SCHEDULE OF TECHNICAL REQUIREMENTS FOR ...rdso.indianrailways.gov.in/uploads/files/S.pdfASTM A370/05,ASTM A388, ASTMA609/A609M, ASTM E446 Latest version of amendment & Reaffirmed are

REVISION OF SPECIFICATION / STR

ITEM NAME: SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION

MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR

BG DIESEL- ELECTRIC LOCOMOTIVES (ALCO & HHP BOTH) AND DEMUs

Specification/STR No.: MP.STR.EM-01.01.12 (Revision-02)

1. RDSO is reviewing the specification/STR to cater to the latest technological

developments in the field, modify clauses not relevant in the present context and

making them more enabling with focus on functional requirements.

2. It is requested that your comments / suggestions with regard to improvements

/modifications in specification / STR of the above mentioned item may be submitted

in the following format along with the justification for the changes required.

Part A: Basic Information

SN Particulars Information

1 Name

2 Designation

3 Professional Qualification

4 Organization / Firm’s Name

5 Address for Correspondence

6 Contact No.

7 Email ID

8 Whether firm is registered with RDSO for the subject item. If yes, details like date of registration, current status etc. If no, firm’s experience in manufacturing of subject item or similar item

9 Whether any technical document/Report/Study to support suggested changes is available / enclosed for better appreciation

Part B: Comments / Suggestions on the specification:

SN Clause No. of RDSO STR/ Spec

Clause, as it exists in RDSO STR/ Spec

Clause , as it should read after incorporation of comments /suggestions in the RDSO Spec / STR

Justification for changes

Comments may be sent to following address within 15 days from the date of

publication on rdso.indianrailways.gov.in

B P S Bhadoria, Joint Director/MP (EC&EM), Mobile No.-9794863120, E-mail ID: [email protected], [email protected] Phone no. : 0522-2450020 Fax No. 0522-2453916

mailto:[email protected]

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GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

बड़ीऱाइन डीजऱ विधुतीय ऱोकोमोटीि (एऱको और एचएचऩी ) एिं डी.ई.एम.य ू.हेतु कर्षण मोटर केई टेऩर रोऱर सस्ऩेंन्शन बीयररगं ट्यूब ि

उऩभागों हेत ुतकनीकी आिशयकताओ की अनुसूची

SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR

ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG

DIESEL ELECTRIC LOCOMOTIVES (ALCO & HHP ) AND DEMUs

एस टी आर सं – एम ऩी एसटीआरईएम.01.01.12(संशोधन-०२) दिसम् बर 2020

STR No. MP.STR.EM-01.01.12 (Revision-02 ) December 2020

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RESEARCH DESIGNS & STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW-226 011

RESEARCH DESIGNS & STANDARDS ORGANIZATION

Manak Nagar, Lucknow – 226011

LIST OF AMENDMENTS

S. No. Amendment Date

Revision No

Reasons for Amendment

Second issues

Following changes have been incorporated/ changed in the STR No. MP.STR.EM-01.01.12(Rev-02)

1

Dec‟2020 02 1. Clause 1.0 Minor modification made in Scope to remove Vendor make Drawing.

2. Clause 5.1 IS:1030,IS:1387,IS:2062,IS:2269,IS:5517, IS:12117, ISO:9001,BS:1486 ,ASTM A513, ASTM A519. Latest version of amendment & Reaffirmed are added.

3. Clause 5.2 IS:1500, IS:1599, IS:1608, IS:1757,IS: 3739 & IS: 4897 , ASTM A370/05,ASTM A388, ASTMA609/A609M, ASTM E446 Latest version of amendment & Reaffirmed are added.

4. Clause 5.3 IS: 3739 & IS: 4897 ,Latest version of amendment & Reaffirmed are added

5. Clause 7.1 IS:1030, IS:5517, IS2062, IS:2269 & BS:1486 Latest version of amendment & Reaffirmed are added

6. Clause 7.2 (SN-4&5)

ASTM A519 & ASTM A513 Latest version are added

7. Clause 7.3 (SN-3)

ASTM A513 Latest version are added

8. Clause 11.1 IS:1387 Latest reaffirmed 2018 is added

9. Clause 11.6 Test Certificate of Raw materials incorporated.

10. Clause 12.1 & Clause 12.2

IS : 12117 –First revision. reaffirmed 2017 added

11. Clause 16.1 IS : 1608 & ASTM A 370/05 Latest version added.

12. Clause 16.2 IS : 1500 Latest version added

13. Clause 16.3 IS : 1757, Latest version added

14. Clause 16.4 IS : 1599 Latest version added

15. Clause 17.0 MPI & DP Test incorporated in table in line with clause no. 17.4 and 17.5

16. Clause 17.1 ASTM E446 latest version added

17. Clause 18.1 Type Test format for conducting the detailed test on Prototype mentioned and Type test format is incorporated at Annexure-IV

18. Clause 18.2 Acceptance Test , Sampling plan for conducting the purchase inspection mentioned and Acceptance test format is incorporated at Annexure-V

19. Clause 21 Preference to make in India incoporated

20. Clause 22 Reference of ISO documents added (Vendor changes in Approved status) added

21. Clause 23 Field Trials and Performance Feed back incorporated and format is given at Annexure-VI

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Contents 1.0 SCOPE: ............................................................................................................................ 4

