friction buffer- stops, fixed buffer stops braking … · braking wheel stop sets no. e-01-0017.2...

ISRAEL RAILWAYS LTD.

INFRASTRUCTURE DIVISION

Technical Specification

for

Manufacture and Supply of

FRICTION BUFFER-

STOPS,

FIXED BUFFER STOPS

and

BRAKING WHEEL STOP

SETS

No. E-01-0017.2

August 2020

ISRAEL RAILWAYS LTD

FRICTION BUFFER-STOPS, FIXED BUFFER STOPS and

BRAKING WHEEL STOP SETS No. E-01-0017.2 August 2020

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:AMENDMENTS

April 2020 1.1700-10-This technical specification differs from version No. E

:as follows

i. Section 4.11 has been revised;

ii. Section 4.12 has been revised;

iii. Section 4.14 has been revised;

iv. Section 4.15 has been revised;

v. Section 10.3 has been revised;

vi. Section 10.13 has been moved to section 11;

vii. The technical specification has been editorially revised.

ISRAEL RAILWAYS LTD

FRICTION BUFFER-STOPS, FIXED BUFFER STOPS and


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CONTENTS

1. SCOPE 2

2. REFERENCE DOCUMENTS 2

3. REFERENCE DOCUMENTS 3

4. GENERAL REQUIREMENTS 3

5. TECHNICAL DRAWINGS 7

6. CALCULATIONS AND TESTS 7

7. INSPECTION BY A REPRESENTATIVE OF ISR 8

8. MARKING 8

9. PACKING 9

10. LIST OF FILES (in PDF Format) TO BE SUBMITTED WITH BIDDER'S

PROPOSAL 10

11. LIST OF FILES (in PDF Format) TO BE SUBMITTED BEFORE SIGNING THE

AGREEMENT 11

12. LIST OF FILES (in PDF Format) TO BE SUBMITTED WITH EVERY ORDER 12

TECHNICAL APPENDIX A – DRAWING DSB 2A 17409 – DBS82-1 WHEEL PROFILE 13

TECHNICAL APPENDIX B – STOPING DISTANCE DEFINITION 14

TECHNICAL APPENDIX C - ISRAEL CLIMATE AND ENVIRONNEMENTAL

CONDITIONS 15

TECHNICAL APPENDIX D – EXAMPLE FOR RED AND WHITE REFLECTOR SIGN 16

ISRAEL RAILWAYS LTD

FRICTION BUFFER STOPS, FIXED BUFFER STOPS and


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1. SCOPE

1.1 These technical specifications describe the requirements for the

manufacture and supply of Friction Buffer Stops with different

working mechanism methods (friction, hydraulic), and different

amount of energy absorption for restrain Passenger Trains; Freight

Trains; locomitives; and Railbound Construction and Maintenance

Machines ("Railway Vehicles") in emergency cases without

serious injury to the driver and passengers and minimum impact to

the vehicle construction.

1.2 In additionally these technical specifications describe the

requirements for the manufacture and supply of Fixed Buffer Stops

to be installed on track ends.

1.3 In additionally these technical specifications describe the

requirements for manufacture and supply of Braking Wheel Stops

Sets (*), to be installed on rail heads to use on depot tracks and

marshalling yard tracks to stop track motor vehicles, locomotives

or light train. ISR using wheels of several diameters the wheel

profile types are in accordance with UIC510-2; EN13715 --- wheel

type S1002 : h=28, e=32.5, reverse slope 15%; and with DSB82-1

wheel profile type (IC3 trains) (see Technical Appendix A).

(*) Braking Wheel Stops Set - means two braking wheel stops, one

for each rail of the track.

