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                            Government of India 

Ministry of Railways Signal Directorate Schedule of Technical Requirement (STR)

For Signalling Cable for Railways 0701 ( Ver.2 ) Research Designs and standards Organisation Manak Nagar, Lucknow – 226011
   

......January – 2012
       
 

factory area with minimum area break up for manufacturing. Version 2 0701 The schedule of technical requirements covers the norms for manufacture of different types of signalling cables for Railway applications. ft.0 Requirements: Vendors seeking approval for manufacture and supply of above cables shall procure the specification for the concerned item and go through the detailed technical stipulations.0 Scope:  Effective from…………. Office area inside the factory premises   . It should have a proper shed/ manufacturing hall. : 8000 sq.No. Covered area break up . given below. Item Description 1. They shall comply the requirements given below:2. 4. The manufacturing. Separate godown with interlocking and sealing facility for the offered lot V. Manufacturing floor area (a) for signaling. power & indoor cable (b) for signaling cable (c) for power cable (d) for indoor cable II. unscreened underground power cable PVC Insulated Railway Signalling Indoor Single Core Cable PVC Insulated Railway Signalling Indoor Multi Core Cable PVC insulated DST armoured. : 1000 sq.ft. 5. testing. : 900 sq. The infrastructure should be adequate for manufacture of the cable (applied for) as per concerned specification and to ensure adherence to quality assurance plan.1 GENERAL Infrastructure facility : The factory/manufacturing unit shall be located in an approved industrial area and shall have proper access road. STR for signaling cable No. : 500 sq. shall be close by and adjacent to each other. aluminium screened. : 7500 sq.ft. 3. 2.Page 1 of 11 1.ft. as follows:S.ft.ft. storage facilities etc. Godown area for keeping the finished product IV.ft. testing. PVC insulated armoured. : 7000 sq. Laboratory area : 10000 sq.ft. : 500 sq. ft. : 5000 sq. storage etc.ft. ft. underground cable PVC Insulated armoured. : 1800 sq. : a) Air conditioned Lab area for carrying out physical tests b) Cage for high voltage test with Interlocking facility c) Electrical Laboratory adjacent to high voltage cage III.minimum requirement I. underground cable Specification IRS S 63/2007 IRS S 63/2007 & IS:1554 IRS S:76/89 IRS S:76/89 IRS S 35/93 2. unscreened. : 400 sq. Stores for keeping raw material VI.

Suitable arrangements for maintenance and upkeep of the plant and machinery by way of AMC or in-house maintenance shall be ensured.3 The plant & machinery shall be suitably laid out process wise and each line duly labelled. date of installation etc. 2. It shall be so arranged as to facilitate smooth flow of product from one stage to the next stage & avoid unnecessary blockages or to & fro movement. manufacture & sale of the product by the firm shall be available & submitted. Essential Plant & Machinery: The minimum essential plant and machinery shall be available for the concerned type of cable as stipulated in clause 5.Page 2 of 11 Effective from…………. 2. 2. The plant and machinery should be in good working condition. It is preferable to run the sheathing line on diesel generating set so that there are no interruptions and continuity in the finished cable is maintained. Version 2 0701 As far as possible the space for conducting physical tests and electrical tests should be adjacent to each other.5 2.0 of this document. Test and measuring facilities : The testing and measuring equipments shall be available as stipulated in clause 6. are kept in air conditioned area while equipments generating excessive heat like water baths are kept outside the air conditioned area. computerized test setup/ electrical test equipments etc.2 All the statutory approvals by local. No. STR for signaling cable No. Diesel generator set back up with adequate facility for storage of diesel oil shall also be available. test house or other agency having trace-ability to National standards ). make.0 of this document.   . which have been indicated at the time of capacity-cum-capability assessment except for repairs/renewals. rating. shall be duly maintained and submitted. The complete details of each plant and machinery like make. shall be duly maintained and submitted along with the application for registration. All the equipments shall be calibrated at regular interval specified by calibrating agency ( Govt. . valid calibration shall be ensured.7 The firm shall not withdraw any machinery and plants or testing equipments. It can be combined also. 2. the concerned cable IRS specification shall be referred. The laboratories should be arranged in such a fashion that the equipments requiring air conditioning like tensile testing machine. For details regarding the test requirement/set up. For equipments requiring calibration.4 Sanctioned Power Load should be adequate for meeting the load requirements for the plant. date of installation. There should be a clear view of the cable drums kept in the cage for electrical testing from the electrical lab. The complete detail of each testing and measuring equipment like Sl. state & Central Government authorities for running the factory at the given premises. rating.6 2. serial number etc.

