For railway transport

Rail Wash

Table of Contents:

Section 1: Overwiew

Capability:

Automatic train washing system, capable of cleaning front, sides, and rear of large locomotives and railcars. Designed to fit individual customers’ requirements. This system shall be fully automatic by means of infrared fiber optic beams, starters, and overloads. If needed, washer controls may by overridden at any time by manual controls as desired for concentrated drive-through, washing action.

Operation:

After activating the wash system, the train enters the six (7) arch wash bay at 3 MPH or less, breaking first set of sonic beams which then powers up the Detergent Arch thoroughly covering front, sides, roof, and rear of each railcar within the train. A heightened detergent spray will focus on the fronts and rears for best possible clean.

After exiting the detergent arch the train will enter the 3 - Arch Brush tower station. Here, in the first two arches, a total of four side brushes (2 on each side) will concentrate the cleaning action using flagged end bristles. One set will rotate clockwise while the other rotates counter clockwise. 1 top (arch) brush will also be supplied to target the roof of the rail cars for maximum cleaning. Current sensing will be used on all brushes to maximize contact with the train surface as it passes by.

A high-volume Blaster Arch is incorporated with the brush tower spraying reclaim water. This arch contains fixed fan blaster nozzles spraying towards the front of the train and as the rear nears the exit of the arch, a second set of blasters will spray back towards the rear of the train for maximum spray coverage and to impact hard to reach areas. This blaster arch will also aid in lubrication for the brush arches.

Once the train exits the brush arches, it will then activate the fresh water Pre-Rinse Blaster Arch. This operation will be the same as the first blaster arch with the exception of only spraying fresh water to remove suds & displace the reclaim water.

The final arch before exiting the wash bay is the Final Rinse Arch. Here, the train will be flushed at low pressure, with fresh rinse water and drying agent for a clean crisp shine.

Once the beams are broken at each arch, the arches will continue to be activated until the train exits the arch allowing the spray action to be timed out.

Section 2: Spray Arch Sequence

Detergent Arch

Complete detergent coverage on sides, front, rear, and roof of the train shall be achieved by 36 angled soap nozzles, 10 on each side spray bar dividing the spray patterns to target the front and rear of the railcars. 16 nozzles will direct the spray for the roof section. This will achieve complete and consistent detergent coverage. This arch will utilize a precise mixture of alkaline detergent. Water softener systems will be included for this application. To maximize cleaning on fronts and rear, a heightened spray will target these areas by utilizing larger nozzle size. See 3.01 for frame construction.

Blaster Arch (1 & 2)

The blaster arch shall have 36 blaster nozzles to ensure uniform coverage on each rail car. Nozzle arrangement will be 12 on both sides and 12 on top with a 25-degree fan spray for each nozzle. By allowing two blaster bars in this arch, 30* angles in each direction will be used to target front & rear of the railcars. With the overlay of each nozzle, this will also be effective in cleaning the sides without harm to decals & logos. In this application, the first blaster arch will spray reclaimed water to aid in the lubrication before entering the brush arches and to impact hard to reach areas of the train.

The second blaster arch will be mounted after the brush arches and will be spraying fresh water to rinse the train before passing through to the final rinse arch. See 3:01 for frame construction.

Brush Arch (1, 2 & 3)

Brushes shall target sides and roof of railcars. Two brushes per side, in sequence, will achieve complete coverage of the side panels of the train. The brush system will utilize current sensing to maintain maximum contact with the painted surface of the train. Brushes shall move in and out via stainless steel air cylinders as the train passes through the arches to maintain positive brush contact. All brushes are made of Polyethylene filaments and all brush ends are feathered to prevent damage to vehicle surface areas. As the brushes wear, they will continue to feather to protect the paint finish and prevent the windows from becoming scratched over time.

All brushes are separately replaceable in no longer than 12" sections in case of brush wear. Side brushes shall be 50" in diameter.

All brush shafts will be 4 1/2" diameter and are flange bearing mounted, direct wormgear drive. Three and one-half inch brush shafts are not acceptable. Side brushes have stainless steel frame supported at top and bottom.

Brush rotations do not exceed 125 rpm to prevent damage to the train paint finishes and obstacles such as handrails, etc.

Brush extension (pressure) will be controlled using SMC pneumatic air cylinders. This will automatically allow the brushes to adjust to the surface if wider or narrower units come through the wash bay. This feature will aid in the life of the brush and maintain proper cleaning length on the brush ends.

