REVISION OF SPECIFICATION / STR

Ref: Current Spec. No. C-K105, Rev-1, Amendment-1- Schedule of Technical

Requirements for Bolster Suspension Hanger of BG & MG Mainline &

EMU/DMU/MEMU Coaches.

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 this 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 In case of Firm / Individual: Manufacturing experience of item (or similar Item) on which comments are offered

9 Where relevant: Whether any technical document 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 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:

Director/CD/Carriage

Research Designs and Standards Organization

Manak Nagar, Lucknow – 226011

Email: edcar.rdso@gmail.com Or jdircd@gmail.com

Ref: CG-WI-42.4 ! Page 1 of 2 (Ver. -1) I Date ·of Issue: Spec. No. C-K 105 (Rev.1) J

S. No.

1.

12. I .

3,

I i ~ 4

December- 2016

INDIAN RAILWAYS

SCHEDULE OF TECHNICAL REQUIREMENTS FOR

BOLSTER SUSPENSION HANGERS OF BG & MG MAINLINE AND EMUlDMUlMEMU COACHES

MonthlYear Revision I I Page I Issues/Changes I I

of issue Amendment ~o. I , I I

November, 1 1st

Issue , Nil ' -N/A- I

2001 I I I i August, 2002 Amendment I Clause ! The hardness in the wearing surface I SlipNo.1 11.12 J shall be between 50 to 60 Re. March,2003 Amendment I Clause ! a. 65 RC 's for BG Mainline, BG EMU !

Slip No.2 1.5 'a' I trailer and MG high speed Coaches. I I and 'b' , b. 60 RC's for EMU Motor Coach & .

DMU-Driving Power Cars . I July, 2014 Rev.1 All Detailed on page no. 2 I

5. ! Dec., 2016 Amendment 4 I To include the ISO Document No: QO- 1

- -'--_---l~ _ _ __ _'I Slip No. 1 I D 7.1 11 , New sub para has been I added after existing 1 st para of Scope.

Issued By: Research Designs and Standards Organization

Manak Nagar, Lucknow - 226011 .

! Signature I ~'O\.~Oi' - [ ~--. - - ..-kul/'1 ~1.J>~ I Name & I Prepared By: _·-r---=::cCC-h-ec-ok-'-e=d".:!B"'y"-': --'-'--+- Approved By~ I I, DeSignatiOnlJ V. K. Yadav Phoni Mandai Deependra Kumar I

JE/Design/Caniage SSE/Design/Carriage Director/Stds.lCarriage I ~ ___ -L ______ ~ ____ ~ __ ~ _____ _ ~~ __ ~~__ ,

Ref: CG-WI-4.2.4 (Ver. -1)

Page 2 of2 Date of Issue:-l Spec. No. C-K105 (Rev.1) ~I Oecember- 2016 I I

Amendment Slip No.-1

Amendments slip no. 1 of December, 2016 to RDSO specification No. C-K105 (Rev. 1) for schedule of technical requirements for bolster suspension hangers of BG & MG Mainline and EMU/DMUlMEMU coaches.

Add new sub Clause after existing 1 st para in Scope, as under:

All the provisions contained in RDSO's ISO procedures laid down in Document No. 00-0-7.1-11 dated 19.07.2016 (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.

:," Signature II 'l I 14. r--. p , ~.o,;~O\' . ~~~1 !-: -;N:7a-m- e---;o&-t,--- Prepared By: --j---'=:C:O:h:":e=--c';:'ke'--d:;-B;fy"':"l-'-'--''-+---;A'''p~p'''ir i'H'e~;I------I

',: Designation II v, K. Yadav Phoni Mandai . __ I Deependra Kumar . JE/Design/Carria_g_e __ -,-__ S_S_E_/D_e_s_ig_n/Carria~~irectorlStds ./Carriage

, I !

I • •

Ref: CG-WI-4.2.I-I , Ver. 1.0 Page loflO Month of issue: July, 2014 STR No. C-K\05 (Rev. I)

rr S. No.

1. 2.

3.

3.

