Doc No.

GR/TD/6969
R&D CENTER Date 15.02.2025
BEML LIMITED, BANGALORE Rev. No 1
Page 1/13

PROCUREMENT TECHNICAL SPECIFICATION (PTS)

OF
EP BRAKE SYSTEM WITH MICROPROCESSOR
FOR
8W CMV (SG) WITH CBTC - CMRL

LoA No.: CMRL/SYS/CP26/ARE02A/003/2024, Dtd: 27.11.2024

Reference Document: Part 2 – Section VI B: ERTS – DM&P CMV

Customer: CHENNAI METRO RAIL LIMITED (CMRL)

Name Date Signature

Approved By S. HARI KUMAR 15.02.2025

Reviewed By S. HARI KUMAR 15.02.2025

Prepared By MANOHAR YADAV 14.02.2025

 Doc. No. GR/TD/6969
PROCUREMENT TECHNICAL SPECIFICATION (PTS) Date 15.02.2025
OF Rev. No. 1
EP BRAKE SYSTEM Page 2/13

REVISION HISTORY:
Rev. No. Clause No. Page No. Changes Revision Date
- - - - -

BEML LIMITED
 Doc. No. GR/TD/6969
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Table of Contents

SL. No. Description Page No.

1.0 Introduction 4
1.1 General 4
1.2 Climatic Conditions 4
1.3 Operating Environments 5
2.0 Abbreviations 6
3.0 General Requirements 7
3.1 Defining of unclear aspects 7
3.2 Responsibility of sub-contractor 7
3.3 Eligibility Criteria 7
4.0 Brake System 7
5.0 Interface Requirements 8
6.0 Responsibilities 9
7.0 Spare parts 10
8.0 Design Submission 10
8.1 Design Information 10
8.1.1 General 10
8.1.2 Design 10
8.1.3 Testing of Air Brake equipments 10
8.1.4 Vehicle Level testing 10
8.1.5 Training 12
9.0 Operation & Maintenance Manual 12
10.0 Warranty 12
11.0 Handing over 12
12.0 Data submission schedule 13
13.0 Enclosure 13

BEML LIMITED
 Doc. No. GR/TD/6969
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1. Introduction
1.1 General
This document describes EP type Brake System with Microprocessor to be design, manufacture
& supply for 8W Catenary Maintenance Vehicle (SG) with CBTC for CMRL Phase 2 –corridor 3,4
& 5 Project.
BEML shall carry out all required works and activities as supplier for 8W Catenary Maintenance
Vehicle (SG) with CBTC, while the sub-contractor shall be responsible for all works required in this
PTS with regard to EP Brake System with Microprocessor and shall be responsible for supporting
the BEML activities for installation & testing (at BEML works) and commissioning at CMRL Phase
2 –corridor 3,4 & 5 Project.

1.2 Climatic Conditions:

The 8W CMV (SG) with CBTC shall be in continuous operation during the varying atmospheric
and climatic conditions and should be designed to use on CMRL Phase 2 –corridor 3,4 & 5
Project.

Ambient Temperature 0OC - 55OC

Maximum relative Humidity 100%
Max. Temperature in Sun 75 OC
The equipment, subsystem and their mounting
arrangements shall be designed to withstand
satisfactorily vibrations and shocks encountered
in service.
Vibration
a) Maximum acceleration- 3.0g
b) Maximum longitudinal acceleration- 5.0g
c) Maximum train acceleration- 2.0g
where g being acceleration due to gravity
The rainfall is fairly heavy and during dry weather the
atmosphere is very dusty. The car should be able to
Rainfall negotiate waterlogged track with water level about 100
mm above the rail top for which the equipment should be
suitably designed.
High wind speed in certain areas, with wind
Wind Speed
pressure reaching 150 kg/m2
Pollution severity level “VERY HIGH” as per IEC-60815 Latest edition

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 Doc. No. GR/TD/6969
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1.3 Operating Environments:

The dimensional operating and other requirements for 8W Catenary Maintenance Vehicle (SG)
with CBTC as shown in Table:

Track Gauge 1435 mm

120 m at Elevated & grade sections.
Minimum radius of curve 200 m at Underground,
100 m Depot & other sections.
Maximum super elevation 120 mm
Cant deficiency 85 mm
Maximum wind pressure In compliance to IS [Link] latest
Shall conform to the kinematic envelope &
Maximum moving Dimensions (Both in
Schedule of dimension SG (CMRL) with the
static & Dynamic conditions)
pantograph and platform in lowered condition.
Maximum gradient 4%
3800 mm (With pantograph, platform and crane
Maximum Height of CMV
and cradle in knock down condition)
Shall conform to Schedule of dimension SG
CMRL). Adequate clearance shall be allowed so
Maximum permissible wheel base length that no component of the CMV shall cause any
of the car, overhang beyond bogie center, infringement as per CMRL specific requirements
coupler height draw bar height. above rail level with wheels in fully worn-out
conditions, full deflection of springs and effect of
dynamics.
Tare Weight (inclusive of all items). Approx. 50 Ton +/- 5%
Axle load (in fully loaded condition) 16 ton maximum
Maximum speed 80 Km/h
Maximum speed with elevated swiveling Maximum speed 10Km/h when swiveling
platform platform is in raised condition.
Performance capabilities:
Pay load (excluding Power equipment and
Minimum 12 ton
hydraulic platform)
Period of continuous running at 60 km/h
on generally tangent track followed by
5-1/2h total (4h+1-1/2h)
frequent to and fro movement at walking
pace for 1-1/2 h)

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 Doc. No. GR/TD/6969
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Period of continuous running at 40 km/h

up or down gradient of 1 in 60 to be
-1/2h total (4h+1-1/2h)
followed by frequent to and fro movement
at 5 km/h for 1-1/2 h on same gradient.

Performance in monsoon and squally

Un- restricted
conditions

2.0 Abbreviations:

“CMRL” Chennai Metro Rail Limited

“Sub- Supplier of Air Brake system to BEML
contractor”
“ERTS” Employer’s Requirements Technical Specification.
“PTS” Procurement Technical Specification.
“MP” Main Pipe.
“BP” Brake Pipe.
“AR” Auxiliary Reservoir.
“ATP” Automatic Train Protection.
“CBTC” Communication Based Train Control.
“BFCF” Bogie brake equipment with service brake, parking brake and anti-
compounding valve.
“BFC” Bogie brake equipment with service brake and anti-compounding
valve.
“PBPS” Pressure switch – parking brake.
“PCF” Pressure switch – Brake cylinder pressure.
“HPS” Pressure switch – Horn.
“MPPS” Pressure switch – Main Pipe.
“EMI” Electro Magnetic Interference
“EMC” Electro Magnetic Compatibility

BEML LIMITED
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3.0 General Requirements

The sub-contractor shall supply EP Brake System into this PTS, Purchase order requirements and
applicable drawings.

3.1 Defining of unclear aspects

If any term or clause is not described or not clear in the specification, sub-contractor shall discuss
those with design team in BEML, prior to making a contract, to confirm their definitions.
After making a contract, sub-contractor shall follow the definition and opinion of BEML design
team.

3.2 Responsibility of sub-contractor

Sub-contractor shall have the responsibility for design, manufacture and supply of EP Brake
System.

3.3 Eligibility Criteria

The sub-contractor shall be an OEM of EP Brake system having experience in the Design,
Manufacture, Testing & Commissioning of the complete EP brake system and shall have supplied
the same or similar type of EP system to any of Railways Vehicle and in service operation for more
than three years.
Supporting documents for the above shall be submitted along with technical offers. The offers of
bidders qualifying the above criteria will only be technically evaluated.

4.0 Brake System

4.1 The vehicle must be equipped with proven compressed EP type with microprocessor air brake
including: -
I. Automatic brake
II. Direct brake
III. Emergency brake
IV. Park brake acting on the two axles actuated by an electrical signal.
4.2 The braking system of Maintenance Vehicles shall be compatible with Rolling stock braking
system, so that in case of failure, when the vehicle is coupled with the rolling stock and the
brake is applied to the Rolling stock, it shall be extended to Maintenance Vehicle also.
Maintenance Vehicle Supplier shall carry out necessary interface with Rolling stock Supplier
for the same.
4.3 The emergency braking distance (EBD) for fully loaded CMV from maximum speed of 80 km/h
shall not be more than 500m.
4.4 The parking brakes shall be capable of holding the fully loaded CMV in steepest slope on CMRL
network.

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4.5 Brake Control Panel (BCU) should be provided in order to achieve high reliability, low weight,
better sensitivity and easy maintainability.
4.6 The application of any type of brake shall result in simultaneous cutting of the power to the
driving axles.

4.7 Brake system shall be provided with automatic slack adjuster built into the brake cylinder.
4.8 Adequate safety straps shall be provided below the moving components of the brakes
rigging and other components to prevent falling in the track in the event of failure of any
component. Air dryer of approved make should be provided in line with latest equipment.
4.9 Main reservoirs of adequate capacity shall be provided. In addition, a separate braking
reservoir and a non-return valve be provided for braking only. Suitable drain/cock valve shall
be provided to drain off the condensate in the reservoir. An automatic drain valve shall be
provided where feasible in addition to manually operated drain valves/stocks.
4.10 The system should have 10 bar in MR pipe & 5 bar in brake pipe, similar to the MR & BP
pressure of rolling stock. This will help in safe braking at the time of towing failed CMV with
help of train. The brake system must be compatible with that of CMRL Metro rolling stock so
that the vehicle can be coupled with CMRL Metro trains in case of failures/ emergency.
4.11 Air dryer of approved make conforming to spec. No [Link] (Rev. 05) March-2011 should be
provided.
4.12 The supplier shall submit details of EP brake system covering brake schematic diagram, working
principle, brake power diagram calculation for EBD, number, dimension and type of brake blocks
and literature on brake equipments proposed along with offer for approval.

4.13 The sub-contractor shall submit estimated weights of all the equipments used in the schematic
diagram of the Air Brake system offered to BEML.

5.0 Interface Requirements

5.1 The CMV shall be equipped with CBTC equipment with redundant ATP systems to operate in
GoA 1 mode as per EN62290.
5.2 The Signalling system shall use continuous moving block approach for CMV similar to that of
approach for Rolling stock.
5.3 The Automatic Train Protection (ATP) system shall issue the Emergency braking commands
to CMV when safety limits are exceeded or when over-speed is detected. The removal of
traction effort and the correct application of Emergency brakes in CMV shall be the
responsibility of sub-Contractor. The ATP system shall be responsible for monitoring of speed
and the issuing of braking commands when safety speed limits are exceeded.
5.4 The sub-contractor to provide the acceleration and braking rates of the CMV. The Guaranteed
Emergency Braking rate shall also be provided to the signalling Contractor for incorporating
in his design.
For more details refer: Part 2 – Section VI B: ERTS – DM&P CMV
BEML LIMITED
 Doc. No. GR/TD/6969
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6.0 Responsibilities;
The sub-contractor shall be responsible for the overall design and engineering of complete brake
system in accordance with his Scope of Supply.
The sub-contractor shall be responsible for design change of his scope of supply and work from
the technical discussion between BEML and / or the CMRL or the sub-contractor under the
contracted price and delivery between BEML and the sub-contractor.
The sub-contractor shall be responsible for dispatching his engineer to BEML for the technical
meeting.
Any changes of the components shall be defined by the sub-contractor and approved by BEML in
order to avoid the mechanical interference with other equipment for the CMV.
The sub-contractor shall be responsible for the scope of work as described below.

Work Responsibility
SI.
Description Sub-
No. BEML
contractor
1 Design X X
2 Calculations X
3 Approval of drawings X1 X2
4 Type & routine test X
5 Manufacturing X
6 Technical documents X
7 Manuals (O&M, Parts catalogue) X
8 Pipes, Clamps & End Fittings X
9 Installation X1 X2
10 Factory Test X1 X2
11 Testing & Commissioning at site X1 X2
12 Training X2 X1
13 Warranty for each component X
Note:
1. X - Sole Responsibility or Both
2. X1 - Leader i.e., responsible for activities required for the specified element of the scope of
Supply including any calculation, drawing, documentation and test connected with the
design.
3. X2 - Support i.e., responsible for extending the support to leader by sharing the relevant
Information required by the leader to produce a satisfactory design.

BEML LIMITED
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7.0 Spare parts

7.1 DLP Period
The Sub-contractor shall submit list and price for spares as required for Defects Liability Period
(DLP) of 24 months to maintain and change during schedule maintenance activities.
The Sub-contractor shall consider back-to-back warranty (DLP) & maintain the supply of spares
(consumables during DLP period) for the normal life of the respective equipments.

7.2 Comprehensive Maintenance Contract (CMC)

The sub-Contractor is required to carry out 15 years Comprehensive Maintenance Contract (CMC)
for EP Brake system after completion of DLP period. The sub-Contractor shall provide key
maintenance staff as per qualification and experience detailed under Part 2, Section VI C ERTS
(CMC).

8.0 Design Submission

The sub-contractor shall provide BEML with all necessary drawings (2d & 3d), RAMS Plan, reports,
calculations, specifications, technical data, system assurance, quality assurance, manufacturing
and testing with respect to PTS according to the time schedule approved by BEML.
These drawings and documents shall be delivered in English with the data format of, respectively,
latest AutoCAD release. (Document - MS Word / PDF, spread sheet - MS excel).

8.1 Design information

8.1.1 General
The sub-contractor shall provide, but not be limited to, the following general information in
accordance with the schedule approved by BEML before contract award. To satisfy BEML that the
sub-contractor has the ability to supply the brake system in accordance with the requirement of
PTS, before contract award, the sub-contractor shall provide BEML for review and approval the
following information.
Plan covering the following:
• Design Submission Plan
• Preliminary Technical system/product/function description (including Lay-Out drawing)
• RAMS Plan
• Test Plan
• Training Plan
• O&M Manual Submission Plan
• Clause by Clause comments on PTS

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8.1.2 Design
The proven Brake Schematic Diagram is considered & shall be as per drawing No. 82660001.
The sub-contractor shall provide, but not limited to, the following design information in
accordance with the time schedule approved by BEML. If any further documents are requested by
CMRL, the same needs to be supplied by the sub-contractor.
• Drawings of all components under scope of supply
• Electrical circuit diagrams
• Technical Description
• Product Description
• Emergency Braking Distance Calculation with Parking brake at 4% gradient.
• RAMS Plan
• Routine test procedure & record sheet
• Routine test report
• Material certification
• O&M Manual – 5 sets/CMV
• Parts catalogues - 5 sets/CMV
• Training manual - 5 sets /car
• Special tools and test equipment
• Spare parts list for DLP schedule (24 months).
• Comprehensive Maintenance Contract (CMC) for 15 Years

8.1.3 Testing of Air Brake Equipments

The sub-contractor shall be responsible for performance tests of the components under scope of
supply. BEML and/or CMRL representative have the right to witness any of these tests at any stage
of test progress.
The sub-contractor shall carry out the routine test of equipment and assembly and submit the test
reports.
In the event of any test for the components is failed, the sub-contractor shall, at his own expense,
take whatever action is deemed such as rectification, re-adjustment or design changes to the
satisfaction of BEML and CMRL, in order to meet the testing requirements.

8.1.4 Vehicle Level Testing

The sub-contractor shall extend the support during Installation & factory acceptance test (FAT)
at BEML plant. Also, at customer depot (CMRL) for site acceptance test (SAT) during Testing &
commissioning.

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8.1.5 Training
The sub-contractor shall provide the class room training & materials for BEML's comprehensive
training activities and works of Air supply and Brake system to the Employer's staff (Maintenance,
operating, training and engineering) at BEML plant & at customer site.
The sub-contractor shall provide the training materials (presentation & student guide) and training
activity for the required days to assure that the Employer’s staff is thoroughly trained in the
operation, maintenance, and overhaul of the equipment supplied under this PTS.
The sub-contractor shall propose the required days for the supplied equipments for Operation and
Maintenance staffs.
• The sub-contractor shall submit information of instructor and training material of proposed
training at least 6 weeks in advance of actual training schedule.
• Sub-contractor shall depute the trainer(s) to the end user works/depot and BEML plant.
• The sub-contractor shall provide the training according to BEML Training Plan for End user.
• The sub-contractor shall provide, but not limited to, training materials (Hard copies &
Electronic files).
• Sub-contractor shall provide training program about operating and maintaining all the system
devices provided. Training should be provided enough so that the corporate personnel may
practice and learn how to use the operation, interface with other devices and testers.
• The training material and the entire training program shall be approved by BEML/ CMRL
Engineer (GC/ CMRL).
• If End user or BEML request more training courses, sub-contractor shall provide them.
• All expenses for trainings shall be borne by sub-contractor.

9.0 Operation and Maintenance Manual

The sub-contractor shall provide necessary Operation and Maintenance Manual, Spare Parts
Catalogues and troubleshooting manual for the equipments supplied in hard copies (5 sets) and
electronic format exclusively for CMRL CMV contract.
The Operation and Maintenance Manual, Spare Parts Catalogues and troubleshooting manual
shall be provided for approval by BEML according to the time schedule approved by BEML, the
sub-contractor shall provide softcopy for all O&M Manual according to detail requirement and
required formats provided from BEML.

10.0 Warranty
The warranty will be as per General Terms & Conditions (GTC).

11.0 Handing Over

The sub-contractor shall hand over the complete equipments to BEML in accordance with the time
schedule approved by BEML.

BEML LIMITED
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12.0 Data submission schedule

The Supplier shall basically comply with PTS.
The Supplier shall submit data submission schedule for BEML’s approval before placement of
contract.

13.0 Enclosure:
• Air Brake Schematic Diagram to drawing No. 82660001.
• Air Brake System Equipments Scope to drawing No. 82660002.
• PTS to doc. no. GR/TD/6969.
• Extract of Customer technical specification & Interface Management.
• Extract of CMC requirements.