2.0 GENERAL REQUIREMENTS: ....................................................................................... 4 3.0 QUALITY ASSURANCE PLAN (QAP): ........................................................................ 4 4.0 QUALITY CONTROL ORGANIZATION: ................................................................ 5 5.0 GOVERNING SPECIFICATIONS: .................................................................................. 65 6.0 INCOMING MATERIAL: ............................................................................................. 76

7.0 DIMENSIONS AND TOLERANCES:............................................................................. 7 8.0 PROCESS OF MANUFACTURE: .................................................................................... 10 9.0 QUALITY ASSURANCE PROCESS – INSPECTION & TESTING PLAN: ............. 10 10.0 CHEMICAL COMPOSITION: ...................................................................................... 11 11.0 MATERIAL SPECIFICATION: .................................................................................... 11

12.0 REQUIREMENT FOR CASTINGS: ......................................................................... 1211 13.0 REQUIREMENT FOR FORGINGS: ............................................................................ 12 14.0 INSPECTION: ................................................................................................................ 12

15.0 SAMPLING FOR MECHANICAL TESTS: ................................................................... 13

16.0 MECHANICAL TESTS: ............................................................................................... 13 17.0 OTHER SPECIAL TEST FOR SUSPENSION TUBE & ACCESSORIES: ................. 14

18.0 Type Test and Accetance Tests Formats ........................................................................ 14 19.0 MARKING: .................................................................................................................... 15 20.0 PACKING: ..................................................................................................................... 15

21.0 PREFERENCE TO MAKE IN INDIA: ............................................................................ 15 22.0 VENDOR CHANGES IN APPROVED STATUS: ....................................................... 15

23.0 FIELD TRIAL & PERFORMANCE FEEDBACK : .................................................... 15

ANNEXURE - I ............................................................................................................................... 16

ANNEXURE - II .............................................................................................................................. 17 ANNEXURE – III ............................................................................................................................ 18

ANNEXURE – IV ............................................................................................................................ 19 ANNEXURE – V ............................................................................................................................. 20 ANNEXURE – VI ............................................................................................................................ 21

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SCHEDULE OF TECHNICAL REQUIREMENTS FOR

TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES WITH COMPONENTS FOR BG DIESEL- ELECTRIC LOCOMOTIVES (ALCO & HHP BOTH) AND DEMUs.

STR No. MP.STR.EM.01.01.12(Rev-02) December 2020

1.0 SCOPE:

The Motor Suspension Unit (MSU) tubes are vital parts of traction motors used on Alco and HHP diesel electric locomotives as well as DEMU of Indian Railways. These components are procured by DLW, DMW and Zonal Railways from RDSO approved sources as per DLW, DMW & BHEL/CGL drawings. In addition, a number of assembly components are also procured as per DLW, DMW & BHEL/CGL drawings. The schedule of technical requirement (STR) mentioned hereunder is being issued to serve as a guide to manufacturers and shall be read in conjunction with the relevant drawings. The firms shall satisfy themselves to having complied with, all the requirements of the drawings and STR. Approval shall be granted to a firm that has the capability to supply fully machined suspension tube as per the STR.

2.0 GENERAL REQUIREMENTS:

2.1 The firm shall have valid ISO-9001(2015) certification issued by an approved agency with the activity desired clearly mentioned in the scope of certification. The firm shall have a Quality Manual indicating the extent of control over production.

2.2 A system of regular submission of rejection details of material giving rejection rate, cause of rejection, corrective action taken etc. on quarterly basis shall be followed by the firm.

2.3 The firm shall have a system of documentation with respect to rejection at customer end, warranty replacement and failure of item supplied by them during service.

2.4 The firm shall have a system of recording the plant, machinery and control equipments remaining out of service, nature of repairs done etc.

2.5 The testing and measuring equipment shall be duly calibrated and the validity of calibration shall be current and verified by physically checking the calibration certificate issued by the Calibration Agency from where it was calibrated.

2.6 The firm shall have a system of easy traceability of the product from manufacturing stage to finished product stage.

2.7 At the time of application, the firm must submit clause wise compliance of this STR.

3.0 QUALITY ASSURANCE PLAN (QAP):

The firm shall prepare a Quality Assurance Plan (QAP) for all items for which approval is sought and submit the same as a part of compliance of this STR. The

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QAP shall be a comprehensive document covering the following aspects including all the parameters in accordance with ISO Document No. QM-RF-8.1-3, Version No. 1.0 or latest - Guidelines for preparing QAP during registration. (i) Details of Quality Control Organization of the firm along with key personnel

engaged in the QC function. (ii) Quality Assurance Process of incoming materials used for the subject items. (iii) Process Flow Chart indicating process of manufacture of an individual product

or for a family of products, if the process is same. (iv) Quality Assurance System – Inspection & Testing Plan including stage

inspection. (v) Calibration scheme and status of calibration of equipments used in the quality

process.

Details of the above aspects are described in the following paragraphs. The QAP shall be approved by RDSO and shall form basis of approval process.