INDIAN RAILWAYS

SCHEDULE OF TECHNICAL REQUIREMENTS FOR BOLSTER SUSPENSION HANGERS OF BG & MG MAINLINE AND EMUJDMUJMEMU COACHES

MonthlYear of issue

November, 2001 August, 2002

March,2003

July, 2014

Revision/ Page No. - -- -- _ ._-------

I Issues/Changes

Amendment Nil I -N/A- I Issue

Amendment Slip i Clause 1.12 The hardness in the wearing No.1

I surface shall be between 50 to 60 RC.

Amendment Slip I Clause 1.5 'a' a. 65 RC's for BG Mainline, BG No.2 I and 'b' EMU trailer and MG high speed

Coaches. b. 60 RC's for EMU Motor Coach

& DMU-Drivina Power Cars. Rev. 1 All Detailed on page no. 2.

Issued By: Carriage Directorate

Research Designs and Standards Organization Manak Nagar, Lucknow - 226011 .

~ i Signature --4-v:5· \\~ \: s.,. 7

Authority & mlStd.lCarriage Dy. DirectorlStd.lCarriage Director/Sfd. /Carriage i De.ignalion Prepared By: Checked bX..... . .. __ .. __ .1 - _____ ._ - Approved by:

- •. - - - -- -- -- - -~ --- -*--. - ' ---'-- - ., . . -. -

I Ref: CG-WI-4.2.1-1 , Ver. 1.0 I Page 2 of 10 I Month of issue: July, 2014 STR No. C-KI05 (Rev. I)

Changes made in the Revised ROSe STR No. C-K105 (Rev.1)

SECTION-A

1. SG & MG Mainline and EMUlDMUlMEMU coaches has been included under the title of the STR.

2. Amendment Slip No.1 of August, 2002 & Amendment Slip No.2 of March, 2003 has been incorporated in the STR

3. Index is added after re-numbering of each Para of the STR

4. Para 1: Latest version of the IS:1875 has been specified.

5. Para 15: Sizes of the round corner billets for SG & MG mainline EMU Trailer coaches, High Speed coaches, EMU Motor coaches and DMU-Driving Power cars has been specified.

6. Para 2.11 : Procedure of masking of non-wearing surfaces and preheating of the hangers is detailed in gas carburizing process.

7. Para 2.13: Tempering period of 1.5 hours for the hangers has been specified.

8. New Para 2.13 for variations in the weight of all finished hangers has been added.

9. Para 3.1 : Type of Code for MG High Speed coaches and SG DMU Power cars has been specIfied

10. New Para 3.5 for marking locations has been added.

11. Para 4.1: Detailed inspection plan for raw material has been specified.

12. Para 4.3: Dimensional check as per applicable drawings and proof load for hangers of MG HIgh Speed coaches and SG DMU Power cars has been specified.

13. New Para 4.4 regarding maintaining a list of all internal acceptance tests being carried out by the manufacturer ;rt various stages of the manufacturing of the hangers, their proper records and inclusion in the QAP has been added.

14. Para 5: Manufacturing process and quality control as per approved QAP, checking of internal records of stage and finished product inspection and random checking of raw material during inspection has been included.

15. Para 5.1 : Detailed inspection plan for finished product has been speCified.

16. New Para 7 regarding procedure for handling and packing of the hangers has been added.

SECTION-S

Para 2.4: Infrastructural requirements for checking indusion rating and grain size has been detailed.

Para 2.3: Typographical error has been corrected.

Para 3.1: Typographical error has been corrected.

Para 3.3: Typographical error has been corrected.

" ~ t Signatw"e '.JR~' \\ \.J&, L- ~ ~AUlhority & - JE/Std.lCarriage ----I----Director/s~e-----Dy. DiroctorlStd.lCarriage I Designation Prepared Bv: Checked by: Approved by:

I Ref: CG-WI-4.2. 1-1, Ver. 1.0 I Page 3 oflO I Month of issue: July, 2014 I STR No. C-K105 (Rev. I) I