BEML LIMITED
 Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

CHAPTER 3

3. CATENARY MAINTENANCE VEHICLE (CMV) 8 - WHEELER

3.1 GENERAL

3.1.1 Physical Characteristic of the Vehicle

a) It shall be capable of hauling one or more empty/loaded wagon or 8 wheeler vehicle (trailing
load of 64 MT) at a speed not less than 40 kmph.
b) Design Speed of vehicle shall be 90kmph and Operational Speed of vehicle shall be 80kmph.
c) Weatherproof ventilated cab with full visibility for bi-directional working.
d) Standard operational needs for bi-directional operation, warning lights, head lights, Marker
lights, tail lights and couplers standard for CMRL System.
e) The vehicles shall be equipped with air and EP brakes with microprocessor direct brakes acting
on all wheels with emergency and parking brake system and all safety devices necessary to
provide a safe working environment, including temporary grounding devices.
f) The vehicles shall be provided with all necessary tools and accessories as per industrial
practice.
g) The vehicles shall be able to operate at full speed without breaching the line dynamic vehicle
clearance gauge (Kinematic profile) fixed for the routes.
h) The Supplier shall follow the Schedule of dimension of CMRL with latest version.
i) The life of the catenary maintenance vehicle shall be 40years.
3.1.2 Indicative Characteristics of the Catenary Maintenance Vehicle
a) These vehicles shall be dimensioned to meet the requirement of Kinematic profile of CMRL
system.
b) The vehicles shall be able to move bi-directionally at the same regular speed.
c) The vehicles shall be able to operate at full speed without breaching the line dynamic vehicle
clearance gauge (Kinematic profile) fixed for the routes.
d) The vehicles shall be powered by adequately rated water-cooled diesel engines as per
specifications, to meet all requirements for their operation.
e) Dimensional and Operating Requirement

3.2 TECHNICAL SPECIFICATION

The vehicle shall be a Rail mounted 8-wheeler vehicle. The disposition of equipment & storage
space shall be such as to ensure equal axle loads. Design shall be such as to afford easy
inspection and maintenance. Guiding principle in selection of assemblies should be the easy
availability of wearing components.
3.2.1 Driving Cab:
[Link] Driving cab shall be provided at both ends with complete operating and driving control and
dashboard. The general layout and arrangement of equipment in driver's cab shall follow UIC
CODEX 651 with respect to dimensions, safety features, furnishing. lighting, ventilation, noise
level. field of view, driver's desk, seat etc. Spotlights shall be provided at suitable locations.
The cab shall be so arranged as to afford the driver good vision for operation. All controls,
brake handle, hand brake/ parking brake, indication lamps/meters shall be within easy access
and view of the driver. The cab shall be provided with control equipment and
instruments/gauges. Both driving cab and signaling equipment room shall be Airconditioned.
3.2.2 Speed Indicator/Recorder:
[Link] The machine shall be equipped with speed indicator and recording equipment of range
between 0–160 kmph with software for recording the speed of the machine in real time basis

CMRL / Rev 012 3 4 3-1 Jul Oct 2023 Jan Feb May 2024
 Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

and an axle box mounted opto-electronic speed sensor. The equipment shall conform to
RDSO specification no. MP-0-0.3700- 07, Rev-04, Aug’17 or latest. The recorded data shall be
retrievable on computer through memory card/pen drive. It shall be provided in the driving
cabin at suitable place and recording system should have sufficient memory to keep the speed
record of minimum 15 days which should always be stored for retrieving as per requirement.
[Link] Recorder cum indicator unit shall be provided with micro controller containing FLASH
EEPROM internal memory for calculating and recording the journey data a portable FLASH
memory card for external memory. One cab of CMV shall have one recorder-cum-indicator
and the other cab shall have one indicator only.
3.2.3 Engine and Transmission
The Engine & Transmission assembly shall preferably be from a single manufacturer supplied
as integrated arrangement. However, engine and transmission system from different sources
would be also acceptable.
[Link] Engine
The diesel engine must ensure following:
a) Exhaust fumes low pollution (conforming to Euro stage IIIA/B or latest).
b) The power will be about 2 x 400HP minimum.
c) The Supplier has to submit design calculation to meet these criteria.
d) The make of engine shall be a proven one for similar applications and documentary support
shall be given for the same.
e) The Contractor of the engine and its design shall be submitted for approval of CMRL.
f) It is desirable that speed governor may be provided to limit the vehicle speed at 80 kmph
during regular use.
g) Diesel engine complete shall be offered as per specifications under scope of supply. The two
power packs together shall develop not less than 680 hp under standard UIC condition. The
diesel engine shall be of proven make and suitable for traction application. The contractor shall
indicate the continuous horsepower at rated out put of offered engine under site condition.
He shall also indicate if any de-rating of engine is considered for operation in adverse
conditions.
h) The supplier shall indicate the total horsepower required for auxiliaries with break-up of power
requirements for each of the auxiliary machines at rated output and also indicate net power
input to the transmission.
i) The detailed torsional vibration analysis of the complete dynamic system under normal engine
working as well as under conditions of one cylinder misfiring for the complete operating range
including 10% over speed shall be furnished.
j) The Contractor shall submit graphs showing the Break mean effective pressure (BMEP)
/engine output torque and SFC at all notch levels in case a stepped throttle control is
proposed. In case step-less control is proposed, the graphs for above parameters shall be
given at 25%, 50%, 75% and full load.
k) The Contractor shall furnish a copy of Type Test report of the engine by a Statutory Body in
support of their claim regarding performance, reliability and specific fuel consumption. In case
the engine offered is not Type tested earlier, the testing shall be carried out in the presence of
CMRL's authorized representative.
l) The exhaust emission shall be below the limit laid down in latest Euro stage IIIA/B or
equivalent for industrial engines. The Contractor shall indicate the code followed and the
values under various load conditions.
m) Filters for engine air intake shall be of adequate airflow capacity with restriction indicator to
ensure satisfactory performance under dusty environment.
n) Air intake arrangement with filters, ducts and exhaust arrangement shall be compatible with
engine system and shall be located at suitable position within the overall dimensions of the
vehicle.

CMRL / Rev 012 3 4 3-2 Jul Oct 2023 Jan Feb May 2024
 Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

o) The exhaust pipe shall be horizontal and located under floor avoiding the position near
footsteps to the CMV car.
p) The diesel engine shall work satisfactorily with fuel oil to Indian Standard Specification
No. 1460 (2005).
q) The Contractor shall supply engine driven alternator of adequate capacity as standard
accessory for charging battery for engine cranking and coach lighting and controls.
r) High speed diesel oil to Indian Standard specification shall be normally used. Fuel tank will be
about 600 liters minimum. The capacity of fuel tank shall be commensurate with engine
capacity sufficient for vehicle running upto 16 hours without refilling and 200km of travel will
be desirable. There should not be possibility of any oil leakage from joints/gaskets or anyother
equipments while either moving or working in the section. Any oil leakage may lead to unsafe
operation of trains.
s) The engine shall be capable of propelling the vehicle in fully loaded condition at gradient of
4%.
t) The engine shall have Electronic Control Module (ECM) or similar arrangement for taking out
operating parameters on real time basis such as RPM, load, fuel consumption, temperature,
pressure and diagnostic data as well as trip and historical data. These data shall be displayed
and stored on a panel/PC to be provided in operator’s cabin. It shall also be possible to
transfer these data on USB device.
u) By diesel engines to ensure that CO presence has to be kept to minimum level so that exhaust
gases do not cause any harm to working staff while working in tunnel upto the next revenue
day. In any case it should not exceed 400ppm within 50meters distance operation machine.
v) Both Engines shall have protection for running in different rpm.
w) The sensors, transmitter’s and filters shall be mounted in such a way to easy access.
[Link] Diesel Engine in gauges and indicator
a) Engine starting switch/push button.
b) Lube oil pressure gauge
c) Lube oil temperature gauge
d) Cooling water temperature gauge
e) Battery charge/discharge Ammeter
f) Engine hour meter and engine speed indicator
g) Engine throttle control
h) Operating control for reversing
i) Engine stop switch/push button
j) Emergency stop (Engine)
k) Fuel level indicator
l) Radiator water level indicator
[Link] Transmission
The vehicle must be equipped with hydraulic transmission:
a) Hydraulic transmissions complete for running up to 80 km/h shall be offered as per scope of
supply. In case hydro-mechanical power shift transmission is offered, the gear shifting shall be
automatic, and it shall not call for any attention from the operator. The transmission shall be
offered with all the necessary accessories, standard attachments and safety devices.
b) The supplier shall carryout torsional vibration analysis of the matched power equipment
system to ensure that there is no secondary vibration in the system that can lead to failure of
any component of the transmission during operation at idle or under loaded condition.
c) The transmission shall be suitable for cardan shaft connection with the diesel engine (if
remotely connected) and axle drive gearbox.
d) Special care shall be taken to ensure reliable and efficient performance of the transmission
CMRL / Rev 012 3 4 3-3 Jul Oct 2023 Jan Feb May 2024
 Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

without developing a temperature beyond the safe permitted limit during full load operation.
The system shall not call for any special care on the part of the driver to protect the
transmission from damage under any circumstances.
e) The system shall ensure both transmission should engage simultaneously.
f) Special care shall be taken to avoid leakage of lubricant oil in pistons.
g) The Contractor shall furnish a copy of Type Test Report of the transmission from a statutory
body in support of their claim regarding performance and reliability.
h) Transmission shall have provision of secondary lubrication arrangement to protect the
transmission from damage during towing in train formation.
i) The make of transmission shall be a proven one for similar applications and documentary
support shall be given for the same.
j) The Contractor shall submit TE vs speed curve for various operating condition.
[Link] Cooling System
a) The cooling equipment shall be guaranteed to work efficiently under climatic conditions
specified. Apart from meeting the requirement of Diesel engine including after cooler, the
cooling equipment shall be required to dissipate heat of lube oil, hydraulic oil used for
hydrostatic fans with 30% chocked condition of radiator used. Airflow required for the radiator
fan shall be at least 15% more than actually required to make up for any reduction in air flow
due to train movement. The limiting ambient capability of the cooling system should be
minimum 55°C with 30% chocked condition.
b) The fan and the cooling arrangement shall be of adequate capacity to cope lip with the service
demands under the most severe temperature conditions. The maximum water temperature
shall not normally exceed 85°C, the safe operating temperature of the engine. The
system shall be adequately pressurized and vented to avoid all possibilities of
cavitations. The complete technical details of the Radiator and its fan shall be furnished.
c) The initial fill of hydraulic oil for hydrostatic operation of fans in the cooling system as
recommended by the manufacturer shall be in the scope of supply.
d) Hydraulic hoses of proven make with adequate factor of safety shall be used for cooling
system. The hoses shall be properly routed and secured so that it does not fail due to vibration
or infringement also easy to handle during replacement.
e) The suitable location for mounting radiator and submit mounting details of radiator assembly,
fan drive arrangement such that all equipment fit completely within the overall dimensions of
Maintenance Vehicle.
f) Suction type roof mounted radiator shall be provided such that the fan sucks air from the side
mounted radiator and blows out through the opening provided for fan.
g) During operation at maximum output, the radiator fan shall not be source for noise and
vibration.
h) The maximum temperature of hydraulic oil shall not exceed 70°C.
i) The hydraulic oil tank shall be of robust construction, made up of weatherproof, corrosion
resistant material like stainless steel. It shall be provided with oil level indicator,
temperature indicator, oil level switch and oil filter with restriction indicator. A
micro/limit switch shall be provided and interlocked with delivery side shut-off valve.
j) The following calculations in support of offered cooling system shall be submitted:
i. Cooling requirement for all sources of heat (with break up)
ii. Heat dissipation characteristics of the radiator and its resistance characteristics.
iii. Radiator fan characteristics showing the air' flow Vs total heat at different speeds.
iv. Cooling system-matching calculations.
[Link] cooling circuit diagram showing water, oil and air flow through each
equipment.
k) The Radiator house shall be provided with a drain hole to prevent stagnate of water.
CMRL / Rev 012 3 4 3-4 Jul Oct 2023 Jan Feb May 2024
 Chennai Metro Rail Project – Phase 2
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l) The mounting area of radiator (cmv roof/underframe) shall be suitably designed to prevent
bent and stagnate of rain water.
m) All water lines shall be of stainless steel.
n) The radiator water level and temperature shall be displayed in drivers desk.
o) Radiator water top up arrangements with motor pump shall be provided in case of roof
mounted.
[Link] Braking Systems
a) The vehicle must be equipped with proven compressed EP type with microprocessor air brake
including: -
I. Automatic brake
II. Direct brake
III. Emergency brake
IV. Park brake acting on the two axles actuated by an electrical signal.
b) The braking system of Maintenance Vehicles shall be compatible with Rolling stock braking
system so that in case of failure, when the vehicle is coupled with the rolling stock and the
brake is applied to the Rolling stock, it shall be extended to Maintenance Vehicle also.
Maintenance Vehicle Supplier shall carry out necessary interface with Rolling stock Supplier
for the same.
c) The emergency braking distance (EBD) for fully loaded CMV from maximum speed of 80 km/h
shall not be more than 500m .
d) The parking brakes shall be capable of holding the fully loaded CMV in steepest slope on
CMRL network.
e) The CMV shall be fitted with gradual release air brakes. The brake system shall be of UIC
1 approved type and shall meet all UIC requirements. It shall have the following distinct
positions:
I. Release positions.
II. Minimum reduction position
III. Full service position
IV. Emergency position
f) Panel mounted airbrake system of approved make should be provided in order to achieve high
reliability, low weight, better sensitivity and easy maintainability. The panel shall be IP65 rating
if it located under open shell.
g) Application of any type of brake provided on the CMV shall result in simultaneous cutting of
the power to the driving axles.
h) Brake system shall be provided with automatic slack adjuster built into the brake cylinder.
i) Adequate safety straps shall be provided below the moving components of the brakes rigging
and other components to prevent falling in the track in the event of failure of any component.
Air dryer of approved make should be provided inline with latest equipment.
j) Main reservoirs of adequate capacity shall be provided. In addition, a separate braking
reservoir and a non-return valve be provided for braking only. Suitable drain/cock valve shall
be provided to drain off the condensate in the reservoir. An automatic drain valve shall be
provided where feasible in addition to manually operated drain valves/stocks.
[Link] Cabin:
a) The cab of the car shall be fitted with horns for both end driving of about 120- 125 dB with
different tone which should sound in harmony when blown together. They shall be operated at
3 to 8 kg/cm² pressure or be battery operated and be of sufficient size and intensity so that
they are audible from a distance of 1 km. They shall be controlled by a valve provided on
driver’s control stand.
b) Two fixed look-out glasses of uniform size shall be provided in the end wall of driver’s
compartment and these shall be of glazed with clear, colorless, safety glass of minimum 6.3
CMRL / Rev 012 3 4 3-5 Jul Oct 2023 Jan Feb May 2024
Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

mm thickness. The glass windows shall be shatter proof, protected with expanded metal or
BRC (having least obstruction to visibility). The wind shield shall extend up to the ceiling level
so as to give clear view of overhead equipment.
c) Wind Screen wiper complying to RDSO Spec. No. C-K 306 with latest revision and approved
design shall be provided outside the glazed windows, and a Electrical operating screen wiper
with a long handle for manual operation shall be provided on each of the two lookout windows.
Also sun visors on both the cabin to be provided".
d) Driver's seat shall be placed in a suitable position. Adequate leg space shall be provided for
the driver when he is seated.
e) Sitting space in the driving cabs for 4-5 persons in addition to the driver should be provided.
For this purpose, a foldable cushion sheet shall be provided. The storage layout and sitting
arrangement inside the cab should be got approved from CMRL. The cab should be so
designed that it has adequate space for personnel and equipment’s.
f) All controls, speedometer, brake handles, Vigilance control device /Dead man’s device, switch
for horn and indication lamps/meters shall be within easy access and view of the driver and
shall be separate for each cab.
g) 2 nos., 240 V sockets for hand signals and tetra(radio) charging should be provided in cab.
h) OHE Voltage sensing device shall be provided on each cabs.
i) Flasher lights, search lights and marker & tail lights should be provided at ends of the each
cab.
j) Flashing light and harmonic sound/horn shall be provide at both ends of cab which operate
automatically on the rear end only during reverse movement of CMV.
k) The cab shall be equipped with ceiling light of LED type and brushless fans. Full width, splinter
proof glass wind shield protected with expanded metal or BRC (having least obstruction to
visibility). The wind shield shall extend upto the ceiling level so as to give clear view of
overhead equipment.
l) `Two point for mobile charging (240V) shall be provided in driver’s cab.
m) The vehicles shall be able to move bi-directionally at the same regular speed.
n) Inter Communication facility shall be provided for communication between cabs, and
crane/basket through hand free sets with loudspeaker in its own battery.
o) External communication arrangements and power source shall be provided in both cabs. The
requirements shall be interface with S&T/CMRL.
p) Cabs shall be provided with 10 inch TFT monitor connected with outdoor remote (from cab)
adjustable HD night vision camera to monitor pantograph and the activities of the
Crane/basket & lifting and swiveling platform.
q) During the reverse movement, to view the obstruction at rear side, CCTV camera and display
monitor at the cab of the opposite end may be provided. The switching on of rear side
headlight should be interlocking with reverse movement.

3.3 LIGHTING

3.3.1 External lighting includes:

a) Two driving headlights of suitable wattage of LED type on each front side
b) Two central headlights of suitable wattage of LED type fixed on the top of the vehicle
c) Two orientable search lights fixed on each roof of the cab.
d) For illumination for night inspection, plug points (240 volts) shall be provided for fixing portable
lights.
3.3.2 All lights should be of LED type including headlights.
3.3.3 There shall be provision that with the removal of engine ignition key, the flood lights are also
switched off. This is required to avoid draining of batteries after the work is completed.
3.3.4 A steel wire mesh should be provided in the filler neck to prevent theft of diesel. The filler cap
CMRL / Rev 012 3 4 3-6 Jul Oct 2023 Jan Feb May 2024
 Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

should be lockable with padlock. Cab should be provided with digital fuel gauge & low-level
alarm / indication. Prismatic / sight glass with level marking should be provided in diesel tank
for monitoring level of fuel.