3.1 Firm shall have to declare details of the manufacturing operations to be conducted

in house or by outside agencies. Details of the outside agencies shall be indicated and prior approval shall be taken from RDSO, which reserves the right to inspect these firms also.

A general format for guidance is given below:

Product / Name of the process and details of machine used indicating their capacities / accuracy limit

Acceptance limit of the parameters to be inspected during different operations of MSU Tube and components

Standards followed for acceptance of the test parameters

Sample size & its frequency of inspection

Format no. for recording for traceability

Action taken on rejection, if any

Calibration scheme and status of calibration of equipments used in the quality control process

4.0 QUALITY CONTROL ORGANIZATION:

4.1 The complete organizational setup of the quality control key personnel and officials

along with their qualification and experience shall be furnished. 4.2 The Quality Control Organization shall be headed by a senior level official having

adequate technical qualification who shall directly report to plant in-charge.

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5.0 GOVERNING SPECIFICATIONS:

The latest revisions as applicable to the specification referred below shall be followed.

5.1 For Materials: (i) IS: 1030-1998 (5th Rev.) Reaffirmed 2017 or latest version - “Carbon steel castings

for general engineering purposes- specification”. (ii) IS: 1387-1993 (Second Rev.) Reaffirmed 2018 or latest version - “General

requirements for the supply of metallurgical materials”. (iii) IS: 2062- 2011 (7th Revision),Reaffirmed 2018 or latest version Steel for general

structural purposes – Specification (Fifth Rev.). (iv) IS: 2269-,2006(5th Revision ) Reaffirmed 2016 or latest version Specification for

Hexagon socket head screws. (v) IS: 5517-1993(2nd Revision), Reaffirmed 2019 or latest version Steels for hardening

and tempering – Specification. (vi) IS: 12117 – 1996(1st Revision) Reaffirmed 2017 or latest version : Norms for

classification of Steel Foundries for quality assurance (First Rev.), Feb.2002. (vii) ISO: 9001- 2015: Purchasing Procedure. (viii) BS: 1486 Part-II 1961( or latest version) for Zinc Plated Grease Nipple. (ix) ASTM A513 – 20 or Latest version Steel Tubing. (x) ASTM A519-17 or Latest version – Hot finished seamless tubing. 5.2 For tests: (i) IS: 1500(Part-1)(5th Revision ) 2019or latest version „Method for Brinell hardness test

for metallic materials (ii) IS: 1599 - 1985 4th revision 2019 or latest ‟Method for bend test for steel products

other than sheet, strip, wire and tube).‟ (iii) IS: 1608(Part-1) – 4th Revision 2018 or latest „Method for tensile testing of steel

products‟. (iv) IS: 1757(Part-1) - 3rd revision 2014 or latest version „Method for Charpy Pendulum

impact test (V-Notch) for metallic materials‟. (v) ASTM A370/05 -19 or latest version Tensile Test. (vi) ASTM A388, 2007- 19 or latest Ultrasonic Test for steel forgings. (vii) ASTM A609/A609M- 91-12 (Reapproved 2018) or latest - Ultrasonic Test for steel

castings. (viii) ASTM E446 -15 or latest version - Radiography test Level- III for central portion and

Level- II for both side housing bores. 5.3 For dimensional tolerances: (i) IS: 3739-1987 (First Rev.) Reaffirmed 2018 - Dimensional tolerances for carbon and

constructional steel products. (ii) IS: 4897- 1994(3rd Revision ) Reaffirmed 2017or latest version Deviations on

untoleranced dimensions and mass of steel castings. 5.4 For welding:

A.I 1651- EMD welding, brazing and soldering specification.

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6.0 INCOMING MATERIAL:

6.1 A complete Bill of Material (BOM) indicating all input material required for

manufacturing of the product, governing specification and their sources of supplies as approved by the firm in accordance with clause 7.4.1 of ISO:9001 (2000) shall be furnished.

6.2 Test results of incoming raw material with reference to test certificate issued by the

supplier and the results of internal tests carried out by the firm for verification shall be submitted as a part of QAP.

7.0 DIMENSIONS AND TOLERANCES:

The MSU tube and components shall conform to the respective drawings indicated for dimensions, tolerances, finish and material etc.:

7.1 List of drawings of Suspension Tube & Accessories (10 Components) for traction motor type TM 4907 application (Class of locos WDM3A & WDG3A):

Sl. no.

Description DMW Drawing no.

Material Specifications & Tests

1 Suspension Tube (Machined) for TM 4907

1/DCW/M/TM-398, Alt- W

Casting - Carbon Steel- IS: 1030-1998 (Fifth Rev.)Reaffirmed 2017 or latest , Gr. 280-520W.

2 Bearing Housing for TM 4907

1/DCW/M/TM-414, Alt- Nil

Forging - IS:5517-1993:(2nd Revision), Reaffirmed 2019 or latest version for Carbon Steel, Gr. 45 C8.

3 End Cover (RWE) for TM 4907

1/DCW/M/TM-416, Alt-Nil

Forging - IS: 5517-1993:(2nd Revision), Reaffirmed 2019 or latest version for Carbon Steel, Gr. 45 C8.

4 End Cover (GWE) for TM 4907


Forging - IS: 5517-1993 :(2nd Revision), Reaffirmed 2019 or latest version for Carbon Steel, Gr. 45 C8.