2. REFERENCE DOCUMENTS

EN10204 Metallic products - Types of inspection

documents;

EN12899-1 Fixed, vertical road traffic signs - Part 1: Fixed

signs;

EN13481-2 Railway applications - Track - Performance

requirements for fastening systems - Part 2

Fastening systems for concrete sleepers;

EN13674-1 Track - Rail - Part 1: Vignole railway rails 46

kg/m and above;

EN13715 Railway applications - Wheelsets and bogies -

Wheels - Wheels tread;

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EN15020 Railway applications – Automatic coupler –

Rescue coupler – Performance requirements,

specific interface geometry and test methods;

ISO1461 Hot dip galvanized coatings on fabricated iron

and steel articles — Specifications and test

methods;

ISO9001 Quality management systems – Requirements;

ISO10684 Fasteners — Hot dip galvanized coatings;

ISO12944 Paints and varnishes — Corrosion protection

of steel structures by protective paint systems;

UIC510-2 Trailing stock: wheels and wheelsets.

Conditions concerning the use of wheels of

various diameters.

Note – The latest edition of the referenced document should be

considered

3. REFERENCE DOCUMENTS

3.1 60E1 Rail Profile as defined in EN13674-1, Annex A,

figure A.23;

3.2 60E2 Rail Profile as defined in EN13674-1, Annex A,

figure A.24;

3.3 Automatic Coupler-Type 10 in accordance with EN15020

4. GENERAL REQUIREMENTS

4.1 The Friction Buffer Stops, Fixed Buffer Stops and Braking Wheel

Stop Sets shall be designed for used on railway track with 60E1

Rail Profile and/or 60E2 Rail Profile.

4.2 The Friction Buffer Stops and Fixed Buffer Stops, shall be

designed for use on ballasted track, with concrete sleepers (1667

sleepers per km) and on ballastless track (Slab track), on depot

track (non-ballasted track), with railway track nominal gauge of

1435 [mm], and with rail inclination of 1:30 on concrete bearers

of ballast track and 1:40 slab track.

4.3 The Braking Wheel Stop Sets shall be designed for use on rails in

depot and shunting area with rail inclination of 1:30; 1:40 and of

zero.

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Stop Sets shall be designed for restrain Railway Vehicles having

axle load of up to 22.5 [ton].

4.5 The Friction Buffer Stops and Fixed Buffer Stops shall be designed

to enable safety stop of Railway Vehicles running at speed up to

10 [km/h] or at speed up to 15 [km/h], as detailed in the table in

section 4.12.

4.6 The Fixed Buffer Stops shall be designed to enable safely stop of

Railway Vehicles running at speed up to 5 [km/h], as detailed in

the table in section 4.12.

4.7 The Braking Wheel Stop Sets shall be designed with height above

the rail head of 85 or 90 [mm]; and 125 [mm] to enable safely stop

Railway Vehicles running at speed up to 5 [km/h], as detailed in


4.8 The Friction Buffer Stop and Fixed Buffer Stops shall be designed

to arrest the full range of Railway Vehicles between the heaviest

and lightest using a track without risk of serious injury to people

on the Railway Vehicle. Railway Vehicles shall be brought to a

controlled halt from the determined impact speed with an average

deceleration rate not exceeding 0.15g (1.47 m/s2). Where site

constrains make it unavoidable, lightweight trains may be

subjected to higher deceleration rates, but the average acceleration

rate for any train shall not exceed 0.25g (2.45 m/s2), as detailed in


4.9 The Friction Buffer Stops, Fixed Buffer Stops design shall be taken

in consideration absorbing extra energy based on the following

energy coefficient factors - 1.5; 1.8; 2, as detailed in the table in

section 4.12.

4.10 The Friction Buffer Stops and Braking Wheel Stop Sets shall be

design with maximum stopping distance (Lw) (see Technical

Appendix B), as detailed in the table in section 4.12.


with two large side strikes fit to absorb Railway Vehicles with

anticlimbers height of 1030−20+20 [mm] above top of the rails and

with distance between the center of the two side strikes of 1650−8+8

[mm], and at the same time to absorb Railway Vehicles with

buffers height of 1060−10+10 [mm] and 1050−20

+10 above top of the

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rails, and distance in between the center of the two side strikes shall

be 1750−5+5 [mm].

