TECHNICAL SPECIFICATIONS FOR HYDRAULIC PRESS BRAKE (CAPACITY–80T)

1.0 Description
1.1 Non CNC Hydraulic Press Brake of Capacity 80 Ton (Tooled up) as per
Specification No WRWS/VDPD/HPB/80T/2025/01 is required for
manufacture of sheet metal components/sub-assemblies of rolling
stock of Indian Railways.
.
1.2 The Press Brake of 80T should be capable of bending profile of all the
components. The profile of the components is given in their
relevant drawings along with material specification

1.3 The Non CNC Press Brake of 80T should be capable to carry out all
press forming operations through bending (i.e air bending operation
and coining/bottoming operations) on sheets/plates of components.

1.4 The press brake should be capable to work in severe workshop

conditions at full capacity continuously in double shift with ambient
temperature 00C – 480C, relative humidity up to 98% and dusty
environment. Changes in ambient conditions should not affect the
performance of machine.
1.5 The Press brake shall be supplied tooled-up, with all tools and fixtures
capable of producing bending profile on all the components.

2.0 MAJOR PARAMETERS: Requirement

2.1 Bending Capacity 80 Tons

2.2 Bending Length 3000 mm(min)
2.3 Bending Material &Thickness Refer Annexure – F
of Section – VI and
drawings of
components.
2.4 OTHER PARAMETERS:
2.5 Throat depth 200 mm(min)
2.6 Beam Stroke 150 mm
2.7 Day light 400 mm(min)
2.8 Table Width 100 mm
2.9 Distance between housing/distance between 2400 mm
frames
2.10 Approach speed 60 mm/sec
2.11 Pressing or bending speed 8 mm/sec
2.12 Return speed 60 mm/sec
2.13 Back gauge
2.14 Range of Travel in X-axis 500 mm

2.15 Positioning speed of X-axis 240 mm/sec

2.16 Positional accuracy (X-axis) +/- 0.01mm or better

2.17 Main Motor Power (100% duty cycle) 7.5 KW

 3.0 Geometrical and Performance Standards
3.1 The machine should meet the performance and testing criterion as
laid down in DIN-55222 standards, IS: 2062 or equivalent International
standards for machine
3.2 frame and other associated structure such as table, machine
hydraulics as per ISO: 4401/4400 or DIN 24346/24340.
3.3 The machine should meet the quality standard/tolerances in
forming/bending of the
Components
3.4 The Non CNC Press brake(s) machine should be capable of making
multiple bends on work pieces to reduce set up and tear down time and
maximize production i.e. it should be high productivity machine. The
tolerances should also indicate the bending accuracies for different
components given above to be processed on the machine offered.
Contractor shall provide effective means for preventing “CROWNING
EFFECT,” i.e. bow at the center of formed components.
4.0 Productivity Requirement
4.1 The machine is to be provided completely tooled up and shall be utilized
in double shift working on a regular basis. The cycle time (floor to floor
timing) for components as listed in Annexure –I should be maintain. The
period shall be assumed as one shift of 8 hours with 85% availability of
machine. The cycle time shall include the various elements involved
such as given below:
i. Set up time of the work/ components
ii. Loading/ unloading time of components
iii. Checking/ measurement time
iv. Operation time for each component
v. Total time for each component
vi. Tear down time i.e. tool & die change time
4.2 The basis of the timing should be clearly given with break up of all
the parameters.
4.3 The timing should be maintainable for regular 08 hrs shift for
Single/Double/Triple shift working 6/7 days a week with machine
availability of 85%.
4.4 Productivity shall be as per items mentioned in Annexure-I
4.5 Cycle time for all components need to be given by the bidders.