5 Abutment Piece for TM 4907


Forging - IS: 5517-1993 :(2nd Revision), Reaffirmed 2019 or latest version for Carbon Steel, Gr. 45 C8.

6 Enclosure for TM 4907


Forging - IS: 5517-1993:(2nd Revision), Reaffirmed 2019 or latest version for Carbon Steel, Gr. 45 C8.

7 Adjustment Washer for TM 4907


IS: 2062- 1999 7th revision 2011 (Reaffirmed 2016)for Steel Plate Gr- B.

8 Socket Head Screw M10 x 30 long

4/DCW/M/TM-421, Alt-Y

IS: 2269- 1995,2006 P 12.9 5th revision (Reffirmed 2016) or latest version







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11 Grease Nipple 4/DCW/M/TM-420, Alt-Nil

BS: 1486 Part-II 1961 (Zinc Plated). or latest version

7.1.1 In case cast components (i.e. item at sl. no. 2 to 6 mentioned above) are chosen as

per clause 11.2, then the material shall be Carbon Steel- IS: 1030-1998 (Fifth Rev.) Reaffirmed 2017 or latest version , Gr. 280-520W.

7.1.2 Hardware‟s as per item no. 8 to 11 of clause 7.1 if not manufactured by the supplier

itself, shall be out sourced from reputed brand / manufacturers to be declared in the QAP. (If sources are not specified in the relevant drawings)

7.2 Housing Bearing Kit for HHP Loco (consisting of 11 items) as per DLW Part

No 17454499 & DGR. No. K- 1745037 Alt. ‘e’:

S. No.

Description DLW Part No. / Drawing No.

Material Specifications and Tests

1 Housing Bearing Machine

17020864 / 40075563 Alt. „d‟ or latest.

EMS 15 – Cast Steel as per casting drawing no. 40075432. A.I 1651- Weld Braze Specification mentioned in drawing no. 40075563.

2 Cap (CE) Axle Bearing Mach.

17250626 / 40086808 Alt.

„c‟ or latest.

Material as per casting drawing no. 40076800: Casting- EMS 9 Nodular Iron and ETI 827 or Plate - MS 4361 steel.

3 Cap PE Axle Bearing Mach.

17250365 / 40076796 Alt. „b‟ or latest.

Material as per casting drawing no. 40076797: Casting- EMS 9 Nodular Iron and ETI 827 or Plate - MS 4361 steel.

4 Seal PE 17250493 / 40076794 Alt. „b‟ or latest.

Material as per casting drawing no. 40076795: Tubing- ASTM A519-17 or latest version or latest version Hot finished seamless tubing or Plate - MS 4361 steel.

5 Spacer CE 17087636 / 40076798 Alt. „b‟ or latest.

ASTM A513-20 or latest version Type 5 (DOM) Steel Tubing as per drawing no. 40076798.

6 Seal 17271472 / 40076990 Alt. „b‟ or latest.

Nitrile (Buna-N) as per drawing no. 40076990.

7 Seal 17271496 / 9084265 Alt. „c‟

or latest.

Nitrile (Buna-N) as per drawing no. 4084265.

8 Plug 1/8 PT 17300083 / 8348617 Alt. „Ba‟ or latest.

Steel as per drawing no. 8348617.

9 Plug 3/8 PT 17300010 / 8348619 Alt. „Ba‟ or latest.

Steel as per drawing no. 8348619.

10 Screw Hexagon Socket Head Cap

19250010- 138293 Alt. „g‟

or latest.

Alloy Steel- Quenched & Tempered to Surface Hardness of Rockwell C37- 45 as per drawing no. 138293.

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11 Screw Hexagon Socket Head Cap

19250022- 138299 Alt. „Bc‟

or latest.

Alloy Steel- Quenched & Tempered to Surface Hardness of Rockwell C37- 45 as per drawing no. 138299.

7.2.1 Hardware‟s as per item no. 8 to 11 of clause 7.2, if not manufactured by the supplier

itself, shall be out sourced from reputed brand / manufacturer as recommended in the DLW drawing no. K- 1745037 of Housing Bearing Kit.

7.2.2 Nitrile seals as per item no. 6 & 7 of clause 7.2, if not manufactured by the supplier itself, shall be out sourced from reputed manufacturers already approved with RDSO for similar items. The sources shall be declared in the QAP.

7.3 Housing Bearing Kit for HHP Loco (consisting of 4 items) as per DLW Part

No. 17454487 & DRG. No. K-1745036 Alt. ‘c’:

S. No.

Description DLW Part No. / Drawing No.

Material Specifications and Tests

1 Seal Gear 17250756 / 40009050 Alt.

„a‟ or latest

MS 4361 Steel as per drawing no. 40009050

2 Cover Assembly

17250390 / 40012764 Alt. „Ab‟ or latest

MS 4361 Steel as per drawing no. 40012026 for Cover-GR Case AY- Mach.

3 Tube 17203510 / 40076189 Alt. „Bb‟ or latest

ASTM A513-20 or latest version Type 5 (DOM) Steel Tubing as per drawing no. 40076189.