In additional to the two side strikes the Friction Buffer Stop shall

be design with center strike fit to absorb Railway Vehicle

Automatic Coupler - Type 10, with height of 1030−10+10 above top

of the rails.


Stop Sets shall be designed in accordance with the following

parameters:

Parameter Friction

Buffer

Stop Type

ISR101A

Friction

Buffer Stop

Type

ISR102A

Friction

Buffer Stop

Type

ISR103A

Friction

Buffer Stop

Type

ISR104A

Friction

Buffer

Stop Type

ISR105A

Fixed Buffer

hydraulic Stop

Type

ISR201A

Braking Wheel

Stop set

Type ISR301

Braking Wheel

Stop set

Type ISR302

Impact speed 10 km/h 10 km/h 15 km/h 15 km/h 15km/h 5km/h 5 km/h 5 km/h

Maximum mass 2200 ton 3500 ton 760 ton 760 ton 760 ton 116 ton 101 ton 180 ton

Minimum mass 120 ton 670 ton 410 ton 410 ton 670 ton 44.7 ton -

Rail profile 60E2 60E2 60E2 60E2 60E2 60E2 60E2 60E2

Track gradient -2.5‰ -2.5‰ -2.5‰ -2.5‰ -2.5‰ 0‰ 0‰ 0‰

Maximum

Stopping distance

(Lw) (see Technical

Appendix B)

20 meter 25 meter 7 meter 10 meter 12 meter

3 meter 3 meter

Plain Track

Distance in front of

stop device

20 meter 20 meter 20 meter 20 meter 20 meter 100 meter

Energy safety

factor 1.8 2 1.5 1.8 2 1.8

Average

deceleration

0.25g

(2.45 m/s2)

0.25g

(2.45 m/s2)

0.15g

(1.47 m/s2)

0.15g

(1.47 m/s2)

0.15g

(1.47 m/s2)

0.25g

(2.45 m/s2)

Wheel diameter

Not

relevant Not relevant Not relevant Not relevant

Not

relevant

Not relevant

850[mm] trains with

wheel type DSB

82-1

920[mm] and 1010 mm

(UIC510-2)

Center strike in

addition to side

strike

+ + + + + - Not relevant Not relevant

Braking wheel stop

set -height above

the rail head

Not

relevant Not relevant Not relevant Not relevant

Not

relevant Not relevant 125[mm] 85mm or 90mm

Sleepers type concrete concrete concrete concrete concrete concrete Not relevant Not relevant


Stop Sets life cycle shall not be less than 40 years. A signed

statement approving it shall be submitted.


to be installed on -- electrified track with 25 [kV AC] and/or on

non-electrified track with electrical circuit signaling and/or on

track with electronic signaling and/or on depot track. A signed

statement approving it shall be submitted.

The Friction Buffer Stops and Fixed Buffer Stops installed on

electrified track with 25 [kV AC], will be design to ensure the

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safety of one standing near and/ or touching the Friction Buffer

Stops and Fixed Buffer Stops.

4.15 All components – metallic and non-metallic shall be made of hot

weather resistant materials, suitable for use at ambient temperature

of up to 50 [ᵒC], and rail temperature of up to 70 [ᵒC], and under

high corrosion conditions. All metallic components shall be

painted or galvanized – The Buffer stop Body shall be painted, all

the rest of the metallic components shall be galvanized, and all

non-metallic components shall be UV protected. Israel climate

condition shall be considered (see Technical Appendix C). The

certificates approving the requirements above shall be submitted.

4.16 The components painting shall be done with two layers: the first

layer shall be premier layer, and second layer shall be pearl dark

grey paint (RAL 9023). The second paint layer shall have high

resistance to the environment condition including UV sun

radiation, and corrosion environment, and high resistance to wear,

to comply with ISO12944. Document describing the painting

process and a statement approving its compliance with ISO12944

and with quality control in accordance with ISO9001 shall be

submitted.