3.4 MECHANICAL DESIGN

3.4.1 Materials:
[Link] Materials used in the construction of the CMV shall comply with the relevant IRS
Specifications or Indian Standard Specifications (IS). Alternative materials can only be used
with the prior approval of CMRL. Where IRS or IS do not exist for specialized components, the
Supplier shall submit his proposed material specifications for approval of CMRL.
[Link] The Supplier shall arrange for the required manpower for commissioning of the Maintenance
Vehicle immediately after their receipt at ultimate destination. Adequate number of teams of
technical experts will be made available so that the commissioning delays are eliminated. The
Supplier will be required to inspect the Maintenance Vehicle at the consignee end and carry
out a joint check of the receipt of components to avoid subsequent complaints regarding short
shipment or transit damages.
3.4.2 Electric Arc Welding:
[Link] Indian Railways Standard Code of Practice for Electrical Arc Welding shall be followed. If the
Supplier desires to follow any other Code of Practice, it shall first be submitted for approval of
CMRL. The welding standard followed for manufacturing of machine shall conform to ISO:
3834, EN: 15085 or any other equivalent standard for welding railways vehicles and
components. The manufacturer shall specify the standard followed and certify that it meets the
welding standard mentioned above.
[Link] Welding symbols are to be in accordance with Indian Standard Specification No. 813.
Drawings on which such symbols appear, are to bear a note on the bottom left hand corner,
"WELDING SYMBOLS ISI SPECIFICATION NO. 813".
3.4.3 Body shell and Under Frame
[Link] The main structural frame has to be robust, corrosion resistant and sturdy, made of reinforced
steel rolled sections folded plates or pressed sheets with front and rear head stocks fitted with
Coupler without electrical head to be provided. Material used for construction of carbody shell
shall be of low alloy high tensile strength.
3.4.4 Under frame and Cabin
[Link] The structure shall be of corrosion resistant low alloy high tensile steel. The entire body
structure framing shall be sheathed with steel sheets and welded to the main members. The
cabin shall be in full contact with frame members and shall be evenly applied without bulges or
depressions that might appear after painting. Concavity or convexity in excess of 1.5 mm in a
length of 2.5 m and in this proportion for shorter lengths, shall not be accepted
[Link] The design of the Cabin shall be such as to provide continuous free air space between the
outer sheathing and the interior paneling and ceiling for free circulation of air all round.
[Link] Attachments may pass through the airspace as required, but must be designed, so that they
do not cause sections to form sealed chambers or lodgments for condensed moisture.
Ventilators should not violate the schedule of dimensions.
[Link] The cabin shall be thoroughly braced and firmly secured to the under frame by welding.
Attention should be paid to eliminate water or dust pockets in floor and other structural
members.
3.4.5 Headstock:
[Link] These shall be of robust design suitable for coupling and buffing gear arrangements detailed in
this specification as same as rolling stock automatic coupler.
3.4.6 Coupler:
[Link] Coupler shall be provided on either ends of CMVs which shall be same as provided in the
rolling stock.

CMRL / Rev 012 3 4 3-7 Jul Oct 2023 Jan Feb May 2024
 Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

3.4.7 Lifting Pads:

[Link] As the CMV body shall be subjected to repeated lifting in workshop by lifting jacks in service,
suitable lifting pads shall be provided and marked in a readily distinguishable manner on the
CMV body so as to make sure that CMV body does not get deformed with the passage of
time.
[Link] The lifting points may be clearly indicated and provided on bogie and CMV body.
3.4.8 Insulation:
[Link] An insulation layer of suitable thickness of non-asbestos material shall be provided inside the
CMV shell. The end walls and sidewalls shall be provided with suitable anti-drumming and
anti-corrosive compound. The underside of the under frame over the engine area shall be
properly insulated to minimize heat transfer to the compartment.
3.4.9 Bogie:
[Link] The general design shall be similar to the bogie provided on Indian railway 8- wheeler CMV.
The CMV shall have two 4-axle bogie of well proven design. It shall be of robust welded
design suitable for taking the brake gear, final drive, suspension etc. The bogie shall be
capable of withstanding the maximum static and dynamic stress under loaded conditions &
load upto 40% in excess of maximum gross load and to meet the performance requirements.
The weight of the bogie shall be as lowest as possible consistent with strength and
robustness. The design shall provide primary and secondary suspension. The design shall
ensure that the sperling ride index value does not exceed 4.0 at a maximum speed of 80kmph
plus 10%.
[Link] The general design of the bogie shall permit easy access to running gear and brake gear and
to final drive in the case of powered bogie when in position under the CMV body and shall
permit easy replacement of brake blocks without a need of special arrangement on the track.
The whole arrangement of bogie along with design along with details shall be submitted to
CMRL for approval before manufacture is commenced.
[Link] The suspension systems shall be of two stage type with suitable spring and damping
arrangement. Springs for primary and secondary suspensions shall be designed to cater for
actual service conditions. Calculations for determining the spring characteristics and damping
values in various modes shall be submitted to CMRL for approval. Any alternate design
proposed will be submitted to CMRL for review and approval. The manufacture and supply of
the helical springs shall be as per RDSO specification No. C-8303 or equivalent.
[Link] Effective measures shall be adopted to minimize the weight transfer while starting, stopping
and during runs. The Contractor shall furnish detailed calculation for weight transfer and
adhesion efficiency for the powered bogie. Safety straps of adequate size or alternate
measures shall be provided to ensure supports in the event of failure of links, hangers or other
components.
3.4.10 Wheel and Axles:
[Link] The details of Wheel profile shall be suitable for CMRL Project along with technical details for
Standard Gauge respectively as follows:
a) The wheel tread shall be of the wear adapted wheel profile S 1002 / h28 / e32.5 / 6.7% as
1 defined in EN 13715. Proven Wheel Profile to RDSO drawing no. 91146 (Latest Revision)
shall be provided.
b) Maximum diameter on the tread measured at 63.5 mm from wheel gauge face-915 mm
c) Minimum diameter on the tread measures as 63.5 mm from wheel gauge face -813 mm
d) The manufacturer shall provide the RDSO approved UST pattern of free axle and wheel and
axles assembled on complete wheel. He will also provide training for UST of axle.
e) The wheel and axle shall be compatible with the Pit wheel lathe Machine of the respective
lines for maintenance etc.
f) Wheel and axle dimensions shall meet the requirements of CMRL Schedule of Dimensions
1435 mm gauge-(SG)
g) Wheels shall be to IRS R-19/93 or EN13262 and axles shall be to IRS R-16/95 or EN 13261
CMRL / Rev 012 3 4 3-8 Jul Oct 2023 Jan Feb May 2024
 Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

for non-powered axles and IRS R-43/92 or EN 13261 for powered axles designed to take up
roller bearings of approved design.
[Link] Only solid multi wear type wheel shall be used.
3.4.11 Details of Doors, windows & roof of the both drivers cabins shall be got approved from CMRL.
[Link] Cabin Door: One sliding door (entry and exit) shall be provided at the rear end of the cabin to
enable easy entry of operator.
[Link] Cabin Window: Body side windows shall be provided.
[Link] Windows:
a) The window guides, and sills shall be of FRP, and shall be as per RDSO of Technical
Requirement (STR), C- 9502 (Latest Revision)
b) Glass window frames and louvers shutters shall be of FRP as per RDSO 9403 (Latest
Revision).
c) Frames, guides and sills should be manufactured from sheet compound (SMC) to RDSO spec.
C-8409 (Latest Revision)
[Link] All window and door glasses shall be of the shatterproof type plate glass set in sun heat
resistant synthetic rubber section. The front windows shall be of hinged type.
[Link] All window openings shall be true to dimensions square and of uniform width. The window
opening shall not at any point exceed 2 mm over or under the specified dimensions and shall
not be out of square by more than 2 mm.
[Link] The windowsills of the body side windows shall have an outward slope of approximately 50.
[Link] The body side windows shall have two shutters, one louver on the outside and a glass on the
inside.
[Link] The glass used for windows/shutters shall be either of toughened quality or safety laminated
quality to IS:2553, weighing not less than 9.76 kg/m", Gravity safety catches of approved
design shall be provided at two intermediate positions to arrest the glass and louver shutters
from falling down. The shutters should be balanced by balancers of suitable design.
[Link] The louver shutters shall consist of a light alloy framing of robust design fitted with louver
panel or pressed light alloy, designed as to exclude water, but permit air freely. The louver
shutters shall be provided with shoot bolt type safety catches to secure the shutters firmly in
closed and open position.
[Link] Door Footsteps: The door footstep assembly shall be of mild steel and have compreg board
(RDSO spec C-9407 latest). The edges shall be protected with metallic treads. Any other
suitable anti slip arrangement can also be considered.
[Link] Door hand holds: Door hand holds of stainless steel with malleable cast iron brackets shall be
provided on either side of all body side doors and shall be so fitted as to clear the side walls
sufficiently to prevent injury to knuckles. Hand holds shall also be within the CMV profile so
that mechanized CMV washing is not hindered.
[Link] Door Locks: All doors shall be fitted with reliable locks to be operated from outside and inside.
Hasps for external padlocking shall also be provided on all doors opening out of the CMV.
[Link] Noise Suppression: The Contractors shall indicate any noise suppression features incorporated
in the design. The noise level should not be more than 75 dB inside the driving cabs and at
25mtrs away and 1mtr above rail level should not be more than 80dB.
3.4.12 Corrosion Protection:
[Link] Sheets and plates used for CMV construction shall be suitably treated against corrosion before
fabrication.
[Link] Sub-assemblies shall be treated against corrosion as per UIC Code 842-5/latest after they are
manufactured.
[Link] CMV shall be treated after fabrication as per UIC Code 842-5/latest.
[Link] In addition to above, the CMV design shall be such as to minimize the incidence of corrosion.
[Link] The Contractor may suggest any better corrosion protection system that he may have adopted
CMRL / Rev 012 3 4 3-9 Jul Oct 2023 Jan Feb May 2024
 Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

with success in CMVs manufactured by him.

[Link] The floor construction should be such that it does not permit water to seep through the floor
and cause corrosion to trough floor and under frame members.
[Link] Extra fittings:
a) Doorsteps shall be provided at all body side doors.
b) Continuous water wriggles from one end of the CMV to the other shall be provided.
c) Tail lamp bracket to IRS Drg. No.C.BFwl13 shall be fitted at each end of the shell.
d) Rainwater gutters of suitable design over the door way shall be provided.
e) The CMV may be washed mechanically and also in automatic washing plants.
3.4.13 Ceiling & paneling: Side wall paneling shall be constructed so as to facilitate removal for
attention to window shutters, runners and interior steel surface of the body panels. The interior
panel on the ceiling will be of a suitable material, preferably non- asbestos. The ceiling in
compartments shall be of 2 mm thick NFTC to RDSO spec. No. C- K 511 (Latest) or non-
asbestos limpet sheet to RDSO spec. No C-K601 (Latest). The ceiling of engine Room shall
be of 1 mm thick mild steel sheet.
3.4.14 Flooring: Floor construction arrangement shall consist of aluminum checkered plates of
approved quality laid over compreg board to RDSO Specs C-9407) screwed on the trough
floors. Floor construction should be such as not to permit water seepage through floor.
3.4.15 Trap Doors: Suitable trap doors shall be provided on the flooring for attention of under- slung
equipment, during service. The design of trap door shall be such that it can be conveniently
lifted when attention to equipment is required but strong enough to withstand normal
passenger loading. The leakage proof trap door shall remain in level to the floor of the CMV.
3.4.16 Anti pilferage measures: While securing compartment fittings, anti-pilferage measures shall be
incorporated.
3.4.17 Cattle Guard: Detachable type cattle guards shall be provided under each buffer beam. The
cattle guard shall be fitted with adjustable rail guards so as to maintain free space above the
rails.
3.4.18 Interior Finish and Furnishings: The interior finish and furnishing must be to the best standards
of coach work, and shall combine an excellent and clean appearance with durability and
serviceability. The interior surfaces, such as walls partitions, bulk heads etc shall be rounded
and joints shall be avoided. All surfaces liable to frequent handling shall be finished with
materials suitable for periodical washing or cleaning, and shall be of a colour which will not
show up stains. The materials used for finishing and furnishing shall be suitable for use under
all climatic conditions and shall be fire-proof, non-hygroscopic and vermin and insect proof.
3.4.19 Seals and gaskets: The seals and gaskets used for arresting oil leakage to be such that there
is no oil leakage.
3.4.20 Paneling: The interior paneling in the cabin shall consist of 1 mm honey comb stainless steel
material to AISI 409M. The interior paneling in the compartment shall consist of 3 mm thick
resin bonded thermosetting laminated plastic sheets of approved shades. The laminated
plastic sheets shall conform to STR for decorative thermosetting synthetic resin bonded
laminated sheet for coaching stock no. C-K-514 (latest). Sidewall partitions of Engine Room
shall be 1 mm thick M.S. Sheets.
3.4.21 Driver cabin shall have steel step iron below the entrance to driver’s compartment and shall be
so located as to provide a convenient foot-hold without infringement of maximum moving
dimensions.
3.4.22 Doors shall be provided in Driver’s cabin for complete isolation so that when working on stand
still position, smoke is not filled inside driver’s cabin.
3.4.23 Exterior Painting: Exterior painting of the CMV shall be executed as per Supplier’s standard
procedure. However, prior approval of the purchaser for the same shall be taken. The colour
scheme for interior and exterior of the CMV and particular for marking and number plates shall
also be approved by the CMRL. (RDSO Latest Specification for Indian Railway Shall be
applicable. RDSO Specification M&C/PCN/100/2009).
CMRL / Rev 012 3 4 3-10 Jul Oct 2023 Jan Feb May 2024
Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

3.5 COMPRESSOR

3.5.1 The CMV shall be provided with a suitable air-cooled compressor, directly driven by the diesel
engine. The capacity of the compressor at idling speed of engine shall be adequate to meet
the requirement of braking and horn when operated simultaneously. The Contractor shall give
a technical justification for the compressor capacity such that the requirements of braking,
horns and other accessories are fully met. (The bed plate of compressor unit shall be
sufficiently strong to withstand the vibrations during run). Main reservoirs of adequate capacity
shall be provided.
3.5.2 A filter of adequate capacity shall be provided at the compressor’s inlet to protect the machine
from dirt and dust entering into it. Additional filters, if considered necessary, by the suppliers
for particular valves shall be provided in the system.
3.5.3 The compressor shall be provided with suitable governor/ unloader to cut-in and cut-out at a
nominal pressure of 8.5 kg/cm2 and 10 kg/cm2 respectively. In addition a safety valve of
sufficient capacity set at 11 kg/cm2 shall be provided to safeguard the system against
overcharging.
3.5.4 Suitable inter-cooler and after-cooler shall be provided to cool the compressed air delivered by
the compressor.

3.6 FIRE EXTINGUISHER, FIRST AID EQUIPMENT & ELECTRIC SHOCK TREATMENT
CHART

3.6.1 Two Clean Agent type fire extinguisher of 5 kg capacity shall be provided in each cab.
Adequate space shall be provided for keeping a first aid box and one stretcher. Design /
drawings shall be furnished for provision of space for first aid box and display of Electric shock
treatment chart for approval of CMRL.

3.7 PIPING

3.7.1 The tubes shall be of stainless steel in annealed condition to ASTM A269 Gr. TP304.
(SEAMLESS & ANNEALED) of hardness in the range of 75-80 HRB. They shall be free of
scratch, and smooth inside and outside. The tests on the tube such as chemical test, flaring
test, hardness test, bending test, etc., shall be as per ASTM [Link] fittings used for air
brake system shall be stainless steel as per RDSO Spec. No. 04-ABR (Latest Revision). It will
be preferable if sizes of pipes are limited to a minimum. Sharp bends must be avoided and
where necessary, connections shall be used. Double ferrule pipe fitting consist of body, front
ferrule, back ferrule and nut shall be provided. The material for nut, body shall be Stainless
Steel ASTM A 479 TP 304 (Bar stock) and ASTM A182 F 304 (Forgings). The ferrule and back
ferrule shall be made from stainless steel to ASTM A276 TP 316 SS.
3.7.2 Pipes, ducts and conduits shall conform to an identification colour scheme, which shall be
approved by Purchaser after the contract is awarded.
3.7.3 Chart showing the colour for identification of pipes shall be displayed in cab at a prominent
place where it is likely to be needed for reference.
3.7.4 All pipe joints will be as per standard practice. Schematic piping to suit the engine shall be in
accordance with the relevant drawings. Flexible pipes shall be provided at the locations prone
to vibrations.

3.8 LUBRICATION:

3.8.1 Flexible pipes used for lubrication purposes shall be of special quality to withstand the climatic
conditions.
3.8.2 Grease nipples shall conform to IS specification No.4009; all the grease nipples & adapters,
wherever used, shall be tack welded to prevent them from unscrewing and falling off in
service.

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Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

3.9 BELTS

3.9.1 Special attention shall be paid to all belt arrangements, which shall permit easy, and quick
replacement when required and which can be adjusted and replaced in service.
3.9.2 Sizes and shapes of belts used on the CMV shall be selected from those available in India.

3.10 CARDON SHAFT:

3.10.1 The Cardon Shaft shall be of robust design and well proving in performance capability,
suitable for transmitting rated horse power and maximum torque encountered during
operation.

3.11 AXLE DRIVE GEAR BOX WITH POWERED AXLE:

3.11.1 One of the axles of the bogie will be powered.

3.11.2 Proven axle drive gearbox of suitable gear ratio, complete with powered axles & torque
reaction arm shall be offered. The Contractor shall take care that the offered power equipment
is well matched with the axle drive and meets the performance requirement.
3.11.3 The axle drive gearboxes shall be robust in construction and designed to transmit continuous
rated horsepower/maximum torque transmission capacity of the axle drive gearbox at start.
3.11.4 The input flange of the axle driver shall be oil injection mounted.
3.11.5 Drive gear should have oil level glass for visual checking.
3.11.6 Drive gear should have suitable lubrication system for lubrication of gears and bearing at slow
speed.