INDEX

S. No. Description Page No. 1. Changes made in the Revised ROSa STR No. C-Kl05 (Rev.l ) 2 2. Index 3

-3. Scoe.e ._-----------------------.-

4 4 . Section-A 4 5. Material 4 6. Process of Manufacture 4 7. Marking Particulars 5 8_ Inspection by the Manufacturer 6 9. Inspection by Inspecting Authority 7 -----10. Inspection at Consignee End 8 11 . Handling and Packing 8 12. Section-B 9 13. Requirements 9 14. Testing Facilities 9 15. Quality Control Requirements 10

I I Signature *'Q , - -u\\llit/ ___ ,b I Authonty & -

c(. ~ . \..' _ _ ,

\--JE/Std.lCarriage --.. ---~ . . -

Dy. Director td./Carriage Dircctor! td./CaTriage i Designation Prepared Bv: Checked by: Approved by:

I Ref CG-WI-4.2.1-1 , Ver. 1.0 I Page 4 oflO I Month of issue: July, 2014 I STR N o . C-KI05 (Rev. I) I SCHEDULE OF TECHNICAL REQUIREMENT FOR BOLSTER SUSPENSION

HANGERS OF BG & MG MAINLINE AND EMUIDMUlMEMU COACHES

SCOPE:

This schedule has two section i.e. Section-A & Section-B. Section-A covers the technical requirements, methods of sampling and tests for bolster suspension hangers used on Mainline and EMU coaches. Section-B covers schedule of infrastructural requirements for manufacturing, testing facilities and quality control.

SECTION-A

1. MATERIAL:

The material shall invariably conform to class-I steel of IS: 1875-1992 (Reaffirmed 2004).

1.1 Billets for forging of hangers shall be manufactured from killed steel made by electric/basic oxygen/combination of these processes with secondary refining or any other suitable method approved by ROSa which will meet the requirement of this schedule.

1.2 Billets shall be reasonable free from any external or internal cracks, flakes, laps and other injurious surface imperfections. The billets shall be reasonably straight.

1.3 The inclusion rating shall not be worse than 2.0 A, B, C, 0 in both thin and thick series as per IS: 4163-2004.

1.4 The grain size shall not be coarser than 5 as per IS: 4748-2009.

1.5 Only billets of suitable size should be used so as to provide a reduction ratio of 4:1 min. from billet to final product and satisfactory grain flow at the corner of the hangers. The different sizes of round corner billets to be used for manufacture of hangers for different types of coaches are as follows :

a. 65 RC's for BG Mainline, BG EMU Trailer and MG High Speed coaches.

b. 80 RC's for BG EMU Motor coaches and DMU- Driving Power cars.

c. 60 RC's for MG Mainline coaches, MG EMU Motor and Trailer coaches.

1.6 Use of rolled flat / plates to manufacture the hangers is strictly prohibited .

2.0 PROCESS OF MANUFACTURE:

2.1 Cut the blanks on sawing/shearing machine.

2.2 Heat the cut blanks in oil fired furnace batch type/pusher type provided with temperature controller to control temperature within +f- 100C of maximum range.

2.3 Forge the hot blanks into hangers on drop hammers in a set of closed dies ensuring proper grain flow all over and at the comers. Bending of grains at the corners should be clearly visible during testing.

2.4 Trim the outer fins and inner fins with the help of trimming die.

2.5 Allow the hangers to cool in air on the shop floor.

2.6 Normalise the forged hangers in an electric or indirectly heated oil fired furnace at a temperature varying between 870°C to 950°C. The soaking time should be at the rate of 45 minutes minimum per 25mm thickness. The hangers should be allowed to cool in air on the Shop floor after normalizing.

2.7 Mill the radius of the wearing surface ensuring that inner length between the wearing surfaces and thickness of the horizontal arm is maintained as per relevant drawing of the hanger.

2.8 Any other method like grinding or cutting of the wearing surface to generate 12.5mm radius is strictly prohibited.

I , Signature .-j0, :~hlL-- _ _ Jmv ~uthOrity &----.-~---==--- " - - :;...;..-- --

JEfStd.fCarriage Dy. DirectorfStd.fCarriage Director/Std.lCarriagc Dl:!signation Prepared By; Checked by; Approved by;

I Ref: CG-WI-4.2. J-J, Ver. 1.0 I Page 5 of10 I Month of issue: July, 2014 I STR No. C-KI05 (Rev.l) I

2.9 Deburr the machined surface and corner grooves, if required, by pencil grinder or hand filing.

2.10 Shot blast the hangers ensuring that the hanger surfaces are free from oil, grease, dust or any other type of foreign material.