4.17 The components galvanizing shall be done with hot dip galvanized

process, to conform the requirements of ISO10684 and ISO1461,

all surfaces shall be thoroughly covered. Documents describing the

galvanizing process and a statement approving its compliance with

ISO10684 and ISO1461 and with quality control in accordance

with ISO9001 shall be submitted.

4.18 The Friction Buffer Stop and Fixed Buffer Stops shall be equipped

with 1[m] length red and white reflector sign in front of it, (see

Technical Appendix D). The reflector sign material shall be of a

material used for traffic reflector sign, with the highest

reflectibility (day and night) in accordance with EN12899.

Certificate of the complince with EN12899 shall be submitted.

In addition, the Friction Buffer Stops and the Fixed Buffer Stop

shall be equipped with affixation plate suitable to carry a red light

illuminator electric device, all to increase safety.


Stop Sets Components shall be manufactured in accordance to the

Manufacturer's quality management plan complying with ISO9001

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and based on the relevant EN, UIC and ISO standards and these

Technical Specifications. A list of components and the referenced

standards and components test results shall be submitted.

4.20 Detailed List of Sub-Contractors, which are the components

manufacturers, shall be submitted (Name and Factory address, E-

mail, and its experience).

The components shall be manufactured only by the components

Manufacturers, which are listed in the Detailed List.


Stop Sets installation, maintenance and safety manuals shall be

submitted.

5. TECHNICAL DRAWINGS

5.1 The Technical Drawing, with dimensions and table of Components

with quantity and material main characteristics and coating

material, including relevant EN and/or ISO standards, for each type

of Friction Buffer Stops, Fixed Buffer Stops and Braking Wheel

Stop Sets, in accordance with the table in section 4.12 above, shall

be submitted and shall include the following:

Assembled Friction Buffer Stops, including clamping

components to the track;

Assembled Fixed Buffer Stops, including clamping


Assembled Braking Wheel Stop Sets with installation

components, including blow up drawing.

5.2 ISR uses, SKL W14 fastening systems, and the fastening system

overall dimension are inside the envelope described in EN13481-

2 section 5.8. It shall be taken into consideration when the Friction

Buffer Stops, Fixed Buffer Stops and Braking Wheel Stop Sets will

be designed.

6. CALCULATIONS AND TESTS

6.1 For each type of Friction Buffer Stops, Fixed Buffer Stops and

Braking Wheel Stop Sets, as detailed in table 4.12., the energy

absorbing calculation results and limit cases, shall be submitted.

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6.2 The test reports, done by the Bidder or in his behalf, and include at

least the following: documentation detailing test date; location and

which laboratory or facility performed the tests; the test procedure;

and test results, shall be submitted.

7. INSPECTION BY A REPRESENTATIVE OF ISR

7.1. The ISR technical team and/or an inspection body appointed by the

ISR ("The Inspector") shall have the privilege to inspect the

manufacture processes and/or the Friction Buffer Stops, Fixed

Buffer Stops and Braking Wheel Stop Sets, during and/or after

production.

7.2. It is the manufacturer’s responsibility to guarantee dimensional

accuracy and to ensure that the inspection is carried out with the

appropriate and calibrated measuring instruments.

7.3. The Manufacturer shall be responsible to coordinate inspection

process time table with The Inspector in accordance to the delivery

date defined in the purchase order.

7.4. The Manufacturer shall extend, to The Inspector, all necessary

assistance and cooperation, and shall give access to all test records,

calibrations and calculations that contribute to the results.

7.5. All the gauge/measuring instruments for manufacture verification

and inspection of Friction Buffer Stops, Fixed Buffer Stops and

Braking Wheel Stop Sets shall be made available by The

Manufacturer to The Inspector on request.

7.6. All Tests results shall be made available to The Inspector on

request.

7.7. The Calibration Certificates of the gauge/measuring instruments

signed and other relevant documents shall be made available to The

Inspector on request.