3.12 AUXILIARY ALTERNATOR :

3.12.1 Engine mounted auxiliary alternator of adequate capacity with rectifier for the speed range
between idle and maximum of engine speed shall be provided to supply 24V DC for charging
the provided for engine starting and control.
3.12.2 Engine driven Auxiliary Alternators with rectifier and voltage regulator of adequate
capacity shall be provided. The drive for the alternator shall be taken from auxiliary end of
engine. The auxiliary alternators shall cater to the following electric loads:
a) Two twin beam head lights, one at each end.
b) Flasher Light and marker light
c) 110/24 V supply for controls and cab equipments
d) Charging of 110/24V, 120 Ah batteries
e) Light & Fan load of OHE maintenance vehicle.

3.13 BATTERY:

3.13.1 The battery specification are as below:-

a) 24V,450Ah, lead acid batteries conforming to IS: 7624 / RDSO Specification: MP.[Link]
(Rev 00) Dec'09 or latest will be provided for engine starting controls & Lighting. It shall cater
to all auxiliary electrical load of the CMV for five hours in case of auxiliary alternator failure.
External batteries charging terminals will be provided on either side of the coach
b) 110V/24 V DC, 120 Ah Tubular batteries for lights, fans, main control circuit conforming to
relevant RDSO/IS/specification Latest revision.
c) It is desired to have a warning system to indicate that the battery is about to drain out so as to
warn the operator and save battery for further starting of Engine.
3.13.2 The location of the batteries shall be such that there is no danger of their getting damaged due
to tools and equipment inadvertently falling on them. Terminals for charging the batteries from
external charging equipment shall also be provided.
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Chennai Metro Rail Project – Phase 2
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3.13.3 The battery shall be charged by the engine driven alternator/rectifier and voltage regulator.
3.13.4 Rectifier-Regulator conforming to IEC: 571 shall be under frame mounted. Crimping sockets
required for interconnecting and output cables shall be supplied along with the equipment. The
rectifier regulator box with protection level IP 55 (Hose proof) shall have an open able front
cover, which shall be capable of being closed and locked. This box shall be electro-galvanized
and painted grey. The regulator shall have provision of potentiometers for currents and voltage
setting for adjustments depending upon service conditions.
3.13.5 A socket for charging the battery from an external source shall be provided. Battery should be
draw out type mounted in movable crate to facilitate maintenance of battery. Float type
electrolyte level indicator should be provided in battery for monitoring of electrolyte level.
3.13.6 The location of the batteries shall be such that there is no danger of their getting damaged due
to tools and equipment inadvertently falling on them. Terminals for charging the batteries from
external charging equipment shall also be provided.
3.13.7 The battery shall be placed in suitable tray for rack in and rack out easily for maintenance.
3.13.8 The battery compartment shall be provided with locks to prevent theft.
3.13.9 The battery of suitable capacity conforming to IS:6848 – 1972 latest specification, shall be
provided to cater for the power supply for lights and fans for 5 h. the battery fuse shall be
located close to the battery terminals.

3.14 CONTROL AND GAUGES:

3.14.1 CMV shall be provided with driving control cab for bi-directional operation of vehicle. Adequate
control equipment including gauges, instruments, and safety devices shall be provided for safe
and satisfactory operation of the CMV. The equipment and controls shall be so arranged in the
driving console so that they facilitate easy access for operation and maintenance.
3.14.2 Interlocks shall be provided such that Maintenance Vehicles can be operated from one cab
only at a time. The driver should be able to start or shut down the engine from his cab.
3.14.3 Power ON/OFF indication for power pack shall be provided on control panel of driving cab.
3.14.4 Gauges, Instruments and Safety Devices:
3.14.5 The gauges, sensors, transmitters and switches indicated below is included and not limited to:
a) Other Gauges/Switches
I. Main reservoir pressure gauge:
II. Brake Cylinder pressure gauge
III. Duplex type indicating brake of both the bogies: 4 inches
IV. Brake pipe gauge: 4 inches
V. Vehicle speed indicator cum recorder (in Driving cab)
VI. Switch for horn
VII. Switch for wiper
VIII. All gauges shall be of proven and reliable design with backlight. Graduations of the
gauges shall be in metric units.
IX. Transmission oil temperature gauge
X. Transmission oil pressure gauge
XI. Forward/Reverse/Neutral indicator
b) Brake Application indicator: The Contractor shall provide digital gauges of proven design
3.14.6 The following safety devices shall be provided:
a) Water temperature too high- Engine to idle & Transmission to neutral
b) Transmission oil temperature high- Engine to idle & Transmission to neutral
c) Low lube oil pressure- Engine to shut down and Transmission to neutral
d) Engine speed too high- Engine to shut down & Transmission to neutral
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 Chennai Metro Rail Project – Phase 2
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e) Radiator water level too low- Engine to shut down & Transmission to neutral vi Emergency
engine stop- Fuel supply to engine cut off & Transmission to neutral.
f) Emergency brake application- Engine to idle & Transmission to neutral
g) Vigilance Control Device (VCD) generally conforms to RDSO Specification No. [Link]
(Rev. 04) Dec 2008 or latest.
h) OHE ON OFF indicator inside the each driving cab.
i) In addition, space shall be provided for installing ATP systems for which the tenderer has to
interface with Signalling and Telecom Contractor.
3.14.7 Following Audio-Visual Signals or Reference panel lights shall be provided in the driver’s cab:
a) Lube oil temperature too high
b) Radiator water temperature too high
c) Engine lubes oil pressure low.
d) Engine shut down by safety relay
e) Forward/Reverse proving lamp.
f) Engine starting
g) Battery charging
h) OHE On/Off Indication.
3.14.8 The control system shall have the provision for connecting the Vigilance Control Device. When
the device operates, the engine should come to idle and simultaneously the declutching of
transmission and application of brakes should take place.

3.15 ELECTRICAL EQUIPMENT:

3.15.1 Illumination
[Link] Driving cab, staff cabin shall be provided with level of illumination at least 60 lux at the working
plane level 1 m above the floor level).
[Link] The electrical circuitry shall be such that tail, cab and car lights, fans and the plug points for
inspection lamp, get the electric supply at the rated voltage from the generator when the
engine is running and from the storages battery when the engine is not running.
[Link] The changeover of supplies shall be automatic for which resistance and resistance cut-in
relays may be employed. Complete schematic of electrical circuitry with above provisions shall
be got approved from Purchaser before execution.
[Link] Tail light: Tail lamp (Red aspect) of LED type 24 V 15 W as per RDSO’s Specification No.
RDSO/PE/SPEC/TL/0119-2000 (with latest revision) shall be provided at each end to comply
with General & Subsidiary Rules of Indian Railways. The tail light at both ends shall burning
when parked.
[Link] Marker Light: Marker light of LED type(White aspect) as per RDSO’s Specification
[Link]/SPEC/PR/0022 (Rev-1) Oct. 2004 or latest shall be provided on both ends of the
CMV.
[Link] Flasher light: One flasher light each of LED type as per RDSO’s Specification [Link]/
SPEC/LFL/0017 (Rev-1) Sept, 2004 or latest shall be provided on the roof at both ends of the
CMV.
[Link] The cab lights shall be capable of being switched on by a switch on the driver’s panel.
[Link] Head Light: Twin beam Head light: Twin Beam head lights shall be provided at both ends. The
head light shall confirm to RDSO’s Specification No. ELRS/SPEC/PR/0024 (Rev-1) Oct.2004
or latest. The operating voltage of head light shall be 24 V DC. 24 V DC, supply for twin beam
head light shall be taken from 110/24 DC-DC convertor. DC-DC Convertor shall be as per
RDSO’s Specification No. ELRS/SPEC/DC-DC Convertor/0021 Rev.1 or latest.
(Recommended to go for LED type head light.)
[Link] Search light: CMV shall be provided with six nos. with sufficient illumination LED type light with

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 Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

suitable wattage and capable of swiveling on universal joints type supports. Also the light
fittings shall have IP 65 protection.
3.15.2 Brushless Electrical fans 110V/24V shall be provided in cab. The fans shall be provided with
suitable guards and their location will be fixed at the time of approval of drawings by the
Purchaser.
3.15.3 Electrical equipment on CMVs, like lamps, lamp holders, switches, fans, wires and cables, etc.
shall conform to IRS/Indian Standards Specifications, as applicable. List of the specifications is
attached herewith. All electrical wires and equipment used on the CMV shall be suitable to
withstand tropical climatic conditions.
3.15.4 Driving cabs, staff cabin shall be provided with 300mm brushless DC fans.
3.15.5 3nos of rechargeable Three color hand torch light shall be provided for hand signals.
3.15.6 Wiring:
[Link] All Electrical wiring in the CMV shall be done with e-beam cables conforming to RDSO’s
Specification No ELRS/SPEC/ ELC/0019 Rev.-1 dated 06.07.2010 with latest amendment.
Cable markers used for identification of the cables shall last for the life of the cables.
[Link] Suitable means shall be provided to illuminate instruments, gauges, switches etc. in the
operating CMV and adequate shading of the lights shall be
[Link] allowed to avoid any glare or distraction to the driver. Luminescent illumination of the desks
will be preferred.
3.15.7 Circuitry: The load shall be suitably distributed based on standard practice.
3.15.8 Generator/Alternator: An engine mounted DC generator or an alternator with rectifier and
regulating equipment of suitable capacity shall be provided to deliver power at 27.5 V d.c. The
output of the generator shall cater for battery charging for diesel engine starting (battery
voltage 24V)& head lights, search lights, cab lights, tail lights, plug points, fans, wiper, panel
illumination, control and safety circuits. The maximum power demand will be required when
the CMV is stationary and with engine running at low idling speed.
3.15.9 Diesel Generator: A suitable capacity of three phase, 415V, silent diesel generating set as per
CPCB norms for power supply to Crane ,Lighting, Battery charger, swiveling platform etc shall
be provided in the CMV.
3.15.10 Battery Charger: One variable voltage charger of input : 415V AC± 10%, 50 Hz ± 3% to 110V
& 27.5 V DC) should be provided to manually charge the 24 V and 110v battery from Genset
(provided in the CMV) and also from external source. The battery charger panel shall be IP65
rating.
3.15.11 Earthing Arrangement of Catenary Maintenance Vehicle (CMV): All metallic parts of CMV
including shell structure and bogie shall be integrated electrically to ensure proper earthing of
CMV through wheel to rail. The body of the lifting motors, control panel and other electrical
equipment shall be connected to earth as per standard practice of rolling stock.

3.16 CRANE & LIFTING PLATFORM OF CMV

3.16.1 One hydraulic Crane having capacity of 2 ton load at a distance of 4 meter and also
replaceable with interchangeable bucket suitable for 2 persons with their tools, with a capacity
of maximum of 300Kg.
3.16.2 Lifting platform capable of carrying 4 to 5 persons with their tools. It should have capacity of
lifting minimum 500kg. The platform shall be of lifting and swiveling type.

3.17 CRANE WITH INTERCHANGEABLE BUCKET

3.17.1 The Vehicle has to be equipped with a crane with interchangeable basket. The performances
must be as follows:
a) Nominal load of Crane with basket shall be 300Kg and it should easily and conveniently carry
two workers of normal built with their tools in bucket. The safe working load shall legibly be
stamped on a non- vital part of the Bucket, an authentic test certificate shall be supplied.
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Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

b) Horizontal reach for the workers in the Basket from the track axis should be upto 8.5 meters.
Vertical reach for the workers in the Basket from rail level should be upto 12meters.
c) The crane shall conform to EN 12999:2007 or latest version or equivalent.
d) When using Hook instead of basket, it should be able to lift heavy traction equipment load of 2
ton minimum from a distance of 4 meters. The safe working load shall legibly be stamped on a
non- vital part of the hook, an authentic test certificate shall be supplied.
e) The basket control should be in the basket itself itself or radio remote shall be provided.
f) The basket has to be fitted with a radio remote control panel for the hydrostatic transmission
for controlling movements.
g) All the hydraulic movements have to be secured by a hand backup pump and platform frame
of the vehicle.
h) The basket must be fitted with plugs for electrical tool (5KW), with lighting and two search light.
The arrangement shall be approved by CMRL.
i) In addition to one panel at basket, one redundant panel shall be provided at CMV. There
should be one stop mushroom type switch in panel to be used for application of brake and
engine idle if basket is operated. Manual operation of basket shall be possible in case of
electrical/hydraulic circuit failure. Functions to be archived with emergency stop needs to be
listed clearly in detailed design.
j) The wiring of the crane and bucket shall be carefully designed so that during complete
movement and rotation of the unit, it does not get entangled with any other object of the CMV.
In case of short circuiting of the wiring, abnormal movement shall not take place. Each circuit
shall be protected with MCB of suitable rating. Fail safe design of bucket control to be
elaborated in detailed design.
k) The make of the crane shall be proven one for similar applications and documentary support
shall be given for the same.
l) The Contractor of the crane and its design shall be submitted for approval of CMRL.
m) Speed of 10kmph should be governed by means of speed governor at the time of using
Crane/bucket.
n) During movement of the vehicle the operation of the crane shall be strictly prohibited.
Provision in the crane operation shall be provided so that no power from traction power packs
shall be transmitted during movement of the Vehicle.

3.18 LIFTING AND SWIVELING PLATFORM:

3.18.1 There shall be one platform on the car with specification as under:
a) Lifting platform capable of carrying 4 to 5 persons with their tools. It should have capacity of
lifting minimum 500kg.
b) The minimum height of the platform shall be 3 meters and extendable upto 5.5 meters. The
platform shall be capable of 180 degree rotation
c) The Contractor of the lifting platform and its design shall be submitted for approval of CMRL.
d) The raising and lowering of platform shall be gradual and not sudden or too fast.
e) Suitable safety measures including interlocks between various equipments, access doors, line
equipment shall be followed to ensure safety on roof/platform.
f) Speed of 10kmph should be governed by means of speed governor at the time of using
platform.
3.18.2 Dimension of Platform
a) Length of platform : 5000mm min req.
b) Width of platform : 1500 mm
c) Platform floor level above rail level when elevated : 5500mm
d) Maximum lifting time to full height : 45 s
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 Chennai Metro Rail Project – Phase 2
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0
e) Rotation range of platform towards sides 90
f) Side shifting reach of platform :4000mm min req.
g) Full height of collapsible railing above platform floor :800 mm
0 0
h) Maximum time of rotation from 0 position to 90 :45 s
Note: Control panel for lifting, lowering and swiveling platform shall be secured from ingress of
rainwater and the wiring to the control panel shall be suitably enclosed with flexible hoses.

3.19 PANTOGRAPH:

3.19.1 The pantograph of CMV shall be provided same as rolling stock .Scale marking shall be
provided on the pantograph for measuring stagger. The pantograph pan shall be solidly
earthed to body. It shall be provided with a proper arrangement to keep it locked down when
not in use.

3.20 DESIGN

3.20.1 General Conditions

[Link] The Rail mounted Overhead CMV is a self-propelled 4 axle ,8-wheeler vehicle uses the power
generated by the Diesel Engine set.
[Link] The CMV will be required to operate at grade, on viaduct and in underground sections of
CMRL.
3.20.2 Design Development:
[Link] The Supplier shall develop the design based on the details given in this specification and
sound engineering practice. The entire design data shall be furnished with technical details
and calculations to CMRL for review before commencing manufacture/construction of CMV or
placing orders on sub-Contractor. The Supplier will interface with track and other system wide
Contractor for design inputs required for developing the design.
[Link] The design shall be developed in the S.I. Units.
[Link] The supplier shall develop full set of working drawings in standard size complete in all respect
taking in consideration specification requirement, exhibited drawings and instruction of CMRL.
They will submit this set of working drawings to CMRL for their review.
[Link] Material specifications, manufacturing tolerances and other details which are necessary for
manufacture for each component shall be indicated on the relevant drawing and copies of
such specifications shall be supplied to CMRL for approval on award of contract.
[Link] The vehicle shall be robust, reliable, and suitable for working on CMRL. Quality assurance
during manufacturing shall be according to ISO-9001/latest.
[Link] Assumptions made with regard to live load, impact load etc. with the stipulated calculations of
the design as finally developed to satisfy the requirement of the specification are fully complied
with.
[Link] In addition to above the vehicle should also have Earmarked space for easy loading,
unloading and keeping a dry type transformer, OHE Masts/structures.
3.20.3 Details of Track network
[Link] The Supplier shall furnish fully equipped Catenary Maintenance Vehicle designed for operation
in CMRL Phase 2 installation.
[Link] The maintenance vehicles shall be suitable for the main line, underground and depot area, the
general parameter of track is given in Table below:
[Link]. Item: Unit Main Line Depot
1. Track type Ballast less Ballast less
2. Track rail UIC 60 UIC 60

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 Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

3. Maximum cant 120 mm (S.G.) ---

[Link] The vehicle should be designed for use on CMRL phase 2 –corridor 3,4 &5 of SG having
following parameters: -
S. No Parameter Requirements
Track gauge (Please refer attached
1 1435 mm
sheets for track structure)
➢ 200 m at Underground &
➢ 120m at elevated and grade
sections (as per CMRL phase 2
track alignment)
➢ 100 m Depot and other lines.
2 Minimum radius of curve
➢ It should also be capable of
negotiating a radius of 213m in
case of 1 in 8-1/2 SG turnout with
6.4mtr overriding switch.
➢ 175m radius incase of 1 in 8-1/2
SG scissor crossing.
120 mm (as per CMRL phase 2 track
3 Maximum super elevation
alignment)
85 mm (as per CMRL phase 2 track
4 Maximum Super elevation deficiency
alignment)
5 Maximum wind pressure In compliance to IS [Link] latest
Shall conform to the kinematic
Maximum moving Dimensions (Both in envelope and Schedule of dimension
6
static & Dynamic conditions) SG (CMRL) with the pantograph and
platform in lowered condition.
4% or as per CMRL phase 2 track
7 Maximum gradient
alignment
3800mm (With pantograph, lifting
platform with 1st stage hand rail raised
8 Maximum Height of CMV
condition and crane and cradle in lock
down condition)
Shall conform to Schedule of
dimension SG (CMRL). Adequate
clearance shall be allowed so that no
Maximum permissible wheel base component of the CMV shall cause
length of the CMV, overhang beyond any infringement as per CMRL
9
bogie center, coupler height draw bar specific requirements above rail level
height. with wheels in fully worn-out
conditions, full deflection of springs
and effect of
dynamics.

