WD-17-CASNUB-22HS-BOGIE INDIAN RAILWAYS SPECIFICATION WD-17-CASNUB-22HS-BOGIE-92 (Revision –3) FOR CASNUB 22 HS CAST STEEL BOGIES WITH FRICTION DAMPING ARRANGEMENT FOR BROAD GAUGE (Amendment No.-1 of Oct.2005) (Amendment No.-2 of Dec.2006) (Amendment No.-3 of July.2009) (Amendment No.-4 of Feb.2010) Issued by: Research Designs and Standards Organization Ministry of Railways Manak Nagar, Lucknow - 226 011. September 2004 Price: Rs. 8600/-
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WD-17-CASNUB-22HS-BOGIE
INDIAN RAILWAYS
SPECIFICATION
WD-17-CASNUB-22HS-BOGIE-92 (Revision –3)
FOR
CASNUB 22 HS CAST STEEL BOGIES
WITH FRICTION DAMPING ARRANGEMENT
FOR BROAD GAUGE
(Amendment No.-1 of Oct.2005)
(Amendment No.-2 of Dec.2006)
(Amendment No.-3 of July.2009)
(Amendment No.-4 of Feb.2010)
Issued by:
Research Designs and Standards Organization
Ministry of Railways
Manak Nagar, Lucknow - 226 011.
September 2004 Price: Rs. 8600/-
2
AMENDMENT SLIP NO.4 OF FEBRUARY 2010 TO SPECIFICATION NO. WD-17-CASNUB-22HS BOGIE-92 (REVISION-3 OF SEP 2004)
************ Add new clause no. 17. Warranty after 16. Clarifications, as follow:- 17. Warranty: The firm shall stand warrantee for complete bogie/ components, unless otherwise specified in the specification of individual component/ sub-assembly, for a period of 30 months from the date of manufacture or 24 months from the date of fitment/commissioning of the wagon, whichever is earlier. In case of pre-mature failure of any component/sub-assembly, the firm will be liable to make free replacement of failed component/sub-assembly to the depot where failure has been reported within reasonable time.
******************
3
AMENDMENT SLIP NO.3 OF JULY 2009 TO SPECIFICATION NO.
WD-17-CASNUB 22HS BOGIE-92 (REVISION-3 OF 2004) ************
1. Drawing No. WD-08093-S/2, ALT-1(Brake Gear General Arrangement For
BMBS) included in the list of construction drawings (Annexure VI).
2. BMBS Specification No. WD-23-BMBS-2008 (Latest) included in the list
of specifications (Annexure VII).
3. Bogie fitted with brake gear components of BMBS to drawing No. WD-
08093-S/2 does not require the existing brake gear components to drawing
No. WD-89067-S/5(except wear plate at S.No.-8).
******************
4
Amendment no.2 of Dec. 06 to specification no. WD-17-CASNUB 22HS BOGIE-92 (Rev.3) Of 2004.
1. Drawing No. WD-87078-S/1(Brake Beam Support) deleted from Annexure-VI.
2. Annexure-VI (List of construction drawings) updated with latest alteration nos.
Annexure –VI
( A) LIST OF CONSTRUCTION DRAWINGS (For BOXNHS with CASNUB 22 HS Bogie )
Drawing No. Description Alt No.
WD-92058-S/1 Index 3
WD-04038-S/2 General Arrangement (with spherical centre
pivot & constant contact side bearer)
4
WD-04078-S/1 General Arrangement (with flat centre pivot &
constant contact side bearer)
3
WD-89067-S/3 Cast steel side frame 17
WD-92058-S/3 Cast steel bolster 6
WD-92058-S/4 Bogie details 7
WD-92058-S/5 Spring details 11
WD-89067-S/5 Bogie Brake gear arrangement. 16
WD-85079-S/2 Centre pivot assembly & details (spherical type) 23
WD-97049-S/3 Centre pivot assembly & details ( flat type) 2
WD-04038-S/3 Centre pivot & Side Bearer Arrangement (with
spherical pivot & constant contact side bearer)
3
WD-04078-S/2 Centre pivot & Side Bearer Arrangement (with
flat pivot & constant contact side bearer)
2
WD-89033-S/1 Brake beam details 20
SK-69597 Bogie brake gear details 41
WD-92058-S/7 Leading dimensions and tolerances 4
WD-85054-S/7 Assembly procedure 5
SK-77579 Wedge 7
WD-89067-S/9 Narrow jaw adapter 6
WD-95005-S/1 Modified Elastomeric pad 7
Annexure-IIIB of Spec. No.
