Kota- Modification and Relocation of Chlorine Filter in IR-DRDO Bio-digester in LHB type Coaches

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Scope of work 1.Name of Work: Kota-Modification and Relocation of Chlorine Filter in IR-DRDO Bio- digester in LHB type Coaches. 2.Quantity: 760 Nos. 3.Procedure of work: The contractor has to carry out the work as per the Coach Alteration Instruction No. CAI/RCF/MECH/LHN/085 dt: 04.12.2024 and as directed by the Sr.DME/Co and its representative. 4.Removal of chlorine filter: 1.Remove the chlorine filter from Bio-digester tank completely. If the chlorine filter is directly mounted onto the bio-digester tank pipe: (i)Cut the connecting pipe attached to the bio-digester tank, right at the surface of the chlorine filter. (ii)Remove the remaining female threaded part from the bio-digester tank pipe connection using appropriate tools. Disconnection (Union fitting): If the chlorine filter is connected using a union: Loosen the union to separate the chlorine filter, using appropriate tools. 5.Modification Work: i.Chlorine filter modification: Socket Removal: Carefully cut the projecting socket with the surface of the chlorine filter's side. ii.Plugging the Old Hole: The hole created by cutting the projected socket on the chlorine filter side face needs to be sealed. This should be done by welding a Stainless Steel cut piece (provided by the Railways) over the hole using TIG (Tungsten Inert Gas) welding. iii.Creating a New Hole: A new hole (sized to accommodate a 2-inch socket) needs to be created on the surface of the chlorine filter (i.e., 90 degrees away from the original hole and opposite to the outlet pipe). iv.Welding the Socket: A 2-inch male socket (connecting pipe) must be TIG welded onto this newly created hole. v.Ball Valve Removal and Plugging: Remove the existing ball valve. Plug with appropriate dummy provided by Railways. Ensure a tight, leak-proof seal. 6.Bracket modification: i. Removing Old Bracket: The existing holding bracket on the chlorine filter needs to be removed. ii Welding New Bracket: A new holding bracket must be TIG welded onto the surface of the newly modified hole area on the chlorine filter. This new bracket should be positioned to align with the existing bracket on the bio-digester tank for proper mounting. iii.Bio-digester Tank & connecting pipe repair: If the union is tack/spot/welded with the outlet pipe of the Bio- digester tank, the welded portion to be cut by suitable cutting machine or other appropriate tools without damaging the Bio- digester tank and the connecting pipe. iv.If connecting pipe is welded with union permanently the existing connecting pipe of the Bio-digester tank to be cut right at the surface of the Bio- digester tank. v.Resizing of existing Hole: The existing Hole should be enlarged/modified (sized to accommodate a 2-inch socket). New connecting pipe supplied by Railways to be welded to the Bio-digest tank as per the requirement to connect the chlorine filter. 7.Fitment of chlorine filter: i.Connecting Union Tail Piece: Fit and tighten the union tail piece to the connection point on the bio-digester tank. ii.Connecting Union Thread Piece: Fit the union thread piece to the modified connection point on the chlorine filter.

iii.Aligning and Locking: Position the modified chlorine filter precisely against the bio-digester tank's connection port. Carefully align the filter's union nut with the tank's threads. Hand-tighten the union nut, then use a wrench to fully tighten it, ensuring a secure, leak-proof seal. Verify that the holding clamp aligns correctly with both the filter and the tank, and secure it. iv.Fastening Clamps: Secure the chlorine filter in place by fastening the holding clamps using the necessary bolts and nuts. 8.Leakage Testing: After fitment of the modified chlorine filter along with Bio-digest tank in coaches, the chlorine filter shall be filled with sufficient water and its outlet securely plugged by necessary plugging for leakage testing. In the event of any leakage detected in the chlorine filter or its joints, the contractor is required to take immediate action to rectify the leak. 9.Items under the scope of Contractor: i.Contractor has to deploy sufficient number of staff to execute the work. ii.Contractor has to bring necessary TIG Welding Plant, filler rod, Argon gas & Plasma cutting plant. iii.Contractor has to bring his own labour, necessary tools, equipment, machineries viz., Drilling machines & Drill bits, Cutting machines & Cutting Wheels, Angle grinders, Grinding discs, TIG Welding - safety shields, Plasma cutting safety shields, etc., iv.Contractor has to provide Personal Protective Equipment (PPE) to his labourers. v.TIG welding nozzles, Plasma cutting nozzles and other accessories as deemed necessary shall be brought by the Contractor. 10.Items under the scope of Railways: i.Materials required for the work will be supplied by Railways. ii.Water, Electricity and Compressed air will be provided by Railways .