Tare Weight in working order (inclusive

10
of all items). Approx. 50 Ton +/- 5%
11 Axle load (in fully loaded condition) 16 ton maximum

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 Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

S. No Parameter Requirements
12 Maximum speed 80 Km/h
Maximum speed 10Km/h when
Maximum speed with elevated swiveling
12a swiveling platform is in raised
platform
condition.

13 Performance capabilities: -

Pay load (excluding Power

Minimum 15 ton
equipment and hydraulic platform)
Period of continuous running at 80 km/h
on generally tangent track followed by
frequent to and fro movement at walking
pace for 1-1/2 h) 5-1/2h total (4h+1-1/2h)

Period of continuous running at 60 km/h

up or down gradient of 1 in 60 to be
followed by frequent to and fro
movement at 5 km/h for 1-1/2 h on
same gradient. 5-1/2h total (4h+1-1/2h)
Performance in monsoon and squally
Un- restricted
conditions

3.21 INITIAL LETTERS/LOGO:

3.21.1 Where parts are required to be marked with initial letters / Logo, they shall be CMRL.

3.22 MANUFACTURER’S TEST CERTIFICATE:

3.22.1 Copies of the Maker’s certificate guaranteeing the performance of the vehicles shall be
supplied in duplicate along with the delivery of each equipped vehicle.

3.23 OPERATOR’S TRAINING:

3.23.1 The requirement of operators and allied staff for running the vehicle shall be furnished to the
Supplier for the purpose of the training, specifying their duties and minimum qualifications.
3.23.2 The Supplier shall provide training for at-least two such groups of 8 persons & one supervisor
at site per vehicle supplied.

3.24 TRANSPORTATION OF GOODS:

3.24.1 Supplier shall comply with the provisions of the Carriage by Road Act 2007 or latest and
Carriage by Road rules, 2011. As per this, it will be incumbent on the supplier to the transport
contracted material/supplies only through registered common carriers in accordance with the
Carriage by Road Act 2007 or latest.

3.25 DRAWINGS & MANUALS

3.25.1 Technical specification of drawings submitted shall include the following:

[Link] Complete overall dimensions of the individual units of vehicle superimposed on the Maximum
Moving Dimensions (MMD) and Kinematic Envelope (KE) of vehicle super imposed on KE of
SOD (SG) to ensure that no part of the vehicle goes beyond these dimensions. (Refer SOD of
CMRL) Further any details required CP26/ARE02A Contractor shall interface with Track, Civil,
S&T, Elevated/UG Contractor, OHE and Rolling stock Contractors.

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 Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

[Link] Weight of all the major subcomponents shall be furnished.

[Link] Calculations to establish the adequacy of installed power for different functional combinations
of vehicle.
[Link] Any calculations, designs, drawings, schedules, information, data, progress, charts etc.
required by the CMRL in connection with the contract shall be furnished by the Contractor. In
case of any ambiguity in the interpretation of design and drawing, the decision of CMRL shall
be final and conclusive.
3.25.2 The manufacturer shall also supply schematic diagrams of electrical, hydraulic, pneumatic and
electronic circuits used on the vehicle. Trouble shooting diagram/ table shall also be supplied.
Main features of items like hydraulic pumps-motors and such other bought out items shall be
furnished by the supplier.
3.25.3 As built drawing sets shall be dispatched with the consignment of CMV and the supply shall
not be considered complete until the sets of prints are delivered. Drawing on Auto CAD ,CD &
PDF shall also be provided.

3.26 SUPPLIER’S RESPONSIBILITY:

3.26.1 Provisional Speed Certificate/Approvals:

[Link] The Supplier shall interface with concerned statutory authorities to obtain the certificates viz
provisional speed certificate, oscillation trial test report and final speed certificate after
1 oscillation trials at his cost. It shall also be ensured that there are no infringements to Schedule
of Dimension of SG of CMRL. Supplier shall support & provide all relevant drawings /
documents related to CMV required for obtaining speed certificate & CRS inspection. CMRL
will process for approval from statutory authorities. However shall be considered as part of
final commissioning of CMV.
[Link] The Supplier shall also provide all necessary assistance for getting approval of Commissioner
of Metro Rail Safety for CMV.
3.26.2 CMRL is engaging an ISA (Independent Safety Assessor). CMV Supplier shall interface with
ISA for following activities:
[Link] System Safety Case provided by Signaling Supplier and Maintenance Vehicle (CMV) Supplier
to be assessed by ISA to give permission to run during revenue operation.
[Link] Based on the issue of speed certificate by manufacturer (CMV Supplier) and test
reports/certificate submitted, ISA/appropriate authority shall issue speed certificate for regular
use of CMV.
3.26.3 Submission for Approval
[Link] The Contractor shall submit design document and proposal for proven Contractor for the
approval of all major subsystems by CMRL as listed below: -
a) Wheel set and Bogie
b) Engine and Transmission
c) Crane
d) Lifting and Swiveling Platform
e) DG
f) Braking System
g) Battery
h) Battery Charger
i) Pantograph
j) The prior approval of CMRL for the make and design of the subsystems/components must be
ensured by the Supplier before adopting any design or product.

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 Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

3.27 MANUALS:

3.27.1 The Supplier shall submit 5 copies of the following detailed manuals and documents for getting
notice of no objection from CMRL for:
a. Operation/user manual (The OEM’s manual shall also be submitted for each system)
b. Preventive Maintenance Manual
c. Testing and commissioning Manual GTP, Test parameter, equipment specification and RDSO
approval sheet etc.
d. Cable wiring schedule.
e. Electrical circuit working details.
f. Trouble shooting Manual
g. OEM equipmentmanual & drawing of Engine, DG set, Cradle, Hydraulic transmission, brake &
pneumatics etc.
h. Drawing of body and bogie of CMV including under floor, cabin and roof etc.
i. Detailed part list including part no. with sketch of each equipment.
j. Contact list of OEM & service agency of different equipment.
k. Maintenance schedule along with check sheet of each equipment.
l. Corrective & overhaul manual of different equipment. The items required for common overhaul
shall be listed with details of part no., manufacture, specification ref etc.
3.27.2 Supplier shall also provide 3 copies/CMV each of original manual for each of the engine
subcomponent used in the vehicle.
3.27.3 Detailed operating manual, maintenance, service and assembly overhauling manuals shall be
specifically prepared in English language and three copies of these shall be supplied with each
vehicle.
3.27.4 The manufacturer shall also supply schematic diagrams of electrical, hydraulic, pneumatic and
electronic circuits used on the vehicle. Trouble shooting diagram/ table shall also be supplied.
Main features of items like hydraulic pumps-motors and such other bought out items shall be
furnished by the supplier.
3.27.5 While offering vehicle for first inspection the supplier shall submit three copies of complete
technical literature including operation, service and field maintenance instructions and
workshop manuals for overhauling of the assemblies and the vehicle, complete electrical,
hydraulic and pneumatic circuit diagrams, troubleshooting charts, component drawings/
description and other relevant technical details for the reference of inspection officer.
3.27.6 Testing
[Link] Weighment
a) Each completed vehicle in working order with full complement of fuel, oil, sand, water shall be
weighed 4 times successively and vertical load exerted by each wheel on the track shall be
measured, with due regard as to the accuracy of the measuring equipment. The Weighment
shall be done in presence of inspecting officers nominated by the Purchaser and the results
obtained shall be entered in a standard form to be obtained from the inspecting officer. The
pre-Weighment run shall be over a section of track containing difference of levels. No
alteration or adjustment shall be made to the CMV after passing over this section of track and
before weighment. The arithmetic mean of the values taken during 4 successive weighment
shall be the value of measurements.
b) After weighment, a check shall be made to ensure that Total weight is within +/- 1% of the
nominal weight. Axle load is within +/- 2% of nominal axle load.
c) The difference between the two wheel loads of any axle is not more than 4% of the axle load.
d) The manufacturer should preferably have in-house facility and adequate skills to carry out
squeeze test on one completed CMV shall be subjected to squeeze test as per standard to
ensure that it shall withstand a maximum end load of 100T without any signs or permanent
distortion.
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 Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

[Link] Performance capability tests:

The cmv shall be subjected to tests to establish its performance based on the supply by the
Contractor against the specification. The Supplier shall at his own expense provide the
services of competent Engineers / Supervisors and supporting staff during the performance
capability tests of the CMV.
[Link] Riding Quality Test:
a) The riding quality tests shall be conducted at a speed which is 10% higher than the maximum
specified operating speed, on a section of mainline track over which there are no temporary
speed restrictions and which is considered by CMRL as being in a generally run down condition
for main line standards but without speed restrictions. The tests shall be conducted from a
reasonably low speed, which is considered safe by the CMRL, upwards in steps of 10- 15
km/h to establish the performance at the specified speed.
b) The CMV shall be suitable for track being provided at the Viaduct, underground and in depot
area of CMRL Project.:
c) Cross section of track on viaduct sloping inwards w.r.t. standard gauge and rail cross-section
is attached for reference.
d) Supplier has to interface with concerned system wide Contractor for ensuring the correct
design inputs for developing their design and submit to Purchaser for approval before
manufacturing.
[Link] Vibration Requirements
The equipment and their arrangement shall withstand satisfactorily the vibration and shocks
normally encountered in service as indicated below:
Maximum vertical acceleration 3.0g
Maximum longitudinal acceleration 5.0 g
Maximum train acceleration 2.0 g (g being the acceleration due to gravity)

3.28 TESTS

3.28.1 Type tests

[Link] Following tests shall constitute type tests which are to be carried out at the manufacturer's
works to ensure compliance of the specifications.
a) Verification of dimensions of assemblies' auxiliary alternator, rectifier and regulating
equipment.
b) Temperature rise test at minimum speed for full output as well as the maximum speed.
c) Insulation resistance test.
d) Load test.
e) Drooping voltage characteristics test.
f) Water tightness test for rectifier-regulator.
3.28.2 Factory Acceptance Test:
a) The factory test plan shall be submitted for CMRL review. The plan shall adopt a top down
approach and describe the FAT strategy as regards to methodology, procedures to be
followed and records to be submitted. Contractor shall submit the comprehensive list of
specifications to be followed.
b) The FAT plan/submission shall include the appropriate testing and inspection items for notice
of no objection.
c) The FAT shall demonstrate that each subsystem meets its functional specification.
d) No equipment’s or software should be delivered to the site until the Contractor has
demonstrated to the satisfaction of CMRL that the equipment or software conforms to the
specifications by carrying out the FAT.
e) The site for the FAT of equipment shall be notified to CMRL prior to the commencement of the
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FAT.
f) CMRL shall have the right to witness the FAT.
g) Cost related to travel and stay of CMRL during FAT at manufacturer site as per FAT Program
will be borne by CMRL.
3.28.3 Pre-installation Test & Inspection:
a) Prior to installation, the Contractor shall ensure that equipment delivered to site has not been
damaged in transit. Inspection and testing shall be conducted by the Contractor to determine
that the equipment has not been damaged or the performance impaired in any manner
subsequent to shipment.
b) Test procedures shall be carefully planned to ensure that the work can be completed in the
time available. If the available time is restricted, this planning shall include a contingency plan
to be implemented if testing proceeds slower than anticipated or defects are identified, which
cannot be corrected.
c) The Contractor shall submit to CMRL a site preparation plan before installation.
d) The Contractor shall prepare the site in all respects required for installation.
3.28.4 Post Installation Tests:
a) Site tests shall be carried out in order to verify that the installations are correct and that, when
the system as whole is connected together, they function safety as an integrated system.
b) All tests shall be documented and tests results recorded. Test certificates with completed test
records, which demonstrate equipment and components meet the performance requirements
of the specification, shall be submitted for information.
c) Post installation shall be carried out by the Contractor for each vehicle following installation but
before functional test to demonstrate that the installation has been carried out correctly.
d) The Contractor shall submit a post installation inspection and testing plan prior to te
commencement of the post installation inspection and testing.
e) The inspection shall verify that equipment has been installed to the procedures and designs
that have received a notice from CMRL and equipment is correctly located and labeled.
f) The inspection shall verify that any false feed, temporary wiring and redundant items have
been remove3d and that equipment is correctly protected against interference, damage and
deterioration.
g) The Contractor shall maintain inspection records to demonstrate that each item of equipment
has been inspected and found to be satisfactory and attach to this record a detailed list of any
discrepancies found and remedial work carried out. Inspection records shall be kept for all
installed equipment and detailed list attached of any discrepancies.
h) As the discrepancies are rectified, the record sheets shall be amended to record the
correction.
3.28.5 System Acceptance Tests
a) System acceptance tests shall comprise comprehensive testing of the completely installation
to ensure that every item has been installed, adjusted and to demonstrate that all train
vehicles operated correctly in accordance with the specification, perform 9in accordance with
the specification and the local configuration and are available for integration, testing and
commissioning.
b) Prior to system acceptance testing, the Contractor shall submit a system acceptance plan to
CMRL for the notice of no objection. The plan shall adopt a top-down approach and describe
the system acceptance strategies and processes.
c) The System Acceptance plan shall identify a comprehensive list of specifications, standards,
method statements, procedures, drawings and records to be submitted to CMRL for notice of
no objection. The plan shall also include a program which identifies the dates for system
acceptance submission and tests.
d) Any test carried out which are deemed as system acceptance tests shall be identified. If these
tests have been carried out earlier or form the part of earlier carried tests, the same need not
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be repeated unless desired by CMRL. However, these tests should be identified and included
in the system acceptance test plan.
e) These tests shall be conducted in the presence of the CMRL who may decline for witness.
f) Any defects which become apparent in the course of these tests shall be made good and
modifications as approved shall be implemented and recorded. All attached equipment shall
be retested and certified before the system is accepted.
g) Prerequisites for SAT:
i All documentation for the safety report shall be submitted to CMRL for the notice.
ii All SAT shall be completed and test records submitted to CMRL for a notice,
iii Facilities for the maintenance of the system shall be in place.
iv The SAT plan shall be submitted to CMRL for a notice at least 60 days before the
commencement of the SAT.
3.28.6 System Acceptance Test Requirements:
a) It shall be the Contractors responsibility to conduct all tests and record data, and restore the
vehicle to full operational use following the SAT.
b) During the SAT, all interfaces with external systems other than those pertaining to the
designated Contractor shall be tested.
3.28.7 Integration Testing and Commissioning:
This section is applicable for interface with other systems and contracts.
a) On completion of testing and commissioning of the Contractors own system to the satisfaction
of CMRL, the Contractor shall carry out all tests necessary to integrate the CMV with all other
systems such as tolling stock, Track, Communication, S&T, Overhead Equipment, Civil etc
and demonstrate correct operation of all internal and External Interfaces.
b) Integration testing and commissioning plan containing the schedule of integration tests in
coordination with the interface Contractors and test procedures shall be submitted to CMRL for
a notice of no objection. The tests shall be carried out in coordination with the interface
Contractors.
c) The Contractor shall be required to lead in certain integration testing and commissioning
where such tests are required to prove the performance of system provided by the Contractor.
d) All the defects and shortfalls in the Contractors system discovered in the course of integration
testing and commissioning shall be made good and related to the satisfaction of CMRL before
the dates fixed for service trials.
e) The test and commissioning shall be managed without perturbation and/or interruption of
operation and maintenance,
f) CMRL may require additional tests if needed.
g) Final proved out test certificate will be issued by CMRL after reviewing performance for 2
months.

3.29 MANAGEMENT WITH SIGNALLING SYSTEM

3.29.1 Interface protocol between Signalling and Train Control system (STC) and Overhead Catenary
Maintenance Vehicle system (CMV)
3.29.2 This specification covers the interface requirements between Signalling & Train Control
Contract ASA-04 and CP26/ARE02A contract.
3.29.3 This document shall be read in conjunction with the relevant paragraphs of the General
Specification. The Contractors shall ensure all requirements of the General Specification and
PS pertaining to interfaces are fully resolved and implemented.
3.29.4 In the event of a conflict between any Particular Specification and this specification, the
requirements of this Interface Specification shall prevail.
3.29.5 The responsibility for specification and provision of the requirements for the works that

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interface with Designated Contractors’ equipment are tabulated in corresponding section of the
document.
3.29.6 The requirements specified herein are by no means exhaustive and it remains the Contractors
responsibilities to develop and execute jointly an Interface Plan after the commencement of
the works and throughout the execution of works, to ensure that:
a) All interfacing issues between the two Contracts are satisfactorily resolved.
b) Supply, installation and testing of equipment and software are fully coordinated.
c) That all equipment supplied under the Contracts is fully compatible with each other, whilst
meeting the requirements of the respective Specifications.
d) All the construction tolerances at the interface shall meet the requirements of the respective
specifications relating to the interface points.
e) Interface Contractors shall mutually respect each other’s project timelines with respect to the
interface requirements.
f) Interface Contractors shall finalize their respective interface equipment only after clear
agreement on interface requirements with the other designated Contractors.
g) Interface Contractors shall ensure that in any case, no equipment of their system shall be put
into production or installation without meeting the interface requirements spelt out in this
Appendix or in the Technical Specification.
h) Test procedures, troubleshooting manuals and any other documentation shall be updated with
technical details from of each Contractor and shall be submitted to CMRL.
3.29.7 Signalling and Train Control Contractor (STC) shall be the Lead Contractor. The Lead
Contractor shall be responsible to initiate, plan, coordinate and produce jointly with the
Participating Contractors all the required interfaces and interface design documents and
interface progress reports for submission to CMRL for acceptance. The Lead Contractor shall
also prepare and issue all interface meeting of minutes within 3 days of the meeting and
provide bi-weekly interface progress reports to all the participating Contractors for information.
Later, forwarding of issued minutes of meeting and bi-weekly interface progress reports to
concerned Contractors shall be lead Contractor’s responsibility.
3.29.8 CP26/ARE02A Contractor shall be the participating Contractor. The Participating Contractors
shall collaborate fully with the Lead Contractor in the development and finalization of the
interface design, joint production of the interface documents and interface progress reports.
3.29.9 The Signalling & Train Control system awarded as a separate contract for train operation in
Communication Based Train Control (CBTC) system in all the three corridors of Phase 2 and
in-between the corridors as inter-corridor operation. There will be a single STC contract for the
Phase 2 (Corridor-3, Corridor-4, Corridor-5, and all depots). STC Contractor shall interface
accordingly with the CP26/ARE02A Contractor.
3.29.10 All the participating Contractors shall ensure that copy of the Interface design documents
submitted to CMRL.
3.29.11 The costs for all interface design and testing works shall be deemed to be included in the
Contract sum of respective contracts regardless of the actual extent of effort required or
expended by the Contractor.
3.29.12 The Contractors shall be fully responsible for the management and control of their respective
Subcontractors in relation to all interfacing activities carried out under the Contract.
3.29.13 Where-ever requirements of OCC are mentioned, the same shall mean to be implemented for
both Operations Control Centre (OCC) and Backup Control centre (BOCC).