8. MARKING

8.1 Each Friction Buffer Stops, Fixed Buffer Stops and Braking Wheel

Stop Sets shall be inscribed with at least the following marks:

The Manufacturer mark,

The last two figures of the year of manufacturer,

The product identification type.

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Drawing number.

Item type (e.g. ISR101A)

8.2 Each Friction Buffer Stops, Fixed Buffer Stops and Braking Wheel

Stop Sets components shall be inscribed with at least the following

marks:

The Manufacturer mark,

The last two figures of the year of manufacturer,

The product identification type.

9. PACKING

9.1 The Friction Buffer Stop, Fixed Buffer Stops and Braking Wheel

Stop Sets components shall be packed in wooden boxes and will

put in container.

The dimensions of the wooden shall be according to EN standard,

to enable maximum effective storage capacity in containers.

It shall be possible to put at least 3 wooden boxes one on the other.

wooden boxes will be tied to one another, and to wooden platform

by metal bands, and all shall be wrapped with Stretch wrap.

9.2 Each package shall include packing list with the following details:

o Components name and type;

o Production batch number;

o Date of manufacture;

o Component barcode;

o Component quantity in box;

o Gross and net weight;

o Manufacturer recognition number or name;

o ISR recognition number;

o ISR order number;

o Ordinal number on the packing list.

The labeling shall be with black letters and shall be on 3 spots on

the package (one on top of the package and the two others on the

sides).

9.3 Each type of Friction Buffer Stop, Fixed Buffer Stop and Braking

Wheel Stops Sets shall be delivered with 2 technical drawing and

packing list in the package.

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10. LIST OF FILES (in PDF Format) TO BE SUBMITTED

WITH BIDDER'S PROPOSAL

10.1 A signed declaration signed by the manufacturer that the Friction

Buffer Stops, Fixed Buffer Stops and Braking Wheel Stop Sets

estimate life cycle (in years). (see section 4.13)

10.2 A signed declaration signed by the manufacturer that the Friction

Buffer Stops, Fixed Buffer Stops is approved for use on electrified

track with 25 [kV AC] and/or on non-electrified track with

electrical circuit and/or on track with electronic signaling and/or

on depot track. (see section 4.14)

10.3 Certificates approving that All components – metallic and non-

metallic shall be made of hot weather resistant materials, suitable

for use at ambient temperature of up to 50 [ᵒC], and rail

temperature of up to 70 [ᵒC], and under high corrosion conditions.

All metallic components shall be painted or galvanized – The

Buffer stop Body shall be painted, all the rest of the metallic

components shall be galvanized, and all non-metallic components

shall be UV protected. (see section 4.15)

10.4 Document describing the painting process on the Components and

the certificates approving its compliance with ISO12944. (see

section 4.16)

10.5 Document describing the galvanizing process on the Components

and the certificates approving its compliance with ISO10684 and

ISO1461. (see section 4.17)

10.6 Certificate on the Red and White Reflector Sign, with the highest

reflectibility approving its complying with EN12899. (see section

4.18).


Stop Sets Components Manufacturer's quality management plan

complying with ISO9001 and based on the relevant EN, UIC and

ISO standards. (see section 4.19)

10.8 Detailed List of Sub-Contractors, which are the Components

manufacturers (Name and Factory address, E-mail, and its

experience). (see section 4.20)

10.9 A sample of Friction Buffer Stop Technical drawing. (see section

5.1)

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10.10 A sample of Friction Buffer Stop technical descriptions. (see

section 5.1)

10.11 A sample of Friction Buffer Stop energy absorbing calculation

results. (see section 5.1)

10.12 A sample of Friction Buffer Stop installation, maintenance and

safety manuals. (see section 4.21)

10.13 Moved to section 11.

10.14 The test reports, done by the Bidder or in his behalf, and include at

least the following: documentation detailing test date; location and

which laboratory or facility performed the tests; the test procedure;

and test results. (see section 6.2)