Full load test – The capability test shall be carried out & demonstrated at
5.0 the time of machine inspection at firm’s premises, by means of air
bending of applicable maximum thickness of 3000mm long MS plate on
80 Ton Hydraulic Press Brake
Machine
5.1 In addition, the firm shall also be required to prove out the claimed cycle
time on 05 blanks of each of the components as listed in Annexure-F of
Section-VI on 80 Ton Non CNC Press Brake machine at manufacturer’s
premises during inspection. The manufacturer shall arrange the material/
blanks for required nos. of components for capability and prove-out tests
on its own as per material specifications given in the drawings of the
respective component
6. BASIC DESIGN FEATURES:
Rigidity-Control-Safety
6.1 It shall be possible to modify the operation mode to run the machine
through hand wheel or foot pedal manually if the bending and radius
need minor alteration. Also
While setting the machine it shall be possible to do inching operation
manually.
6.2 Emergency switches shall be provided at convenient locations clearly
visible on either side of the machine.
6.3 Overload protection shall be provided in the machine.
6.4 In case of any hydraulic, mechanical or lubrication failure, machine
shall give
Suitable indication to the operator.
6.5 Protective shrouding shall be provided for all hydraulic hoses and control
cables.
6.6 The machine shall be designed for operation from centralized panel. A
foot pedal switch shall also be provided to enable the operator to initiate
bending cycle. The foot pedal switch shall be shrouded to prevent
accidental operation of the Press Brake.
6.7 The machine offered shall be free from vibrations and abnormal
operational noise which shall not exceed 85 dB even when working at
full rated capacity. There shall be no resonant vibrations throughout
the working range of the machine at all load levels and working
speeds.
6.8 A temperature sensor shall be provided in press brake to detect rise in
hydraulic
Oil temperature beyond safe limits and an audio alarm and visual
indication shall be actuated after crossing the safe limit.
6.9 In case of power failure, the ram shall not move automatically when
the power supply is resumed but shall operate only on pressing of cycle
start switches.
6.10 The doors provided on the electrical panel shall have interlocking so
that the doors cannot be opened till the electric supply is disconnected
by the main isolation switch. The press brake shall not start till such
time the panel doors are closed and
Main isolation switch placed in ‘ON’ position.
6.11 The press brake shall be provided with auto stroke setting facility at
a pre-set
Stroke range.
6.12 All limit switches provided in the machine(s) shall be of reputed
make.
6.13 The Hydraulic Press Brake machine should be provided with fluorescent
light to illuminate work area with minimum illumination level of 300lux.
7.0 Fabrication of Machine Frame and Associated Steel Structures
7.1 The Press Brake Machine frame and other associated structure such as
table etc. shall be fabricated out of quality steel plates conforming to
IS:2062 or equivalent international standards. The supplier shall have
sound infrastructure facilities, good working system and practices for
fabrication and machining of various structural components of press
brake.
7.2 All welding equipment and accessories should meet the requirements of
the corresponding Indian Standard specifications (or International
Specifications where IS specifications do not exist). The contractor shall
be responsible for satisfying the Inspecting Officer that all welding
equipment and accessories being used meet these requirements.
7.3 The stress relieving of welded structure should be carried out in
thermoelectric or gas fired furnace having proper facilities for
temperature controlling and recording. Alternatively, structure can also
be stress relieved by vibration techniques. It should absorb all
working forces and only minimum stresses should be
transmitted to the foundation.
7.4 All the surfaces to be painted shall be cleaned by grit/shot blasting. The
shot blasted surface shall provide a degree of roughness where total
range of unevenness is less than 40 microns so that anti-corrosion
protection coat covers the profile of clean surface continuously. After
shot blasting, the surface must be brushed and dusted, then a coat of
anti corrosive primer shall be applied, the thickness of which must be at
least 40 microns.
The structural surfaces to be painted shall be prepared as per method
given in IS:
7.5 The machining of fabricated components should be carried out in single
set up on horizontal boring and milling machine to get proper
7.6 accuracy.
An appropriate working platform with safety cum fencing arrangement
should be provided for safety of maintenance staff on the top of the
machine(s). A suitable ladder should also be provided.
8.0 Specific Characteristic – Electrical / Electronics
The Electricals of the machine shall meet the requirements specified in
Clause 2, General Specifications (Electrical), as modified/ added to the
details given below: -
8.1 The machine tool shall be suitable to work in three phase, three
wire,415V+ 10%
.50 Hz + 3% enclosed distribution system , with neutral solidly earthed at
the source.
8.2 The motors shall be AC squirrel cage induction motor, confirming to
IS:12615- 1989 pertaining to “Energy efficient three phase squirrel cage
induction motor” or equivalent ISO/DIN specifications.

8.3 The electrical items like induction motor, operated through conventional
(“Direct on line” or star Delta) starter shall be so selected that they are
suitable for operation directly in the electrical system referred to in
Clause 1.10.1 i.e. without the use of voltage stabilizer, ultra-isolation
transformer etc. irrespective of the rating. However, electrical items
sensitive to voltage variation, harmonic distortion, transients, EMI etc.
shall be connected through voltage stabilizer , Ultra isolation
transformer , uninterrupted power supply, filters etc, as needed.
8.4 Power factor improvement device- The power factor improvement
device should be provided with adequate rating of capacitor bank to
effect savings in energy bills. The capacitor bank shall conform to
IS:7752(Part of 1975)
The power factor of the machine tool at the input supply shall be 0.95 +
0.2 lag for input voltage of 415V and while performing under maximum
load. The capacitor(s) therefore, shall take care of the variation in
voltage/frequency specified in Clause
1.10.1 above, the control gears/scheme employed for switching ON/OFF
of the capacitor(s) shall take care of the poor power factor in the input
supply etc. the following details for power factor improvement device
should be furnished: -
a. Manufacturer’s name
b. Rated capacity in KVAR
c. AC voltage across phase, no. of phase and frequency
d. Frame size
8.5 The maximum distance of power point to the machine control cabinet
would be 10 meters. Bidder is required to supply suitable cable of 10
meters’ length. The foundation of the machine tool shall include
provision of trenches for laying inter connecting cables as well as laying
of incoming cable from the power point. The location of trenches shall
be got approved from the consignee along with GA drawing.
8.6 The earth continuity of the machine tool shall be ensured by connecting
two bare copper conductors /flat of required cross section to the existing
earth distribution net work of the consignee from common earth pits. In
case the machine calls for separate earth pit, provision of two earth pits
shall be in the scope of the supplier. This may please be clearly
specified in the offer.