WD-17-CASNUB 22HS-
BOGIE-92(Rev.3)
Constant contact side bearer assembly & details -
WD-89006-S/1 BG, MG & NG coil spring drawing codes 7
WD-86038-S/1 Marking scheme for cast steel sideframe &
bolster
4
WD-94068-S/1 Bulb cotter 4
LIST OF PART DRAWINGS: W/BG-6150 Brake shoe key 2
W/PN-90 Pin 3
5
Amendment no.1 of October 05 to specification no. WD-17-CASNUB 22HS BOGIE-92 (Rev.3) Of 2004.
3. Annexure-IIA (Spring groups for various axle load) has been added.
4. Annexure-IIIB (List of constant contact side bearer) has been added.
3. Annexure-VI (List of construction drawings) has been updated with latest alteration nos.
4. Drg.no. -WD-04038-S/2 and WD-04078-S/1 have been attached with their latest alteration
nos.
5. Under heading `General’
`Polymer side bearer to Drg.No AAL-021101’ shall be read as `constant contact side bearer
approved by R.D.S.O’.
6. Under heading ` Scope of supply’
i) `Polymer side bearer’ shall be read as `constant contact side bearer approved by R.D.S.O.
ii) `Polymer side bearer assembly is strictly manufactured as per Drg.No. AAL-021101’
shall be read as `constant contact side bearer assembly is strictly manufactured as per
drawing nos. given in Annexure-IIIB’.
7. In Para 9.6.4
at serial no. (v)
‘Polymer side bearer assembly’ shall be read as ` constant contact side bearer assembly
approved by R.D.S.O’.
8. Para 10.4 shall be read as follows-
`Contractor shall ensure that constant contact side bearer assembly is properly secured to
avoid the falling off during transit.’
9. In Annexure-VI Drg.No. AAL-021101 has been deleted and Annexure-IIIB has been added.
10. In Annexure-IX (sheet 9 of 16)
at S.No. 3 `Polymer side bearer to Drg.No. AAL-021101’ shall be read as ` constant contact side
bearer shall be as per Annexure- IIIB’.
11.Para 5.3 (Load Testing)
Test load table has been deleted & first two lines shall be read as follows:
“ The bogies shall be tested for loads representing tare, gross load & 50% overloaded
conditions as per annexure IIA”.
6
LIST OF ANNEXURES
Annexure-I Cast components
Annexure-IA Welding repair procedure for side frame and bolster Annexure-II Spring steel components
Annexure-IIA Spring groups for various axle loads
Annexure-III Rubber components
Annexure-IIIA Composite material components Annexure-IIIB List of constant contact side bearer
Annexure-IV Forged components and fasteners
Annexure-V Fabricated components
Annexure-VI List of construction drawings
Annexure-VI List of construction drawings
Annexure-VII Specifications for bogie Manufacture
Annexure-VIII Chemical composition and mechanical properties
Annexure-IX List of important bogie components and their inspection procedure
Annexure-X Recommended Foundry Practices
7
Annexure-IIIB
List Of Constant Contact Side Bearer
S.NO DRAWING NO. DESCRIPTION ALT. NO.
1. AAL-021101 Polymer side bearer assembly & details 5
8
Annexure –VI
( A) LIST OF CONSTRUCTION DRAWINGS (For BOXNHS with CASNUB 22 HS Bogie )
Drawing No. Description Alt No.
WD-92058-S/1 Index 3
WD-04038-S/2 General Arrangement (with spherical centre
pivot & constant contact side bearer)
4
WD-04078-S/1 General Arrangement (with flat centre pivot &
constant contact side bearer)
3
WD-89067-S/3 Cast steel side frame 17
WD-92058-S/3 Cast steel bolster 6
WD-92058-S/4 Bogie details 6
WD-92058-S/5 Spring details 10
WD-89067-S/5 Bogie Brake gear arrangement. 16
WD-85079-S/2 Centre pivot assembly & details (spherical type) 23
WD-97049-S/3 Centre pivot assembly & details ( flat type) 1
WD-04038-S/3 Centre pivot & Side Bearer Arrangement (with
spherical pivot & constant contact side bearer)
3
WD-04078-S/2 Centre pivot & Side Bearer Arrangement (with
flat pivot & constant contact side bearer)
2
WD-89033-S/1 Brake beam details 19
SK-69597 Bogie brake gear details 39
WD-92058-S/7 Leading dimensions and tolerances 4
WD-85054-S/7 Assembly procedure 5
SK-77579 Wedge 7
WD-89067-S/9 Narrow jaw adapter 6
WD-95005-S/1 Modified Elastomeric pad 6
Annexure-IIIB of Spec. No.