Version 2 0701 3. This system should also facilitate to identify the raw material composition from the finished product stage. compliance of QAP etc. 3.0 3. IS standards should be available and properly documented with the firm. 3. STR for signaling cable No. and should be responsible for testing and quality control of the product right from raw material stage till the finished goods stage.0 CHECK LIST Local.6 3. Guideline for preparing of QAP is given at Annexure-II.4 3. The responsibilities for quality control person shall be separately laid out.e. Adequate qualified and trained technical manpower shall be available. stage by stage in process testing to final product testing i. The firm should have acquired ISO – 9001/2008 series certification and the product for which the approval is sought. complete process.  All the relevant specification.9 4. 3. quality inspection and compliance of QAP.   . This shall positively implement the process flow chart given at Annexure-I.2 There should be a system to ensure the traceability of the product from raw material stage to finished product stage.5 Ensure that the system of First in -First out is followed for raw material and the intermediate stage product.Page 3 of 11 Effective from…………. He should be actively responsible for day to day inspection. state & central authorities & other commercial documents/certificates required to be ensured & submitted with the application along with the summary/checklist.3 3. should be broadly covered in the scope of the certification for manufacture & supply. The quality assurance plan & flow chart shall cover the complete process from the testing of raw material.8 3.1 Quality control requirements: The Quality Assurance Plan for the product should detail various parameters and to ensure control over them.7 3. It should be ensured that proper analysis is being done on monthly basis to study the rejection at various internal stages and it is documented. quality inspection. He shall be technically qualified and have adequate experience and shall be actively involved with day to day inspection. The Quality manual of the firm for ISO 9001 should clearly indicate at any stage the control over manufacturing and testing of the said railway product. Process Flow Chart for broad guideline is given at Annexure-I to this document. Quality In charge shall be free from day to day production.

2. bare/ tinned copper / aluminium conductor. If AC motor and drives are used then these drives must be synchronized for the line.8 5.7 5.6 5.12 5.3 5.2.0 5.2.4 5. Core marking machine.11 5. Counter meter.2.1 POWER :Contract demand of 400KVA.9 5. master batch & preheating facility (with on line dia controller for both ends & PID control for temperature).2.D. On line automatic dia controller ( Beta control ) one each for 45 mm and 65 mm extruder.5 5. Set 400 KVA (minimum) in covered room/enclosure to minimize noise pollution.2 5. Wire straightened with wiper. Conductor preheated between with Current control. Self centering head.ray Diffraction m/c for PVC testing Insulation extrusion line for PVC to insulate annealed.(10 meters ) with air sponger at the end. 45mm or 65 extruder with proper (24:1) L/D ratio of screw and barrel with automatic feeding of PVC. Version 2 0701 ESSENTIAL PLANT AND MACHINERY REQUIRED FOR PRODUCTION   5.2.1 Pay off should pneumatic/Electrical/Mechanical brakes and DC Motor and drive in tension control mode. PVC conveying / drying unit with air circulation. The blowers to be used for temperature control.  (i) Single unit.Page 4 of 11 Effective from………….I. Suitable capstan Synchronized with AC(VFD)/DC control drive.2. (ii) On line UPS 100KVA minimum in redundant mode 25 minute back up for extruder operation of inner sheath & unarmoured outer sheathed cable RAW MATERIAL/INSULATION 5.2.14   .2 (i) Drawing and annealing of Copper/Aluminium (of high conductivity Electric grade as per IS:8130) with following m/c a) RBD machine b) Wire drawing (Medium/Fine) c) Annealing (on line/pot/Tandom line/Tube) d) Copper purity test set up by electrolysis e) Tinning Machine(Electro/Hot Dip) (ii) X. for PVC cores. Gradient water cooling arrangement followed by stainless steel cooling trough of length 30 ft.10 5.2. P.2.2. D. (Proportional Integral Differential) type pyrometer controlled heating system with display for each zone of barrel and cross head of extruder.13 5.2. G. STR for signaling cable No. The head has to be self centering. Dancer with speed control for proper spread out winding of cable on drum. On line AC spark tester 0-10 KV with numeric fault counter meter and with audio visual alarm.2.2. 5. producing high quality signalling wire equipped with :- 5.