8.7 The earth continuity shall be connected to copper flats of size 30x30mm
brazed to the machine control panel. The contact surface on these
copper flats shall be tinned. Connecting the earth continuity
conductors to MS hardware, on painted
surface, to foundation bolts etc. shall not be acceptable.
8.8 All the connections shall be either through armored cables with cable
glands or through flexible cables laid in rigid conduits/reinforced flexible
pipes of reputed makes with end fittings. This may be specified in the
offer.
8.9 The Tenderer shall furnish the total connected load of the machine tool
with break up for each motor/sub-system in KW/KVA indicating
maximum starting as well as running current.

9.0 Beam and Beam Guides

9.1 The beam shall be of single piece construction. The beam movement
shall be through hydraulic cylinders. with regard to beam stroke
adjustment and its repeatability, maintenance of cylinders, prevention
of shock to hydraulic system in case of blanking operation and beam
return.
9.2 The beam stroke should be infinitely variable over the entire stroke. The
types, makes and location of measuring device for the feed back system
for the desired accuracy should be indicated in the bid.
9.3 The upper beam should be precisely guided in both sides by wide guide
ways throughout the length of stroke. The guide ways shall be precision
machined and fitted with renewable and non ferrous material such as
turcite. The guide design shall be such that perfect guidance can be
ensured without any loss of guidance
during travel. Manufacture shall specify the perpendicularity of the
stroke.
9.4 Parallelism of the top beam during fast approach and return shall be
ensured by suitable design of the system. The maximum deviation
permissible on the parallelism shall be furnished in the offer. The
permissible deviation on parallelism
shall be such that the same shall not affect the parts of machine.
9.5 The movement of the ram at bottom dead point shall be within the
accuracy ± 0.01mm on the set values.
9.6 Measuring system for the ram shall ensure measurement of travel of
the beams
with reference to the table so that the same is not affected by the
side frame deflection. The firm is to explain the hydraulic balancing
system adopted.
9.7 Heavy components of the machine like ram, table etc. shall have
provision for
lifting during major maintenance.
9.8 The top beam shall be provided with hydraulic clamping arrangement for
fixing top tools.

10.0 Table
10.1 A rigid table to accommodate lower tools shall be provided. The table of
press brake(s) should be provided with suitable hydraulic tool clamping
system for the upper tool and manual damping system for lower tool.
The beam and table structure shall be designed in such a way so that
perfect parallelism between the table and beam is ensured at any point
of stroke/load.
10.2 The flexure compensation system to be provided in the machine should
ensure a uniform bending angle irrespective of material rolling.
Thickness tolerances or otherwise tolerances applicable should be
commented upon.

11.0 Back Gauge

11.1 The machine shall have Numerically controlled, two finger type back
gauge with
digital readout for monitoring its position.
11.2 The accuracy and repeatability of the back gauge system shall be +/-
0.05 mm.
The back gauge shall be provided with suitable digital readout for
positioning.
11.3 The drive to the back gauge movements shall be provided through AC
servomotors of reputed make. The back gauge shall be provided with
suitable mechanism to prevent backlash.
11.4 To prevent the damage of the fingers/probes of the back
gauge by the
Components during bending cycle, the movement of the back gauge
shall be suitably designed so that it will retract immediately after
 dwelling cycle.

12.0 Toolings:
The toolings shall have the following features:

12.1 The material used for tooling shall be 42 CrMO4 steel – hardened
and ground to 45 – 50 HRC and UTS of 90 – 110 Kg/mm2. The
alternative material for tooling can be Grade XT 160 CR 12 of IS: 3748:
90 for Tool and Die Steels. The accuracy should be 0.015mm/1000mm.
12.2 The angular
Punches accuracies
shall of toolsclamped.
be hydraulically should be within ± 15’.