WD-17-CASNUB 22HS-
BOGIE-92(Rev.3)
Constant contact side bearer assembly & details -
WD-87078-S/1 Details of brake beam support 3
WD-89006-S/1 BG, MG & NG coil spring drawing codes 6
WD-86038-S/1 Marking scheme for cast steel sideframe &
bolster
4
WD-94068-S/1 Bulb cotter 4
LIST OF PART DRAWINGS: W/BG-6150 Brake shoe key 2
W/PN-90 Pin 3
9
10
11
INDEX
S.
No.
Description
1. General
2. Scope of supply
3. Specification
4. Grouping of Components
5. Bogie Assembly Requirements
6. Drawings
7. Deviation
8. Chemical Composition, Mechanical Properties and tolerances.
9. Inspection
10. Despatch
11. “As Made” Drawings
12. Proto type approval
13. Quality Assurance Programme
14. Quality audit
15. Other requirements
16. Clarifications
LIST OF ANNEXURES
Annexure-I Cast components
Annexure-IA Welding repair procedure for side frame and bolster
Annexure-II Spring steel components
Annexure-III Rubber components
Annexure-IIIA Composite material components
Annexure-IV Forged components and fasteners
Annexure-V Fabricated components
Annexure-VI List of construction drawings
Annexure-VI List of construction drawings
Annexure-VII Specifications for Bogie Manufacture
Annexure-VIII Chemical composition and mechanical properties
Annexure-IX List of important bogie components and their inspection procedure
Annexure-X Recommended Foundry Practices
12
Schedule of Technical Requirements
For Casnub 22 HS Cast Steel Bogies
For Broad Gauge Wagons
1. General :
This Schedule covers the technical requirements for the manufacture and supply of light
weight CASNUB 22 HS Cast Steel Bogies fitted with a spring plank, long travel helical
springs and load proportionate friction damping arrangement for Broad Gauge (1676
mm) Wagons.It has been kept optional to assemble `Flat Centre Pivot` to RDSO Drg. No.
WD-97049-S/3 in place of conventional hemispherical centre pivot to RDSO Drg. No.
WD-85079-S/2.
These bogies shall be suitable for fitment of standard wheel sets to RDSO’s drawings No.
WD-89025-S/1, Cartridge bearings to AB/RB/39/2002 (Rev. 2) and Elastomeric pads to
STR No. 20-Misc.-95 (Rev. 3) and polymer side bearers to Drawing No. AAL-021101
respectively.
2. Scope of Supply:
The bogies shall be supplied complete with centre pivot assembly components as per
relevant drawings, Polymer side bearer and brake rigging including brake shoes,
elastomeirc pads, but without wheel sets, bearing, narrow jaw adapters, side frame key
and side frame key bolt, nut and washer which shall be supplied by the purchaser free of
cost for fitment on the bogies. However, the bogie manufacturer shall ensure that the
polymer side bearers assembly is strictly manufactured as per Drawing No. AAL-021101.
Since this bogie is to be used under different types of wagons with different tare weights,
to maintain designed load sharing requirement, the center pivot and side bearer
arrangement drawings pertaining to the particular wagons are required to be the referred
to and the following dimensions are to be strictly maintained under tare condition.
1. Bogie bolster top to top center pivot top = 120 + 2
- 0
2. Centre pivot top to side bearer seat on bogie bolster – as per relevant centre
pivot and side bearer arrangement drawing.
3. The difference between top of top centre pivot to bottom of body side bearer
(this dimension may change after shim adjustment as per relevant drawings).
13
The bogie general arrangement may also be different for different type of wagons as the
heights are to be adjusted by means of packings. However this specification gives list of
the construction drawings and load testing methods with BOXNHS wagons.
