item name: air dryer, alco, hhp & electric locomotives and

REVISION OF SPECIFICATION / STR

Item Name: Air Dryer, ALCo, HHP & Electric locomotives and EMUs/ MEMUs/DEMUs, Unified PL No. 11810725 (Diesel loco) 25186619/29162051 (Electric Loco) 31357179 (DEMU) 31357209 (EMU/MEMU).

STR No.: MP.STR.BK.01.06.11 (Final Draft under revision)

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. Email ID

7. 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.

8. Whether any technical document/ Report/ Study to support suggested changes in 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 RDSO Spec / STR

Justification for changes

Comments may be sent to following address within one month from the date of publication

on rdso.indianrailways.gov.in

Jt. Director/ Brake Research Designs and Standards Organization Manak Nagar, Lucknow – 226011

Email: [email protected]

441411/2021/O/o JD/BK/MP/RDSO170

(For official use only)

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GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

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SCHEDULE OF TECHNICAL REQUIREMENTS FOR MANUFACTURE AND SUPPLY OF TWIN TOWER HEATLESS REGENERATIVE TYPE AIR DRYERS FOR DIESEL–ELECTRIC AND ELECTRIC LOCOMOTIVES (INCLUDING HIGH HP LOCOMOTIVES), ELECTRICAL MULTIPLE UNIT (EMU) & MAIN LINE ELECTRICAL MULTIPLE UNIT (MEMU) AND DIESEL-ELECTRIC MULTIPLE UNIT (DEMU)

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STR NO. – MP.STR.BK.01.06.11 (Rev.-01)

March- 2021

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RESEARCH DESIGN & STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW-226 011

441411/2021/O/o JD/BK/MP/RDSO171

SCHEDULE OF TECHNICAL REQUIREMENTS FOR MANUFACTURE AND SUPPLY OF TWIN TOWER HEATLESS REGENERATIVE TYPE AIR DRYERS FOR DIESEL–ELECTRIC AND ELECTRIC LOCOMOTIVES (INCLUDING HIGH HP LOCOMOTIVES), ELECTRICAL MULTIPLE UNIT (EMU) & MAIN LINE ELECTRICAL MULTIPLE UNIT (MEMU) AND DIESEL ELECTRIC MULTIPLE UNIT (DEMU)

CONTENTS

S. No Description Page No

1 Scope 1

2 General Conditions/Requirements 1

3 QAP and Inspection Plan 1

4 Eligibility criteria for the firm 2

5 Manufacturing & testing facilities 2

6 Prototype testing and field trial 2

7 RDSO Approval for Air Dryer 3

8 Preference to Make In India 3

9 Vendor Changes in Approved Status 3

Annexure

1 List of Manufacturing Facilities 4

2 Test equipment for Type/Routine test of Air dryer 6

3 Field performance feedback format 7

441411/2021/O/o JD/BK/MP/RDSO172


List of Amendments:

S. No. Amendment

Date

Version Details

1 January’ 21

March’ 21

01 Revision of clause no. 6.2 to add field trial

performance feedback format in compliance of

MOM of the VC meeting on Specification/ STRs

held on 29.08.2020.

Annexure III: Add Field performance feedback

format

441411/2021/O/o JD/BK/MP/RDSO173


STR NO.: MP.STR.BK.01.06.11 Rev. 01 Page 1 of 7


1. Scope:

The Twin Tower Heatless Regenerative Type Air Dryers to RDSO Specification No. MP.0.01.00.06 shall be used in Diesel–Electric and Electric Locomotives (Including High HP Locomotives), Electrical Multiple Unit (EMU) & Main Line Electrical Multiple Unit (MEMU) and Diesel-Electric Multiple Unit (DEMU) on Indian Railways. This Schedule of Technical Requirement (STR) is being issued to stipulate the qualification criterion for the manufacturers who offer the Twin Tower Heatless Regenerative Type Air Dryers for IR. This document shall be read along with the RDSO‟s Specification No. MP.0.01.00.06 for the Twin Tower Heatless Regenerative Type Air Dryers.

2. General Conditions/ Requirements

2.1 Application for approval

The firm seeking approval for manufacturing and supply of compressed air dryer shall register online on RDSO website www.rdso.indianrailways.gov.in.

2.2 The firm and its foreign collaborator (if any) shall be ISO 9001 certified company in compliance to Para 4.3.1of ISO document QO-D-8.1-5 (latest) and shall have a well structured system for the following;

2.2.1 A system of regular submission of rejection details of material, giving rejection rate, cause of rejection, corrective action taken etc. on quarterly basis.

2.2.2 The firm shall have a system of documentation with respect to rejection by the customer, failure of items supplied by them during service and warranty replacement.

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

2.2.4 Established system for calibrating the testing and measuring equipments through NABL accredited lab.

2.2.5 The firm shall have a system of easy traceability of the product from manufacturing stage to finished product stage. Identification marking with serial number of air dryer should be used forthis purpose.

3. QAP and Inspection Plan:

The tenderer shall have a well-defined Quality Assurance Plan (QAP) for products offered by them. The submitted QAP shall require approval of RDSO. In general, the information

441411/2021/O/o JD/BK/MP/RDSO174



may be furnished by the tenderer in the QAP as per RDSO ISO document no-QM-RF-7.1.3 Ver-2.0 (or latest) - Guidelines for preparing QAP during registration.