12.3 The top tools shall be segmented type for easy loading and unloading
on the machine without using a crane.

13.0 Front Support Unit:

13.1 The front support unit shall consist of four adjustable bed mounted
detachable arms for easy handling of the plates. The minimum length of
each arm shall be 1 meter. A minimum of three balls shall be provided
on each front arm, which shall help to feed the plate to be bent. The
complete unit shall be able to feed a plate of approximately 1000 kg
13.2 weight
The fourinto the machine
detachable for bending.
supports shall be able to move in a T slot along the
width of the bed independently. It shall also be possible to adjust them
in height so as to bring them at the same height as that of the die in
13.3 Stay fixing T-slots shall be provided on both front and rear side of the
table for supporting the job.
14.0 Hydraulic System
14.1 The operation of beam carrying bending tool shall be done with the
help of two hydraulic cylinders. The machine shall have downward
operating stroke.
14.2 Overload protection of hydraulic pressure system shall be available. The
hydraulic system shall be fitted with a suitable indicator to show the
pressure being developed in the hydraulic cylinders and corresponding
bending force exerted by the beam.
14.3 An internal gear type pump of reputed make shall be provided. The
maximum pressure should me maintained that can be developed by the pump
under safe operating conditions .
14.4 The hydraulic system shall be such that parallelism of top beam with
respect to bottom beam is maintained even in case of off center
loading.
14.5 The hydraulic cylinders shall be machined out of close grained forging
made out of high grade alloy steel such as C – 50 or equivalent EN
grade of steel. The hydraulic cylinder should be finished by honing and
the Ra value of honed surface shall be in the range of 0.1 – 0.2
microns. The ovality and cylindricity of hydraulic cylinder shall be within
50 microns.
The maximum pressure that is developed inside the cylinder during normal
14.6 working
The and area
piston shallofbe
cylinder
madeshould be maintained.
of hardened .
and ground alloy steel such as C
– 50 or equivalent EN grade of steel and be suitably heat treated to
 provide surface hardness of 58 ± 4 HRC. The piston surface shall be
super finished and coated with brass/PTFE to avoid direct contact of
piston with the cylinder. The surface finish value of piston shall be in
the range of 0.1 – 0.2 Ra micron. The ovality and
cylindricity of piston shall be within 50 microns.
14.7 The Hydraulic system shall be provided with strainers / filters at suction,
delivery (high pressure) and return lines respectively with capability of
filtration down to 6.3 and 10 microns or less to ensure purity of oil at
required level. In addition, sophisticated valves shall be provided with
filters as recommended by the manufacturers of these valves. The
pressure drop across these valves / strainers shall be continuously
monitored and suitable indication shall be provided to operators /
maintenance staff to ensure timely attention.
14.8 The maximum hydraulic oil temperature should be maintained up to
600C even under the highest ambient temperature condition of 48 0C.
The refrigerant type oil cooler shall be provided to keep the hydraulic oil
temperature with in this limit for continuous working of machine in
double shift at maximum ambient temperature. The refrigerant type oil
14.9 cooler shall
Oil level be of
sight reputed
gauge makes. equipment showing the minimum and
or suitable
maximum oil level in the tank shall be provided. The indicator shall
have marking to show the lowest and highest permissible oil levels for
the convenience of the operator. In addition, an oil dipstick with
graduated markings clearly indicating minimum & maximum permissible
oil levels to be provided. A drain plug at the lowest point of the
hydraulic tank shall be provided so that oil can be drained out
without
disconnecting any pipe or connection.
14.10 All pipes used in hydraulic system shall conform to DIN 2391/C and pipe
fittings shall be of Ermeto type (vibration proof) confirming to SAE
grade. The pipes shall be given anti corrosion treatment.

.Pipes shall be clamped at suitable locations so that they do not

leak/break under vibrations. Location of flexible pipes, if any, in the
hydraulic circuit should also be clearly indicated.
Stackable valves and manifold shall preferably be used for ease of
assembly, reduced piping and leakage through fittings.
The hydraulic oil tank inner surface shall be provided with anti-corrosion
treatment such as phosphating or hydraulic oil resistant anti corrosive
paint.
Minimess connections shall be provided as a facility for pressure
checking wherever required. The pressure gauge provided for hydraulic
system shall preferably be glycerin filled.
14.11 Various elements of hydraulic system shall be clearly numbered and
shown on circuit diagram. The operation of press brake must be
explained sequentially through the circuit diagram.
14.12 All elements in the hydraulic system such as pump, valves, filters etc.
provided in
the machine shall be from same manufacturer wit reputed brands
15.0 Deflection Compensation System (if applicable)
15.1 Mechanical Crowning system shall be incorporated in the bed to
compensate for
deflection of bed and beam.
15.2 The system shall be able to ensure 0.5 deg/meter and max. upto 1 deg.
Variatio in bending angle along the entire bending length.