3. Specification:
The bogies and its components shall conform to this Schedule of Technical requirements,
relevant drawings with latest alteration number, and latest relevant specifications. In case
of conflict among the STR/Drawings/Other Specifications, the drawings shall take
precedence over the STR and the Specification. The STR shall take precedence over the
specifications.
The foundry should satisfy the requirements of category ‘A’ foundries specified for all
the cast steel items and updated by the Bureau of Indian Standards/RDSO from time to
time and for infrastructure, manufacturing, testing and quality control requirement of
cast steel components and other components included in this specification, the suppliers
should comply the technical requirement as laid down in the following :
Component STR No.
1. Cast steel components of CASNUB bogies IL –09:2000
2. Metal Bonded Rubber components-Elastomeric pad
IL –05:2000
3.Spring steel rounds IL –16:2000
4.Hot coiled helical spring
IL –17:2000
5.Silico manganese liners
IL –22:2000
6.Spring plank
IL –23:2000
7. Side frame key IL –24:2000
8. Brake beam IL –25:2000
9. Narrow jaw/wide jaw &Modified adapter IL –26:2000
10. Metal bonded rubber components IL –06:2000
14
4. Grouping of components:
Various components, which form the bogie assembly, are grouped below. Details are
given in the Annexure shown against each group.
I. Cast components a) Steel – Side frame, bolster, top &
bottom centre pivots , brake beam strut
and end pieces, wedges and top & bottom
side bearer housings (Annexure No. I, IX).
II. Spring Steel Outer, inner, snubber springs, Brake Wear
Plate, Brake beam liners, side frame/bolster
liners & center pivot liners (Annexure No.-
II).
III. Rubber Components Elastomeric pads and Centre pivot washer,
poly sleeve & poly rings (Annexure No.
III).
IV. Forged Components & Fasteners Side frame key, rivets and various types of
cotter pins, top & bottom side bearer
housings, Huck/Avdel bolts (Annexure No.
IV.)
V. Fabricated components Various types of steel components,
machined, formed, welded and pre
assembled like brake beam, spring plank
etc. (Annexure No. V).
VI. Composite material components Brake block L type- (Annexure III A).
5. Bogie Assembly Requirements:
5.1 The detailed procedure of bogie assembly is given below -
5.1.1 Gauging of Bolster & Side frame:
This is to be done on 100% of Bolster and Side frame. Only those castings which are
found within the specified dimensions should be taken up for assembly and the rest
rejected. Investigations should be made for the reasons of dimensional inaccuracies;
causes arrived at, remedial action introduced and defect rectified.
Bolster and Side frame should be inspected for all the important dimensions as per the
gauging scheme approved by RDSO before offering for inspection or taking up for
assembly and results recorded.
Welding of Liners:
Welding of all the liners on side frame shall be done before taking up side frames for
riveting. Welding of liners on bolster shall also be completed before taking them up for
assembly. Welding procedure to be followed as indicated in Drawing No. WD-92058-
S/3 & WD-92058-S/4. Following steps have to be taken to ensure proper quality.
15
i) Welds shall be visually inspected for any weld defects. Use of correct electrodes,
welding current setting and correct welding procedure has to be ensured.
Welding parameters should be standardized and its implementation ensured.
ii) It will be preferable to weld the liners on suitable fixtures so that down hand
welding can be ensured.
iii) Surface on which liners are welded shall be smooth and flat providing proper seat.
Also, Pocket for Side frame liner shall be correctly formed in the casting.
Castings having imperfect pockets on the Side frame shall be rejected.
Matching of Side frame – Side frames which have been duly inspected, gauged and passed
shall be taken up for assembly. These shall be matched for wheel base according to RDSO’s
Drawing No. WD-89067-S/3. Crack detection
(Annexure-1) and weld reclamation (Annexure- I A) should also be completed before
proceeding to next stage. No welding is permissible after this stage on Sideframe as well
as on bolster.