2.11 Gas Carburizing: Gas carburize the wearing surface of the horizontal arms of the hanger up to a total case depth of 1.5mm +0.1/-0.0mm by carburizing in a gas carburizing fumace. Ensure that only wearing surfaces of the hanger are gas carburized, a suitable masking compound should be applied on remaining surfaces of the hanger. The masking of all remaining surfaces (other than wearing surfaces) of the hanger shall be achieved by giving double coat of anti carb paste up to thickness of 180 - 200 microns. The masking compound must be able to effectively prevent carbon penetration in the vertical arms of the hanger. After suitable masking , the hangers shall be preheated slowly at a temperature of 400°C for a period of 1 hour before putting into the carburizing furnace. The hardness in the arms (including corners) shall not exceed 190 BHN.

2,12 Case Hardening of Wearing Surfaces: Heat the hangers at 930°C and in carburizing atmosphere, Soak it for a minimum of 3 hours, Take out the first test piece and check the case depth, When required case depth is achieved, carburizing fluid may be stopped and diffusion cycle may be carried out for one hour at the same temperature. Subsequently quench the hangers in oil/water. The hardness in the wearing surface shall be between 50 to 60 RC.

2,13 Tempering of the hangers for stress relieving shall be done by heating them at 250°C maximum in an electric/neutral fumace for a period of 1,5 hours,

2,14 Check the straightness and dimensions of the hangers. The dimensional accuracies should conform to the relevant drawing of the hanger

2,15 All hangers should be given one coat of rust preventing oil of a standard make to avoid corroSion on the hangers.

2,16 To avoid any damage to hanger due to looseness during transit, small bundles consisting of 4 hangers each tied with wire at all the corner grooves shall be made before packing,

2.17 The variations in the weight of all finished hangers should be within +5/-3 %,

3, MARKING PARTICULARS:

3.1 Type of Code:

BG Mainline coaches T BG EMU Motor coaches E

BG EMU Trailer coaches 0

MG EMU Motor coaches D MG Mainline coaches M

MG EMU Trailer coaches M

MG High Speed coaches M

BG DMU Power cars E

32 Manufacturer's initials,

3,3 Month and year of manufacture,

3.4 The marking should be in 6mm high raised letters. Cold punching or use of depressed letters is strictly prohibited.

3,5 Marking Locations shall be as mentioned in the relevant drawings,

-~~--•

. Signature ~' . .liwv_ .~.---

Aulhority & JE/StdJCarriage Dy. DirectorlStdJCarriagc Director td.lCarriage Designation Prepared By: Checked by: Apl'roved by:

I Ref: CG-WI-4. 2. 1-1, Ver. 1.0 I Page 6 of 10 I Month of issue: July, 2014 STR No. C-K105 (Rev. I)

4. INSPECTION BY THE MANUFACTURER:

4.1 The manufacturer shall maintain test certificates issued by steel manufacturers with details of cast No .. chemical composition. steel making processes etc. They shall also carry out the following tests. The test samples shall be made from round comer billets used for manufacture of that particular type of suspension hangers.

Inspection of Raw Material- for lot size of 100 nos. of BSS Hanger or Part thereof:

S.No. Description Sample Size Acceptance Criteria 1. Visual inspection 5% in a lot or part Surface shall be reasonably free

thereof from any external or internal cracks. laps, rough, jagged, imperfect edge and other injUrious surface imperfection.

2. Chemical 03 samples in a lot or IS: 1875-1992, Steel to Class-I . com position of the part thereof material (Sample should be

drawn from a lot for spectro analysis randomly).