16.0 Controls:
16.1 The machine controls shall be ergonomically designed. Provision shall
also be provided to indicate the position of cylinders.
16.2 In addition to NC controls provided on the machine for inching/semi
automatic operations, separate provision shall also be provided to
control/operate the machine in manual mode in case of failure of NC
controls.
16.3 The electrical control cabinet should be of IP55 or better degree of
 protection and of reputed make such as RITTAL, Siemens etc. The
control cabinets& panels should be dust and vermin proof. The electrical
components in the cabinets should
be mounted on DIN Rail.
16.4 All electrical/electronic panels to be provided with adequate door locks.
All electrical & electronics panels including operators panel should have
sufficient illumination and power receptacles/plug points of 220 Volt,
5/15 Amp AC with on/off switch for maintenance purpose. All electrical
adopters/receptacles, fittings,
consumables etc. should be compatible with Indian equivalents.
16.5 The bidder/supplier shall lay out the electrical cabling with suitable 3
phase 50Hz AC electrical power cable from mains to voltage stabilizer,
voltage stabilizer to Isolation transformer & Isolation transformer to
machine on-off switch in the machine electrical/control panel as well as
within the machine, along with supply of
all materials.
16.6 The control gear for electrical system should be of reputed make/

17.0 GENERAL ELECTRIC SPECIFICATION

17.1 The provision of this General Specification shall apply, wherever relevant.
17.2 All equipment’s and material shall comply with appropriate Indian
Standards (latest) or National Standards of the country of origin
provided the latter are equivalent to or better than the former. Items
for which Indian Standards are not published, National Standards shall
IS : be acceptable - Three phase induction motors (corresponding to IEC
325-1979
(latest) pub-34-
1) (Latest).
IS : 1248 (Latest) - Direct acting indicating analogue electrical
measuring instruments and their
accessories (corresponding to IEC
Pub-51) (Latest).
IS : 1231-1974 - Dimensions of three phase induction motors
(Latest) (corresponding to IEC Pub-72-1) (Latest).
IS : 1271-1985 - Classification of insulation material for electrical
(Latest) machinery & apparatus in relation to their thermal
stability in service (corresponding to IEC-Pub-85)
(Latest).
IS : 6875 (Latest) - Push Buttons and related control switches
corresponding to IEC Pub/73) (Latest).
IS : 375-1963 - Marking and arrangement of switch gear, bus bars,
(Latest) main
connection & auxiliary wiring.
IS : 996-1979 - Single phase small AC and universal electrical motors.
 (Latest)
IS : 1356 (Latest) - Electrical equipment of machine tools.
IS : 2516 (Latest) - Circuit breakers (corresponding to IEC Pub-56) (Latest)
17.3 Unless specified in the main specification, the AC motors and starters
shall be of the following type. Bidder is, however, free to give
alternative proposal along with justification, if in his view alternative
proposal in warranted by site conditions. Type of motor type of starter.
TYPE OF MOTOR TYPE OF STARTER
17.4 Any type of AC motor starting Direct on line.
current of which does not exceed
75 amps.
17.5 AC squirrel cage, introduction Star delta or Auto transformer type.
motors, starting current of which
is above 75
amps. if started direct on line
17.6 AC slipring type motor Resistance type air/fan Cooled
17.7 AC synchronous or Suitable makers standard.
synchronous induction
motor.
17.8 DC motor Resistance type/Thyristor type.
17.9 The control gear for AC/DC motors shall incorporate the following
protection devices as concomitant accessories.
17.10 No Voltage Protection - No voltage protection shall be provided so that
machine
will not start up again by itself when, following an interruption the
supply is restored.
17.11 Short Circuit Protection - To protect against short circuits due to
insulation failure of faulty connections HRC fuses shall be provided for
each motor. The rating of the fuse shall be such as to take care of the
over current due to motor starting.
17.12 Over Load Protection - To prevent motors from overloading, overload
protection
shall be provided separately for each motor. Three phase motors
shall be protected by overload tripping devices on each phase.
17.13 Single Phasing Protection - A separate current sensitive delayed action
single phasing preventor shall be provided for each motor separately.
Overload protection shall not be treated as single phasing preventor.
17.14 Control equipment shall be mounted in separate drip proof enclosures.
Control enclosures and compartments are to be so designed as to give
adequate protection against ingress of dust, oil, coolant or chips. All
control devices like contractors etc. shall be front mounted on a rigidly
fabricated metal panel for ease of operation. All other electrics shall be
installed that they are readily accessible when the doors and covers
are opened. Hinged covers shall be interlocked with
the machine tool control to prevent operation of the machine when cover
is open.
17.15 The motor shall be totally enclosed with or without fan cooled
frame. Screen
protected drip proof type motor may be provided if it is mounted inside
protective enclosures.
17.16 The electrical equipments shall comply with the requirement of Indian
 Electricity Act and Rules.
17.17 All instruments shall be of the Industrial Grade “A” (IS-1248) switch
board type the
range of the instrument shall be such that the maximum load
expected in the circuit shall produce a deflection of 60% to 80% of the
full scale.
17.18 The supplier shall furnish 04 sets of complete electrical and electronic
wiring diagrams in full details to enable the maintenance staff to
locate faults in the
circuits, 04 sets of part catalogues, maintenance manuals operating
instructions
 with details of coils and windings, used in the equipment as per Clause 4
in this section to facilitate repairs and maintenance should also be
supplied.
17.19 For main motor class minimum “B/F” insulation shall be provided. If
any other
class of insulation is proposed, detailed justification for providing
different class of insulation shall be given.
17.20 Motors shall be designed to withstand frequent starts, stops and
reversals as demanded in the operation of the machine.