PART IV Special conditions of Contract for Works 1)The Bio- digester tanks in which this work is proposed to be carried out will be available inside the premises of Coaching depot, Kota. 2)The Bio-digester tanks will be offered to the contractor by the SSE/C&W/Kota 3)The contractor has to carry out the work as per the Scope of work and according to the instructions of SSE/C&W/Kota. 4)The contractor shall remove, strip, dismount or cut the Chlorine Filter from the Bio- digester tank, depending on the existing fitting arrangements and transport the Chlorine Filter to the nominated location using their own transport equipment, as per the instructions of SSE/C&W/Kota. 5)The contractor shall report to SSE/C&W/Kota about progress of work daily after completion of day's work so as to plan for the work to perform during next day. 6)The contractor shall during the progress of work, entirely responsible for the handling and custody of stores given to him by the Railway. 7)Railways will provide Water, Compressed air and Electricity at free of cost. However the accessories for the daily use of electrical power such as extension cords, plugs, water hoses, compressed air hoses and other items that are required for the said work have to be arranged and installed by the contractor at his own cost. 8)TIG welding plant, filler rod, Argon gas, Plasma cutting plant, drilling machines, drill bits, cutting machines, cutting wheel, angle grinders, grinding discs shall be brought by the Contractor. 9)TIG welding nozzles, Plasma cutting nozzles, Pressure gauges, flash back arrester, TIG Welding - safety shields, Plasma cutting safety shields, chipping hammer, wire brushes and other accessories as deemed necessary shall be brought by the Contractor. 10)All the necessary tools like spanners, hammers and other special tools required to carry out the work shall be arranged by the contractor. 11)Necessary space will be provided for storing tools and equipment's. 12)The quantum of work arising will vary according to the need of SSE/C&W/Kota and the contractor shall provide sufficient manpower to undertake the work as per allotment accordingly. 13)The payment shall be made based on actual work done and as per the record in the Measurement Book which is maintained by SSE/C&W/Kota. 14)The contractor shall be responsible to take necessary precautionary measures in order to ensure the safety against injury etc., of his personnel when working at the Railway premises and should confirm to the rules and regulations of the Railway. Contractors must provide adequate insurance coverage (workman compensation Insurance) to their labourers. 15)The cost of any damage caused to the Railway material/facilities in the working spot as assessed by SSE/C&W/Kota or representative of Sr.DME/Co will be deducted from the Bills of the Contractor. 16)Stipulated minimum wages enforced by labour enforcement officer shall be ensured by the Contractor. Any hike in minimum wages during the currency of contract shall be followed by the Contractor. 17)The contractor has to engage full time responsible supervisor to ensure the quality of work. Supervisor should be provided with mobile and should immediately respond to call given by the Railway Administration. 18)Contractor should be solely responsible for taking care of their staff and supervisor against any accident or safety risk.