4 Ring 17043980 / 40076190 Alt. „Ab‟ or latest

MS 4361 Steel as per drawing no. 40076190.

7.4 List of drawings of Suspension Tube & Accessories for traction motor type TM 4303 / C1005TM application (1400 HP DEMU):

S. No.

Description BHEL Drg. No. CGL Drg. No. Qty.

1 General Arrangement Axle Suspension Unit.

04391580002 (Latest) CGM/106001 (Latest) 1

2 Roller bearing suspension tube


3 Bearing Housing 14451575001 (Latest) CGM/206803 (Latest) 1

4 Adjustment Washer 14451575002 (Latest) CGM/206805 (Latest) 1

5 End Cover- RWE 14451575003 (Latest) CGM/206806 (Latest) 1

6 End Cover- GWE 14451575005 (Latest) CGM/206802 (Latest) 1

7 Abutment Piece 14451575004 (Latest) CGM/206804 (Latest) 1

8 Enclosure 14391580001 (Latest) CGM/206801 (Latest) 1

9 Socket Head Screw (M10 x 30 Long)


10 Socket Head Screw (M12 x 70 Long)


11 Socket Head Screw (M30 -- CGM/406801 (Latest) 8

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x 110 Long)

12 Grease Nipple 34394028003 (Latest) CGM/42203 (Latest) 2

13 Spring Washer A30 -- CGM/32204 (Latest) 8

The manufacturer shall supply suspension tube & components for DEMU application as per the details & drawings provided above or by the purchaser. Quality control aspects of the tube & components shall conform to this STR.

7.4.1 Hardware‟s as per item no. 9 to 13 of clause 7.4 if not manufactured by the supplier itself, shall be out sourced from reputed brand / manufacturers to be declared in the QAP. (If sources are not specified in the relevant drawings).

8.0 PROCESS OF MANUFACTURE:

8.1 Complete process flow chart covering all steps of process of manufacture for an

individual product (or for a family of products, if the process is same) shall be clearly enlisted as a part of QAP.

8.2 The following details of machines used for all the steps of machining operations

shall be included:

Make and Model of the machine Accuracy. Details of machining operations.

8.3 Machining process shall be such that all critical dimensions are final machined on

CNC machining centers, preferably in single setting. 8.4 Details of Jigs and Fixtures used during manufacture shall be furnished along with

the manufacturing process, wherever used. 8.5 List of typical machinery & plant (M&P) required for manufacture is furnished in

Annexure- I. The list is for general guidance only and actual manufacturing operations shall be submitted and got approved by the firm as a part of QAP.

9.0 QUALITY ASSURANCE PROCESS – INSPECTION & TESTING PLAN:

9.1 Complete inspection and testing chart covering all steps of process of manufacture

for an individual product including final inspection shall be clearly enlisted as a part of QAP.

9.2 The following details of measuring instruments / equipments / jigs / fixtures used for all the steps of measurement operations shall be included: Make and Model of the measuring equipment Accuracy Value to be measured and acceptable value range

9.3 Stage inspection detailing inspection procedure, inspection parameters and method

of testing/ test procedure including sample sizes for destructive and non-destructive

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testing. Record of test results of stage inspection shall be available and furnished where needed.

9.4 The list of measuring machines / instruments & testing facilities are furnished in

Annexure- II & III respectively for general guidance only. However, the specific testing and measuring instruments, gauges used by the firm will also form part of QAP, which shall be submitted and got approved by the firm.

9.5 Dimensional measurements shall be made on three-dimensional co-ordinate

measurement machines as mentioned in Annexure – II on prototype & on sample lots. Periodicity of measurement shall be as indicated in clause 17.0 (Sl. no.4) of the STR. Measurements shall be included as a part of QAP.

10.0 CHEMICAL COMPOSITION:

The permissible variation in chemical composition and ladle analysis of steel shall

conform to the respective requirements given in Clause 7.0 of this STR.

11.0 MATERIAL SPECIFICATION:

11.1 General requirements relating to the supply of material shall conform to IS: 1387-

1993 (Second Rev.) Reaffirmed-2018 or latest version „General requirements for the supply of metallurgical materials‟, as per Clause 5.1 (ii) of this STR.

11.2 The material used for cast or forged components shall be so chosen that none of

the specified properties in this STR is compromised. 11.3 The suspension tube shall only be manufactured from castings supplied by RDSO

approved Class “A” foundries. 11.4 The suspension tube components i.e. accessories or any other components shall be

manufactured from normalized carbon steel castings or forgings as applicable & mentioned in Clause 7.0 of this STR.

11.5 In case the manufacturer proposes to supply forged suspension tube components

instead of cast components, the same can be accepted only with the prior approval of RDSO. The forging shall be manufactured from killed steel produced by open hearth furnace, electric furnace or any other approved process.

11.6 Rough machining of the forgings shall be carried out in case of procurement of

forgings by the purchaser & forging shall be supplied to the dimensions specified in the drawing of rough machined components to be provided by the purchaser. Tube supplier shall collect the Test Certificate from the raw material supplier and verify the same.

11.7 In case, finished component is procured by the purchaser, machining shall be done

in suitable sequence approved by the purchaser.