3.30 INTERFACE REQUIREMENTS

3.30.1 The CMV shall be equipped with CBTC equipment with redundant ATP systems to operate in
GoA 1 mode as per EN62290.
3.30.2 The ATP operation of CMV is envisaged with no other vehicle coupled into it. The coupler
status shall be vitally monitored.

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3.30.3 The Signalling system shall use continuous moving block approach for CMV similar to that of
approach for Rolling stock.
3.30.4 The Automatic Train Protection (ATP) system shall issue the Emergency braking commands
to CMV when safety limits are exceeded or when over-speed is detected. The removal of
traction effort and the correct application of Emergency brakes in CMV shall be the
responsibility of CP26/ARE02A Contractor. The ATP system shall be responsible for
monitoring of speed and the issuing of braking commands when safety speed limits are
exceeded.
3.30.5 The Signalling system design shall provide facility for the ATP movement of CMV into the work
zone. Once inside within the work zone, the CMV shall be able to move as many times as
possible in both the directions in ATP mode without the intervention from the OCC/SCR. The
system shall protect the CMV from moving outside the work zone area in ATP mode unless a
route is set by the Operator from OCC/SCR.
3.30.6 The CP26/ARE02A Contractor shall provide the Signalling Contractor the acceleration and
braking rates of the CMV. The Guaranteed Emergency Braking rate shall also be provided to
the signalling Contractor for incorporating in his design.
3.30.7 The signalling system shall design the speed curves for the CMV taking this into consideration.
The model for calculating the Safe Braking Distance (SBD) shall identify and take into account
various system’s response times and Train Operator’s reaction times and shall be in
accordance with IEEE 1474.1 standard.
3.30.8 The STC Contractor shall design the system in a way that no additional length shall be added
to the Interlocking overlaps designed based on the Rolling stock characteristics because of
CMV characteristics. Instead, the sectional speed of CMV be reduced to match the overlaps, if
requirement arises.
3.30.9 The CP26/ARE02A Contractor shall ensure that the CMV is designed for a maximum speed
which provides a nonstop average speed of the CMV as a minimum 40 kmph. The signalling
system shall control the CMV in such a way that the ATR regulates the recommended speed
based on the Operational scenario.
3.30.10 The CP26/ARE02A Contractor shall provide the tare weight of the CMV to the signalling
Contractor in the design phase. The signalling Contractor shall use this data for ATS related
reports and calculation.
3.30.11 The high critical alarms and information shall be transmitted to ATS through the CBTC radio
itself. The mode change, Emergency brake etc are some of the critical alarms. The
instantaneous speed of CMV, Direction of travel etc shall be some of the information to be
transmitted to ATS by Train-borne signalling system. The list of high critical of signalling
system shall be decided in design phase.
3.30.12 Since the CMVs are Diesel Powered Vehicles, signalling system shall not take the OHE status
while providing authority of movement for CMVs.
3.30.13 Both the Contractors shall provide adequate support for CMRL (as interface designs,
installation checks, test documents, technical information etc.) for liaison with the independent
safety assessors (ISA) and with other statutory regulators.
3.30.14 Mode of Operation
[Link] Automatic Train Protection (ATP or Coded Manual Mode)
a) Identification and enforcement of maximum speed at which the CMV may operate, shall be in
accordance with the maximum design safe speed.
b) Identification and display of actual speed, target speed, target distance, and the operating
speed (recommended speed/advisory speed).
c) Provision of an audio-visual warning to the CMV operator when the system identifies that the
CMV is operating at a speed more than the maximum safe speed; recognition of a delay of 2s
for the CMV operator to react and do service brake application to reduce the speed. If the
operator fails to reduce the speed below the maximum safe speed in a specified time an
irrevocable Emergency Brake application shall be made, automatically till the vehicle attains
zero speed.
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 Chennai Metro Rail Project – Phase 2
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[Link] Restricted Manual (RM) and Run-on Sight (ROS) Mode

a) In RM mode, the maximum train speed shall be controlled by the on-board ATP to a limit not
exceeding 25 kmph. This mode shall be available only when the on-board ATP equipment is
operational.
b) The running monitoring shall be the same as for RM. The ATP shall give cab signal indications
as soon as the train reaches a track position where normal running can be resumed. The ATP
authorizes the ROS request.
[Link] Cut-out (or By-pass) Mode
a) By-pass Mode shall be provided for use in the event of failure of the ATP system. In this mode,
the CMV speed shall be controlled entirely by the operator, to a limit speed as in Operating
orders.
b) The ATP Cut-out (By-pass) Mode shall be initiated by the CMV operator operating a sealed
Safety Cut-out Switch (SCS) and simultaneously breaking its seal. The operation shall be
recorded by the on-board digital counter and OCC/BCC & DCC. The SCS shall be provided by
CP26/ARE02A Contractor. The on-board non-resettable digital counter shall be provided by
the Signalling Contractor.
3.30.15 Hardware Interfaces
[Link] The Signalling Contractor shall provide the CP26/ARE02A Contractor with a list of equipment
to be supplied by the Signalling Contractor and installed by the CP26/ARE02A Contractor on
the CMV. The list of equipment shall include, but not be limited to the following:
a) Train-borne ATP/ATO equipment for CMV
b) Communication Based Train Control (CBTC) modules
c) Various types of antennas
d) Speed / acceleration measuring devices including tacho-generators, accelerometers, switches
etc., as appropriate.
e) Signalling driving console display with buzzer for both cabs of all CMVs.
f) All complete length of cables and connectors to connect Signalling equipment to the Train-
borne signalling unit including all intermediate connectors as applicable.
[Link] STC Contractor shall supply to CP26/ARE02A Contractor , as per the requirement of the
CP26/ARE02A Contractor, pre-wired equipment racks with all other equipment.
[Link] The train-borne signalling equipment shall consist of separate compact modular sub-rack for
each function, readily replaceable and mounted on the train-borne signalling equipment rack
located in the ATC compartment provided in the CMV (only one location). The hardware shall
be the same as that of used in Rolling stocks of CMRL phase 2 projects except the ATO/UTO
equipments required for ATO or UTO mode of Operation, which shall not be required as
ATO/UTO mode of operation is not envisaged.
[Link] Any train borne signalling equipments to support ATS related functionalities like timetable
operation, ATR etc, if required, shall be part of the train borne signalling equipments for CMV.
The ATR functionality for CMV shall be based on the run time control as no dwell time/ station
stoppage is defined for it.
[Link] The ATP systems shall have similar configuration of the Rolling stock similar level of
redundancy for train borne equipment and other peripheral equipments like antennas, tacho
meter etc.
[Link] The CBTC radio shall have similar level of redundancy that of the rolling stock. For non-CBTC
radio and its switch, redundancy is not required. Currently, non-CBTC radio will be used for
centralised diagnostic data/log collection of Signalling. The future provisions of virtual networks
making use of the non-CBTC bandwidth shall be provided (similar to that of the rolling stock)
for operator to utilize for various future purposes.
[Link] The Signalling Contractor shall submit drawings showing the recommended placement of their
train borne ATP/ATO equipment in the CMV in consultation with the CP26/ARE02A
Contractor. This is in addition to specifying the locations where the exterior equipment has to
be mounted for optimal performance.
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 Chennai Metro Rail Project – Phase 2
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[Link] The CP26/ARE02A Contractor shall ensure that ATC compartments shall be compatible with
the CMV without affecting the intended maintenance utility of CMV. The complete assemblies
shall be capable of being mounted in a suitable position. The assemblies shall be secured
from inadvertent human interference but shall be easily accessible for inspection and
maintenance when required. The Signalling driving console (HMI) display shall be mounted in
the appropriate position in CMV Operator’s desk on both ends considering the overall
ergonomics.
[Link] The Signalling and CP26/ARE02A Contractor shall develop and produce detailed descriptions
of interfaces, as follows (Not exhaustive):
a) Signalling equipment cubicle environment requirements.
b) Signalling equipment internal temperature.
c) Vibration and shock.
d) Humidity.
e) Ventilation requirements.
f) All equipment dimensions, mounting arrangements and necessary clearances.
g) Cable size/type/routing and specifications.
h) Electro-magnetic interference protection.
[Link] In addition to the above, the Signalling Contractor shall provide the following information (Not
exhaustive)
a) Weights and dimensions
b) Quantity
c) Equipment layout and clearances relative to the rack enclosure, including envelopes for
operation, installation, and removal.
d) Models of all train-borne equipment with fixing holes and cable connectors together with
installation details and layout details
e) Fixing details
f) Smoke and toxicity level release information.
g) Enclosure performance, IP rating
[Link] The Signalling and CP26/ARE02A Contractor are required to develop in more detail the
electrical interfaces, not limited to, as follows:
a) Type and Number of Interface Points - If relays are to be used for interface, only voltage-free
contact shall be used.
b) Signalling System Outputs and Train Control Interfaces
c) Power Supply Interface - The power supply wiring between the CMV power supply and the
signalling connector shall be supplied and connected by CP26/ARE02A Contractor. The
Signalling Contractor will specify the power requirements. There shall be no relays or contacts
between the negative return connection and the battery terminals.
d) Power Supply Isolation – The Signalling Contractor shall co-ordinate with the CP26/ARE02A
Contractor to ensure that all electronics can withstand the voltage spikes at the input of the
ATC equipment, as specified in EN50155.
e) Transient Suppression – The Signalling Contractor shall interface with the CP26/ARE02A
Contractor for the required details where Signalling Contractor can produce the design of the
Signalling's relay coils spike suppression circuit to eliminate the possible interference due to
disconnection of power from the ATC system.
f) Earthing Requirements - The earthing shall be designed to minimize the noise voltage
generated and to avoid creating earth loops susceptible to magnetic field and differences in
potential. The Signalling Contractor shall specify the earth impedance required for the earthing
point.
[Link] The Signalling and Rolling Stock Contractors shall coordinate with each other to ensure all
works are carried out seamlessly. The following split (Not limited to) of installation works are
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envisaged between the Signalling and Rolling Stock Contractors:

a) Signalling Contractor Responsibilities:
i. Supply of the train-borne signalling equipment rack (for CMV) containing the signalling
equipment, fully wired and tested.
ii. Train-borne signalling equipment rack supplied with anti-vibration pads which shall be
installed by CP26/ARE02A Contractor
iii. Junction box, where signalling cables terminate, if applicable
iv. Complete set of Signalling Cables from the signalling equipment rack to all signalling
equipment.
v. Supply of all free mating connectors, plug couplers etc for vital and non-vital information
communication between CMV and Train-borne signalling equipment.
vi. Supply of all connectors for power supply requirements of train-borne signalling equipment.
vii. Provide equipment such as antennas, tachometer, sensors, relay coils, etc related to the
Signalling system.
viii. Provide the non-resettable digital counter for cut-out mode operation.
ix. Mounting details and dimensions of interior and the exterior equipment.
x. Suitable coupling for connection to the ATC system, if applicable.
b) CP26/ARE02A Contractor Responsibilities:
i. Provide all supports, brackets braces, mounting holes, etc. to ensure proper mounting and
to allow adequate maintenance access to the train-borne signalling equipment.
ii. Provide adequate supports and stress relieving provisions for the cabling of signalling
equipment after these are mounted to ensure that cables are not fouling, chaffing, or unduly
stressed with other equipment.
iii. Good ventilation facilities (e.g., ventilation louvers/ openings) in the train-borne signalling
compartments shall be provided to allow air into the train-borne signalling equipment rack
and to prevent condensation.
iv. Shall install each of exterior Signalling equipment on CMV.
v. Mounting brackets for junction box housing.
vi. Appropriate cables for Power supply and earthing till the interface connectors of the train
borne signalling equipment rack and its termination in the connector.
vii. Appropriate cables till the interfacing connectors for all vital and non-vital inputs and outputs
and its termination in the interfacing connectors.
viii. Suitable support or clamping arrangement on the bogie for the flexible conduit to ensure
that the connectors or cables shall not work loose or break due to the movement of flexible
conduit even during the most adverse operation of the Trains. Such support / clamping
arrangement shall ensure non-chaffing with other equipment or create undue stress on
cables or connectors.
ix. Mounting plates and brackets for the exterior equipment
x. Suitable push buttons for RM selection etc.
xi. Rotary switches for the cut-out mode operation.
[Link] The screened cables used for the train-borne signalling equipment shall be properly
terminated so that no return loops are formed to cause an electrically noisy environment within
the train-borne signalling equipment cubicle wiring.
[Link] STC Contractor shall certify the procedure of fixation of relevant connections, cables to on-
board STC equipment after their assembling in first vehicle at CP26/ARE02A Contractor’s
premises. This procedure shall be agreed between STC Contractor and CP26/ARE02A
Contractor and the same shall be followed for all the subsequent vehicles of the
manufacturing. STC Contractor shall conduct random inspections in CP26/ARE02A
Contractor’s manufacturing unit, if required, to ensure proper procedure is followed in all
CMVs. Any change to the agreed procedure based on the subsequent supplier
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 Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

recommendations, or failure observed in previous CMVs, modification in the design, mounting

arrangements shall be incorporated in complete fleet of CMVs.
[Link] Any re-installation, replacement of cables, connectors, equipment, antennas or modifications
in mounting arrangements etc because of failures, damages, replacement because of quality
issues, during the installation, T&C as well as DLP period, shall be taken up by the respective
Contractors, who was responsible for the supply or for the installation as per the original work.
These replacements are included in the scope of this interface.
[Link] For compatibility, CMV and the train detection system (CBTC antennae/track circuits/axle
counters), shall conform to EN 50238.
[Link] Vehicle control circuits shall be developed by the CP26/ARE02A Contractor. During the design
stage, all the vehicle control circuits incorporating the identified interfaces shall be provided to
STC Contractor. STC Contractor shall provide specific observations on these circuits to
CP26/ARE02A Contractor. CP26/ARE02A Contractor shall suitably incorporate these
observations in the design.
[Link] STC Contractors to ensure that all input and output signals exchanged between CMV
equipment and on-board signalling equipment shall be recorded and shall be available for
retrieval on demand for analysis/record in a centralised location.
[Link] CP26/ARE02A Contractor to ensure that safety/train control related signals including brakes,
position of safety cut out switches, direction, coupler status etc. are communicated to the
signalling Contractor.
3.30.16 Factory Installation and Testing
[Link] All the special equipment associated with the train borne ATC system, including the interface
cables / wires between the train borne ATC and Train Radio shall be designed and supplied by
STC Contractors, as applicable, to CP26/ARE02A Contractor factory. Each Contractor shall be
aware of the locations of manufacturing plants.
[Link] STC Contractor shall be responsible for providing all data and training of CP26/ARE02A
Contractor staff in all aspects of ATC installation and verification wherever applicable.
Necessary training material shall be provided to CMRL and CP26/ARE02A Contractor for this
purpose. The first set of ATC equipment shall be installed by CP26/ARE02A Contractor, under
the supervision of STC Contractor representatives, including the wiring for the interface of the
ATC equipment with CMV.
[Link] STC Contractor while handing over the STC equipment to CP26/ARE02A Contractor for train
fitment in manufacturing facility, shall provide the equipment fitness certificates and quality
assurance certificates for all the equipment being handed over to CP26/ARE02A Contractor.
[Link] STC Contractor has to provide the material list, Part numbers, unique serial numbers for all the
STC components of all CMV(s).
[Link] CP26/ARE02A Contractor shall provide facilities for comprehensive static and interface tests
between Signalling and Telecommunications systems at his premises or at Depot as jointly
agreed. Signalling and Telecommunication Contractors shall be responsible for the provision
of special test equipment and instrumentation.
[Link] The Signalling, CMV and TETRA Contractors shall coordinate and conduct the integrated
testing of CMV in mainline. The basic features of ATC, Braking and acceleration of CMV,
Testing of Vital inputs (e.g.: Coupler status) etc shall be tested apart from TETRA calls to OCC
and other talk groups.
[Link] Should the need arise for modifications in the configurations of respective equipment or
systems as a result of Integration Test or otherwise, the scope of work and division of
responsibility shall be jointly agreed amongst the Contractors and detailed procedure shall be
developed. CP26/ARE02A Contractor shall provide the requisite manpower to monitor and/or
implement the modifications on CMV for work involving scope as identified in above clause.
3.30.17 EMI/EMC Interface
[Link] Regarding electromagnetic interference, STC Contractors shall provide a list of working
frequencies and other sensitive requirements to the CP26/ARE02A Contractor, to enable
CP26/ARE02A Contractor to avoid such frequency bands in design, and to provide devices to
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isolate the source of emission wherever required. STC Contractor will have first right of use for
radio frequency 2.4GHz/5.8 GHz for CBTC application.
[Link] CMV, STC & TETRA Contractors shall ensure that the emission and immunity level of their
respective equipment meet the requirements of EN50121-3-1 & EN50121-3-2.
[Link] CP26/ARE02A and STC Contractors shall also jointly develop a test plan for verification of
electromagnetic compatibility of CMV with signalling systems. The Contractors shall work
together to assure that all electronic and electrical equipment on CMV works properly without
interfering with signalling sub-systems.
[Link] The cable layout of the signalling system in the cable ducts provided by CP26/ARE02A
Contractor shall be jointly agreed. The separation between signalling cables and power cables
of 25kV, 415 V 3 phase AC, 230 V AC 1 phase, 110 V DC and further other DC voltages rating
shall be in accordance with accepted international practice and jointly agreed.
3.30.18 INTERFACE- Division of Responsibility
[Link] Signalling Contractor shall coordinate with Telecom Contractor(s) in order to achieve the
functional and operational requirements of the system. The roles and activities of the
Contractors shall broadly include the following as a minimum but not limited to those
mentioned in table below. Apart from the below table, the Contractors shall also adhere to all
the Interface specifications (as above) and the GS and PS requirements.
S. No Item STC Contractor CP26/ARE02A Contractor
Train borne ATC
1
equipment
Antennae for ATP
2 To provide space in the
and TWC
vehicle design for fixing and
Speed measuring installation at the
sensors and To supply the equipment, its manufacturer’s facility, by the
3 CP26/ARE02A Contractor,
speedometer and its mounting details to the
cables. CP26/ARE02A Contractor ‘s under the supervision of STC
Works as per manufacturing Contractor.
ATC Cab Displays schedule of CP26/ARE02A
(The speed measuring
(Train operator MMI) Contractor.
4 sensor(s) and odometer(s) for
including special
non-ATC mode will be
cables etc.
provided by CP26/ARE02A
Cab mounted Contractor. )
TETRA radio for
5
communication on
each cab of CMV
Antennae for CBTC, To supply the equipment to
6 CCTV including the CP26/ARE02A To provide space in the
special cables etc. Contractors Works. vehicle design for fixing and
installation at the
Furnish the requirement manufacturer’s facility, by the
To review the Cable CP26/ARE02A Contractor,
under the supervision of STC
Input and output Principle Scheme (CPS) and
7 to Verify the installation at Contractor.
signals interface
CP26/ARE02A Contractor To provide CPS to STC
manufacturing premises Contractor.
before dispatch the CMV.

