection with TASD and work order
change request.
2) Sand boxes shall be reconditioned, and/ or repaired as per
joint inspection with TASD and work order change request.
3) Sand fillers shall be mounted on side of the locomotive (not
on top of the hood).
103.07 ENGINE
103.07.01. Engine System
103.07.01.a General Engine Specification 1) Cummings QSX 15 In-Line, 4-Cycle, 6 Cylinder or
that meets USEPA emission regulations for 2012 under
Tier 3.
2) Displacement = 915 cu. in. 15 Liters
3) Rated Power = 400-600 HP 298-447 KW
4) Peak Torque 1500-2050 lb-ft 2035-2779 N•m
5) Bore and Stroke 5.39 in x 6.65 in 137 mm x 169 mm
6) Aspiration Turbocharged and Charge Air Cooled
7) Oil Capacity 24 Gallons 90.8 Liters
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8) Length 56.8 in 1443 mm
9) Width 40.6 in 1032 mm
10) Height 51.1 in 1298 mm
11) Weight (Wet) 3,166 lb 1,436 kg
12) (Dry) 3,009 lb 1,365 kg
13) (After-treatment System)*** 125 lb 57 kg
14) Variable Geometry Turbocharger
15) Total Engine protection alarm and shutdown functionality
for oil and water pressures, temperatures and levels.
16) All fuel, oil and water hoses and connections certified to -
40F.
17) All gasket materials certified to -40F.
103.07.01.b Main Alternators New alternators shall be installed as part of the new diesel
generator package - 240 Volt, 60 Hz @ 1800 rpm
103.07.02. Engine Cooling and Lube System
103.07.02.a Engine Lubrication System 1) Each GenSet contains a system that automatically
replenishes engine oil, utilizing an oil supply tank that
holds 14 gallons of oil.
2) Two sight glasses are mounted on the left side of the tank
to monitor oil level in the tank.
3) Each GenSet contains a lube oil system suitable for a
minimum of 184 days between services – with oil
sampling.
103.07.02.b Engine Cooling System 1) New mechanical bond radiators with coolant sensor shall
be installed.
2) The radiator fan shall be driven by a three phase AC
motor.
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103.07.03. Diesel Particulate Filters (DPF)
103.07.03.a DPF system will be regenerative manufactured by the engine manufacturer for specific use on the selected diesel engine and will be designed to regenerate during normal operation.
103.07.03.b DPF system will be designed to not require replacement during useful life of the engine.
103.07.03.c Each DPF module shall be designed for easy removal by a single mechanic in less than 1 hour with standard hand tools, expecting any tools necessary to overcome the theft prevention system.
103.08 AUXILIARY POWER AND CONTROL SYSTEMS
103.08.01. Control Systems The control system will be a NRE Electronics NFORCE microprocessor or
equivalent microprocessor system with operator interface panel designed
to maximize the adhesion of the traction motors and monitor as many
practical system parameters and log fault data as follows:
103.08.01.a Contactor and Relay Control 1) The Microprocessor will control the following contactor and
relay pick-up and drop-out:
Power Contactors, Reversing Transfer Switches, Air
Compressor Loading Relays and Contactors, Air
Compressor Drive Motor Contactors, Ground Relay, Alarm
Relay, Load Shedding Contactor, Traction Motor Cut Out
Relay, and Equipment Blower Contactor.
103.08.01.b Functions to be Displayed 1) The Microprocessor will monitor and have available for
display with a laptop, a serial connection to an onboard
computer and an Operator Interface panel and will display
the following functions:
Generator, Voltage and Current of each Gen Set, All
Traction Motor Currents, All Traction Motor Volts, Throttle
Notch, Contactor and Relay Position, Air Compressor
Cycle, Battery Charging Voltage and Current, Generator
Set Fault and Warning Status, Train line Status, Total
Horsepower, Locomotive Speed, Main Reservoir Pressure,
Sanding Status, and Engine RPM
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103.08.01.c Microprocessor Controlled Systems
1) The Microprocessor will control the following systems:
Wheel Slip Detection and Correction including Auto
Sanding, Traction Power Regulation, Air Compressor
Functions, and Auto Start/Stop Functionality as per AAR S-
5502.