4 Suitable capstan synchronized with AC (VFD)/DC control drive.2 M dia reel. 5. Master Batch mixing & preheating facility (with online dia controller for both ends & PID control for temperature). Pay off should essentially motorized operation for lowering and lifting of cable drums. Fine arrangement for adjustment of gap and overlap.3 Gradient water cooling arrangement followed by stainless steel cooling trough of length 30 ft.4. 5.3.4.7 Pay off should pneumatic/Electrical/Mechanical brakes and DC Motor and drive in tension control mode. with air sponger at the end .4. Capstan/caterpillar synchronized with laying machine.4.(Proportional Integral Differential) type pyrometer comtrolled heating system with display for each zone of barrel and cross head of extruder. 5. 5.4.5.5.8 AC (VFD)/DC drive take up with proper tension control.1 5. Steel drum. 5. 5. Version 2 0701 5.1 Pay off suitable for 2. For other operation pay off may have either DC Motor and drive or AC Motor and drive in tension control mode. It can have DC/AC drive. 5.3. Essentially motorized operation for lowering and lifting of cable drums.Page 5 of 11 Effective from………….4 5.3 LAYING UP with minimum 36 bobbins and extendable arrangement with alternate direction & variable lay up arrangement.5.3.15 (i)Dual take up (ii)AC(VFD)/DC control drive (iii)Proper tension control (iv)traverse arrangement (v)Slip clutch (vi) Synchronized for the line .4.4. For other operation pay off may have either DC Motor and drive or AC Motor and drive in tension control mode alternatively it may have clutch or a brake to ensure appropriate tension between laying machinr and pay off. 5.2 Mtr.3. 5.3   . 5.2 P.4.3 5.2.1 5.2 5. Lay changing arrangement.10 PVC conveying / drying unit. Alternatively it may have clutch or a brake to ensure appropriate tension between laying machine and pay off with tension control for 2. Mechanical coupling with laying machine is also possible.9 On line spark tester 0 .D.2 Taping head for polyster tape.10 KV with counter and alarm.4. 5. Take up should essentially motorized operation for lowering and lifting of cable drums.5 (i)AC(VFD)/DC control drive (ii)Proper tension control (iii)traverse arrangement (iv)Slip clutch (v) Synchronized for the line .11 Counter meter for length 5.4 INNER SHEATHING LINE Extruder of 65 mm or higher size with proper (24:1) L/D ratio of screw and barrel with automatic feeding of PVC. The blowers to be used for temperature control.4. If AC motor and drives are used then these drives must be synchronized for the line. 5.I.5 STRANDING CUM ARMOURING machine for steel wire /strip of 36 bobbins with anti torsion arrangement with :5. STR for signaling cable No. 5.6 Speed synchronized cater pillar (pneumatic/Electrical/Mechanical type)/capston with AC (VFD)/DC control drive. For other operation take up may have either DC Motor and drive or AC Motor and drive in tension control mode alternatively it may have clutch or a brake with mechanically coupled drive between take up and capstan/caterpillar. 5.4.

