str _mbr

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GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

SCHEDULE OF TECHNICAL REQUIREMENTS FOR MANUFACTURE AND SUPPLY OF RADIATOR

ASSLY To EMD/DLW PART No 10631855/17450408 & 10631856/17450410 for HHP

LOCOMOTIVES

No. MP.STR.ES.01.09.13,

(Rev.

00)

August ‐2013

Issued by:

MOTIVE POWER DIRECTORATE

RESEARCH DESIGNS AND STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW‐226011

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SCHEDULE OF TECHNICAL REQUIREMENTS FOR MANUFACTURE, SUPPLY OF RADIATOR ASSY TO

EMD /DLW PART No 10631855/17450408 & 10631856/17450410 for HHP LOCOMOTIVES

1. SCOPE

The Locomotive

radiator

assembly

is

a very

vital

part

of

the

locomotive

and

it

needs

to

have

very

high reliability during the entire service of the locomotive. The Schedule of Technical Requirement

(STR) mentioned hereunder is issued to serve as a guide to manufacturers (called the “firm”

hereinafter) and shall be read in conjunction with the relevant drawings & specification

MP.0.0500.01 (Rev. 03). The firm shall satisfy themselves of having complied with the requirements

of the latest product drawings and STR.

The technical requirements are meant to serve as guidelines only and are not exhaustive.

2. GENERAL REQUIREMENTS

2.1 The firm shall have currently valid ISO‐9001 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. preferably on quarterly basis shall be followed by the

firm.

2.3 The firm shall have a system of documentation in respect of 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 whom it was calibrated.

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

finished product stage. Stamped identification marking with serial number of radiator shall be

used for this purpose.

3.0 ELIGIBLILITY:

The firm shall have at least five year satisfactory performance experience in manufacturing &

supplying the MBR of same size or larger / smaller in size of Mechanical Bonded Radiators for use in

stationary / moveable rail road equipments like Gen –set application, earth movers/ excavators or

Rail

Engines

to

reputed

Diesel

Generator

set

/

locomotive

manufacturers

viz.

Cummins,

San

Engg.,

BEML, Mahendra, TELCO etc.

4.0 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 with this STR & specification. The QAP shall be a

comprehensive document covering the following aspects:

i) Detailed Quality Control Organisation of the firm along with key personnel engaged in the QC

function.

ii) Quality Assurance Process of incoming materials used for the subject items.

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iii) Process Flow Chart indicating process of manufacture for an individual product or for a family

of products if the process is same.

iv) Quality Assurance System – Inspection process control & Testing Plan including stage

inspections.

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 the basis of the approval process.

5.0 QUALITY CONTROL ORGANISATION

5.1 The complete organizational setup of the Quality control key personnel and officials along with

their qualification and experience shall be furnished.

The Quality Control organization shall be headed by a senior level official having adequate technical

qualification, who shall directly report to the plant in‐charge.

6.0 INCOMING MATERIAL

6.1 A complete Bill of Material indicating all input material items 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 (2008) shall be furnished. 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 the QAP.

7.0 PROCESS OF MANUFACTURE

7.1 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

the QAP.

7.2 The following details of machines used for all the steps for manufacturing the MBR‐

Preparations shall be included:

o Make and model of the machine

o Accuracy

o Details of machining operations.

o Calibration frequency – firm shall submit the details of the calibration last done and due

dates.

7.3 Machining process shall be such that all critical dimensions (i.e. header plates & tanks) are final

machined on CNC machining centres, preferably in a single setting or may be procured from

another service

having

similar

facilities.

7.4 Details of Jigs and fixtures used during manufacture shall be furnished mentioning the steps of

the process.

7.5 List of typical 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 the QAP.

8.0 QUALITY ASSURANCE PROCESS‐INSPECTION AND TESTING PLAN

8.1 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.

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8.2 The following details of measuring instruments/equipments/jigs/fixtures used for manufacturing

the subject item at all the steps of measurement operations shall be included:

o Make and model of the measuring equipment .

o Accuracy

o Quantity

to

be

measured

and

acceptable

value

range.

8.3 Stage inspection detailing inspection procedure, inspection parameters, destructive / non‐

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

8.4 The list of Testing and Measuring instruments are shown in Annexure‐II respectively for general

guidance only. However the specific Testing & measuring instruments, gauges used by the firm

will also form a part of the QAP, which shall be submitted and got approved by the firm.

8.3 Dimensional measurements shall be made by accurate measuring instruments preferably 3D‐Co‐

ordinate Measurement Machines on prototype and on sample lots. The firm shall have the said

facility with requisite accuracy in accordance with the dimensions of the jobs to be measured.

Measurements shall be included as a part of the QAP.

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ANNEXURE ‐1

A. MACHINERY & PLANT (M& P) FOR MANUFACTURING

The following is the indicative list of machining facilities to be available with the firm:

E= Essential V=Vital D= Desirable

S N Description E/V/D

1. Fin making machine E

2. Precise tube cutting machine E

3. Core builder E

4. Header fixing machine E

5. Baking oven E

6. Tube flaring machine E

7. Uniform tube expander machine E

8. Tube annealing machine V

9.

CNC

drilling

machines

for

headers

V

10. Top tank fixtures / Jigs E

11. CNC Turret machine for side frame V

12. CNC bending machine for side frame E

13. Template Gauges D

14. Torque wrench D

15. EOT crane E

16. Paint booth E

17. Weighing machine D

18. Welding machines D

19.

Spot Welding

machines

D

20. Air Compressor V

21. Pedestal Grinder V

22. Surface Grinder D

23. Power Press D

24. VMC D

25. HMC D

26. Hydraulic Press D

27. Fluxing Bath E

28. Shearing Machines D

29. Bending Machines D

B. LIST OF TESTING FACILITIES

1 Calibration of the Testing / Measuring Equipments shall be done at least once in a year or

prior, according to the criticality of the equipment.

2 Inspection Staff conducting non‐destructive testing shall be adequately trained and qualified

by a recognized agency and shall have adequate experience.

3 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.

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Following testing facilities shall be available with the firm or alternatively may be outsourced:

ANNEXURE‐II

A.

S N Description E/V/D

1.

Vibration test

rig

for

three

axis

up

to

15g

D

2. Wind tunnel test rig for heat dissipation as per IS standard E

3. Pressure impulse testing machine E

4. Hot air & Cold Water cyclic temperature testing machine E

5. Hot water & Cold Air cyclic temperature testing machine E

6. Internal Corrosion Testing D

7. Salt Spray test Stand V

8. Pressure Testing E

9. Chemical Testing of non Ferrous elements D

10. Squareness Testing E

11. Surface Plate E

12.

Air leak

and

water

leak

testing

facilities

D

13. Paint Testing Facilities V

14. Vernier Calliper gauge E

15. Height gauges E

16. Go, No‐go gauge E

17. Measuring tape E

18. Tube solder thickness measurement M/c D

B. METALLURGICAL AND CHEMICAL LABORATORY:

Manufacturer shall have facility to conduct metallurgical testing of the product in their premises or

shall have arrangement to get it done from NABL lab.

o Magnaflux /Dye Penetrate Test (DPT) facilities for checking of surface cracks.

o Magnetic Particle Inspection (MPI) facilities for checking sub‐surface flaws.

o Metallurgical Microscope with magnification power up to 500x & metallographic sample

preparation facilities with appropriate accessories to take photographs of slides.

C. PHYSICAL LABORATORY:

Manufacturer shall have facility to conduct physical testing of the product in their premises or shall

have arrangement to get it done from NABL lab.

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