Final Rinse Arch

Frame mounted, self-standing, automatic Final Rinse arch shall be provided at wash bay exit. A drying agent will be injected into the fresh water supply line before the rinse arch. The rinse arch shall have a minimum of 36 stainless steel spray nozzles threaded into 2” stainless steel pipe arranged to provide full rinsing coverage with fresh water over entire railcar and capable of delivering 80 gallons per minute at 250 PSI. Piping shall be supported by a frame constructed of 2 x 2 x 1/8” stainless steel structural tubing welded to four stainless steel base plates. See 3.01 for frame construction.

Section 3: Mechanical

Frame Construction

All spray arch frames shall be constructed of welded stainless steel tube and stainless steel angle iron. Stainless steel construction stress points will be reinforced and double welded. All bolts, rivets, and fasteners shall be constructed of stainless steel. Operating components shall be easily accessible within the frame for maintenance.

OPTION: Arch and brush frames are also available in mild, painted steel (will be priced as option).

Brush arches are 12 feet wide and 4 feet long. Brushes are mounted on current sensing swing arms within the arch. The other arches are 12 feet wide and 2 feet long. Arches are typically 15 feet high. Heights are from the top of track. Pads or extensions to be provided to obtain correct elevations.

Motors and Bearings

All pump motors are totally enclosed continuous duty wash-down motors. With the exception of the two high volume pumps (140gpm,  300gpm), all pump motors will be controlled by network interfaced AC inverters. Thermal overloads magnetic motor starters are not acceptable.

All brush motors are controlled utilizing network interfaced inverters. The inverters must have the following abilities:

• - Sensorless Vector Control
• - Advanced Auto Tuning
• - Self Diagnostics
• - Controlled Decel in the event of power failure
• - Airflow from cooling fans cannot come in contact with electrical components
• - Capable of network communications
• - Ability to put itself on-line after power failure
• - Overload capacity must maintain 200% of rated motor value for three (3) seconds

- Thermal overloads, motor starters, auxiliary contacts are not acceptable for brush motor control or diagnostics.

Drives

The brushes have direct drive motor couplers

All gearboxes are of heavy-duty worm gear type, lubricated with synthetic gear oil and sealed. Gearboxes will be American made.

Motor and worm gear reducer combinations are as follows:

Side brushes are driven by 5 HP, 1750 RPM, 145TC-frame motor and 15:1 heavy-duty gear reducer. Motor is stainless steel. V.F.D are standard on all brush motors for current sensing control.

Piping and Nozzles

Piping shall include 1” stainless steel pipe for the detergent (chemical) arch and final rinse arch. The blaster arches shall utilize 2” stainless steel piping. All spray nozzles and pipes shall be separately removable for cleaning purposes.

Compressed Air System

The washer shall be capable of operating with 80 to 120 PSI, 20 CFM, air pressure through 3/8” air line. All air hoses/air components shall require no lubrication and shall be NFPA designed for continuous duty. Air control components shall be located behind an access panel and the main air hose shall have an automatic water filtration system (24 CFM #60 PSI is required).

Electrical System

Electrical components shall be UL approved. ..Factory construction and installation shall meet Division 16 specification requirements. Provide wire markings and labeling per Section 16195. Installation will include final connections to customer provided service panels & hook-ups. Electrical requirements for the train wash equipment will be 480V 3 Phase with a 400 amp service. All electrical panels are manufactured by Whiting Systems, Inc. and carry a UL approval status. All panels must carry UL certification and must be certified as a whole. Individual UL components only are not acceptable.

The control system platform utilizes networking capabilities with communication speed up to 500 kbs which is necessary for reading brush currents. The PLC will control brush pressure (depth) by using PID algorithms. These instructions will reside in the PLC. The PLC will use current feedback from A/C inverters for pressure and speed control. This feedback is delivered to the PLC via the network at speeds of 500 kbs. Non network platforms are not acceptable. Current transducers, current relays and AC/inverter PID loops are not acceptable.

OPTION: Mechanical brush application available. This option does not utilize any current or vehicle contour sensing (will be priced as option).

Controls

The control panel shall have numbered terminal strips for external wiring. Push buttons and selector switches shall be rated NEMA 4X. Internal wiring shall utilize conduits. Limit switches are not acceptable. Thermal overloads and motor starters shall be equipped with auxiliary contacts to switch off control circuit in event of any motor failure. The electrical control system shall be hardwired with a master control relay circuit for positive electrical disengagement, so all circuits will de-energize when the stop button is pressed for maximum safety. A separate power push button shall re-engage the master control relay for operation.