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12.0 REQUIREMENT FOR CASTINGS:

12.1 It would be preferred that the approved sources of suspension tubes & other cast

components shall have their own RDSO approved captive foundries meeting Class „A‟ requirements as per IS:12117 – 1996 (First revision)Reaffirmed 2017 or latest version and machining units.

12.2 In case, where the firms don‟t have their captive foundries, they shall fulfill the

following conditions:

They shall use castings from foundries certified Class „A‟ as per IS: 12117 – 1996 (First revision)Reaffirmed 2017 or latest version only. The certification of foundry shall be, by RDSO and currently valid. The machinist firm shall furnish undertaking from casting manufacturer

showing long term commitment to supply castings to the machinist vendor. The Quality Assurance Plan (QAP) of the foundry shall formulate part of

approval process for the individual machinist vendor.

12.3 The QAP of the component shall clearly include the stipulation that “each cast component shall have individual distinct number embossed by the foundry so as to ensure its traceability”. A sample marking on suspension tube is given below:

At least two letter initial of the foundry + Month & year of manufacturing code + 4 digits of unique serial number + at least 2 digits of customer code for the foundry & Job Sr.No.(Example: SMP/01/2006/3991/SMPL/01).

12.4 Stage inspection of all cast components shall be mandatory by the Inspecting Authority at the foundry premises. The QAP of the component shall clearly include such provision.

13.0 REQUIREMENT FOR FORGINGS:

13.1 Source of forging components shall be intimated to RDSO with infrastructure details. Firms shall have to furnish it‟s guidelines / standard regulations against which they have approved the forging units as well as the units where manufacturing of the subject components takes place.

13.2 Heat treatment:

Forgings shall be supplied in ‘As forged’ or ‘As forged normalized’ condition (880ºC - 910ºC) to give the mechanical properties as per respective specification given in Clause 7.0 of this STR.

13.3 Freedom from defects:

The steel forgings shall be free from internal and surface defects such as seams, laps and injurious imperfections etc.

14.0 INSPECTION:

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14.1 General inspection of the tube and components shall be in accordance with IS: 1387 – 1993 (Second Rev.) „General requirements for the supply of metallurgical materials.

14.2 Upon pre-arrangement, the purchaser shall have free entry at all time when work on

the contract of the purchaser is being performed to all parts of the manufacturer‟s works which concern the manufacture of the material ordered under the specification. The manufacturer shall afford the inspector, free of charge, all reasonable facilities and necessary assistance to satisfy him that the material is being furnished in accordance with referred specifications. Final acceptance of all purchased material shall be made at purchaser‟s premises.

15.0 SAMPLING FOR MECHANICAL TESTS:

15.1 Unless otherwise agreed, for the purpose of mechanical tests, the sample shall be

tested for each cast and heat treatment batch. 15.2 If the product is continuously heat treated, the sampling for mechanical tests shall

be as agreed to between the purchaser and the manufacturer.

16.0 MECHANICAL TESTS:

The test piece after being heat treated as per Clause 13.2 shall meet the following tests in the longitudinal direction upto a ruling section of 300 mm. Properties for thicker sections shall be subjected to agreement between the purchaser and the supplier.

16.1 Tensile Test:

The tensile test shall be carried out in accordance with IS: 1608(Part-1)- (Fourth revision) 2018 „Method for tensile testing of steel products‟ or ASTM A370/05-19 or latest version.

16.2 Hardness:

The test pieces shall have Brinell hardness in accordance with IS: 1500(Part-1)(Fifth revision)- 2019 or latest version „Method for brinell hardness test for metallic materials (Second Rev.)‟.

16.3 Charpy Impact Value (V-Notch):

The test pieces shall show the minimum Charpy Impact values when tested as per IS: 1757(Part-1)- (Third revision)2014 or latest version „Method for Charpy impact test (V-Notch) for metallic materials‟.

16.4 Bend Test:

Bend test shall be carried out in accordance with IS: 1599- (fourth revision )2019 or latest version ‟Method for bend test for steel products other than sheet, strip, wire and tube).‟

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17.0 OTHER SPECIAL TEST FOR SUSPENSION TUBE & ACCESSORIES:

The tests to be carried out along with periodicity as mentioned below for ALCo & DEMU as well as HHP (EMD) tube & components; S. No. Testing Parameters Periodicity

Type test Acceptance

1 Radiography test Incoming Firm‟s to declare 10% (Min.)

Finished 100% Firm‟s to declare

2 Ultrasonic test Incoming Firm‟s to declare Firm‟s to declare

Finished 100% 100%

3 Chemical analysis & Mechanical test

Incoming Firm‟s to declare 4% (Min.)

Finished 100% Firm‟s to declare

4 Dimensional measurements on CMM

Incoming Firm‟s to declare Firm‟s to declare

Finished 100% 20% (Min.)

5 MPI test & DP test Incoming Firm‟s to declare Firm‟s to declare

17.1 Radiography test for Alco Loco & DEMU tube:

As per ASTM E446-15 or latest version, Level- III for Central portion & Level- II for both side housing bore of tube & as mentioned in the casting drg. no. 1/DCW/M/TM-397, Alt.- latest.

17.2 Radiography test for HHP (EMD) Loco tube:

As per ETI 827 mentioned in casting drawing no. 40075432.