3. Ultimate tensile 03 samples in a lot or 370 MPa (Min.), IS: 1875-1992, strength part thereof

4. Yield strength 03 samples in a lot or 200 MPa (Min.), IS: 1875-1992, part thereof

5. Percentage 03 samples in a lot or 26% (Min.) , IS: 1875-1992, elongation part thereof

6. Bend Test 03 samples in a lot or As per IS: 1875-1992, Clause 12.2, part thereof 38mm without fracture.

lot ar ~' ---

7. Inclusion Rating 03 sample in a Not worse than 2.0 A, S, C, 0 in part thereof both thin and thick series as per

IS: 4163-2004. 8. Grain Size 03 sample in a lot or Not coarser than 5, IS: 4748-2009

part thereof 9. Size of Billets 03 sample in a lot or As given in Para 1.5 of specification.

part thereof 10. Surface/sub- 03 sample in a lot or Magnetic particle test shall be

surface defects by part thereof carried out in accordance with the magnetic particle method speCified in IS: 10138 testing (wet (Part-III)-1983. method)

4.2 Stage Inspection:

The manufacturer shall carry out stage inspection during manufacturing of hangers and maintain records.

4 .3 Finished Producllnspection by Manufacturer:

a) b) c) d)

Signature

I Authonty & , Designation

Dimensional check as per applicable drawings and straightness Hardness Magnaflux testing Proof load test:

100% 100% 100%

100% hangers shall be proof load lested on a hydraulically operated machine. The machine capacity should be 201 (Min.). Proof load for hangers applicable to different type of coaches is as follows:

I

.A.l&J \"-\~L- lh-nY'_ ~-.. - . ..

JE/Std.lCarriage Dy. D irectorlStd.lCarriage Dircctor/Std./Carriage Prepared By: Checked by: APJ'foved by:

I Ref: CG-WI-4.2.J-l, Vel. 1.0 I Page 7 of 10 I Month of issue: July, 2014 STR No. C-K105 (Rev. I)

BG EMU motor coaChes BG Mainline coaches BG EMU trailer coaches MG EMU motor coaches MG Mainline coaches MG EMU trailer coaches MG High Speed coaches BG DMU Power cars

101 8t 8t 8t 5t 5t 5t 10t

No permanent set is permitted after the proof load test.

e) Case depth: One sample per batch of 100 Nos. or a part thereof.

4.4 The manufacturer shall maintain a list of all internal acceptance tests being carried out by him at various stages of manufacturing of the product. Proper records of such internal acceptance tests shall be maintained by the manufacturer and also included in the QAP. At the time of inspection of the product, these records shall be put up to the inspecting authOrity as and when asked for.

5. INSPECTION BY INSPECTING AUTORITY:

The inspecting authority or his representative shall satisfy himself in respect the following before taking up the inspection of finished hangers.

i) Manufacturing process and quality control followed by the firms is as per approved QAP.

ii) He shall check the internal records of stage and finished product inspection and satisfy himself by carrying out random physical checks.

iii) The raw material used confirms to correct speCification and the size of RC's is as per Clause 1.5. He shall carry out random checking of raw material during inspection as detailed in Para 4.1.

5.1 Inspection of Finished Product: Lot size of 100 nos. of 8SS Hanger or Part thereof.

S. No. Description Sample Size Acceptance criteria 1. Visual inspection 5% of the hangers in a lot Surface shall be reasonably free

from any external or internal cracks, laps, rough, jagged, imperfect edge and other ir]!-Ifious surface imperfection.

2. Dimensional 5% of the hangers in a lot Dimensional check as per accuracy applicable drawings and

straightness. 3. Hardness of the 5% of the hangers in a lot I. The hardness in the arms

wearing and non- (including corners) shall nol wearing (vertical exceed 190 BHN. legs) surfaces II . The hardness in the wearing

surface shall be between 50 to 60 RC.

4. Proof load 5% of the hangers in a lot As given in Para 4.3 of specification.

5. Case depth 1 in 100 or part thereof 1.5mm +0.1/-0.0mm, at six equi-distant locations.

6. Grain flow lines 1 in 100 or part thereof Grain flow lines will be checked at all the four corners.

7. Chemical One sample per heat IS: 1875-1992, Steel to Class-1. composition of the treatment batch or part material thereof (Sample should !

