Rail Vehicle Overhaul

Consideration for Specification Items & Definitions

Overhaul specifications are slightly different than new vehicle specifications since they require evaluation of the condition of existing components, specific descriptions, and then application of different types of actions. Also, there are specific definitions that are applied to overhauls that do not occur on a new car specification. The following items should be considered for Overhaul specifications.

Expected Scope of Work

The "Expected Scope of Work" table defines the percentage of the component or system level work the contractor is expected to supply. This provides the basis for the contractors to bid on the overhaul, and also facilitates the comparisons between proposals. This is also accompanied by a bill of material where the materials are priced so that any quantities above or below the expected quantities may be adjusted.

Scope of Work Table

Scope of Work Table

Each section may include a single table or individual tables where the overhaul item is discussed.

Bill of Materials (BOM)

The bill of materials should be defined for major components that are planned for overhaul activities. The list is generated based upon the scope items defined in the "Expected Scope of Work" tables, and is normally compiled at the end of the specification. The BOM establishes the cost basis for the overhaul for both over and under quantities, as well as in-scope vs. out-of-scope items. Note: it should be clearly stated that the cost listed serves as a fixed value for the cost of the overhaul activity. Any quantity adjustments - either positive, or negative, will use the same unit cost value for each item listed.

Scope of Work Cost Estimating Table

Scope of Work Table Cost Table
Definitions of Terms Used

CAR SETS (C/S) - The quantity or amount of material that occurs on a single vehicle. (i.e. one complete, six-axle, articulated LRV).

CLEAN, INSPECT, TEST (CIT) - The item is to be cleaned, inspected, and tested. The item shall be painted, refinished, and lubricated as per manufacturer's recommendations. If full functionality cannot be achieved, the item shall be repaired, overhauled, or replaced.

FORM, FIT, AND FUNCTION - The physical attributes of a device that allow the device to be used in place of another device due to similarities of general shape (outline, clearances), mounting arrangement (footprint), and operation (inputs/outputs) of the device.

MARRIED PAIR - The operational unit of the HRV consisting of two single vehicles, semi-permanently coupled together to form a revenue service, operational vehicle.

NORMAL WEAR - Normal Wear is the damage that naturally and inevitably occurs to a component or system, due to the normal usage of the item consisting of; wear, aging, degradation, and damage. (Normal wear includes; discoloration, stains, fading, nicks, scratches, abrasions, chipping, pitting, wear of bearing / faying / or friction surfaces, etc.).

OVERHAUL - Overhaul is the "in-kind" restoration of an item to a sound and reliable operating condition and OEM tolerances, from a non-operating condition, deteriorated condition, or normal wear and tear condition. The final performance and configuration shall be the same as the OEM equipment. Items typically included: disassembly of the item; cleaning; replacement of parts (such as bearings, belts, seals, gaskets, lubrication, out-of-tolerance parts as per the manufacturer's recommendation); repair of Normal Wear damage; reassembly; Refinishing; and testing.

REBUILD - (NFTA) The performance of all remanufacturing, testing, and redesigning, and the furnishing and installation of all parts, components, material, equipment, hardware, software, data, services, management, labor, deliveries and incidentals, specified or otherwise, essential for timely completion of the Work required by the Contract Documents.

REBUILD - (LA Metro) Services or actions necessary for the restoration of equipment to like-new condition in accordance with OEM instructions and/or standards. Rebuild is the highest degree of material maintenance applied to Metro equipment. The rebuild operation allows returning to zero those age measurements including, but not limited to, hours and miles considered in classifying Metro equipment and components.

REFURBISH - This is the cleaning, painting (or refinishing), and servicing / lubricating an item. The item is to be cleaned, inspected for damage or deterioration, painted, and tested as per the Specifications to ensure full functionality. The Contractor shall be responsible for all damage that occurred during the refurbishment.

REFINISH - This term is primarily associated with coated surfaces such as paint and powder coating; however it may also include surfaces such as plating, and applied materials. This task includes the striping of the component, cleaning, surface preparation to applied coating manufacturers specifications, the application of the specified finish material per the manufacturer's specifications in compliance with the Materials and Workmanship section. The applied coating shall be equivalent or superior to the original material.

REPAIR (Corrective) - Repairs are corrective actions that may be required when a component is physically damaged from causes other than normal wear. (e.g. collisions, accidents, etc.).

REPLACE - Replace the component or system, with new material that meets, or exceeds, the specified criteria and performance, unless otherwise noted. The Authority is only responsible for replacement components and/or equipment where specifically noted.

REPLACE-IN-KIND - This is the "in-kind" substitution of an existing system, piece of equipment, or component, with a new piece of equipment, or component. The replaced component may be by the same manufacturer, or produced by different manufacturer. Replaced equipment, parts and materials shall provide the same, or superior, performance characteristics with respect to form, fit, function, and reliability. The use of a rebuilt system, piece of equipment, or component is not permitted.

REPLACEMENT PART(s) - The items described in the Contract Documents and necessary to properly and timely complete the rebuild of the Existing LRVs.

UPGRADE - This is the substitution of an existing system, piece of equipment, or component with a new system, piece of equipment, or component that has the superior quality, or improved functionality as the original item. The new item shall exceed the existing item's performance specifications and meet any additionally specified criteria in these technical provisions, including energy conservation. It shall fit into the same allotted space envelope or less than the allotted space envelope of the original system, piece of equipment, or component, except as otherwise noted.

VEHICLE - A vehicle is the single, fully operating unit in a particular configuration. This is the smallest, fully operational unit that could be deployed to revenue service.

  • LRV - A single, bi-directional, four-axle vehicle.
  • LRV - A single, articulated, six-axle vehicle consisting of two cars (car halves) joined by an articulation section.
  • HRV - A Married Pair Unit, consisting of two cars with shared equipment, semi-permanently coupled together.
  • HRV - Multiple Unit, consisting of two Cab cars, each located at opposite ends of a consist, coupled together with non-cab cars in between.