19)The contractor shall provide all appropriate Personal Protective Equipment (PPE's) to his workmen, based on the specific working conditions and is responsible for ensuring that they use it. 20)The contractor shall provide uniform and the safety equipment/ Personal Protective Equipment (Industrial shoes, Helmet, Safety goggles, Nose masks, Ear plugs and Safety hand gloves etc.) to his workmen and is responsible for ensuring that they use it. 21)Sign ON/OFF Register shall be maintained by the Contract supervisor for all the Employees. 22)The contractor has no right to demand more or less quantity or unit. The decision of the Railway is final and binding on the contractor. 23)The contractor has to arrange payment to his contract labour according to the latest minimum wages notified by Chief labour commissioner. Any hike in minimum wages during the currency of contract shall be followed by the Contractor. The contractor should deposit requisite EPF, ESI to contract labour, if applicable. 24)The Contractor has to comply with the Labour laws in force like Contract Labour (Regulation and Abolition) Act (1970), Contract Labour (R&A) Rules (1971), Minimum wages Act (1948), Minimum Wages Rules (1950), Employees Provident Fund and Miscellaneous Provisions Act (1952), Employees Provident Fund Scheme (1952), Employees State Insurance Act (1948), Employees State Insurance Rules (1950), Employment of Children's Act, Hours of Employment regulation's, Work Man's Compensation Act, etc. and all such laws in force from time to time as applicable to this contract. 25)The contractor will at his own expense obtain such permits or parwana from whomsoever necessary for carrying out work or for any other purpose as may be necessary to enable him to perform his part of the contract. 26)The contractor shall obtain Labour License from the licensing Officer as per the contract labour Act 1970 before commencement of the work and shall follow the latest guide lines as laid down by the Labour Commissioner revised from time to time. 27)As per existing norms contractor has to pay/deposit requisite EPF and ESI to employees deployed for the work, if applicable and submit the proof of remittance along with bill. If contractor fails to deposit EPF/ESI to his employees, same will be deducted from the bills. 28)The efficacy of this contract shall be reviewed during mid- term of the currency and quarterly thereafter by the Executive and results put up for decision of the competent authority to continue the contract. In the event of performance of the contractor is not satisfactory, the competent authority shall have the right for the pre closure of this contract on issue of notice and in the event of such pre- closure, the contractor shall not be entitled to get any compensation from the Railways for any loss whatsoever may have suffered. 29)Any miscellaneous work and defects to be attended by contractor before dispatching the coach.

30)The contractor should submit the Police verifications certificate of the staff deployed by him to SSE C&W Kota and copy of the same to the RPF for record within 45 days from the date of appointment / deployment of the concerned staff for the subject work. In case of failure a penalty of Rs.50/- (Fifty only) per person per day (after 45 days grace period) will be imposed on the contractor. In case of redeployment of staff whose police verification was not done earlier grace period will be counted from the date of first appointment. Contractor is required to submit fresh police verification certificate after the expiry of validity of the certificate. 31)Qualification Requirement for outsourced Welders (As per Railway Board L.No 2025/M(W)1/814/6 dated 24.03.2025) 1. Qualification Standards (For Fusion welding of steel) Welders must be qualified according to ISO 9606-1:2017 (or latest) OR IS 7310 (Part 1): 2019 (or latest) for fusion welding of steel as per the approved Welding procedure Specification (WPS), which includes material type, thickness, joint type, welding position, welding process, and consumables. AND 2.Educational and Training Requirements: •Matriculation/SSLC plus ITI certification from a recognized institution (NCVT/SCVT) in the welder trade. OR •Act Apprentices trained and certified in the welder trade by any Railway Unit, Government, Semi Government, or PSU unit are also eligible. AND 3. Competency Test by Railway Unit: Railways shall conduct competency test at their premises on the welders engaged for outsourced work to verify their skills by taking trial test on at least 2 sample pieces at the cost of the Railways and if the trial is found satisfactory, Competency certificate will be issued by respective officer/SSE (incharge). In case competency test trail of the welder is found to be unsatisfactory, cost of the test shall be borne by the contractor. 4. The validity and process of renewal of competency certificate would be as defined in ISO 9606-1:2017 and IS 7310 (Part I)-2019 Para 9. NOTE: - The contractor must submit the above certificates before starting the work.