17.3 Ultrasonic test (UT):

This test shall be conducted as per ASTM A388-19 or latest version, 2007- for steel forgings & ASTM A609/ A609M-91-12 Reapproved 2018 for steel castings.

17.4 Magnaflux / Dye- Penetrant Test (DPT) shall be conducted by the manufacturer/

supplier. 17.5 Magnetic Particle Inspection (MPI) shall be conducted by the manufacturer/

supplier.

18.0 Type Test and Accetance Tests Formats

18.1 Type Test Format for conducting the detailed test on Prototype is given at Annexure-IV.

18.2 ACCEPTANCE TEST: These test shall be conducted, during purchase inspection by inspection agency against individual orders. The inspection shall be done on sample of offered lot as per IS:2500(Part-1)-3rd Revision -2000, Titled “Sample inspection tables Part-I inspection by attributes and by count of defects at AQL of 1 percent and Third level inspection as per Table 1 with single sampling plans. Its inspection criteria of belows has been mentioned on Annexure –V.

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18.3 TEST CERTIFICATES:

Three copies of test certificates shall be supplied unless otherwise stated on the order. The following details shall be furnished in the test certificate:

(i) Dimensional inspection (ii) Detail of heat treatment (iii) Chemical composition (iv) Results of mechanical tests (v) Results of additional tests as called in the relevant drawing / order.

19.0 MARKING:

As per clause 12.3

20.0 PACKING:

Suitably marked and finished MSU tube & components shall be packed to prevent corrosion and damage during transit. Machined surface shall be properly protected with anti-corrosive compounds.

21.0 PREFERENCE TO MAKE IN INDIA:

The Government of India policy on “make in India “shall apply.

22.0 VENDOR CHANGES IN APPROVED STATUS:

All the provisions contained in RDSO‟s ISO procedures laid down in document no. QO-D-8.1-11, dated 01.07.2020(Titled “Vendor –changes in approved status) and subsequent versions/amendments thereof, shall be binding and applicable on the successful vendor/vendors in the contracts floated by Railways to maintain quality of products supplied to Railways.

23.0 FIELD TRIAL & PERFORMANCE FEEDBACK :

After successful completion of type tests, required nos. of the equipment shall be subjected to field trials for specified time period. The Quantity and Period for field trials shall be governed by RDSO Document no. MP-M-8.1-1 A format for field trial performance feed back is given in ANNEXURE VI.

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ANNEXURE - I

MACHINERY & PLANT (M&P) FOR MANUFACTURING The following is the list of typical machining facilities mandatory with the firm: 1. The manufacturer shall have CNC Horizontal Machining Center (HMC) and CNC

turning center of requisite accuracy suitable for the suspension tube & components as per drawings mentioned in clause 7.0

2. Marking / measuring table of suitable size.

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ANNEXURE - II

LIST OF MEASURING MACHINES & INSTRUMENTS:

The following is the mandatory list of measuring facilities to be available with the firm:

1. Calibration of the Testing / Measuring Equipments shall mandatorily be done at least once in a year unless stated otherwise for Vernier Calipers, Micrometers, Inside & Outside Calipers and all other Gauges required during matching operations and dimensional checks.

2. It shall be mandatory for the new manufacturers to have open bridge type Co-

ordinate Measuring Machine (CMM) of requisite accuracy in accordance with the dimensions of the jobs i.e. suspension tube & components etc. to be measured in a single set up. However, the existing manufacturers can continue with the facilities as available at the time of prototype test.

3. Micrometer (outside).

4. Bore Micrometer (one meter inside).

5. Bore Dial Gauge.

6. Vernier Height Gauge.

7. Thread plug gauges for checking threading portion duly calibrated.

8. Hard and ground pins to check accuracy of hole dia. of pole shoes fixing bolts.

9. Fixtures shall be available (mandatory):

Facilitate to check accuracy of GWE & RWE side bores, co-axiality, parallelity, perpendicularity in respect of rotor fixing end shields bore along with GWE & RWE side bores.

Facilitate to check and prove that air-gap has been maintained for all the pole faces. The fixture shall be fitted along with a dial gauge to prove the same in respect of GWE side and RWE side bore.

Facilitate to check clearance between the bore of suspension tube and diameter of axle ( To avoid fitment problem during assembly at workshop ( M/s SMPL supplied 47 nos suspension tube was rejected by DLW due to infringement problem seen during their assembly). The fixture shall be fitted along with a dial gauge to prove the same in respect of GWE side and RWE side bore.The gauges shall be hard and ground to avoid any lapses of accuracy.

10. Calibrated template to check the centre of both poles.

11. Infra-red thermometer for checking temperature of material at standard room before dimensional checking.

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ANNEXURE – III

LIST OF TESTING FACILITIES:

1.0 Calibration of the Testing / Measuring Equipments shall be done at least once in a year, unless stated otherwise.

2.0 Inspection Staff conducting non-destructive testing shall be adequately trained and

qualified by recognized agency and shall have adequate experience. 3.0 Staff conducting tests like Chemical Analysis and Mechanical Properties shall have

adequate skill & competence and shall have under gone sufficient training. Skill of such staff shall periodically be qualified by making them carry out tests on blind samples.