17.21 Two earthing terminals shall be provided on all electric motors
including the control gear.
18.0 POWER SUPPLY
18.1 The machine shall be suitable for operation on 415 volts 3 phase 50
cycles AC 3 wire or 4 wire system with neutral solidity earthed. The
supply voltage may vary up to +10 -20%. The frequency may vary up
to + 3%. However, full rated power of the motor shall be available at
the lower voltage. Firm should confirm satisfactory performance of the
machine at incoming power supply in the range 415 V+10- 20% and
50HZ+3% frequency or should provide voltage stabilizer against Clause
2.13.2 of required capacity as specified below.
18.2 The voltage stabilizer, if required, shall conform to :
i) Input Voltage - 320 to 460 volts 3 phase 4-wire unbalanced supply.
ii) Out put - 415 volts
Voltage
iii) Regulation - + 1% from No load to Full load.
iv) Rate of - 20 volts per second per phase.
correctio
n
v) Wave fro - NIL
distortio m
n
vi) Efficiency - Not less than 97%.
vii) Winding an - Copper wire wound with “B” class of insulation or
class d better.
insulatio o
n f
18.3 In case of machine equipped with NC, SS, CNC, Thyristor controlled
devices and other sophisticated electronic gadgets including
microprocessors etc. which are susceptible to power line spikes and
surges, a suitable voltage stabilizer and ultra isolation transformer of
adequate capacity to cover for the entire electrical load of the machine
shall be offered conforming to Specification for voltage stabilizer as
mentioned in Clause 2.13.2 above and ultra isolation transformer to the
parameters mentioned below. Indigenous make voltage stabilizer and
ultra isolation transformer from the reputed manufacturers are
acceptable.
i) Transform - 1:1
er ratio
ii) Winding - Copper wire wound with “B” class insulation or better.
iii) Protection - To arrest spikes and surges to the order of 3 KV for
200-400
micro seconds duration.
iv) Commo - 120 dB
n mode
noise
rejectio
n
v) Isolation - Capacitance 005 Pf: resistance greater than 1000 Mega
Ohms.
18.4 Voltage stabilizer shall be equipped with a protective relay to trip to
trip the AC
power supply to the machine instantaneously with audio and visual
indication to
 the operator. Settings of the protective relay for low and high voltage
shall be 320 volts and 460 volts respectively.
19.0 OPERATING ENVIRONMENT/ATMOSPHERIC CONDITIONS
19.1 The ambient temperature at the site at which the machine will be
installed may vary from 0ºC to +50ºC over the year. The relative
humidity may be as high as 98%. The atmosphere is expected to be
dusty. The machines offered shall be suitably tropicalised to work under
these atmospheric conditions without any adverse effect on their
performance.
19.2 The temperature rise shall not reach such a value that there is a risk of
injury to
any insulating material or adjacent parts.
19.3 The drive shall be capable of operating at any one of the speed
required independent of the load in accordance with the requirements of
the machine.
20.0 GENERAL CHARACTERISTIC
21.1 RIGIDITY AND STABILITY
21.2 The machine shall be robust, rigid and of sturdy construction. It shall be
designed to meet heavy duty demands of various operations on the
machine under normal Workshop environment for such machines. It
shall be free for vibrations even
when working at full capacity.
21.3 All machine castings shall be made of close grained high grade cast iron
like Mechanite or equivalent materials meeting IS-210 Standards to
ensure durability and rigidity. The casting shall be thermal stress
relieved to ensure stability and continued accuracy.
21.4 All machine fabrications of critical load bearing assemblies like beds,
columns etc.
shall be adequately strengthened and stress relieved.
21..5 Change in ambient temperature shall not affect the performance of the
machine.
21.6 There shall be no change in the performance of the machine either on
switching on the machine or after continuous running.
21.7 There shall be no resonant vibrations throughout the working
range of the
machine at all load levels.
22.0 SAFETY CONTROLS
22.1 The machine shall incorporate safety devices to provide protection to the
operator and machine against all possible operational and machinery
failures.
22.2 Suitable interlock shall be provided to prevent machine operations in the
event of:
22.3 Faulty sequence of operation.
22.4 Fluctuation in supply voltage.
22.5 Resumption of power supply after power failure.
22.6 Non-positioning of safety guards.
22.7 Failure of hydraulic system (where applicable)
22.8 Failure of lubricating system (In case of automatic including drop in
pressure
lubrication)
22.9 A fault or damage in the control circuit or interruption re-
establishment after an
 interruption of fluctuation in whatever manner in the power supply
to the machinery must not lead to dangerous situations in particular.
22.10 The machinery must not start unexpectedly.
22.11 The machinery must not be prevented from stopping if command has
already been given.
22.12 No moving part of the machinery or piece held by the machinery shall
fall or be
 ejected.
22.13 The protection devices must remain effective.
22.14 The machine shall be fitted with an emergency stop device to enable
actual or impending danger to be averted. This device must be:-
22.15 Conveniently located.
22.16 Clearly identifiable.
22.17 Stop the machine as quickly as possible without causing additional
hazards.
22.18 The emergency stop must remain engaged. It should be possible to
disengage it only by appropriate operation. Disengaging the control
must not restart the machinery but only permit restarting.
22.19 Safety features shall also include.
22.20 Safety device against overload for all mechanical and electric items to
the extent possible.
22.21 Safety stops against over-running of slides.
22.22 Guard and protection devices shall protect exposed persons against
risks related to moving transmission parts (such as pulleys, belts, gears,
rack and pinion, shafts etc.) and moving parts directly involved in
the process to the extent
possible. This shall meet the following requirements:-
22.23 Be of robust construction
22.24 Not give rise to any additional risk
22.25 Not be easy to by pass or render non-operational
22.26 Be located at an adequate distance from danger zone