Riveting – After selecting the sideframes, these should be taken up for riveting with spring
plank. Before riveting it shall be ensured that pop marks are placed
on the sideframes as per Drawing No. WD-89067-S/3. Stepwise procedure of assembly
of H-frame is given below :-
i) Sideframe holes shall be drilled using accurate jig.
ii) The two sideframes and spring plank should be positioned on a fixture and
fastened rigidly.
iii) Four holes shown in Item No. 1 in sketch WD-92058-S/4 (spring plank) should be
reamed alongwith the sideframe and secured by M-24 fit bolts as per IS:3640.
iv) In case any mismatch between spring plank holes and sideframe holes is
observed visually, detailed check of sideframe Drill Jig and spring plank shall be
made before proceeding further. Riveting should be done as per IS:7215 Group –
B.
v) The riveted H-frame shall be gauged and dimensions recorded for diagonals and
sideframe –to-sideframe over pop-marks on the fixture and again after removing
from the fixture as per Para 5.1.5.
Gauging of H-Frame After completing the riveting, the sideframe – spring plank assembly (H-Frame) should
be gauged on the fixture as per Drawing No. WD-92058-S/7 and results recorded. It has
to be ensured that all dimensions are within the specified limits otherwise the assembly
should be dismantled, re-inspected to find the causes of any variation and then redone
after eliminating those causes.
The gauging shall again be done on the assembly after removing the sideframe-spring
plank assembly (H-Frame) from the fixture.
This is to be done on 100% of H-frames.
16
Assembly :
Assembly of bogie shall be taken up after completing the activities specified in Para
5.1.5. It has to be ensured that all components have been checked as specified in
respective Annexures.
Dimensions :
The leading dimensions and tolerances of the bogies shall be in accordance with RDSO’s
Drawing No. WD-92058-S/7.
Load Testing :
The bogies shall be tested for the loads representing tare, gross load and 50% overload
conditions as per the details given below :-
Test load on bogie pivot in tonne
Tare Gross 50% overload
6.0 35.30 53.0
Height of centre pivot in mm 932 + 3
- 8
895 + 3
- 8
875 +3
- 8
Scale of this test shall be as below :-
• 100% checking of Assembled Bogies under tare.
• 5% checking of Assembled Bogies under gross load and 50% overload.
RDSO Inspector may carry out random checks to the extent of 5% of Assembled Bogies
under tare, gross load and 50% overload conditions.
17
Painting :
Each bogie shall be given one coat of Red Oxide Zinc Chromate Primer to Specification
IS:2074 followed by one coat of ready mixed paint red Oxide to IS:123. Mating faces of
pivots and friction plates will not be painted.
6. Drawings :
The bogies shall be manufactured according to RDSO’s Drawings No. WD- 04038-S/2 or
WD-04078-S/1 and relevant drawings listed in Annexure VI. The alteration numbers
against each drawing in the Annexure are, however, subject to advancement in the course
of construction of these bogies and the contractor shall comply with these amendments in
manufacturing the components. Copies of such amended drawings shall be supplied to
the contractor free of cost. Changes involving significant costs will be implemented only
after mutual agreement on price implication.
7. Deviations :
Where deviations from the original design, material specifications, dimensions etc., are
desired, specific proposals shall be submitted for prior approval of the RDSO/Lucknow
before commencement of manufacture.
8. Chemical Composition, Mechanical Properties and Tolerances :
The bogie side frame & bolster shall conform to the Material specification and properties
as laid down in Annexure-VIII. Class I tolerances to IS:4897 shall be followed on wall
thickness wherever the tolerance has not been specified.
9. Inspection : The inspection shall be carried out by Director General, RDSO, Lucknow or his nominee in
accordance with the requirements of this schedule, approved drawings and relevant IS
specification. IS specifications referenced are listed at Annexure VII. The listing is, however,
not exhaustive.
The contractor shall at his own cost supply all labour, appliances, details and gauges
necessary for the testing and inspection of the bogies. The contractor will design his own gauges
for the bogie and its components wherever necessary. These gauges shall be approved by the
RDSO before commencing series production.
9.2.1 One complete set of gauges embossed `RDSO’ shall be handed over to inspecting
officer for his exclusive use. This shall remain under the custody of inspecting officer
.
18
The purchaser’s inspecting officer, auditor or any authorised representative shall have access
to all quality related documents i.e. manufacturing process details, quality control, procedures,
records, test results, standardised proforma etc.
Quality of all the castings produced and its workmanship shall be appropriate to the
importance of these castings and any aspect considered by the inspecting officer as
detrimental to the safety and efficient performance of the components shall be sufficient
reason for rejection of the castings.
The bogie shall be offered for inspection before painting.
Following inspections shall be done by the inspecting officer and results recorded in addition
to any other inspection which may be done by him.