32)Delivery Schedule: i.SSE/C&W/Kota will allot generally 5 to 8 nos. of Bio-digester tank with Chlorine Filter every day to the contractor. ii.The contractor has to complete the Removal, Modification work and fitment of Chlorine Filter on the same day of allotment by SSE/C&W/Kota. iii.The contractor shall strictly adhere to the program framed by the Engineer or his representatives so as to complete the work within the time allotted to the contractor. The contractor will have to employ labour in full strength commensurate with work to be executed. The contractor should arrange tools and equipment's to complete the job most expeditiously within the stipulated completion period. The Engineers decision will be final and binding on the contractor. 33)Penalty: i)If the contractor fails to complete the Removal, Modification work and fitment of Chlorine Filter as per scope of work on the same day of allotment, a penalty of Rs.500/- per unit per day of delay shall be levied on the contractor. ii)If the contractor does not bring any staff on any day and coaches are available for allotment to the contractor, a penalty of Rs.2000/- will be levied per day. iii)All the contractor staff shall use required PPE's/Uniform/Identity cards. Any deviation in this regard will be viewed seriously and a penalty of Rs.100/- per employee per day for not wearing of PPE's/Uniform/Identity cards will be levied. iv)In case of any adverse remarks on quality of work and method by any inspecting officials, a penalty of Rs.500/- per occasion will be levied. v)If the supervisor is not available during working hours to execute the work from their staff, a penalty of Rs.500/- per working day shall be levied. vi)In case the contractor fails to commence the work as per LOA , a penalty of Rs.500/- per day will be levied. However, if railway has asked for late commencement of work due to administrative reasons, then no penalty will be levied. vii)If the scrap materials are not disposed properly to an identified location, a penalty of Rs.500/- will be levied per occasion. viii)Exemption of penalty clause can be considered by the competent authority on special cases such as natural calamity, bad weather or any valid reason etc. The decision of the Railway authority (Sr.DME/Co) is final and binding on the contractor. 34. Inspection of work: The work will be inspected through visual Inspection by SSE/JE. During inspection if quality of work is not up to the mark as per scope of work, then firm has to again rework on the same with free of cost. The decision of the Railway administration will be final in this regard. 35)Work Record/diary: The contractor shall maintain a work diary duly recording the stage wise allotment of work and completion details. The contractor shall get the position reconciled and the certification of SSE/C&W/Kota. 36)Measurement Book: This is the basis of all accounts of quantities of work done by the contractor which is to be recorded date wise and signed by both the parties. 37)Bill Passing Authority: i.No advance payment will be made by the Railways. Payment to the tenderer shall be made monthly for the work completed as per measurement recorded in site register and certified/ signed by Sr.DME/Co/Kota or his authorized representative. ii.Bill passing authority is Sr.DME/Co/ Kota & bill paying authority is Sr.DFM Kota. iii.Payment to the tenderer shall be made subject to deduction of income tax, other taxes, penalty Imposed or any other statutory deductio

iv.Depositing of EPF and ESI of contractor's labors & all other Taxes with concerned authorities is the liability of contractor. No bill of payment will be made without documentary evidence of submission of challan of EPF & ESIC of labour deployed and documentary evidence that the same has also been uploaded in I.R. Shramik Kalyaan Portal of that bill month. v.Contractor would have to submit the EPF and ESIC of the deputed staff on or upto every 15th of the month. vi.Payment against each schedule of works will be based on accepted rate of 'BILL OF QUANTITIES& as per their units vii.No interest shall be payable on any amount which is payable to contractor for delayed payment or any other cause. viii.Security deposit shall be released only after on successful completion of the warrantee period of one year. ix.In case of any dispute, the final decision will be of Sr.DME/Co /Kota/West Central Railway.