22.27 Cause minimum obstruction to the view of the production process.
22.28 Rigidly connected and not prone to rattling
22.29 Enable essential work to be carried out without the guard or
protection device
having to be dismantled
22.30 A load meter shall be provided to indicate the load on the machine. The
meter shall have a suitable mark to indicate the maximum load the
machine can take. Full details of the above and other safety
features indicating how each one
functions must be explained in the offer
23.0 OPERATIONAL CONTROLS
23.1 The operation of the machine shall be by push buttons or levers. The
basic rules
for the direction of operation of controls and the corresponding
direction of movements of the machine tools shall be as per IS:2987-
1985.
23.2 The control devices shall be
23.3 Clearly visible and identifiable.
23.4 Ergonomically positioned for safe operation without hesitating or loss of
time, and
without ambiguity.
23.5 CNC Controls (where applicable) should be clearly mentioned with
details.
24.0 LIGHTING
24.1 Integral lighting suitable for the operations concerned where its lack is
likely to
cause a risk despite ambient lighting of normal intensity shall be
provided.
24.2 The manufacturer must ensure that there is no area of shadow likely
to cause
nuisance, that there is no irritating dazzle and that there are no
dangerous stroboscopic effects due to lighting provided by the
manufacturer.
24.3 Integral parts requiring frequent inspection and adjustment and
maintenance areas must be provided with appropriate lighting.
24.4 The machine lighting should be of low voltage so as to prevent any
hazard to the operator.
25.0 MACHINE MAINTAINABILITY
25.1 The machine shall be so designed as to require minimum possible
maintenance and to give trouble free service.
25.2 All assemblies/parts of the machine shall be easily accessible for
maintenance.
25.3 The machine shall not require major dis-assembly for checking and
replacement of a particular part, especially for parts requiring
periodical check up and replacement.
25.4 The manufacturer must provide means of access e.g. stairs, ladders,
cat walks
etc. to allow access safety to all areas used for production,
adjustments and maintenance operations.
26.0 WEAR COMPENSATION ADJUSTMENT( IF APPLICABLE)
26.1 The original built in accuracy of the machine shall be capable of being
maintained conveniently and economically by suitable adjustments for
taking up wear on slides, bearings and load screws. The system of
adjustments incorporated shall be explained in the offer
27.0 COOLANT SYSTEM (IF APPLICABLE)
27.1 Suitable coolant system with pump, motor, tank, filter etc. shall be
provided. The coolant pump shall be as per IS:2161-1962. The filter
shall be of reusable type and indigenously available. If reusable filter
cannot be offered the filter cartridge shall be readily available in India.
Source of supply shall be indicated. Adequate
no. of filters for 2 years working on double shift basis shall be offered as
spare. Details of the coolant system shall be indicated in the offer.
27.2 The supply of coolant shall be in ample volume. Provision to re-circulate
the coolant shall be available. A chip and coolant tray shall be provided.
The volume of coolant flow shall be indicated. It shall be adjustable.
27.3 An enclosure shall be provided to prevent the coolant from splashing
outside the
machining zone. Details of enclosure shall be provided. Specific
requirements of coolant system for grinding machines etc. shall be
clearly indicated.
28.0 LUBRICATION SYSTEM (IF APPLICABLE)
28.1 The machine shall be provided with an automatic lubricating system for
ensuring delivery of adequate quantity of lubricant to areas requiring
continuous lubrication. Suitable arrangements must be provided for
indication of failure of the lubricating
system.
28.2 The system shall be provided with interlock to prevent machine
operating/starting in the event of the failure lubrication system.
28.3 Reusable filters capable of filtering chips, dust particles etc. shall be
provided. Indicators for showing clogged condition of filters shall be
available. The filters shall be indigenously available. If reusable filter
cannot be offered the filter cartridge shall be readily available in India.
Source of supply shall be indicated. Adequate no. of filters for 2 years
working on double shift basis shall be offered as
spare.
28.4 Lubrication and filter cleaning chart shall be displayed on a metal
plate at a conspicuous location on the machine indicating :-
a. Specific location of points on the machine to be oiled lubricated/greased.
b. Periodicity of lubrication of these points.
c. Filter to be cleaned.
d. Periodicity of cleaning filters.
e. Periodicity of replenishing lubricating oil for the centralized system.
f. Any other similar relevant information.
28.5 Points where manual lubrication is needed shall be separately
indicated.
 Frequency of lubrication shall be also clearly mentioned.
28.6 Lubricating oils used in the machine shall be available in India.
Successful tenderer will be required to indicate brand names of
approved oils manufactured
by various Indian Oil Companies.
28.7 First fill of lubricating oils used in the machine shall be provided with
the machine.
Details of lubricating system provided shall be indicated.
29.0 PNEUMATIC SYSTEM (IF APPLICABLE)
29.1 The compressed air supply will be provided by the customer at the
machine within pressure range of 4.5-7.5 kg/cm 2 and a moisture
content or 1000 ppm. The pneumatic system of the machine should be
designed accordingly. An alarm shall be provided for low air pressure.
29.2 Suitable filter/moisture trap shall be provided by the contractor in the
system of pneumatic air intake. The filter shall be reusable type and
indigenously available. If reusable filter cannot be offered, the filter
cartridge shall be easily available in India. Source of supply shall be
indicated. Adequate no. of filters for 2 years
working on double shift basis shall be offered as spare.
29.3 Air pressure regulator, if necessary, shall be provided by the tenderer.
29.4 The make of pneumatic control equipment shall be of reputed make.
The makes shall be indicated.
30.0 Warranty: The Supplier should provide warranty for a period of 02 years
from the date installation of the Machine.
 LIST OF COMPONENTS TO BE LOADED ON THE MACHINE