103.08.01.d Fault Monitoring 1) The Microprocessor will log the following fault conditions:
Ground Fault, Engine RPM, Generator Set Fault and
Warning, Over and/or Under Current and Voltage (Gen
Set, Traction Motor, Air Compressor Motor, Equipment
Blower, Low Voltage Power Supply and DC Chopper),
Contactor or Relay Fault, Undesired Horsepower Output,
Battery Charging Failure, and Air System Failure.
103.08.01.e Fault Log Snapshot 1) The Microprocessor will “Snapshot” the following
3) Remote download port shall be installed. Download cable
shall be supplied.
103.10.02.b Alerter - Integral to Event Recorder 1) The alerter speed-activation time intervals will be in
accordance with AAR Standard S-5513.
2) Alerter Reset button shall be provided as defined in the
Control Console section.
103.10.02.c Speed Indicator Type Q1820 or equivalent shall be installed. 1) Speed Signal - 60 PPR
2) Speed indicator shall be accurate to within 3 MPH
tolerance for speeds of 10 to 30 MPH; and within 5 MPH
tolerance above 30 MPH
103.10.03. GPS and Remote Diagnostic
103.10.03.a NCOMPASS or equivalent shall be installed.
103.10.03.b GPS- Integral to the NCOMPAS System or equivalent shall be provided.
103.10.04. Crossing Bell
103.10.04.a Reuse air-actuated bell.
103.10.05. Horn
103.10.05.a Two (2) electric over air operated three chime horns (with two chimes facing forward and one facing the rear of the locomotive) shall be mounted on the side of the locomotive (not on top of the hood).
103.10.05.b Horn(s) shall be operated from a standard magnet valve and controlled by a horn switch
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103.11 LIGHTING SYSTEMS
The following sections describe the requirements of the lighting system for both the
exterior and interior lights of the locomotive. The lighting system includes headlights,
ditch lights, interior lighting, and compartment lights.
103.11.01. Headlights
103.11.01.a Two (2) headlights shall be provided at each end of the locomotive.
103.11.01.b Headlight type: PAR-56, 75-Volt.
103.11.01.c Headlights shall be controlled by a three position switch.
103.11.01.d Label “75 Volt Bulbs” shall be applied to both ends
103.11.02. Ditch Lights/ Crossing Lights
103.11.02.a Two (2) ditch lights will be at both ends of the locomotive.
103.11.02.b Ditch light type: PAR-56, 75- Volt.
103.11.02.c Ditch lights shall be controlled by a three position switch.
103.11.03. Number Lights
103.11.03.a Fully illuminated at each end of the locomotive.
103.11.04. Exterior Lights
103.11.04.a Platform Lights shall be required
103.11.04.b Step Lights shall be required
103.11.04.c Ground Lights shall be required.
103.11.04.d Mainframe Lighting shall be required. 1) Four (4) angled lights shall be mounted on each side of the
locomotive, angled down at 45 degrees.
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2) This feature increases the locomotive visibility and lights
up the areas outside the locomotive.
103.11.05. Interior Lights 103.11.05.a Cab lights will include two (2) overhead lights - located at the
sides of the locomotive cab.
103.11.05.b Reading light - one (1) for Conductor’s side shall be installed..
103.11.06. Compartment Lights 103.11.06.a Chopper Compartment - Two (2) light shall be installed
103.11.06.b Air Compressor Compartment - Two (2) lights shall be installed
103.12 MISC
103.12.01. Additional Requirements
Software and instructions shall be provided to TASD to facilitate reboot of
systems.
103.12.02. Drawings / Documentation
103.12.02.a The following shall be provided in electronic and hard copy formats.
1) Clearance Diagram (locomotive dimensions and
capacities)
2) General Arrangement (component – part – identification)