Power supply and Furnish required voltage To provide the required

earthing for train- values and earthing voltages and earthing
8
borne unit requirements to To provide earthing scheme
equipment. CP26/ARE02A Contractor to STC Contractor.

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 Chennai Metro Rail Project – Phase 2
Bid No. CP26/ARE02A Part 2 – Section VI B: ERTS – DM&P CMV

S. No Item STC Contractor CP26/ARE02A Contractor

for respective scope.
To review the earthing
scheme, prepared by
CP26/ARE02A Contractor.
CP26/ARE02A Contractor to
Climatic STC Contractor to specify provide Cab Air Conditioning.
requirements for on the total heat load wattage, Suitable ventilation shall be
9
board ATP and maximum permitted provided by the Contractor for
equipment. temperature the backside area of the
console.
EMI/EMC interface STC Contractor shall advise CP26/ARE02A Contractor
between the CMV EMI/EMC plan and test shall ensure the compliance
10 and Signalling and reports for Train borne of the requirements of STC
Train Control, and equipment to CP26/ARE02A Contractors for train borne
Telecommunications. Contractor ATP.
Guaranteed CP26/ARE02A Contractor
STC Contractor shall share
11 Emergency Brake shall furnish value of GEBR
the logics used for GEBR
Rate(GEBR) to STC Contractor.
Any other
STC Contractor shall ensure CP26/ARE02A Contractor
requirements from
all the interface shall ensure all the interface
Employer /Engineer -
requirements pertaining to requirements pertaining to
12 Technical
CP26/ARE02A Contractor STC Contractor are shared,
Specification or this
are shared agreed and agreed and implemented
interface
implemented mutually. mutually.
specification.
STC Contractor shall
prepare DID and shall
CP26/ARE02A Contractor
ensure that it covers Design,
Detailed Interface shall provide the necessary
13 Interface Hazard log,
document (DID) information as requested by
Construction, Testing &
STC Contractor.
Commissioning, Test report
formats, Maintenance, etc.,

3.30.19 Provision for the installation of a Mobile Radio Device shall be provided in driver’s cab.
The Telecom & Radio Contractor shall supply the Radio Device and will coordinate with
2 CMV Contractor for installation, testing and commissioning.

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 Chennai Metro Rail Project – Phase 2 Part 2 – Section VI C: ERTS – CMC of RS
Bid No. CP26/ARE02A & DM&P – CMC Requirements
experience in Railway Rolling Stock. Out of which at least 7 years he shall worked in
Maintenance of Metro Rolling Stock. This person shall be mobilized to CMRL depot premises
180 days prior to arrival of prototype train until completion of CMC period.
v) Asset Maintenance Management System (AMMS) Specialist - with the responsibility but
not limited to configuration of Rolling Stock assets, maintaining warranty information, tracking
the maintenance campaigns, Job card creations, etc. Individual (must be an engineering
graduate in Computer science /Information technology) shall have at least 10 year
experience in information management system in large infrastructure projects. Out of which
at least 5 years shall be in implementation of AMMS of the metro Rolling stock or Computer
maintenance management system like Maximo, SAP, Trimble E2M / R2M or others. This
person shall be mobilized to CMRL depot premises 180 days prior to commencement of
CMC works until completion of CMC period.
vi) Inventory Planning and Procurement Manager - with the responsibility but not limited to of
Planning and Procuring the required spares, consumables, etc. Individual (must be a science
graduate with post-graduation in Inventory planning & management) shall have at least 10
years’ experience in large infrastructure projects in the domain of Inventory planning and
procurement. Out of which at least 5 years shall be in planning, coordination, and execution
of Metro Rolling Stock Maintenance. This person shall be mobilized to CMRL depot premises
180 days prior to commencement of CMC works until completion of CMC period.

1.15 CMC SCOPE FOR DEPOT MACHINERY & PLANT:

1.15.1 This chapter defines requirements that are specific to DM&P Assets. Wherever earlier Chapters
have already defined requirements for “CMC Assets” or their Spares etc. that shall be
understood to have included Depot M&P Assets as well.
1.15.2 Additional maintenance scope which applies to DM&P assets includes (but shall not limited),
 Preventive / periodic / Schedule Maintenance,
 Unscheduled Maintenance, Corrective Maintenance
 Providing Emergency support during Operational failures.
 Software upgradation
 Documentation upgradation
 Remote diagnosis (where applicable)
 And other as applicable
1.15.3 The Contractor shall retain at site all necessary Tools and Test Equipment required to maintain
Depot Machinery and Plant throughout the entire CMC period.
1.15.4 The Contractor shall provide comprehensive maintenance services at CMRL’s depot in-person
without any pre-condition, such as exclusion of weekends, unless otherwise agreed by CMRL.
1.15.5 The Contractor shall be available to attend to breakdowns affecting machine performance /
availability on 24 X 7 basis. The Contractor shall respond within 12 hrs for all Vital DM&Ps as
referred under clause [Link]. For all other categories, the Contractor shall respond within 24
hrs as referred under clause [Link] and [Link].
1.15.6 Notwithstanding the above, the total downtime including response time, preventive maintenance
time and corrective maintenance time shall not exceed the allowed time of 4 days / quarter for
every machinery and plant to achieve the Guaranteed Availability target of 95%.
1.15.7 CMRL may, at any time, undertake a full audit of the Services provided by the Contractor. The
Contractor shall render all reasonable assistance to CMRL in undertaking such audit.
1.15.8 DM&P assets supplied under this Contract, may be required to be utilised by other Contractor(s)
for their undertaking of maintenance on other Chennai Metro Phase-II Fleet(s) at the same
1 depot. Such utilization of CMC Assets shall be at no additional cost to CMRL.
1.15.9 It is clarified that a Standard Operating Procedure (SOP) shall be established by CMRL in order
to provide governance that will fairly and reasonably determine how the allocation of Depot M&P
1
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 Chennai Metro Rail Project – Phase 2 Part 2 – Section VI C: ERTS – CMC of RS
Bid No. CP26/ARE02A & DM&P – CMC Requirements
facilities will be apportioned between the respective fleets; without unreasonable hinderance to
the ARE02A Contractor's ability to deliver the deliverables required under the scope of this
Contract.

4 1.16 KEY PERFORMANCE INDICATORS (KPI) – ROLLING STOCK PASSENGER

SAFETY & COMFORT.

1.16.1 Performance of Maintenance Services rendered by the Contractor Rolling Stock sub-system
related to Passenger Safety & Comfort shall be evaluated against a range of Key Performance
Indicators (KPI).
1.16.2 KPI’s for Rolling Stock are subdivided into Primary, Secondary and Mandatory categories.
Primary KPIs are related to Preventive Maintenance, Secondary KPIs monitor performance as
perceived by passengers (in terms of information, satisfaction & comfort) and Mandatory KPIs
are related to train presentation.
Evaluation of the Contractor’s performance against the KPIs will be carried out on a monthly
basis in accordance with the provisions set out in this chapter. Penalties (if any) will also be
calculated on monthly basis and the total Penalties accumulated over three months will be
deducted from the Quarterly payment.
1.16.3 Evaluation of the Contractor’s performance against the KPIs will be carried out on a monthly
basis in accordance with the provisions set out in this chapter.
A Performance KPI Report shall be submitted by the Contractor every month starting from the
commencement of the DLP period for Rolling Stock. However, payments and penalties shall
only be calculated and applied during the CMC Period. In accordance with Clause 1.18.4(v) the
reports shall be App generated from the start of the CMC Period.
1.16.4 A Performance KPI report shall be submitted by the Contractor every month starting from the
commencement of the DLP period for Rolling Stock. However, payments and penalties shall
only be calculated and applied during the CMC period.
Passenger Safety & Comfort KPI Calculation
Only the below mentioned subsystems will be considered for this KPI calculation. Failure
scenarios identified (after Train fitness) through physical inspection or OCC workstation or were
recorded by the TCMS logs shall be considered. If any of the Failure scenarios listed in below
table are accounted for and penalized under clause 3.3.5, then such incidents will not be
considered for Penalty calculations under this clause.
Deduction shall be calculated on the respective Quarter Price Centre RS-CMC apportioned
amount. The stated deduction % shall only be applied one time per month for each respective
KPI.
Table 1-2: KPI Points and Weightage – Rolling Stock
Item Min Points Max Points
Primary KPI
 Preventive maintenance for Rolling Stock 0 2000
Secondary KPI
 Functioning of Passenger Announcement & Passenger 0 500
Information System (PA/PIS) in Train
 Functioning of CCTV in Train 0 500
 Functioning of Saloon Door in Train 0 500
 Functioning of VAC in Train 0 500
Mandatory KPI
 Train Presentation (cleanliness) N/A N/A

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 Chennai Metro Rail Project – Phase 2 Part 2 – Section VI C: ERTS – CMC of RS
Bid No. CP26/ARE02A & DM&P – CMC Requirements
Table 1-2 : KPI Passenger Safety & Comfort
Deduction
per month
No of incidents
Sub- beyond
KPI Failure Scenarios allowed in the
system allowed
fleet per month
No. of
Incidents
1 PAPIS a) Non-functioning / broadcasting of any
System passenger announcement in a car.
b) Non-functioning / broadcasting of any
display (DRM, FD, ID, advertisement
4 0.20 %
etc) in a car.
c) Non-functioning of PEI in a car.
d) Non-functioning of any internal and
external door indicator in a car.
2 CCTV a) Any non- functioning of CCTV in a
car. 8 0.20 %
System
3 Saloon / a) Failure of train door opening
Detrainment automatically.
Door b) Failure of door closing in a car.
2 0.20 %
c) Isolation of any door in a car.
d) Emergency Door opening and closing
failure.
4 VAC a) Temperature and Humidity are not
System maintained as defined in VAC chapter
in a car.
4 0.20 %
b) Nonfunctioning of Emergency Inverter
in a car.
c) Non-functioning of a VAC in a car.

1.16.5 The total number of available performance points for Rolling Stock across the complete range of
KPIs is four thousand (4,000). Theoretically, the Contractor can earn anywhere between zero
(0) and four thousand (4,000) points in a month depending on applicable performance scores.
1.16.6 Assessment periods taken for payment / penalty calculations shall be monthly. The aggregate of
the three respective months within a quarter shall then be applied over the payments due for
price centers RS-CMC.
KPI Performance Points Payment adjustment (applied over the respective month)
3700 ~ 4000 Full Payment
3600 ~ 3699 0.5% Penalty on the respective quarter Price Center RS-
CMC apportioned amount.
3500 ~ 3599 1% Penalty on the respective quarter Price Center RS-
CMC apportioned amount.
0000 ~ 3499 2% Penalty on the respective quarter Price Center RS-
CMC apportioned amount.
1.16.7 Whenever, the Contractor successfully earns 4,000 points throughout three (3) consecutive

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 Chennai Metro Rail Project – Phase 2 Part 2 – Section VI C: ERTS – CMC of RS
Bid No. CP26/ARE02A & DM&P – CMC Requirements
months’, it will be entitled to receive an incentive payment of INR 1,00,000 (One Lakh Rupees).
Note: Accrued incentive months will always reset to zero at the end of any period following
which the Contractor claims the incentive payment. Hence, the maximum incentive payable
within a 12 month period shall be INR 4,00,000 (Four Lakh Rupees).
1.16.8 Persistently poor KPI performance is not acceptable to CMRL. To discourage lapses in
maintenance standards, CMRL reserves the right to impose an additional penalty of 5% of the
quarterly payment if the Contractor scores below 3,500 points for three (3) consecutive months.
1.16.9 Primary KPI Performance Calculation
a) Preventive Maintenance (PM) of Rolling Stock shall be carried out in accordance with the
applicable manuals and in alignment with the maintenance schedule. PM activities shall be
planned in advance by the Contractor.
The number of scheduled PM activities verses the actual number of activities carried out during
each month shall be recorded in a report, which shall be submitted to CMRL and may subject to
audit. This record shall be used to calculate a percentage score for the primary KPI as follows:-
PM Completion (%) = (PM Carried out / PM Planned) x 100
The number of points for respective percentage scores shall be as follows:-
Primary KPI Percentage Score Primary KPI Points Awarded
100% 2,500
98% 2,300
95% 2,000
93% 1,800
90% 1,500
<90% NIL
Note : In the event that CMRL fails to provide Rolling Stock for planned maintenance activities,
such activity shall not be deemed as incomplete for the purposes of KPI calculations.
1.16.10 Secondary KPI Calculation
Secondary KPIs adopt a points deduction methodology for each instance of for non-
conformance against the five categories (a) through to (d) listed below,
Note: Each category is equally weighted and may earn up to 200 points, meaning 1,000 points
are available in total (as shown earlier in Table 1-2). Score can be depleted to zero (0), after
which there will be no further deductions which cause the score to become negative.
a) Functioning of PA/PIS in Train
1 (one) point shall be deduced for each individual item of the PA/PIS system found to be non-
functioning after the train is inducted to the main line. Defects identified through physical
inspection or were recorded by the TCMS logs shall be counted.
b) Functioning of CCTV System in Train
1 (one) point shall be deduced for each individual item of the CCTV system found to be non-
functioning after the train is inducted to the main line. Defects identified through physical
inspection on the train, OCC workstation or recorded by the TCMS logs shall be counted.
Failures of a redundant or standby equipment which do not directly affect the performance of
the CCTV system will not be counted.
c) Functioning of Saloon Door in Train
5 (five) points shall be deducted for each non-functioning Saloon Door or Emergency
Detrainment door. Defects identified through physical inspection, were identified via CCTV or
were recorded by the TCMS logs shall be counted.
d) Functioning of VAC in Train

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 Chennai Metro Rail Project – Phase 2 Part 2 – Section VI C: ERTS – CMC of RS
Bid No. CP26/ARE02A & DM&P – CMC Requirements
5 (five) points shall be deducted for each incident involving a non-functioning of VAC systems to
the extended that there is a failure to maintain the temperature & humidity (as per Chapter 7
Part 2 Section VIA requirements). Defects identified through physical inspection or were
recorded by the TCMS logs shall be counted.
1.16.11 Mandatory KPI / Train Presentation
CMRL expects the highest standards of train presentation for the travelling public and will
enforce the levels of cleanliness through an inspection audit regime. This KPI has been
categorised as mandatory, meaning a penalty amount of 0.01% for the respective payment
month shall immediately apply whenever the non-compliance threshold is breached and shall be
applicable on each NCR. The number of permissible non-conformance report (NCR) events per
trainset per month are defined as follows
Post Daily Cleaning Audit Post Heavy Cleaning Audit
Area Inspection per trainset Inspection per trainset
Minor NCR Major NCR Minor NCR Major NCR
Saloon Interior 5 3 3 NIL
Exterior / Train Wash 5 1 3 NIL
Note : The compliance and closure of NCR shall be done within 24 hours of date of issue.
The decision to raise NCRs and the awarded level of severity, shall be decided by CMRL in its
reasonable opinion based on a pre-determined audit criteria. A copy of the audit process
document shall be shared with the Contractor for an aligned understanding.

1.17 KEY PERFORMANCE INDICATORS (KPI) – DEPOT MACHINERY & PLANT

4 MAINTENANCE.

1.17.1 Performance of Maintenance Services rendered by the Contractor shall be evaluated against a
range of Key Performance Indicators (KPI) as mentioned in this section. It covers for Rolling
Stock, Depot Machinery & Plant and the RS Maintenance Depot.
1.17.2 KPI’s are subdivided into Primary and Mandatory categories. Primary KPIs are related to
Preventive Maintenance and Mandatory KPIs are related to Depot Machinery & Plant cleaning.
Evaluation of the Contractor’s performance against the KPIs will be carried out on a monthly
basis in accordance with the provisions set out in this chapter. Penalties (if any) will also be
calculated on monthly basis and the total Penalties accumulated over three months will be
deducted from the Quarterly payment.
1.17.3 Evaluation of the Contractor’s performance against the KPIs will be carried out on a monthly
basis in accordance with the provisions set out in this chapter.
A Performance KPI report shall be submitted by the Contractor every month starting from the
commencement of the DLP period for Rolling Stock. However, payments and penalties shall
only be calculated and applied during the CMC Period. In accordance with Clause 1.18.4(v) the
reports shall be App generated from the start of the CMC Period.
1.17.4 A Performance KPI report shall be submitted by the Contractor every month starting from the
commencement of the DLP period for Depot Machinery & Plant. However, payments and
penalties shall only be calculated and applied during the CMC period.
Rolling Stock – Maintenance KPI :
Preventive Maintenance (PM) of Rolling Stock shall be carried out in accordance with the
applicable manuals and in alignment with the maintenance schedule. PM activities shall be
planned in advance by the Contractor.
The number of scheduled PM activities verses the actual number of activities carried out during
each month shall be available in real-time via the Software Application Tool (detailed in Clause
1.18) and shall be summaries in the App generated reports and penalty calculations. The same
may subject to audit.