Following items are required to be proved out on Non CNC Hydraulic Press Brake
Cap. 80T

[Link]. Name of Item Drawing No. Productivity

requirement in 8
hours shift
1. Intermediate Long T-1-1-651 2
Longitudinal Beam(Solebar)

2. Head stock Beam ICF/STD-1-2-002 Not required

Arrangement (Outer)

3. Head stock Beam T-1-2-608 Not required

Arrangement (Inner)

4. Lower side walls sheet RCF/Drg. No. CC14323 2

without elongated holes for
AC Coaches

5. Angles & Channel Mouldings CWM/M/SK-912&911 144

& Solebar

6. Doorway stiffener complete WD-91071-S-59, Alt.-6, 1

for SLE & Parcel Van Item No.4

7. Frame for UIC vestibule WD-91071-S-59, Item No.5 1

arrangement
8. Channel for CBC WD-91071-S-59, Alt-6, 3
strengthening (Doorway Item No.2
stiffener)

9. Channel for SLRD WD-91071-S-58, Alt.-5, 2

Item No.4
 Delivery Schedule Chart

Name of the Machine: 80T Non CNC Hydraulic Press Brake Machine.

Sl. Activity Activity Outer limit of time Schedule

No Code
1 Issue of LOA/PO D1 ----

1 Submitted of PBG by successful D2 D1 + 30 days=30 Days

Bidder
2 Issue of AT/Contract /PO by D3 D2 + 30 days=60days
Stores/WR (after verification of PBG)
3 Submission of GA drawings and D4 D3 + 30 days=90days
requisition for the trial component (S)
(if applicable) to consignee by
successful Bidder/Supplier along with
information on power and other
utilities required for machine.
5 Approval of GA drawings by D5 D4 + 30 days=120days
consignee and confirmation of
availability of components to be
proved out at manufacturer premises
and value of BG required for
providing prove out components.
6 Confirmation of availability of clear D6 By D5 (i.e. at the time of
site by consignee. approval of GA drg.)= 120
days
7 Completion of foundation D7 D6 + 30 days or latest by D9

8 Submission of BG and collection of D8 D5 + 45 days=165 Days

components from consignee by the
supplier for prove out of machine at
manufacturer’s works.
9 Supply/Delivery of machine D9 D5 + 45 days= 165 days

10 Power connection for the machine D10 D9 + 7 days= 172Days

and other on site requirements to be
provided by Railways.
11 Railway to give call to supplier for the D11 D9 + 14 days= 179 days
commissioning of machine
12 Installation, commissioning and D12 D10 + 30 days or
proving out of machine by D11 + 30 days (whichever is
supplier later =202 Days
13 Issue of PTC by consignee D13 D12 + 30 days=232 days