10.15 The manufacturer shall submit technical drawing of clamping

components dimension design in which envelope interface with

fastening system components is avoided in accordance with

EN13481-2 paragraph 5.8. (see section 5.2)


BEFORE SIGNING THE AGREEMENT

11.1 The manufacturer shall submit the relevant technical descriptions

for each type of the Friction Buffer Stops, Fixed Buffer Stops and

Braking Wheel Stop Sets, in the table, in section 4.12 including:

The nature and main characteristics of the metallic and non-

metallic material including the mechanical properties and

chemical composite for every component.

All components shall be conformed to the latest relevant ISO

or EN or UIC standards. A list of components and the

referenced standards shall be supplied.

11.2 The Technical Drawing, with dimensions and table of Components

with quantity and material main characteristics and coating

material, including relevant EN and/or ISO standards, for each type

of Friction Buffer Stops, Fixed Buffer Stops and Braking Wheel

Stop Sets, in accordance with the table in section 4.12 above, shall

be submitted and shall include the following:

Assembled Friction Buffer Stops, including clamping


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Assembled Fixed Buffer Stops, including clamping


Assembled Braking Wheel Stop Sets with installation

components, including blow up drawing.

(see section 5.1).

11.3 For each type of Friction Buffer Stops, Fixed Buffer Stops and

Braking Wheel Stop Sets, as detailed in table 4.12., the energy

absorbing calculation results and limit cases. (see section 6.1).

11.4 Material examination certificates of mechanical characteristics and

chemical composition shall be submitted by request.

11.5 The manufacturer shall submit signed and approved installing,

maintenance and safety manuals. The manufacturer in

maintenance manual shall specify what the needed instructions to

guaranty safe operation during the product life cycle, including

Spare Part List.


WITH EVERY ORDER

12.1 For every order - visual inspection, surface finish, geometry,

mechanical properties and chemical composition tests results,

which shall conform to the drawings, the quality management plan,

these technical specification and the relevant EN and/or ISO

standard, and in additional EN10204, Type 3.1; or Type 3.2, shall

be submitted.

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TECHNICAL APPENDIX A – DRAWING DSB 2A 17409 – DBS82-1

WHEEL PROFILE

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TECHNICAL APPENDIX B – STOPING DISTANCE DEFINITION

Lv – Track length for install Friction Buffer Stop and ensure efficient

stopping distance

Lb – Friction Buffer stop length

Lw - Maximum stopping distance

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TECHNICAL APPENDIX C - ISRAEL CLIMATE AND

ENVIRONNEMENTAL CONDITIONS

C.1 Climate and Environmental Conditions

Max. ambient temperature 50 °C (shade)

Min. ambient temperature -5 °C

Relative humidity 10 to 90 %

Altitude -400 to +800 meter

Sunny 3300 hours per year

UV Radiation 360 to 600 MJ/m² per year

Rainfall 400 to 800 mm/year

C.2 Dust Conditions in the atmosphere

Maximum Half Hour

Value*

Maximum Daily

Value*

Average

NOx 1064 560 71

SO2 780 260 21

O3 312 143 84

Suspended

Dust

- 350 100

*(Microgram per m³ atmosphere)

C.3 Suspended Particulate Matter (SPM)

Particle size to 0.5-1 micron

C.4 Sea Salt Concentrations in the Atmosphere

Salt Element Na* Cl* SO4*

Position Dry Wet Dry Wet Dry Wet

Sea Air at Coast Line 7.3 16.0 12.0 22.0 5.3 7.0

600 m from Shore 3.1 4.8 4.2 7.9 1.9 2.0

6000 m from Shore 1.1 1.4 1.5 1.7 1.3 1.4

* (Micrograms per m³ atmosphere)

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TECHNICAL APPENDIX D – EXAMPLE FOR RED AND WHITE

REFLECTOR SIGN

(Dimensions in millimeters)

100

200

<

100

1000