CMRL / Rev. 0 1 2 3 4 1-20 Jul Oct 2023 Jan Feb May 2024
 Chennai Metro Rail Project – Phase 2 Part 2 – Section VI C: ERTS – CMC of RS
Bid No. CP26/ARE02A & DM&P – CMC Requirements
Note : In the event that CMRL fails to provide Rolling Stock for planned maintenance activities,
such activity shall not be deemed as incomplete for the purposes of KPI calculations.
Table 1-3: KPI Points and Weightage – Depot Machinery & Plant
MACHINE / EQUIPMENT Points
Automatic Train Wash Plant 600
Under Floor Wheel Lathe 600
Synchronised Mobile Lifting Jacks for 3 car length & car body stands for 3 car
200
length
Diesel Operated Rail Cum Road Rescue Vehicle With Rerailing Rescue
200
Equipment & Auxiliary Truck
Battery Operated Rail Cum Road Shunter 280
Bogie Wash Plant 200
Pit Jacks 400
Bogie Testing Unit / Bogie Test Stand 200
Bogie Frame Manipulator / Rotator 80
EOT Crane 400
Bogie Turn Table 80
Wheel Profile Measuring System (way side) 160
Catenary Maintenance Vehicle 400
DM&P-R given list (All Machine) 200

Total 4000
1.17.5 The total number of available performance points for Depot Machinery & Plant across the
complete range of KPIs is four thousand (4,000). Theoretically, the Contractor can earn
anywhere between zero (0) and four thousand (4,000) points in a month depending on
applicable performance scores.
Rolling Stock – Cleaning Schedule :
Rolling Stock Cleaning Schedule shall be carried out in accordance with applicable manuals
and in alignment with the maintenance schedule. Cleaning activities shall be planned in
advance by the Contractor.
The number of Cleaning schedule activities verses the actual number of activities carried out
during each month shall be available in real-time via the Software Application Tool (detailed in
Clause 1.18) and shall be summaries in the App generated reports and penalty calculations.
The same may subject to audit.
Note : In the event that CMRL fails to provide Rolling Stock for planned maintenance activities,
such activity shall not be deemed as incomplete for the purposes of KPI calculations.
1.17.6 Assessment periods taken for payment / penalty calculations shall be monthly. The aggregate of
the three respective months within a quarter shall then be applied over the payments due for
price centers DM&P-CMC.
Depot Machinery & Plant – Maintenance KPI :
Preventive Maintenance (PM) of Depot Machinery & Plant shall be carried out in accordance
with the applicable manuals and in alignment with the maintenance schedule. PM activities shall
be planned in advance by the Contractor.
The number of scheduled PM activities verses the actual number of activities carried out during
each month shall be available in real-time via the Software Application Tool (detailed in Clause
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 Chennai Metro Rail Project – Phase 2 Part 2 – Section VI C: ERTS – CMC of RS
Bid No. CP26/ARE02A & DM&P – CMC Requirements
1.18) and shall be summaries in the App generated reports and penalty calculations. The same
may subject to audit.
Note : In the event that CMRL fails to provide DM&P for planned maintenance activities, such
activity shall not be deemed as incomplete for the purposes of KPI calculations.
Primary KPI Points Awarded % of Penalty for DM&P CMC
Price centre
3800 to 4000 No Penalty(Full payment)
3600 to 3799 2% Penalty of monthly value
3400 to 3599 6% Penalty of monthly value
3200 to 3399 10% Penalty of monthly value
3000 to 3199 15% Penalty of monthly value
0 to 2999 25% Penalty of monthly value
1.17.7 Persistently poor KPI performance is not acceptable to CMRL. To discourage lapses in
maintenance standards, CMRL reserves the right to impose an additional penalty of 5% of the
quarterly payment if the Contractor scores below 3,000 points for three (3) consecutive months.
Table – Maintenance KPI
Deductions (as applicable) will be calculated as below,
Table 1-3 : KPI Maintenance

Critical Measurement Deduction

KPI Attributes
Attributes Frequency rate

KPI 1 – Rolling Stock Preventive Maintenance

Records will be
Schedule taken directly
KPI 1 Preventive activities achieved vs planned from AMMS for 1.00 %
each train every
1 activities for Rolling Stock (according to the Y Month.
approved maintenance plan)

KPI 2 – Depot M&P Preventive Maintenance Schedule

Preventive activities achieved vs planned
1 Y
activities for Automatic Train Wash Plant
Preventive activities achieved vs planned
2 Y
activities for Under Floor Wheel Lathe
Preventive activities achieved vs planned
activities for Synchronised Mobile Lifting Records will be
3
Jacks for 3 car length & car body stands for taken directly
KPI 2 3 car length from AMMS for 1.00 %
each train every
Preventive activities achieved vs planned Month.
activities for Diesel Operated Rail Cum
4 Y
Road Rescue Vehicle With Rerailing
Rescue Equipment & Auxiliary Truck
Preventive activities achieved vs planned
5 activities for Battery Operated Rail Cum
Road Shunter

6 Preventive activities achieved vs planned

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 Chennai Metro Rail Project – Phase 2 Part 2 – Section VI C: ERTS – CMC of RS
Bid No. CP26/ARE02A & DM&P – CMC Requirements

KPI Attributes Critical Measurement Deduction

Attributes Frequency rate
activities for Bogie Wash Plant
Preventive activities achieved vs planned
7 Y
activities for Pit Jacks
Preventive activities achieved vs planned
8 activities for Bogie Testing Unit / Bogie Test
Stand
Preventive activities achieved vs planned
9 activities for Bogie Frame Manipulator /
Rotator
Preventive activities achieved vs planned
10 Y
activities for EOT Crane
Preventive activities achieved vs planned
11
activities for Bogie Turn Table
Preventive activities achieved vs planned
13 activities for Wheel Profile Measuring
System (way side)
Preventive activities achieved vs planned
14 Y
activities for Catenary Maintenance Vehicle
Preventive activities achieved vs planned
15
activities for DM&P-R given list (All Machine)

KPI 3 – Rolling Stock Cleaning Schedule Score will be

taken directly
KPI 3 Cleaning activities achieved vs planned from AMMS for 0.10 %
1 activities (according to the requirements Y each train every
specified in Clause 1.6.16) Month.

KPI 4 – Rolling Stock Internal Cleaning

Noticeable dust / dirt / stain / improper
1 Y
cleaning on Floor or Seat.
Noticeable dust / dirt / stain / improper Once in a
2 cleaning on Glass surface like Window, Y month for 20
KPI 4 Draught, Door. 0.30 %
Rakes
Noticeable dust / dirt / stain / improper randomly.
3 cleaning on Interior Panel, Gangway panel,
Emergency operator desk.
Noticeable dust / dirt / stain / improper
4
cleaning on VAC grill, Saloon Light.

KPI 5 – Rolling Stock External Cleaning

Noticeable dust / dirt / stain / improper
1 Y Once in a
cleaning on cab masks.
month for 20
KPI 5 Noticeable dust / dirt / stain / improper 0.20 %
2 Y Rakes
cleaning on Rake Side walls. randomly.
Noticeable dust / dirt / stain / improper
3
cleaning on Rake Underframe.

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Bid No. CP26/ARE02A & DM&P – CMC Requirements

KPI Attributes Critical Measurement Deduction

Attributes Frequency rate
Noticeable dust / dirt / stain / improper
4
cleaning on Rake Roof.

KPI 6 – Depot M&P Cleaning

Planned Cleaning activity of Depot M&P as
1 Y
approved by CMRL is not fulfilled. Five (5)
KPI 6 UFWL : Not removing Metal chips after work inspections in 0.60 %
2 Y a month
completion.
Water stagnation, improper cleaning of
3
ATWP / BWP zone.

KPI 7 – RS Maintenance Depot (Premises Areas

Allocated to the Contractor)
Noticeable dust / dirt / stain / improper
1 Y
cleaning of floor in IBL or SBL or RBL.
Non removal of garbage / debris / cotton Five (5)
2 Y
waste in RS Maintenance Depot.
KPI 7 inspections in 1.20 %
Evidence of Cobweb / Termite nest / Pigeon a month
3 dropping / animal dropping in RS
Maintenance Depot.
Any area has a prolonged / lingering bad
4 smell (which is not perceived to be
temporary).

KPI 8 – Safety and Work ethics

Safety incident occurred in Employer's
1 premises for the reasons attributable to the Y Any time
Contractor during the
KPI 8 1.00 %
assessment
Contractor's Staff not following Safety
2 period.
Practice

3 Evidence of creating unsafe conditions.

1.17.8 KPI Performance Calculation for Depot Machinery & Plant

a) Preventive Maintenance (PM) of Depot Machinery & Plant shall be carried out in accordance
with the applicable manuals and in alignment with the maintenance schedule. PM activities shall
be planned in advance by the Contractor.
The number of scheduled PM activities verses the actual number of activities carried out during
each month shall be recorded in a report, which shall be submitted to CMRL and may subject to
audit. This record shall be used to calculate a percentage score for the primary KPI as follows,
PM Completion (%) against each DM&P = (PM Carried out / PM Planned) x 100
Note : In the event that CMRL fails to provide DM&P for planned maintenance activities, such
activity shall not be deemed as incomplete for the purposes of KPI calculations.
b) Mandatory KPI
CMRL expects the highest standards of DM&P area and will enforce the levels of cleanliness
through an inspection audit regime. This KPI has been categorised as mandatory, meaning a
penalty amount of 0.05% for the respective payment month shall immediately apply whenever
the non-compliance threshold is breached and shall be applicable on each NCR. The number of

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 Chennai Metro Rail Project – Phase 2 Part 2 – Section VI C: ERTS – CMC of RS
Bid No. CP26/ARE02A & DM&P – CMC Requirements
permissible non-conformance report (NCR) events are defined as follows:
Area Post Daily Cleaning Audit inspection
Minor NCR Major NCR
Underfloor wheel lathe area (Removable of
5 2
Metal Chips)
Automatic Train Wash plant Area 5 2
Any other Depot Machinery Area 5 2
Note : The compliance and closure of NCR shall be done within 24 hours of date of issue.
The decision to raise NCRs and the awarded level of severity, shall be decided by CMRL in its
reasonable opinion based on a pre-determined audit criteria. A copy of the audit process
document shall be shared with the Contractor for an aligned understanding.
Conditions For Calculating Penalties based on CMRL Inspection KPI Score.
i) The applicable deductions for each month shall be calculated based on CMRL KPI
Inspection score obtained from minimum 5 times / month conducted randomly.
ii) The Plan for all scheduled activities for Train Cleanliness, Depot Machinery & Plant
cleanliness and Depot Premises Cleanliness shall be submitted CMRL before start of CMC
works and approved by CMRL. During execution of the works, in case of any changes to the
schedules prior approval from CMRL is mandatory.
iii) Conditions for calculating monthly deductions on such Inspection KPI score is as follows:
a) Each KPI is categorised into one or more attributes as listed in above table.
b) Each attribute under a KPI category shall be Inspected.
c) Scores for all attributes from will be taken directly from Application, for the purposes of
calculation.
d) A minimum of five (5) Inspections would be conducted by CMRL in each month.
e) Pass percentage for each KPI category for each inspection shall be calculated
separately as below
Total number of attributes passed under a KPI category
Pass % of each KPI = x 100
Total number of attributes under the KPI category

f) The average pass percentage for that month for each KPI category shall be calculated
as per the formula below
Sum of the lowest five pass percentages calculated at (d) above
Average Pass % for KPI Category =
5
iv) If average pass percentage calculated at (f) is ≥90% in a monthly cycle, no deduction shall
be made for that KPI.
v) If average pass percentage calculated at (f) is <90% in a monthly cycle, a commensurate
deduction shall be made for that KPI from the amounts payable to the Contractor, as per the
following formula
(100% - average pass % of that KPI)
X
Deduction amount for each KPI Deduction Rate in % of that KPI
category = X
Quarterly payment value as per contract*

* for KPI 1, KPI 3, KPI 4, KPI 5 & KPI 8 the “Quarterly payment value as per contract" shall
be the Price Centre RS-CMC apportioned amount the for respective quarter.
* for KPI 2, KPI 6 & KPI 7 “Quarterly payment value as per contract" shall be respective
quarter Price Centre DM&P-CMC apportioned amount.

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 Chennai Metro Rail Project – Phase 2 Part 2 – Section VI C: ERTS – CMC of RS
Bid No. CP26/ARE02A & DM&P – CMC Requirements
vi) If any critical attribute under a KPI category fails in an Inspection, the pass percentage of
that specific KPI category shall be zero for that Inspection in that month.
vii) Nature of CMRL Inspection shall be by way of Periodic and/or High-Level surprise
Inspection, for which the Contractor shall ensure absolute coordination and facilitation.

1.18 SOFTWARE APPLICATION TOOL FOR CMC PAYMENTS, KPI & PENALTY
4
REGIME

1.18.1 Prior to commencement of the CMC Period, the Contractor shall develop a fully functional, App
based Software Application Tool that will be integrated with the AMMS System and will be used
to provide governance for the performance of the CMC Works.
1.18.2 The App shall be developed by the Contractor in accordance with the requirements in this
Chapter and shall be subject to prior approval by CMRL. Development and any reoccurring
costs for the application are deemed to be included in the Quoted Price.
1.18.3 The App shall be used by both the Contractor and CMRL. User privileges shall be securely
demarcated and the role of the user categories shall be broadly as follows:
i) Contractor’s App Users: shall enter data related to planning and execution of the KPI dependant
Works.
ii) CMRL’s App Users: shall enter details of the inspection / audits.
1.18.4 The App shall facilitate the following, but shall not be limited to:-
i) Recording of entered data (as well as data fetched from AMMS) in relation to the KPI and
Penalty regime.
ii) Tracking of scheduled KPI dependant Works vs. Actual Works achieved.
iii) Recording of data entered by CMRL during inspection done as part of the audit regime
(including image / video capture).
iv) Calculation of billing for all CMC Price Centers (including deduction of any penalties).
v) Report generation.
1.18.5 The Contractor shall not be entitled to submit penalty calculations performed outside of
application environment; thus the full rate of penalties shall apply if the Contractor f to develop
fails to develop the App to produce the requisite calculations once the CMC Period commences.
1.18.6 CMRL performance and acceptance parameters shall be incorporated in the App in a checklist
format to facilitate CMRL’s audits and performance evaluation.
1.18.7 All data available in this system is confidential and shall be the property of CMRL. The
Contractor shall ensure that the data is also stored in the AMMS system.
1.18.8 The Contractor shall ensure that there is a facility to apply changes to the App (if required) to
evaluation check sheets and other documents as per the discretion of CMRL, without any
additional cost.

4 1.19 CMC PAYMENTS

1.19.1 Payments will be made on a quarterly basis subject to the submission of valid invoice / IPA by
the Contractor and approval of CMRL.
Whenever, the Contractor successfully completes the works without any Deductions / Penalties
based on KPI for three (3) consecutive months’ an incentive payment of INR 1,00,000 (One
Lakh Rupees) shall be awarded.
Note: Accrued incentive months will always reset to zero at the end of any period following
which the Contractor claims the incentive payment. Hence, the maximum incentive payable
within a 12 month period shall be INR 4,00,000 (Four Lakh Rupees).
1.19.2 The quarterly payment amounts shall be calculated based on the Price Centre ‘RS-CMC’ &
‘DM&P-CMC’ apportionments duly applying the penalties / incentives (available in Part 2-
Section 6C) as applicable during the quarter.

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 Chennai Metro Rail Project – Phase 2 Part 2 – Section VI C: ERTS – CMC of RS
Bid No. CP26/ARE02A & DM&P – CMC Requirements
Whenever, the Contractor gets any Deductions / Penalties of >8% of Quarterly CMC payments
for TWO (2) consecutive quarters, then CMRL reserves the right to Terminate the Works in
accordance with GCC.
1.19.3 Price adjustment as per clause 2 (Table D) & clause 3.2.7 of Part-1, Section IV-Bidding Forms,
shall be calculated on the amount arrived at 1.18.2 above (i.e. after application of penalties /
incentives as applicable).
Payments will be made on a quarterly basis subject to the submission of valid invoice / IPA by
the Contractor and approval of CMRL.
1.19.4 The quarterly payment amounts shall be calculated based on the Price Centre ‘RS-CMC’ &
‘DM&P-CMC’ apportionments duly applying the penalties / incentives (available in Part 2-
Section 6C) as applicable during the quarter.
1.19.5 Price adjustment as per clause 2 (Table D) & clause 3.2.7 of Part-1, Section IV-Bidding Forms,
shall be calculated on the amount arrived at 1.19.4 above (i.e. after application of penalties /
incentives as applicable).
1.19.6 Taxes shall be calculated on 1.18.1 & 1.18.2 1.19.4 & 1.19.5 and paid to the authorities by the
Contractor.
1.19.7 IPA / Invoice shall be raised only for the amount payable considering the above.
1.19.8 Taxes will be reimbursed by CMRL to the Contractor subject to the conditions of Contract.

1.20 DELIVERABLES

1. Submission of Compliance matrix for entire works (NTP + 35 63 days)

2. Submission of Design Submission Programme with all activities for all works (NTP + 42 70days)
3. Submission of Master Schedule Programme with all activities for entire works (120 days before
Completion of DLP).
4. Submission of a Price List covering all categories of Spares for all categories of CMC Assets
shall be submitted during Design Phase. The Key Dates for Final Design Documents (Part-3,
Section - VIII Particular Conditions (Part A: Contract Data) shall be considered as final deadline
for submission.

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