PLC

The PLC will be Omron CJ1G-H CPU 43 and will be equipped with device net networking capabilities. It will communicate intelligently with all motors (with the exception of “HP” motor. It will communicate with network interfaced control modules. Discreet I/O modules are not acceptable and rack mounted I/O modules are not acceptable. The PLC will be accessible by factory mounted modem from manufacturer for diagnostic capabilities. It will have flash memory protection for maintaining software residing in the PLC, in case of power failure. Battery backups are not acceptable.

Network

The network system must be based on CIP (Common Industrial Protocol) and must be able to adapt CIP to CAN (Controller Area Network). The following are requirements for the network:

• Support 64 nodes with baud rate @ 500 KBS
• Follow open systems inter connection model
• Infrastructure must be passive so that it is inherently tolerant to lost nodes
• Configured with distributed control architecture using peer to peer communication
• Provide 24 VDC and 8 amps on trunk line
• Application layer protocol
• Constant communication with all brush, detergent pump, and wash water pump motors
• Communicate with air control system
• Constant communication with all I/O modules - modules must be network interfaced - discreet I/O modules are not allowed.

The WSI network may be compatible with customers’ existing network. This to be determined upon further examination of customer network.

RFID Reporting

For fleet tracking ability, customer can track wash information relevant to wash frequency, wash user(s), wash costs, and wash equipment maintenance log.

Operating in the license-free 900MHz UHF band, the LR-2000 is the first Access Control reader that combines the convenience of UHF technology with a programmable repetition rate and the Access Control industry’s standard Wiegand format. It „is manufactured in an ISO 9001:2000 certified facility providing the highest quality standard. This reader is furnished with an impressive combination of high styling and ranges from 8 feet tov15 feet, dependent on the type of tag. It offers Wiegand and RS-232 protocol interfaces with simultaneous data output, providing compatibility with all standard access control panels and systems. The LR-2000 integrated RFID reader antenna system is ideal for outdoor AVI application as well as indoor applications such as asset monitoring and tracking. The system offers price/performance characteristics over traditional long-range proximity card systems.

Control Station

Mounted inside the equipment room, the control station will include wash pumps, detergent metering pumps, blaster pumps, U.L listed electrical panels, and miscellaneous equipment to fully support washer operation. A touch screen will allow for diagnostics of wash system. This to include precise detergent metering at the detergent spray arch and detergent storage levels for reorder points. An automatic freeze protection system for the spray arches will be activated if ambient temperatures drop to freezing. This is a standard component with W.S.I systems.

Customer to provide adequate supply of city feed water source with RPZ valve per city codes. This should be a 4” line at a maximum inlet pressure of 60 psi.

Pump Package: Factory mounted on powder coated skid, plumbed, and wired prior to arriving at job site.

1. 1 - High Volume Pump: 40hp, 140 GPM at 390 PSI. Grundfos model CR32-11-2 Multi­stage centrifugal, motor-stacked, chamber and impeller design, 80% efficient pump with water-resistant bearings and cartridge shaft seals. One pump will discharge reclaim water with the brush system for a more targeted contact in hidden crevasses and to aid in brush lubrication.
2. 1 - Rinse Pump: 25hp, 80 GPM at 125 PSI. Grundfos CR15-11-25 HP Multi-stage centrifugal, motor-stacked, chamber and impeller design, 80% efficient pump with water- resistant bearings and cartridge shaft seals. This pump will deliver fresh city water to displace wash detergent and reclaim water before entering the final rinse arch.
3. 1 - Wash Water: 5hp, 20 GPM at 250 PSI Grundfos model CR5-16 5 HP Multi-stage centrifugal, motor-stacked, chamber and impeller design, 80% efficient pump with water- resistant bearings and bellow shaft seals. This will only pump soft, city water for the detergent application for maximum cleaning performance.
4. 1 - Network based precise detergent metering system: Grundfos model CR3 10 GPM. Injection pump meters the detergent and then injects the stream into the wash water pump suction line. Detergent volumes will be applied to achieve maximum cleaning of trains to customer requirements. This pump will be controlled through the touch screen for precise metering using the network as specified in sections 3:09 and 3:10.
5. 1 - Final Rinse: 5hp, 20 GPM at 125 PSI. Grundfos model CR 5-16 5 HP Multi-stage centrifugal, motor stacked, chamber & impeller design. 80% efficient pump with water- resistant bearings and bellow shaft seals. This pump will discharge fresh water with drying agent as the final step in the wash process. This will allow the train surface to dry without any water spots on railcar surface.