! Signature . -t .~\\);,v .1Nrv

I Authority-& -· · ... lh.-___ r---Direct(~~ge _ . -

JE/Std.lCarriage - Dy. DirectorlStd.lCarriage -j Designation Prepared By: Checked by: Approved by:

I Ref: CG-WI-4.2.1-1, Ver. 1.0 I Page 8 oflO I Month of issue: July, 2014 I STR No. C-Kl 05 (Rev. I) I

8.

9.

10. 11.

12

13.

Percentage elongation

be drawn from vertical leg of hanger for Spectro analysis). One sample per heat 26% (Min.) treatment batch or part thereof

Ultimate strength

tensile 1 in 100 or part thereof 370 MPa (Min.)

Yield strength 1 in 100 or part thereof Inclusion Rating 1 in 100 or part thereof

Grain Size 1 in 100 or part thereof

Surface/sub-surface 5% of the hangers in a lot defects by magnetic particle testing (wet method)

200 MPa (Min.) Not worse than 2.0 A, B, C, 0 in both thin and thick series as per IS: 4163-2004 . Not coarser than 5, IS: 4748-2009. Magnetic particle test shall be carried out in accordance with the method specified in IS: 10138 (part-III)-1983.

6. INSPECTION AT CONSIGNEE END:

6.1 Railways shall carry out Audit checks on all new hangers procured by them.

7. HANDLING AND PACKING:

i) The BSS hangers should be properly handled during manufacture. These should not be thrown on floor at any stage of manufacture to avoid any damage. BSS hangers should be suitably packed in small bundles consisting of 4 hangers each tied with wire at all the corner grooves before packing to ensure their safe transportation. Transportation of BSS hangers in wooden boxes / plates shall be preferable. Any other precaution in packing as may be deemed fit for safe transportation should be taken by the manufacturer to avoid damage during transportation.

ii) All hangers should be given one coat of rust preventing coating of a standard make viz. ROZ (Red oxide Zinc chromate) to avoid corrOSion on the hangers.

*.IrIrl>"''''

! i_ Signature ,y\ l\\ IJ- L--- I ft-nv"_

..f~':. ' ---i- Dy. DireclorlStdJCarriage--

f--- .- .- .. ~. -- -~Uthority & JE/Std.lCarriage Director Std.lCarriage

Designation Prepared Bv: Checked by: Approved by'

I Ref: CG-WI-4.2.1-1 , Ver. 1.0 I Page 9 of 10 I Month of issue: July, 2014 I STR No. C-K I05 (Rev. I) I SECTION-B

1. Requirements:

The vendors seeking approval shall comply with all the requirements mentioned below:

General and Manufacturing Facilities:

1.1 Covered area with adequate space undemeath for storage of raw materials e.g. billets , round corner squares. rounds etc. The covered area should have display board showing different colour shades nominated to different grades of steel to avoid mix up of materials.

Arrangement of painting the billets, RCS. rounds etc. with particular paint shade previously nominated according to the grade of steel should be available.

1.2 At least one number fork lift/overhead crane/pulley block of 2t capacity shall be available for material handling .

1.3 Minimum 2 numbers power hacksaw/ band saw or one number billet shealing machine to cut/shear the billets/ReS/rounds shall be available.

1.4 At least 2 numbers of drop hammer of 2t or equivalent capacity shall be available.

1.5 At least one number 400t capacity mechanical press for stamping/trimming shall be available .

1.6 Minimum 2 numbers compressors of 75 cfm each shall be available.

1.7 Minimum 2 numbers of batch type oil-fired or gas-fired or induction fumace of sufficient capacity should be available. The temperature range should be up to 12000C and the furnaces should be provided with temperature controllers. The furnaces shall have an arrangement of controlling the internal atmosphere to avoid undesirable scaling and decarburization.

1.8 Minimum one number pit type electric or equivalent tempering furnace of adequate capacity should be available. The fumaces shall be equipped with automatic temperature controllers .

1.9 Facilities for gas carburizing the wearing surface of the hangers should be available.

1.10 One number oil quenching/water quenching tank of sufficient capacity with heal exchanger and continuous oil circulation facilities should be available.