9.6.1 Inspection of sideframe and bolster – steel castings- shall be governed by Annexure-I
and also details given under para on “Bogie assembly requirements” (Para 5).
a) Each cast has to be cleared by the Inspecting Officer on the basis of tests
indicated at para 8,9, 14 and 15 of Annexure-I.
In addition chemical composition and mechanical properties should be tested as
per Annexure –VIII.
b) Tests indicated at Para 14,17,18 and 19 are in the nature of audit check and reflect
on the quality of manufacturing process.
9.6.2 Gauging of H frame shall be done on 5% of the frames assembled, as per para 5.1.5.
9.6.3 All components as per Annexure-IX to be inspected as per details given in the
respective Annexures. This is to be done by random sampling on components received
by Bogie Manufacturer. If any sample among the test pieces drawn fails, then double
the number of test pieces drawn earlier shall be again selected and tested. If the
`Double’ sample passes the tests, lot shall be considered acceptable. Should any of the
sample fail, the complete lot shall be rejected.
9.6.4 The Inspector shall also conduct random stage inspection of different stages of
production –
i) Finished Sideframes and Bolsters.
ii) Drilling of Sideframes.
iii) Welding of liners.
iv) Matching of springs.
v) Polymerd side bearer assembly.
vi) Record keeping by the contractor at different stages of manufacture.
19
10 Dispatch :
10.1 Each bogie shall be given one coat of red oxide zinc chromate primer to spec. IS:2074
followed by one coat of ready mixed paint of red oxide to IS:123. Mating surface and
friction plates shall not be painted.
10.2 Contractor shall ensure that assembled bogies are handled carefully so that no distortion of
spring planks take place. The bogie shall be loaded carefully on the trucks/wagons and
properly strapped so that no shifting can take place. Loading scheme shall be got approved
by the Engineer.
Care shall also be taken while unloading the bogies to ensure that no damage takes place.
10.3 The items which are dispatched loose alongwith the bogie i.e. Elastomeric pad, top centre
pivot, center pivot retainer and centre pivot pin, shackle lock, lock pin etc. shall be
properly secured to ensure that no damage takes place during transit.
10.4 Contractor shall ensure that spring loaded side bearer assembly is properly secured to
avoid the springs and side bearer seat falling of during transit.
11 “As Made” Drawings :
11.1 The bogie suppliers shall supply tracings on cloth of “As Made” drawings followed in the
manufacture of the bogies where deviations from the original design, material
specifications and dimensions etc. have been adopted.
12 Prototype Approval Procedure :
All manufactures seeking approval for supply of casnub bogie assembly covered under
this specification, to Indian Railways shall follow the procedure outlined below :-
12.1 Manufactures shall apply to executive Director (I&L)/RDSO, Lucknow on a prescribed
format obtainable from Zonal officers of RDSO. The information to be provided through
this format includes details of manufacturing and quality control facilities, organisation
structure, staffing in quality control department and previous experience.
Manufacturer must satisfy the requirements of Category-A foundries (IS:12117) specified
and updated by Bureau of Indian Standards from time to time and other infrastructural
facilities as laid down in para 3 .
12.2 On receipt of this information, the capability or otherwise of the manufacturer shall be
judged by RDSO. In case the manufacturer is considered capable, a team of RDSO officials
shall visit the manufacturer’s premises to verify the manufacturing and other facilities and
submit a report.
20
12.3 Based on this report, a decision shall be arrived at regarding permission to manufacture a
prototype. On receipt of order for prototype manufacture, the manufacturer shall submit the
documented procedure of manufacture, methoding system for castings, as-cast drawing,
details of castings quality check to be followed, gauging scheme, quality conformance
testing arrangements, assembly procedure and other relevant details which will be followed
during manufacture.
12.4 These documents shall be studied in consultation with DG (Wagon) and a final clearance
to manufacture prototype bogie shall be issued by RDSO if the details are considered
satisfactory towards maintenance of quality.
12.5 Casting quality
12.5.1 The manufacturer shall produce two sets of castings of bogie assembly complete with
integrated test blocks & annealing lugs, ( separately cast sample for smaller castings).
Duly cleaned and shot blasted castings shall be offered for examination of RDSO in the
as-cast and heat treated condition.