7 PVC SHEATHING line on 100 mm minimum extruder (with on line Beta controller) with following arrangements: Pay off suitable for 2.4 5.7.7.7.5. Alternatively it may have clutch or a brake with mechanically coupled drivce between take up and capston/caterpillar 5.3 PID controlled heating of barrel and cross head pyrometer with digital display.8 Hoist OUTER SHEATHING LINE As per clause 5. 5. For other operation pay off may have either DC Motor and drive or AC Motor and drive in tension control mode.6 5.3 Take up suitable for 2.2 M steel drum.2 M dia reel. 5. Essentially motorized operation for lowering and lifting of cable drums.2 % accuracy with auto tape feeding and hot stamping.Page 6 of 11 Effective from………….2 M steel drum. 5. STR for signaling cable No. Alternatively it may have clutch or a brake with mechanically coupled drivce between take up and capston/caterpillar Butt / brazing welding machine.1 5. Alternatively it may have clutch or a brake to ensure appropriate tension between laying machine and pay off with tension control for 2.2 Fine arrangement for adjustment of gap & overlap.6. 5.2 Mtr.4 5. Essentially motorized operation for lowering and lifting of cable drums. 5.5 5. Essentially motorized operation for lowering and lifting of cable drums.8 Pneumatic cater pillar ( belt later type ). Essentially motorized operation for lowering and lifting of cable drums. 5.7.2 M dia reel.6 Counter meter for length.2 Mtr.6. Steel drum. Pneumatic/Electrical/Mechanical catter pillar or capstan synchronized with AC/DC control drive STEEL TAPE ARMOURING machine with :Pay off suitable for 2. Steel drum.7 5.6.6 Take up suitable for 2.2 M steel drum. For other operation pay off may have either DC Motor and drive or AC Motor and drive in tension control mode. For other operation pay off may have either DC Motor and drive or AC Motor and drive in tension control mode.7. 5.6.5.6 Tapping head for bedding tape(for screened cable). 5. For other operation pay off may have either DC Motor and drive or AC Motor and drive in tension control mode.6. 5.7.4 Spot/brazing welding machine.7 Sequential length marking machine of ±0. 5.7. Alternatively it may have clutch or a brake with mechanically coupled drivce between take up and capston/caterpillar 5.5. 5. For other operation pay off may have either DC Motor and drive or AC Motor and drive in tension control mode.7. 5.1   .6. Essentially motorized operation for lowering and lifting of cable drums. embossing wheel. 5.7. 5. Alternatively it may have clutch or a brake to ensure appropriate tension between laying machine and pay off with tension control for 2. Micro butt welding for fine dia conductor.9 Take up suitable for 2.6.5 Stainless steel cooling trough of minimum 10 mtrs length with air sponger at the end.2 PVC conveying / drying unit.7. 5.4 Marking and drum no.5 Pneumatic/Electrical/Mechanical catter pillar or capstan synchronized with AC/DC control drive. Version 2 0701 5.7 Tapping head for steel tape.6.10 Ink jet printing machine for indoor signalling cable & core marking.5.

Spooling machine ( min.13 5. Take up suitable for 2.15 5. H. Preheater cum mixer for PVC granules ( one for each extruder ). grinding machine and welding machine. ).8. Water bath for 60°C±1°C (with sealing arrangement) of size 120cm X 90cm X 60cm with digital temp.   .0 6. Core printing machine.8. two numbers) for measurement of insulation resistance. Essentially motorized operation for lowering and lifting of cable drums. Small workshop with minimum one number of lathe.6 5. 100 Amps primary current . indicator temperature recorder and hour meter.11 Hot rolling mill with hydraulic press for testing of PVC compound before extrusion.8. (min. 5. Roller guide. AVO meter.12 5. Million Meg ohmmeter. H.6 6.19 5.8.4 Speed control facility.5 5. C. min two numbers for conductor resistance measurement. size 54 inch. 22 KVA capacity with arrangement for measurement of both primary and secondary side voltage and currents.17   5. Dot marking machine for indoor signalling cable. Coiling stands . for Power Cable shaped conductor. Alternatively it may have clutch or a brake with mechanically coupled drivce between take up and capston/caterpillar Sufficient space to inspect the cable. V. with facility of measuring 0-10 kV AC duly calibrated by a Govt.3 6. drilling machine. Drum Twister/ Laying machine.16 5. EOT crane or fork lift or hoist for handling of cable drums (minimum 5 ton capacity). H. 30 Amps primary current .V Tester 0-10 KV.3 5. D. Proper approach road for reaching the transport in the factory at loading site.5 6. Digital resistance meter (ohmmeter).1 6.minimum two nos. ESSENTIAL TESTING EQUIPMENTS REQUIRED FOR QUALITY ASSURANCE Senior Kelvin bridge of one meter length for measurement of specific resistance.8. STR for signaling cable No. 2 nos.(For Indoor signaling cable) Stranding machine with minimum 61 bobbins with proper tension control & AC (VFD) Drive and Pay off & take up arrangement (For Indoor signaling cable).18 5. 5 amp primary current capacity. Indicator temperature recorder and hour meter.1 5.7 6. 5. For other operation pay off may have either DC Motor and drive or AC Motor and drive in tension control mode.V Tester 0-10 kV.14 5. 10 KVA capacity with arrangement for measurement of both primary and secondary side voltage and currents.21 5.2 6.10 5. One meter long steel scale.22 6. Counter meter for length measurement. High speed bunching machine.4 6. Water bath for 50°C± 1°C (with sealing arrangement) of size 120cm X 75cm X 60cm fitted with digital temp.9 5.2 M steel drum.8 REWINDING Machine suitable for 2.20 5.9 High speed twister with DC drive.8 6.8.Page 7 of 11 Effective from…………. Tester 0-2 kV. Shaping and compacting setup for Power cable.2 5.2 M steel reel with :5. Version 2 0701 5. test house or other agencies having traceability to National Standards.