4. Eligibility criteria for the firm:

4.1 The firm or / and its foreign collaborator, who intends to supply air dryers to Indian Railways, shall have proven technology of air dryer. The firm or / and their collaborator shall have supplied atleast 1000 sets of air dryers in last 10 years for locomotive or similar heavy duty applications. The firm should have qualified and competent design personnel acquainted with the design and manufacturing technology required for air dryer manufacturing.

The firm or / and its foreign collaborator shall give the list of customers where air drying units have been supplied by them.\

4.2 The firm shall submit supply details and evidence of satisfactory performance of their Air Dryer along with the application for approval. Failure rate per component per year (FRPCPY) shall not exceed 3 %.

5. Manufacturing & testing facilities:

The firm or its sub vendor shall have the necessary machinery,plant and testing facilities

required for manufacture, assembly and testing of the equipment. An indicative list has

been shown in Annexure –I & II. Deviations, if any, from the indicative list shall be explained

by the firm to the satisfaction of RDSO.

6. Prototype testing and field trial

6.1 Prototype test shall be done in accordance to specification No. MP.0.01.00.06 for air dryer.

6.2 After successful prototype development and testing, a development order can be placed on the firm. Installation of the first prototype shall be the responsibility of the supplier. Assistance with regard to labour and other facilities which are available in the sheds/production units, may, however, be provided to the supplier during prototype installation. The prototype shall perform satisfactorily for at least 12 months during field trial. Field performance feedback format is given in Annexure III.

441411/2021/O/o JD/BK/MP/RDSO175



7. RDSO Approval for Air Dryer

On satisfactory performance in field, the firm shall be considered for placement in RDSO Vendor for Developmental Order in RDSO Vendor Directory. Qualifying quantity & Period for approval for RDSO vendor for developmental order is given in Master list of safety & critical items document no. MP-M-8.1-1 Ver-1.2/ (or latest).

8. PREFERENCE TO MAKE IN INDIA

The Government of India policy on „Make in India‟ shall apply

9. VENDOR CHANGES IN APPROVED STATUS All the provisions contained RDSO‟s ISO procedures laid down in Document No. QO-D-8.1-11, dated 04.12.2020 (Titled “Vendor-changes in approved status”) and subsequent version/amendment thereof, shall be binding and applicable on the successful vendor/vendors in the contract floated by Railways to maintain of products supplied to Railways.

441411/2021/O/o JD/BK/MP/RDSO176



Annexure- I

List of Manufacturing Facilities

The following is the indicative list ofmachineries and plant to beavailable with the firm or its sub-vendor, as the case may be. The capacity of the machines shall be suitable for manufacturing the required job:

1. Machining facilities

a) Horizontal/Vertical Machining Centre

b) Turning Centre

c) Radial drilling machine

d) Machine for Deburring of machining parts

2. Machines & tools for assembly of air dryer

a) Pneumatic tools for assembly line,

b) Hydraulic/Pneumatic lifting trolley/table for assembly

c) A high-pressure water jet arrangement/Ultrasonic cleaning machine should exist for cleaning of machined components before surface treatment.

d) Crane/ Hydraulic stackers

e) Torque wrenches of suitable range for proper tightening of bolts/joints

f) Normal spray painting and facilities for masking and finishing

g) Surface treatment facilities like powder coating, anodizing etc.

h) A name plate punching machine for preparing plates indicating the serial number & date of manufacturing to be fixed should be available.

i) Test benches to check different sub assemblies & final assembly.

3. Physical Laboratory & Standard Room:

a) Spring Load testing machine to check springs

b) Hardness testing machine for checking hardness of casting and forging items (Rockwell / Brinell Hardness Testing Machine).

c) UTM (for checking tensile strength & elongation of the rubber slabs), Muffle furnace & oven of suitable range to check rubber slabs.

441411/2021/O/o JD/BK/MP/RDSO177



d) Digital surface finish tester.

e) Height gauges

f) Inside micrometers

g) Outside micrometers

h) Thickness tester for rubber items

i) Plating/Coating thickness gauge for checking layer of surface treatment

Note:

i. The inspection staff conducting non-destructive testing shall be adequately trained and qualified by recognized agency and shall have adequate experience.

ii. Staff conducting test likes chemical analysis and mechanical properties shall have adequate skill and shall have under gone sufficient training. Skill of such staff shall periodically be qualified by making them carry out tests in blind samples.

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Annexure- II

1.0 Test equipment for Type/Routine test of Air dryer:

The firm shall have facilities and major equipments needed for conducting

Type/Routine test as per RDSO‟s specification as follows:

Air flow meter

Pressure gauge

Dew point meter

Variable Power supply

Stop watch

Dimension measuring equipments

Temperature measuring equipments

Compressor

Test rig for testing of air dryer

Calibration of the testing/ measuring equipments shall be done at least once in a years

unless stated otherwise. Supplier shall demonstrate that test equipments, gauge etc. are

calibrated.

441411/2021/O/o JD/BK/MP/RDSO179



Annexure- III

Field performance feedback format

Loco

No

Make Of

Air Dryer

Date Of

Fitment

Performance of Air Dryer

(Failure if any with date)

Change Of consumable/equipment

before schedule, if any (e.g. desiccant/

precoalescer filter/final filter)

Please indicate the periodicity also

Remarks

If Any

Condition

of PCB

Working of

Cyclic

changeover

Purging

Operation

Colour of

Humidity

Indicator

Desiccant Pre-Coalescer

Filter

Final

Filter

441411/2021/O/o JD/BK/MP/RDSO180

item name: air dryer, alco, hhp & electric locomotives and

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