Air Control

All pneumatic devices will be controlled utilizing SMC VQ2000 Series Solenoids. The SMC manifold will be network interfaced and it will send and receive commands via the network. Commands from discreet I/O are not acceptable.

Section 4: Reclaim

Waste Water Disposal: This shall provide maximum containment and adequate flow to proper wastewater treatment.

Wash-bay floor: WSI to provide specifications. Existing floor to be examined for use.

Center Trench: WSI to provide specifications. Existing floor to be examined for use.

Drain: Drain configuration to incorporate a sump. Two each Goulds Pump Model 3SD52F43EAH, 150 GPM, 480 3 phase 1.5Hp, ANSI class 125, 1750 RPM. Pumps installed with proper check valves plumbed to the existing pipes that terminate in the collection pit. These pumps will work in conjunction and will be network interfaced for activation. One low-level float in the drain sump and high-level float switch in the receiving pit will monitor the activation of the pumps.

Pit design: WSI to provide specifications. Existing floor to be examined for use.

Reclaim: Reclaim to be simple, yet functional. Reclaim system to be stainless steel skid mounted with Goulds brand or equal pumps. Reclaim to feature centrifugal separation technology, along with oxygen injection for organic control to minimize odor. Reclaim will provide constant flow to drain pits for additional solids removal and additional organic control.

Environmental Impact

The train washing system utilizes a water reclaim system. The reclaim system produces a 140 gallon per minute water flow to the spray arch for high impact cleaning in hard to reach areas. It is anticipated the reclaim pump will run for approximately 3 minutes dispensing a total of 420 gallons of used water per 2 car washes. A yearly water savings will be a minimum of 3,690,960 gallons of water assuming 338 cars are washed per week.

By also utilizing Current Sensing technology, this enables the polyethylene brushes to not wear as fast due to the applied pressure and the ability to read the contours of each railcar.

PLC’s will operate the pumps and motors so that they are not operated at full capacity, only at demand needed. This also incorporates a “soft start” on all motors, which will eliminate any unnecessary wear on equipment and additional power usage.

Section 5: Warranty

Coverage

The wash equipment comes with a 1-year parts warranty from the date of completed installation. With the exclusive purchase of Whiting Systems, Inc. SmartWash® cleaning detergents, customer will receive 4 visits per year for preventative maintenance on all wash equipment. On-line monitoring is available. An Operational Service Agreement also available (see below).

 Section 6: Demolition

Performance

The removal of the existing train washing equipment shall be performed by Whiting Systems, Inc. All debris will be removed from job site in a safe and expeditious manner. Materials will be sorted and discarded to the proper authority for the purpose of recycling. With customer approval, any plumbing or electrical chase lines deemed suitable for continued use shall be reused with new washing equipment.

Existing drainage trench and pits shall be inspected during demolition to ensure adequate drainage flow to reclaim system and sanitary sewer.

Section 7: Installation

Performance

Installation of wash equipment will be performed by Whiting Systems, Inc.. Customer to provide all building - plumbing, drainage, electrical, and chase line runs from equipment to wash bay arches. The wash equipment will be installed to the customer’s satisfaction and to the customer-supplied utilities such as water and electrical supply. Customer to supply phone line for program adjustments and service monitoring. Any unscheduled or additional work or permits needed will be time plus material- see below. All plumbing and electrical must conform to city and state codes.

Section 8: Items Included for the Train Wash System

Equipment

• Smart Wash® Sprite Train Wash and necessary components listed in specifications. All panels, software, and programming for the wash equipment will be assembled, installed, and tested at the factory prior to shipping to job site.
• Current sensing technology for brush systems for positive brush contact
• Splash Shields for Brush Tower
• Factory installation and commissioning
• Wash Equipment Drawings
• Above Ground Detergent and Water Storage Tanks
• Soft Water System (Detergent Application)
• Final Rinse (using Drying Agent)
• Reclaim System
• Air Compressor
• Freight
• Sales Tax

Section 9: Contingencies

Time Plus Material/ Options

• Turn Key Construction of wash bay
• Water Strippers (Blowers)
• Digital Speed Readout Package
• Permits
• All Building - Electrical and Plumbing for Wash System
• PLC BASED RFID AUTOMATIC TRACKING SYSTEM

1. Monthly Reporting ( detailed maintenance reports and wash activity)
2. No charge on per wash or national account.