Apparatus for heat shock test. COPY HOLDER : ED / QA / S&T   . No. duly calibrated by a Govt. 0-200°C.24 6.24 6.22.1 mg.21 6. 5/6 Channel Data logger for Temperature recording. Version 2 0701 6. Travelling microscope/profile projector for thickness measurement.R. hour meter and air flow meter (Rotometer) as per IS specification.1mg and relevant chemicals.24 6.32 6.29.28 6.15 6. 6. temp.33 6.(min. Apparatus for bleeding and blooming test.14 6. Two numbers) Digital / Analog Thermometer (0-100°C. S. Digital vernier.24 6.12 Calibration box for C.11 6.13 6.39 Note: Stamping die (for cutting dumbell). For indoor signalling cable.5. Calibration box for I. Torsion testing machine for steel wires (Motor drive with counter arrangement). Spark tester 0-15 kV separately for off line testing of cores. Apparatus for specific gravity test. indicator.36 6.37 6. test house or other agencies having traceability to National Standards.20 6.25 6. Heating oven 0-300°C fitted with digital temp indicator.19 6. hygrometers & glass apparatus for different chemical tests of PVC. (a) Tensile testing machine 0-50 kgf (b) Tensile testing machine 0-250 kgf (c) Tensile testing machine 0-1500 kgf.35 6.( at -20°C). In addition S. and air flow meter (Rotometer) as per IS specification. Apparatus for colour fastness to daylight exposure.24 6. duly calibrated by a Govt. 6.(min. test house or other agencies having traceability to National Standards. armour and copper. with accuracy of ± 0.30 6. recorder. Conditioning chamber 27°C. (for DST) 6. temp. Monopan digital chemical balance.38 6. hour meter temp. 6. Apparatus for cold bend test. Apparatus for testing colour fastness to water. (for screened cables) (d) Tensile testing machine 0-2500 kgf. No.10 6. Reduction factor measurement set up (for screened cables).17 6. Two numbers) with least count 0.26 6. Small water bath. 6. (for indoor signalling cables). Fire resistance test apparatus. Electronic balance with accuracy of ± 0.31 6. Hot deformation test apparatus.16 6.   Thermal stability test apparatus at 200°C.29 6. Apparatus for winding testing of Armour strips and Tapes. 6.34 6. Apparatus for cold impact test.(min. recorder.18 6. accuracy ±1°C.Page 8 of 11 Effective from…………. 0-300°C) minimum two each.R. 6.27 6.22 6.001 mm Digital/Analog stop watch.35 are not required. STR for signaling cable No.01 mm Digital micrometer.( at -20°C). Multicell aging oven 0-150°C with temperature accuracy of ± 1°C fitted with digital temp.23 6. Two numbers) with least counter 0.12(b).13 is not required for single core Indoor signalling cable.