12.5.2 Quality conformance shall be checked with respect to the requirements of STR. All
tests listed in Annexure-I of the specification shall be done. Components shall be
checked as per the scheme given in Annexure.
12.6 Manufacturers shall develop the manufacturing facilities and process, QAP and assembly
procedures as per the relevant portions of this specification. In case manufacturer has a
better alternative, same may be suggested to RDSO for consideration.
12.7 Approval shall be granted to the manufacturer on successful completion of all the tests and
procedures as provided in this specification, which shall be subjected to periodic revision.
13 Quality Assurance Programme : All activities relating to quality assurance shall be the responsibility of Quality Manager
who shall form the interface with the RDSO inspecting officer. The relevant records for
maintaining quality for each of the following items shall be maintained and made
available to the inspecting officer.
13.1 Pattern and Core Boxes
13.2 Sand Preparation
13.3 Moulding and Core making
13.4 Assembly of Core
13.5 Metal Pouring
13.6 Heat treatment
13.7 Visual examination
13.8 Gauging scheme
21
13.9 Stagewise manufacturing quality checks/test during bogie assembly and its components.
13.10 System to ensure quality of all components used in assembling a bogie in addition to
casting.
13.11 System for disposal of defective components identified during various stages of
manufacture and implementation of QAP, so that such components are not mixed up with
lot being offered for inspection.
13.12 Records of Internal Quality Programme for future references/investigations.
13.13 Records to identify the manufacturing details/tests of components with Serial Number
marked on components.
13.14 Records of the mechanical and chemical test reports covering the heats representing the
purchased castings. The period for which records will be preserved can be decided between
supplier and inspecting authority.
14 Quality Audit : This part covers the aspects of manufacture and quality assurance which will be audited
by RDSO at specified periodicity. The audit shall be conducted at two levels i.e. one at
the level of RDSO’s Inspecting Engineers and the other by officers nominated by
DG(Wagon) RDSO, Lucknow. The former will be conducted at a periodicity not
exceeding 3 months and the later at least once a year. The report of the audit shall be
submitted to DG(Wagon) and DG(I&L), RDSO, Lucknow.
15 Other Requirements :
The accuracy of gauges shall be checked by the Inspecting Authorities before the
commencement of manufacture. Recalibration shall subsequently be made at the
frequency stipulated in internal Quality Assurance Programme. Gauge drawings in
original, shall also be made available for checking the tolerances of these gauges.
Contractor shall have sufficient sets of gauges for his own use.
15.1 In case the offer does not correspond to this specification in any respect, a DEVIATION
STATEMENT shall be submitted by the Tenderer. This statement shall give the
deviations clause wise with technical reasons for the same. Change in drawings, if any,
shall be explained and accompanied by THREE copies of revised drawings. In case the
tenderer does not require any deviation from this specification, a NO DEVIATION
CERTIFICATE shall be submitted.
15.2 The bogie components found having illegible markings at the time of fitment in Railway
Workshops, Maintenance Depot or at Wagon Builder premises, shall be replaced by the
contractor free of cost. The cost of transportation shall also be borne by contractor.
15.3 All contractor’s foundries, material and manufacturing process must be approved by
RDSO. The basis for such approval shall be satisfactory compliance with the provision of
AAR Specifications M-201, M-205, M-211 and this specification.
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The foundry shall satisfy the requirements for category “A” foundries (IS:12117)
specified and updated by the Bureau of Indian Standards/RDSO from time to time.
15.4 Contractor shall have a proper house keeping system to ensure that components are not
damaged during storage. Critical components like springs, centre pivot, elastomeirc pad
etc. must be stored under cover and be protected against corrosion.
16 Clarifications :
Any further clarification required by the supplier can be obtained from the Director
General, Research Designs and Standards Organisation, Ministry of Railways, Manak
Nagar Lucknow – 226 011 ( India ).
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ANNEXURE –I (Sheet 1 of 8 )
CAST COMPONENTS
Steel Casting
Steel castings shall be manufactured as per the following requirements :-
1. Raw material quality – General
All basic foundry processes e.g. moulding, core making, heat treatment, fettling and weld
reclamation shall be done in house for all steel castings. No deviation shall generally be
permitted. In exceptional circumstances, specific approval of Inspecting Officer shall be
necessary which will be for a limited duration.