4.0 Following testing facilities shall be available with the firm; alternately the test can

also be conducted through NABL or Govt. approved lab. This same shall be indicated in the QAP.

4.1 METALLURGICAL AND CHEMICAL LABORATORY:

1. Availability of Emission Spectrometer with necessary standard and automatic printer shall be preferred for verification of chemical composition of material.

2. Suitable Radiography / Ultrasonic testing facilities. 3. Magnaflux / Dye-Penetrant Test (DPT) facilities for checking of surface cracks. 4. Magnetic Particle Inspection (MPI) facilities for checking sub-surface flaws. 5. Metallurgical Microscope with magnification power upto 500x & metallographic

sample preparation facilities with appropriate accessories to take photographs of slides.

4.2 PHYSICAL LABORATORY:

1. Universal Testing Machine of 40 tonne capacity with graphical recording facilities for conducting tensile tests.

2. Direct reading Hardness Tester of capacity 95-500 BHN. 3. Impact Testing Machine (Charpy V- Notch) of 0-300 Joules capacity for

conducting impact test with facilities for notch cutting and undertaking this test at sub-zero temperatures as per the specified standard.

4. Shadow graph facilities for assuring correct notch profile and dimension for impact test

specimen.

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ANNEXURE – IV FORMAT FOR TYPE TEST

1. Reference documents: STR No. MP.STR.EM.01.01.12 (Rev.02) .

2. Date of Inspection :

3. Firm Name :

4. PO No., Date & PO Qty. :

5. Expiry date of DP :

6. Offered no. of Sample for type test : :

7. ID marks on offered Samples :

8. Check availability of specification /Drgs available with firm : 9. Internal test and dimensional check report:

10. Calibration record of gauges, measuring instruments/devices & test equipment

S No

Parameter/Description Value Specified/Ref. Type test Observations

Remarks

1.0 VISUAL INSPECTION The Casting / forging shall be free from any

types of internal , external & surface

defects such as pin holes , blow holes

warpage , cracks. Seams,Laps & injurious

imperfection .

2.0 DIMENSINAL / TOLERANCE

PARAMETERS

As per relevant drawing as enclosed list of

drawings, mensioned in clause 7.1, 7.2,

7.3 & 7.4 drawing list.

3.0 MATERIAL TEST Given in clause 5,6,7, 11, 12 & 13

4.0 BILL OF MATERIAL As per clause 6

5.0 MECHANICAL TEST

As per clause 16 for following test

Tensile test,

Hardness test,

Charpy impact test

Bend test)

6.0 SPECIAL TEST As per clause 17 .0 for

Radiography test, Ultrasonic test

Chemical analysis & Mechanical test

Dimensional measurements on CMM

MPI & DP Test for crack detection

7.0 TEST CERTIFICATES

Collect from vendor during type

test (inhosue labe or from NABL

accrediated Lab.

TC of Raw material, from supplier

TC verification at firm end

Mechanical tests Reports

Detail of heat treatment process with date.

Results of additional Special tests as called in the relevant drawings / order

Overall dimensions check report of offered lot.

Remarks on inspection :

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ANNEXURE – V

FORMAT FOR ACCEPTANCE TEST

2. Reference documents: STR No. MP.STR.EM.01.01.12 (Rev.02) .

2. Date of Inspection :

3. Firm Name :

4. PO No., Date & PO Qty. :

5. Expiry date of DP :

6. Offered no. of Sample for Acceptance test : :

7. ID marks on offered Samples :

8. Internal test and dimensional check report:

9. Calibration record of gauges, measuring instruments/devices & test equipment

S No

Parameter/Description Value Specified/Ref. Type test Observations

Remarks

1. VISUAL INSPECTION The Casting / forging shall be free from any

types of internal , external & surface defects

such as pin holes , blow holes warpage ,

cracks. Seams,Laps & injurious Imperfection

DIMENSINAL /

TOLERANCE

PARAMETERS

As per enclosed list of drawing as

mensioned in clause 7.0 attched drawing

list.

MATERIAL TEST Given in clause 5 & clause 10

Bill of material As per clause 6

MECHANICAL TEST

for Tensile test, Hardness test, Charpy impact value (v-notch) test & Bend test) according to clause 16

SPECIAL TEST (i.e. ) As per clause 17.0

Dimensional measurements on CMM

Ultrasonic ,MPI & DP Test

i) TC from Raw material supplier

ii) TC verification at firm end(Chemical composition)

iii) Mechanical tests Reports

iv) Detail of heat treatment process with date.

v) Overall dimensions check report

vi) Results of additional Special tests as called in the relevant drawings / order.

Remarks on inspection :

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ANNEXURE – VI

FORMAT FOR FIELD TRIAL & PERFORMANCE FEEDBACK :

Format for performance feed back of suspension tube

SN Shed/ Rly

Loco No Make TM location

Date of fitment

Type of failure IF

taken place

Remarks on performance

SCHEDULE OF TECHNICAL REQUIREMENTS FOR ...rdso.indianrailways.gov.in/uploads/files/S.pdfASTM A370/05,ASTM A388, ASTMA609/A609M, ASTM E446 Latest version of amendment & Reaffirmed are

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