 Repairs etc.Armour  Physical Check .S. Sheath Thickness  ‐T.Armouring T.2%  Armouring  with Wires /  Strips / Screening with  99.  O/S Thickness  O/S T.. S. Dia  -Annealing  -Specific Resistance  PVC Type ‘A’ Compound  to IS : 5831‐84 Core extrusion  with spark  Physical/Electrical  Check  ‐Eccentricity  ‐Core Diameter  -Insulation Thickness  -T. Month. & Elongation  -Specific gravity  Physical Check  Core  Printing      Core  Laying  Inner Sheathing  Type ST1  Compound of  Physical Check  ‐Lay up  Physical Check  ‐I/S Thickness  Electrical Check  Physical Check  ‐Aluminium ‐Insulation Resistance  ‐High Voltage Intermediate  Sheathing Type  ST1 Compound of  ‐T. No.S.Winding/Torsio n  . at Interval of every one meter . & % Elongation  Thermal Stability  Reduction factor for   screened cables  Loss of mass  Specific gravity  control  Final  Inspection  as per Check  list  * Embossing of trade mark/Firm’s name.Page 9 of 11 Effective from…………. Specn.O/S Homogeneity joints  Dimensions  . drum no.S.dia Copper Bars   for Annealing  Wire Drawing to  required dia.S. & % Elongation  before  & after FOR SCREENED  CABLE     ageing  Physical Check  ‐Inter.  Annealing at  300°C to 380 °C    Fine copper  conductor for  core extrusion -Cond.5% Aluminium  wires / Strips  Protection of Woven  Tape Impregnated  with Barium  Physical Check  . 0701 Version 2 QUALITY ASSURANCE FLOW CHART FOR RAILWAY SIGNALLING CABLE Check cond. STR for signaling cable No.   & Elongation   Outer Sheathing  Type ST‐1  compound IS : 5831‐ 84 & Marking *  - Lumps. & % Elongation  Physical Check  Sequential length  marking at  intervals of every  one meter   -SLM clearity   Final Testing   -Indelibility  by Quality  -Accuracy ± 0. year.

Qualification of key personnel and the officials deployed in Quality Control Cell. This shall cover the following: Incoming material Process control Product control . Name No. if used. the information shall be given in the format as below : of Drawing No.Page 10 of 11 Effective from…………. inspection parameters.) market The check sheet should be a controlled document of ISO : 9000 quality control systems. c. Inspection criteria at vendors’ premises. System control Gauging scheme – In the format for each operation gauges should be mentioned. Process Flow Chart indicating process of manufacture for an individual product or for a family of products if the process is same. Organisation Chart emphasising Quality Control Set-up. .   . method of testing/test procedure including sample sizes for destructive and non-destructive testing etc. Component / Specn.  . STR for signaling cable No. Stage inspection detailing inspection procedure. f. Name of Sl. In case large no. No. b. e. vendors the Vendors approving Inspection criteria agency (Write details or RDSO/Self/Open check sheet* No. Version 2 0701 Annexure -II Guidelines for Preparing QAP during fresh registration The QAP to be submitted by the vendor in triplicate (along with the application form for registration) shall cover the following aspects – a. The name of components for which it is approved                 Vendor Approving Agency. of bought out items are required. d. Quality Assurance System – Inspection & Testing Plan. Details of vendors .

Each page should be signed by QC in-charge. STR for signaling cable No. QAP covering all the information as asked above under ‘a’ to ‘f’ must be given in the form of single document indicating name of the firm and page no.Page 11 of 11 Effective from…………. used of Acceptance / limits/Criteria/ Specified Value Rejection details Reprocessed /Scraped g. f. ‘x’ of ‘y’ on each page. should be as below: Subject/ Product/ Process Sample Size Parameters & its for Frequency in inspection inspection Mode inspection equip. Version 2 0701 The generalised format covering the information under e. The approved QAP must be a controlled document and a quality record of ISO : 9000 quality control system of the vendor. A certificate to this effect shall be provided along with the QAP by the vendor   .