The foundry shall lay down the specification of all raw materials used in the manufacture
of castings and follow the same. The castings shall be manufactured from appropriate
quality of raw materials i.e. silica sand, steel scrap, foundry returns & ferro-alloys,
whose quality shall be ensured through relevant tests. Quality of all additives to sand,
molten metal and mould/core wash shall be standardised, checked and only acceptable
quality raw material and additives shall be used. Record of all raw materials and
additives, their quality characteristics shall be maintained which shall be made available
to inspecting officer to facilitate scrutiny and establish traceability.
2. Sand Preparation
The foundry shall lay down the characteristics of all sand mixes i.e. moulding sand, core
sand, facing sand and shall have proper arrangement for sand drying & preparation of
sand mix of consistent quality and the characteristics of each batch shall be checked to
ensure conformance to standard arrived at by the foundry. Sand mix of unacceptable
quality shall not be processed.
3. Moulding
Moulds shall be prepared from sand mix of predetermined composition and
characteristics to ensure consistency.
Moulds shall be prepared either by machine moulding or with the pneumatic rammers.
Hand moulding shall not be resorted to. Mould hardness shall be checked for each mould
to ensure proper compaction. Damaged moulds shall not be used for producing casting.
Repair of the moulds can be carried out if the same does not affect that casting quality.
Suitable arrangement shall be made in the mould to obtain manufacturer’s identity,
month and year of manufacture, casting Sr. No., Drg. No. for each sideframe and bolster
casting, center pivot top and bottom casting, brake beam strut casting and other castings
as indicated in drawings.
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Two annealing lugs of size 25 X 25 X 8 mm shall be provided in all castings to facilitate
micro-examination.
To facilitate mechanical testing and chemical analysis, atleast 3 castings per batch shall
have integrated test piece from which samples for tests shall be prepared.
All moulds shall be given a `wash’ of appropriate quality on the entire surface coming in
contact with the molten metal to ensure proper surface finish and undesirable
metal/mould reaction.
4. Core-Making
All cores shall be made in house, the sand, the binder and the additives shall be of
appropriate quality. Damaged cores shall not be used for producing castings.
5. Running, gating an risering
Based on sound foundry practices and adequate experimental castings, the foundry shall
standardise the running, gating and risering system of all casnub bogie castings to
produce sound castings. The methoding system shall be standardised, proper records
maintained and any alteration in the system shall be intimated immediately for obtaining
approval .
Knock-off riser shall be used wherever possible, to eliminate damage to the castings
during finishing operation. All surface of the core coming in contact with the molten
metal and where surface finish is important to ensure proper seating of the mating
components shall be provided with core wash.
6. Melting and Pouring
The foundry shall have proper melting unit and facilities for refining of the molten metal.
To ensure the chemistry of the castings, direct reading vacuum spectrometer shall be
available. The molten metal meeting the specified chemistry shall only be used for
producing castings.
The tapping and pouring temperature of the molten metal shall be standardised by the
foundry and the same shall be determined for each heat. Pouring time for each casting
shall also be arrived at and determined for sideframe and bolster castings.
There should be a positive method to trace the last two castings poured.
7. Finishing operation
The castings shall be dressed and cleaned using mechanical arrangements. Runners and
risers shall be removed without damaging the surface finish and dimensions of the
castings.
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Generally, no grinding shall be necessary except for removal of the parting line.
Adequate precaution shall be taken to ensure that deep grinding marks, notches are not
left on the surface.
After dressing and ensuring its freedom from sand, runner risers etc., the castings shall be
shot blasted to achieve desired degree of cleanliness.
8. Heat treatment
All heat treatment furnaces shall be equipped with adequate number of pyrometers and
recorders. Facility for output chart indicating time verses temperature shall be available
for each furnace.
Plan for placement of castings in the furnace shall be standardised to ensure uniformity of
heat treatment for each casting of a particular batch and the same shall be followed
without any deviation.
All castings shall be normalised by heating the castings at a rate not exceeding 100 Deg.
C per hour, soaking the castings at 900 Deg + 20 Deg. C for adequate period to ensure
elimination of cast structure followed by cooling in still air. The heat treatment cycle
shall be recorded for each batch and made available to the inspecting officer.
9. Visual examination
All castings shall be examined visually and in the event of doubt by using a magnifying
glass. Final examination has to be done by magnetic particle testing method as indicated
in Para 14.1. The castings shall be free from harmful surface defects, inclusions, sand