1.11 One number shot blasting machine should be available. The shot blasting machine should have inbuilt facility of sieving the undersize shots.

1.12 Adequate machining facilities comprising of vertical milling machines, radial drilling machines, horizontal lathes of suitable size and capacities and of standard makes die blocks and machining the forged components should be available.

1.13 Adequate number of hand grinders including pencil grinders should be available.

2. Testing Facilities:

2.1 Chemical lab:

2.1.1 Arrangement to carry out the analysis of five basic elements Le. C, Mn, Si , S & P should be available.

The firm should also have permanent arrangement with a Gov. Approved lab or a reputed steel making company for arranging the speGtro analysis of the material.

2.2 Physical Testing Lab: The firm must possess a well equipped physical lab with following facilities:

a) Universal testing machine of 201 capacity with load/deflection graph plotting arrangement.

b) Rockwell and Brinell's hardness testing machines.

Signature -d-~ ' ._-+-___ ....'.~~t.-'---c +__ V::;.:::-I

Authority & JE/Std.lCarriage Dy. DirectorlStd.lCarriage . Director1Std.lCmge ~~~ig~n~a~tio~n~~ __ ~Pr~C~M~ed~B~vL: __ _ L-__ ~C~b=e~~ed~bLv: _ __ -L _ _ _ _ ~ADCr~ov~ed~b~y~: ___ _J

I Ref: CG-WI-4.2.l-I, Ver. 1.0 I Page 10 oflO I Monlh of issue: JI~ Y, 2014 I STR No. C-KJ05 (Rev. I) I 2.3 Non-destructive Testing:

i) One number magnetic particle testing machine (wet method) with ultra-violet light facilities should be available. The machine shall have arrangement for both longitudinal and circular magnetization. Magnetizing current capacity shall be appropriate 1500 amps minimum.

ii) One number hydraulically operated proof load testing machine having minimum capacity of 201 should be available.

2.4 Other Testing Facilities:

i) Adequate facilities for preparation of test sample shall be available.

ii) Adequate numbers measuring instruments and GO & NO GO gauges shall be available to ensure dimensional accuracies.

iii) One no. optical microscope having eye piece for 100X, 200X & 500X magnifications.

iv) One no. polishinglbuffing machine for sample preparation.

v) Concerned specifications and grain size & inclusion rating charts.

3. Quality Control Requirements:

3.1 There should be a system to ensure the traceability of the product from raw material stage to finished prOduct stage. This system should also facilitate to identify the raw material composition from the finished product stage.

3.2 The firm must ensure that there is a QAP for the product detailing various aspects:

Organization Chart Flow Process Chart Stage Inspection details Various parameters and to ensure control over them

3.3 There should be at least one full time technologist having a minimum bachelor's degree in relevant field with 5 years experience or a person with diploma in relevant field with 12 years experience. He should be free from day-to-day production, testing, and quality control responsibilities. He should be mainly responsible for development of the product, analysis of the products, control over raw material and corrective action in case of difficulties in achieving the parameters.

3.4 The firm must ensure that the in-charge of the Quality Control Section is having a qualification of minimum bachelor's degree in the relevant field and has a minimum of 5 years experience. Anernatively, the in-charge can be a diploma holder with a minimum of 12 years experience. He should be actively involved in day-to-day activities of quality control/stage inspection/compliance of QAP etc.

3.5 The firm should have acquired ISO: 9000 series certification and the product for which an approval is sought should be broadly covered in the scope of the certification for manufacture and supply.

3.6 The quality manual of the firm for ISO: 9000 should clearly indicate at any stage the control over manufacturing and testing of the said Railway product.

3.7 The firm should ensure that a proper analysis is being done on monthly basis to study the rejection at various internal stages and it is documented.

3.8 The firm must ensure that all the relevant drawingslspecifications, IS standards are available with them.

************

A I Signature +~; '\'L0l~ J1 .. v. . ::;::---- D irectorlStd./Carriage

- _. I Authonty & JE/Std.lCarriage Dy_ DirectorlSld.lCarriage Designation Prepared By: Checl<ed by: Approved by: