Ref CGW 0001] Page of 32_| Dale of save Ocober, = Liev. 4) = [2008 INDIAN RAILWAYS Technical Specification for Supply of Fabricated Bogie to IR for Mainline Coaches, EMU/MEMU/DMU Coaches and 40,000 Its. capacity VVN type Milk Tank Van. (Broad Gauge: 1676mm) Tae TT Ra Rees oa 7] gee —[He ot [a — |e eT Ha Ta 6 | pase at 6 nkasuce Fans a mandacver \romstooe 4 | ete eae CL 7 Faber of box amatotte Conga hx ben ren | Aitrager comet rete & on fas ‘ssn Cl 16, Ota of Gag as bot gen Aadet on Aoconse Relrenee ig. Noxol atthe {Snomsentiore cs oI Sop trates soz zea | Sects owses (e) Anebmer 0 of Noe 2007 ma eon nese Ik uaa pore (Atco It aL age $0 tae onen aptly Incr et rng ae. AC HU AST, OS oe Resbe ea, rey on son (@ Setled saving ual ot he na ne ASR cannes cis, 1 me ee Toute er a rt Eee it enon tet ey, HE (A) iam spores. cea (@)rrenament coum 21, dace 6 a 17 stching ‘Shaan place tort eng Issued by: Research Designs & Standards Organisation Manak Nagar, Lucknow - 226 O11.‘Technical Specification for Supply of Fabricated Bogie to IR for Mainline ‘Coaches, EMU/MEMU/DMU Goachies and 40,000 jts. capacity VVN type Milk ‘Tank Van. 1. Scope: LL.” This specification covers the technical requirements to be complied by the tenderer for manufacture, testing and supply of Fabricated Bogie daly assembled to IR for Mainline Coaches, EMU/MEMU/DMU Coaches and 40,000 Its. capacity VN type Milk Tank Van, 1.2 This specification supercedes the eatlier specification No.C-9202 (Rev.0) issued in 1992. It also supercedes the bogie technical specification for 40,000 ts. VVN type Milk Tank Van to CONTR-BGMV-8401 of Aug 1984. 13 Definition Wherever “Inspecting Agency has been mentioned” it shall be taken as “Authorised Inspecting Agency of Purchaser". 2. Bligibility Criteria: 21 The manufacturer shall have adequate fabrication, heat treatment and machining and shot blasting facilities. The manufacturer shall be an ISO- 9001-2000° certified company. The manufacturer shall have prior experience in manufacture of fabricated bogies or other large fabrications subjected to dynamic loading and vibration and shall furnish the complete details of fabrications done in the past to RDSO for appraisal. A well- ‘equipped laboratory for various tests required for a quality product of fabricated bogie must be available with the tenderer. They shall have adequate technically trained staff including welders and non-destructive testing operators for radiographic, ultrasonic and magnetic particle inspection, qualified to approved ISi/international standards. The ‘manufacturers shall normally be employing a minimum work force of at Teast 50 persons including supporting personnel. Since bogie frames are also required to be heat treated, the manufacturer shall have adequate capacity both in regard to heating (furnace) and cooling under controlled condition, The manufacturer shall submit evidence in support of these requirements along with the tender. The manufacturer shall also submit detailed list of machines available for manufacturing the bogies.ROtCGW 0001 |-Bage Sof 32 | Date of ssue Ocober, | Spec NO_C-9202 (Rev.2) 7 -likew B 3. Scope of Supply: 3.1 The fabricated bogie duly assembled is to be supplied conforming in all, respects to the relevant drawings as indicated in annexure. 32 ~ The tenderer is required to coordinate and liaise with RDSO, Lucknow and the purchaser during manufacture of the first two-bogie frame/ bolster, which shall be the prototype bogies. 33. This is a general specification required for manufacturing of all types of bogies used in mainline coaching, stock, EMU/DMU/MEMU coaching, stock, Self Propelled vehicles and for 40,000Its,, capacity VVN type Milk tank van, 4. Governing Specifications: 182062 = Weldable Structural Steel 18813 —_Scheme of symbols for welding T8817 Code of Practice training and testing of welders 1:2102 = General locations for linear and angular dimensions 182074 - _—_Ready mixed paint, air drying, red oxide, zine chrome priming, 12982 - ‘name, synthetic exterior (a) under-coating (finishing ASTM —-_ Straight beam ultrasonic examination of steel plates A835 153658 Code of Practice for liquid penetrant flaw detection 185334 Code of Practice for magnetic particle flaw detection of welds, AWS DL Structural Welding Code (1983)Blue Std. International Institute of Welding, 159595 Metal arc welding of carbon and manganese. IS7307 —-_—_Approval tests for welding procedure, Wherever reference to standards, 18 or any other Standards/code, appears in this specification it shall be taken as a reference to the latest version of the Standard /code.Ref CGW O00T] Page 4a°S2 | Date ofissu Ociober, | Spee No, C9202 (Rew. tev, 4) Slee | 2008 as 5. Deviation: ‘When deviations from original design, material specifications, dimensions te. are desired specific proposals with reason shall be submitted for prior approval of RDSO/ Lucknow before commencement of manufacture, 6 ‘The manufacturer shall have following infrastructure facility at their ‘works for manufacturing of bogies. (@) Degreasing/Derusting plant (ii) Profile cutting machine (oxy-acetylene/plasma) for cutting plates upto thickness 25mm) Gi) Submerged are welding plants (Gv) Edge preparation facility (planer/shapers) () Shot blasting plant (vi) Load testing machine for load testing of bogies (ii) Radiographic testing facility /Ultrasonic testing machine. (wii) Furnace for stress reliving of bogie components (i) Hydraulic press for straightening of components (6) Fixtures for fabrication and assembly of bogie components (xi) Manipulator for down hand welding of bogie components (ii) Plate bending machine (i) MIG welding set with CO2/ Argon as shielding media, {siv) Apparatus to check chemical composition of ste. (ev) Hardness testing machine. (evi) Lab for chemical & mechanical esting having - a) Universal testing machine of 400 KN or have tie up with reputed lab/agency for carrying out testing which should be 130 9001:2000 certified. b) Impact testing machine or have tie up with reputed lab/ageney for carrying out testing, which should be ISO. 9001:2000 certified (evi, Oven for drying electrodes (0-500 degree C) (vil) MPI & DP testing facility (xix) 1t/24/StBOT Cranes 6) Level surface table of size 4000 mm X 2600 mm. 7 Bogie: Bogie consists of the following assemblies 71 Bogie frame assembly 7.2 Bolster assembly 73° Suspension 74 Airsuspension assembly in secondary suspensionPage 8 of 32" | Date Tissue October, | Spec. No.0-9202 (Rev. SS [2008 : = [Ret cGW 0001 | — [Ren =a) = 7A Bogie frame assembly: Bogie frame assembly consists of following sub-assemblies, (Headstock assembly (i) Side frame assembly (ii) Transoms assembly (iv) Longitudinal members 7.1) Headstock a) All parts/members shall be first degreased and derusted in a degreasing/ derusting plant b) All the parts/members shall be placed into the fixtures and tack ‘welded. ©) Weld the straight portion of the parts/members by submerged arc ‘welding and weld the curved contour by down hand MIG welding, in the manipulator. ) Stress relieving shall be done by putting the component along with fixture into oil fired farnace equipped with thermo- couples and recorders and allow to be heated between the temperature of 380° 10 420°C and later allowed to cool down in furnace, ©) The assemblies shall be checked for its dimensions and inspected for its straightness f) In case the component is not straight, straightening of component. shall be carried out followed by stress relieving process. 8) The above process of. straightening followed with the stress relieving process shall be repeated fill complete straightness is achieved 72.(i) Side frame: ) All parts/members shall be first degreased and derusted in a dogreasing/derusting plant b) All the parts/members shall be placed into the fixtures and tack welded. Weld the straight portion of the parts/ members by submerged arc ‘welding and weld the curved contour by down hand MIG welding. in the manipulator. d) Stress relieving shall be done by putting the component along with fixture into oil fired furnace equipped with thermo- couples and. recorders and allow to be heated between the temperature of 380° 0 420°C and later allowed to cool down in furnace ©) The assemblies shall be checked for its dimensions and inspected for its straightness.72 ii) % a 4) a 8 » 7) a) » 4) 2 Date of eave October, 2008 = In case the component is not straight, straightening of component shall be carried out followed by stress relieving process. ‘The above process of straightening followed with the stress relieving process shall be repeated till complete straightness is achieved. ‘Transom: All parts/memabers shall be first degreased and derusted in a degreasing/ derusting plant All the parts/members shall be placed into the fixtures and tack welded. ‘Weld the stzaight portion of the parts/members by submerged arc welding and weld the curved contour by down hand MIG welding in the manipulator. Stress relieving shall be done by putting the component along with fixture into oil fired furnace equipped with thermo- couples and recorders and allow to be heated between the temperature of 380° to 420°C and later allowed to cool down in furnace. TThe assemblies shall be checked! for its dimensions and inspected. {for its straightness. In case the component is not straight, straightening of component shall be carried out followed by stress relieving process. ‘The above process of straightening followed with the stress relieving process shall be repeated till complete straightness is achieved Nose suspension bracket, shall be welded in the transom for Motor bogies using necessary fixture (For powered bogies only). Longtuiral members Al parts/menbors stall be fiat degresed and dered in 2 desrensing/dersing plat ‘A the parte/membe shal be placed nto the fixtures and tack welded Weld the sight portion the prta/members by submerged arc wel Stress loving shall be done by ping the component long with fintre ino oll fed famace equipped with thermo. couples and tecodets ad allow (o be bested between the temperature of SP {e420 and later allowed fo ctl down nfurnace, ‘The asemblles shal be checked for ts diendons and iapeted forisoteaghines:Refi CGW 0007) Page 7.932: [Date otissue October, | Spee. No. C-9262 (Rev) (Rev.=4) = 008 : _ 9) In case the component is not straight, straightening of component shall be carvied out followed by stress relieving process. 2) The above process of straightening followed with the stress relieving process shall be repeated tll complete straightness is, achieved 74 (e) Bogie Frame Assembly: a) b) °) 4 2 f) 8) ») ) dD ‘The sub assemblies of the bogie frame shall be placed in a fixure for final assembly of the bogie frame. ‘The joints between side frames with Transom, Headstock and Longitudinals shall be welded properly for non-powered bogies. The joints between side frames with Transom, Head stock shall be welded properly for powered bogies, ‘The welded joints between side frames with Transom and Headstock shall be cleared by Radiographic Test. ‘The other bogie components eg. brake block hanger, brackets, brake pipe brackets, Shock absorber brackets, Lateral damper brackets(for ‘Air Suspension), Brake cylinder brackets ,BSS brackets, Wire Rope brackets ete shall be fabricated as per relevant drawings. ‘The components shall be placed in the fixures for fitment on bogie frame and full welding shall be done. ‘Axle guides shall be welded in the bogie side frame axle guide welding fixture Alignment of the axle guide shall be checked by using master gauges and straight edge. ‘Any slight discrepancy in location can be rectified by suitable local heating ofthe frame After proper fixing of guide, the dimensions shall be recorded, the help of. 72 Bolster Assembly: a) b) a 4) All parts/members shall be first degreased and derusted in a degreasing/derusting plant All the parts/members shall be placed into the fixtures and tack welded, ‘Weld the straight portion of the parts/members by submerged arc ‘welding and weld the curved contour by down hand MIG welding, in the manipulator. ‘Stress relieving shall be done by putting the component along with fixture into oil fized furnace equipped with thermo- couples and recorders and allow to be heated between the temperature of 380° 10 420°C and later allowed to cool down in furnace,‘Spec, Ne, C9202 (Rev) ‘The assemblies shall be checked for its dimensions and inspected {or its straightness. In case the component is not straight, straightening of component shall be carried out followed by stress r ‘The above process of straightening followed with the stress relieving process shall be repeated till complete straightness is achieved. 721 Following are the assemblies/parts, which shall be fitted on bolster arrangement: a) » 9 4 ») Centre Pivot Arrangement: Centre Pivot arrangement with rubber silent block bushes shall be provided as per drawing nos. given in attached annexure. Side Bearers Arrangement: The side bearer arrangement shall be provided as per drawing nos. given in attached annexure 3 ‘Anchor links (For Non Powered Bogies & Non HCC Bogies) (One Anchor Link in each side of the bolster diagonally across shall be provided to connect bolster & transom as per drawing nos. shown in Annexure. Silent block: Silent block as per RDSO specification no, C-9406 (atest revision) shall be provided in Anchor links, Silent block shall, also be provided in center pivot assembly. ‘Air vent screws: Tapped holes above dashpot shall be provided for replenishing oil in dashpot. Special screw with Cu asbestos ‘washers shall be provided in the dashpot hole to make it at tight. Shock absorber: Shock absorber as per RDSO Specification No. C-8708 (latest revision) shall be provided as per details given in annexure. Equalizing stay: Equalizing stays as per drawing no. given in annexure shall be provided in the bogie between the lower spring, plank and the bolster. ‘Lower Spring Plank: The lower spring plank shall be manufactured in a proper fixture as per drawing no. shown in the attached annexure-3. Proper stress relieving shall be done by patting the component along with fixture into oil fired furnace equipped with thermo- couples and recorders and allow to be heated between the temperature of 380° to 420°C and later allowed to cool down in furnace. Brake Bear load Test: a), Brake beam load test, or Rogie mounted brake system coaches shall be carried out according to the procedure laid down in ICE deg. No. T-3-2-624.‘Spee, No. €-8202 (RevzZ)_ CON WOT] PTET] eS = b). For coaches equipped with Underframe mounted brake system, Brake beam load test required to be carried out according to the procedure laid down in ICF drg, No, T3-2- 804. 73. Suspension (for coiled spring bogies) ©) The primary suspension consists of oil resisting rubber pads and helical spring mounted between axle box and bogie frame. ‘The axle box guide arrangement shall be as per drg. no. given in attached annexure. The items required to be fitted on the axle guide shall be supplied duly fitted and suitably packed. The items of primary suspension ie. primary spring, upper and lower washers, compensating rings, lower spring seat shall be supplied loose in packed condition. 4) For Main Line bogies supper & lower washer will be of Hytrel ‘material to RDSO Specification No. C-K409 (latest Revision) and. as per Drg, No.CG-K4058 & CG-K4059 respectively. @) In case where coiled springs are provided in secondary suspension, these coiled springs shall be mounted in between upper bolster and bolster lower spring plank which is turn is supported on the bogie frame through swing hanger/links as per drg. no. given in the attached annexure-3, | Bolster springs of helical type shall be manufactused as per DSO Specification No, WD-01-HLS-94 (Rev.(2) 74. Air suspension assembly ‘The pneumatic suspension system for the secondary stage of MC and TC stock shall confirm to RDSO specification No. CK-106 for air spring assembly and CK-407 for their control equipments. The air spring bogies shall have two vertical and two lateral hydzaulic shock absorbers with one lateral rubber bump stop provided at each side of bogie between bolster and bogie frame. 75 Assembly of Bogies ‘The bogies shall be supplied by the contractor in duly assembled condition, as per the requirements by the railways, containing all the items as listed in Annexure Ill of this specification except wheel & axle with axle box assembly.82 83 84 85 86 87 9a 92 2008. Raw Material: ‘The chemical composition and mechanical properties of steel shall conform to IS: 2062 Fe 410 WC with Ca, ‘The standard steel plates conforming to IS: 2062 Gr.C Fe 410 WC with Ca shal] be procured from SAIL/TISCO or other reputed manufacturers, having the essential facilites, along with their test certificates. ‘These test certificates shall be co-related with the stamping, on the plates to be taken ‘up for manufacture prior to commencement of work, Wherever test certificates are not available, sample from each shall be drawn and tested both for chemical composition and physical properties in the presence of Inspecting Agency, All records of physical, chemical including impact tests shall be made available to Inspecting Agency. All plates to be taken up for manufacture shall be visually checked for surface defects such as cracks, dents, pittings, bend, rust, scales etc. and they shall be free from all these defects Straightening of the plates can be done with the help of cither straightening machine or Hydraulic press. Hammering shall not be resorted to straighten the plates, Ultrasonic Test: All the plates shall be subjected to ultrasonic test on the entive surface for detection of sub-surface defects or internal flaws, such as eracks, internal lamination ete, in accordance with ASTM-A 435° ‘The tested and accepted plates shall be painting suitably at several places for easy verification atthe time of tack welding, Unaccepted plates shall be suitably stamped/painted and segregated and. records shall be kept in proper way. Cleaning, Marking and Cutting All the plates shall be degreased and derusted before commencing, ‘manufacturing operations. All the plates shall be marked properly to achieve the specified dimensions given in the drawing keeping the required allowances for proper welding and margin for machining,~ Re fei _CGW 0004 | Page 110137 Date afleaus Ociober, | Spee No. ¢-9202 (Rev.2) a = 2008, : 10. 101 102 103 104 105 uL 2B 1 122 Plates shall be cut either by oxy-acetylene plasma or by machine. All nicks/culs on the plates during cutting shell be welded and finish ground before using them for sub-assembly /assembly. Edge preparation All edge preparation shall be done by machining. ‘The weld joint dimensions/edge preparation shall be as per the relevant drawing,/IS specification. ‘The surfaces and edges to be welded shall be ground smooth and uniform and shall be ftee from cracks, undercuts, slags, gauges etc. that would adversely affect the quality and the strength of the weld ‘The roughness of oxygen cut surfaces shall be no greater than 25 microns Plates shall be inspected for dimensional accuracy. Any distortion that ‘occurs duting cutting shall be straightened before tack welding. Fixtures and Manipulators ‘The manufacturer should have the fixtures and manipulators for the following: i) Transom iil) Side frame iii) Air suspension cradle iv) Bogie frame assembly v) Bolster vi) Headstock (vil) Fixture for guide fitment (vill) Lower spring seat ‘Tack welding of Assemblies ‘The welding surfaces and the surrounding area shall be free from loose or thick scale, slag, mill scale, moisture, grease, oil, rust etc. that would prevent proper welding, All members to be welded shall be brought into correct alignment and held in position by clamps, wedges, strong backs, fixtures etc, until ‘welding is completed. Tack welds shall be made with the same electrodes that meet the requirements of the final welds and shall be cleaned thoroughly,Rak CGW WOOT] Page 12732 rifev.= 4) 4 ‘Date ofissie October, | Spec. No. €-9202 (Rev.2). |2008 = 123 14 1B wa 132 133 ng 135 136 wr ‘The length of tack weld and the distance between two consecutive tacks shall be suitably selected by the manufacturer to avoid defects like distortions, warpage etc Procedure for tack welding as specified in 15:9595 should be followed ‘Welding Provedure: Filler metal MIG welding process using COs gas as shielding media shall be used for curved areas where as submerged arc welding shall be used for straight ‘areas, RDSO approved brand of filler wire shall be adopted, Welders qualification, ‘Qualified welder as per 1S: 817 shall be employed for fabrication work and Radiographic test shall be carried out. The edge preparation shall be in accordance with the thickness ofthe plates. The welding shall reveal high standard of workmanship. However, if welders employed are qualified to any other international approved standards, prior approval of Inspecting, ‘Agency is necessary. Joints 1 Gaps and fit-ups shall be checked before starting the welding, 2 Use of Backing plates below the gaps of the joints is not permitted Position ‘As far as possible, all the weld joints shall be welded in down hand position, if necessary by using manipulators. Weaving bead Technique and Interpass cleaning technique shall be adopted by grinding and using wire brushes. Welding parameters as recommended by the electrode manufactures may be followed. PreHeat 1 Interpass temperature of 150 degree C to 200 degree C shall be ‘maintained throughout the welding, 2 Blectrodes shall be pre-heated, in the electric ovens, to a temperature of 150 degree C to 250 degree C for 2 hours before they are used.Ref CGW. (Rev—4) u ma M2 52 | Date oF eave October, — _) 2008... Page 13 073% Quality of Weld joints Visual (By using magnifying glass if required) 11) Weld joints shall have uniform beading and smooth change over from weld deposit to the parent metal and thorough fusion between adjacent layers of weld metal and between weld mnetal and parent metal 2) They shall be free from cracks, craters, undercuts, overlaps, porosities, inclusions, blow-holes et. 3) The fillet veld profile shall be made concave by grinding so that smooth transition occurs at the toe of weld maintaining correct size of the welds, 4) The slags shall be thoroughly removed and cleaned after each interpass. 5) The welds shall be ground to eliminate stress raisers and to improve fatigue life 6) Members distorted by welding shall be straightened by carefully supervised application of heat. ‘The temperature of hheating areas shall not exceed 650 degree centigrade. Mechanical method may also be used with application of heat. All the rework and straightening operations shall be completed before stress relieving. Magnetic Particle Test/Dye Penetrant Test -1) All the fillet weld joints shall be subjected to Dye Penetrant Test on all critical areas, as indicated in relevant Drawings listed in ‘Annexuresl and all the butt weld joints (100%) shall be subjected to Magnetic Particle Test/Dye Penetrant st for detection of weld flaws. The procedure and acceptance standard shall be as per IS specification no 5334/3658 respectively 2) Evaluations Discontinuities and defects shall be indicated by retention of the ‘magnetic particles and rise of Dye Penetrating after applying. developer on the surface of welds shall indicate discontinuities and defects. All such indications are not necessarily the defects, since excessive surface roughness, and the hestaffected zones ete. may produce similar indications, Even if indications are believed to be‘Speo. No. C-9202 (Rov. Rel CGW 0001 | Page 14 of 2 | Dalesohis Se [Bateelieae non-relevant, each type of indication shall be explored to determine iflinear discontinuities are present 143 Acceptance Standard. 41) All linear discontinuities are unacceptable and shall be removed and repaired by chipping or grinding and subsequent welding, 2) When defects appear, they shall be rectified and the area shall be re-examined by the same method to verify that they have been rectified completely. 3) All test reports of Magnetic particle inspection/Dye ‘Penetrant Test will be submitted for review to the Inspecting Agency. 144 Radiographic Ultrasonic Examination 1) All the Butt weld Bevel joints shall be subjected to 100% Radiographic Tests at 2% sensitivity and 2.0.22 film density conforming to Blue Standard of International Institute of Welding aw). 2) As per the specified standards UW Weld joints having cavities, undercuts and porosities shall be within the acceptable limits as per the specified standards. 3) The Radiographic examination shall be carried out by qualified personnel and radiographs shall be submitted to the inspecting agency for interpretation. In case of difference of ‘opinion, the interpretation of Inspecting Agency will be final 4) Alternatively Ultrasonic testing of welded joints shall be carried out as per MéeC dte's Code of Practice No. MC-4 of November 1994 (Reaffirmed in March 2006), 15. Stress Relieving: The stress relieving of the bogie frame/bolster shall be carried out in an cilfired furnace equipped with thermocouples and recorders. Adequate measures shall be taken to avoid any appreciable distortion of the bogie/bolster during heat treatment. If any resetting is required to be one after heat treatment in order to achieve required dimensions, the bogie frame/bolster shall be again suitably heat treated after such re- setting,[ReeCane-o00T Pave ‘The heat treatment shall be carried out as specified in annexure-2. 16. Gauging: List of gauges used for axle guide fitment and checking of Bolster Suspension Spring hangers is following: 1) Longitudinal gauge for axle guide. (As per ICF Drawing No J&T/G0296/01) ii) Transverse gauge for axle (As per ICE Drawing No J&T/G0384/01) fii) Diagonal gauge for axle guide, (As per ICF Drawing No J&T/G0300/01) 16:1 Square ness of the bogie frame, axle guides and BSS brackets shall be checked with the help of transverse, longitudinal and diagonal gauges and stiaight edge, Axle box alignment shall be checked with reference to the BSS brackets with the following gauges. [SNe] Gauges Bitogies Te tbogies [052 ‘Main Line & | EMO/ME | DMUStock | MUStock | bogie 1 [Congitadin {S708 0mm ~~ S70 mam | SOA Om | oO atgauge [equidistant from equidistant | equidistant | mn foraxie |cenizelineofavle |ffomecentre | fom centre side lineofaxde | ine of axle 2 ‘Transverse | 215941.0mm_ a ‘215941.0m [2210 gauge for ™ mn le guide 3 [Diagonal [962A Diam | SOTTO | SGHEAL Dm gauge for m ose ale guide 1mm | Eongitadin | 10083. Gman(7OOE | TOE Om | TDEL.O SOOT algauge {05mm érom | 750805mm | m(670405 | rom fors8 | longitudinal cent | fom ti fom brackets line) Tongitadinal_|Tongituia centreline) | al centre _ Tine 3 [Transverse [S121 0mm | ASSO mn [2159510 | BaD gauge for mm [1mm ss L [brackets| Digonal [250mm [257541 Dam [DsHLs0 | na5e gauge for own 30 bss mm brackets 7 [Distance aE mm PATTEM PABST. Om | TIE between 10m Bs bracket m and i \ adjacent aoleguide | _ 3 [Transverse | 87621 mmm Worm | 87H Ommn | TSE Gauge for | equidistant from | equidistant | equidistant | Oram Brake beam | centre line of sxle | fromentre from entre | equi hanger lineofaxle line of axle | istant bracket from centre | line of ale 162 If the BSS brackets do not lie within the tolerances relocate one or more [BSS brackets with correct alignment after ensuring correct alignment of the BSS brackets. Measure the location of axle guide from BSS bracket. If these measurements deviate from the standard measurements, relocate ‘this aligned plane of axle guides. 17, Shot Blasting: 417A The entire bogie frame/bolster shall be subjected to shot blasting after heat-treatment for cleaning of rust, scales, spatters etc. Special care shall be taken to protect the threads of Axle box guide during shot blasting, 172 Immediately after shot blasting and inspection the bogie frame/bolster shall be coaled with one coat of anti-corrosive paint to spee. no. 1S: 2074 in order to arrest rusting and corrosion. 18. Marking of Bogie Frame/Bolster ‘The bogie frame/bolster shall be placed on the marking table in order to ensure the following: 1) Profile and Geometry 2) Absence of distortionRak CGW OWT] Page TT of 82 | Date cFlssue Ociober, | Spec. No. €-9202 ( — Ai 008 a9, 2. 203 202 203 Record of above checks and Dimension Control Chart shall be submitted to the inspecting agency on demand. Painting The bogie frame/bolster shall be given one coat of Red Oxide Zine Chromate to IS: 2074 followed by two coats of black synthetic enainel paint to IS: 2932, Stages of Inspection: ‘The inspection shall be cavtied out by inspecting agency as indicated below: 1) Stage inspection of major sub-assemblies consisting of a) Side frames b) Bolsters ) Axle box guides d) Air suspension cradle 9) Headstock #)Transoms g) Longitudinal Members 2) Inspection after the above parts are assembled and tack welded. Special care shall be taken to maintain the centers of Axle box guides and bolster spring suspension brackets, 3) Inspection of complete bogie {rame/bolster after complete welding, After completion of the First Two Bogie Frames/Bolster waivel of any or all items of the stage inspection may be considered by RDSO/Purchaser fon request by the manufacturer. This will depend upon the experiences, gained at the time of inspection of first two bogies/olsters and the level of confidence built-up, The manufacturer ‘will proceed further in manufacturing the bogies only after taking clearance at each stage as specified above. ‘The Purchaser/ Inspecting Agency shall have access at all reasonable times to the works where bogie frame/bolster is manufactured and material is stored and the right to inspect die, jig and fixtures and measuring instruments being used by the manufacturer. All the facilities labour,Dale of eave Oclober, 2008, - 204 a1. ma m2 23 a4 appliances, gauges, measuring instruments etc, necessary for testing and inspection shall be provided by the manufacturer fre of cost. Dimension Control Charts, Chemical and Mechanical properties test certificates, Magnetic Particle Test Certificates, Radiography Test Reports, Heat Treatment records etc, shall be supplied along with the Bogie Frames/Bolster to the purchaser. Dimensions and Tolerances All dimension/tolerances shall be as per details given in the drawings. However, special atteition shall be given to check the centers of axle box guides and bolster spring suspension brackets in longitudinal, lateral and iagonal directions. Detailed dimension control charts/ sheets shall be prepared for each bogie {frame in which measurements of critical dimensions shall be recorded and. kept for evaluation and verification by the inspecting agency All the un-toleranced dimensions shall be in accordance with 1S: 2102-1980 (Medium) as indicated in the drawing, Gauges, fixtures and templates and accurate measuring instruments shall be used to ensure the correctness of the dimensions, Periodic Calibration of Gauges and Fixtures ‘The ganges, fixtures and templates shall be calibrated /checked for its correctness and accuracy after every six months and records shall be kept in proper way as per ISO- 9001 requirements. QAP A Quality Assurance Plan which outlines the various processes including inspection in order to obtain a Quality product shall be submitted to RDSO for approval and QAP shall be prepared'on the lines as indicated in ISO: 9001 document, CGG 0001(Rev 01) Vencior approval guidelines,Ref CGW 0007 | Page 18.0f82 [ Date of se Revd) se SS moe 24. Code of Practice for Quality Control and Inspection 24. The systern ‘The manufacturers shall furnish to the purchasing/ inspecting authorities information in respect of quality control systems in force at their works on various materials used in the manufacture of components. 242. Records, Tests & Sampling ‘The manufacturers shall furnish the Purchasing/ Inspecting authorities the details of tests and: inspection records and other relevant records as required under the quality control systems in force. ‘These records and reports shall be maintained by the Competent ‘Technical Authority of the manufactuser and shall be open to examination by the Purchasing/Inspecting Authorities at all reasonable time. The Purchasing/ Inspecting Authorities at their discretion may draw samples of materials referred to in para 8 and products at any stage of production for conformity tests either at the works of the manufacturer of in an approved laboratory. In ease the samples do not conform to the requirements of the specification, double the number of samples from the same lot/batch shall be drawn for re-tests. Should any of the re-test samples do not conform to the requirements, the entire lot/batch shall be rejected, 243° Approved Manufacturers 2431 For reasonable quality assurance, itis desirable that the components are procured from manufacturers approved by Research Designs & Standards Organisation (RDSO), Lucknow or by any other agency as assigned by the Purchasing Authority, based on evaluation of the components as per the specification, manufacturing and quality control facilities and quality/assurance programme. However, such approval does not guarantee the supply of consistent quality of material/components and therefore every Jot/batch offered shall be subjected to inspection and testing as per the specification 2432 ‘The approved manufacturers shall be subjected to periodical re-appraisal (periodicity for each components shall be assigned by the approving authority). The consignee may also periodically arrange testing if so desired, in an approved laboratory for conformatory tests within six ‘months from the date of receipt of the supplies.= E es ‘00% oe avatars Oook = ‘oo 25, Identification Marking: Shoe WoC Ls Bach bogie frame/bolster shall be, provided with an easily visible identification plate indicating the bogie frame/bolster serial number year of manufacture and manufacturer’s name to. facilitate identification correlation with the inspection/test results, 26. Packing: 261 All machined surfaces shall be protected from oxidation and corrosion by applying two coats of rust preventive oil to IS spec. No.493 PL viscosity grade 4s, 262 The packing shall be such that all the machined suxfaces shall be properly protected against rubbing/impact/scratches with other bogies or with ‘mode of transportation ie. wagon/truck/ trailers etc. 27. Warranty: ‘The manufacturer shall warrant the bogie frame for a period of 5 years from the date of commissioning into service for material, manufacture and workmanship as regards trouble-free and satisfactory service performance. If any defects are noticed during service with regards to ‘manufacture/welding quality of the bogie fame, action shall be taken by the supplier to carry out any repairs/rectfication or replacement, as may be considered appropriate, which shall be done at his own cost. The decision of the purchaser in this regard shall be final. 28, Submission of Tender Offer: ‘The tenderer shall submit parawise comments on this specification in his offer. In the absence of parawise comments, his offer will stand rejected He shall bring out the deviations, if any from the specification with adequate justification for such deviations. Unless otherwise stated in his offer, it will be presumed that there are no deviations. 29. Purchase of Drawings: 4) All ICF drgs. mentioned in the specification shall be obtained from ICF Chennai. The cxgs. and technical details would be provided by ICF free of cost, but incidental charges connecting with preperation and printing of cdrgs. and cost of booking of staff would be paid to ICF at actuals,REE CGW O00T | Page 7 of 32 | Date of aeue,Oaiober, Gores) — 2008 = eee ij] i) AILICF drgs. pertaining to VVN type Milk Tank Van shall be obtained from RD8O Lucknow. Static Load Test : The static load test on bogies shall be conducted on level plane for frst two prototype bogies of every order. 2.Bogie frame along with bolster assembly shall be placed on test rig, Axle box springs and bolster springs of the bogie shall be replaced by providing solid cylindrical spacers of 300mm height at axle guide (Location at a b c & d) and also at secondary suspension (Location at P & Q). 3.Anangement shall be made for measuring load deflection at the ceiter ‘of the side frame (Location at A&B) by providing dial indicator gouges ‘with suitable fixing arrangement, intial setup at 0. AThe predetermined load, requived for this test, which is given in the table below according to the type of bogie, shall be applied simultaneously atthe sicle bearer onthe bogie bolster (location at X & Y), 5:The deflection of the side frame at location A & B shal be observed and recorded as per the proforma below. This should not be more than Imm, 6The applied load shall than be removed from the side bearer and the residual deflection (if any) is observed and recorded. This residual deflection should be nil. 7.The sketch of the load testing equipment is given on page 29 On this specification ‘Fale load [Ma Toad | Deflection under Max. | Residual defection GF] Remarks applied on | loadatthe centerof | any) after removal of side bearer | sideframe location at | ~ load a location x 5 * B Cc) 0 (om) | con) | tommy | com ry 6550 1625 | e347 3032 | 900Page 22 of SE | Dale of issue Oter, | Spas No. 65202 (Rev.2) | = [ons one = Annexure-| Location of Radiographic and Dye Penetrating Test on Side frame and Bolstér [ypeatBogs [fring eterna [ Rediogaghi aoation | Bye penetnslieg Bogietrame [Bolster Bogie fame polite [Tinie Tope or sesame [Scns sion MEMU/OMU and Maile bogie (all cold ‘ope Motor Boge ACE bogie | SKATE | oteMu gat cotte type) a[Ret COW 0001 | Page 23 of 32 [Di a 4 200 Annexure RECOMMENDED STRESS RELIEVING PROCEDURE, ‘The temperature of the furnace shall not exceed 315 degree centigrade at the time the welded assembly is placed in it Above 315 degree centigrade, the rate of heating shall not exceed 160 degree centigrade per hour. During the heating period, variation in temperature through the portion of the part being heated shall not be greater than 50 degree centigrade. The same shall be monitored by ‘measurement of temperature using suitable thermocouples. For bogie, frame, 4 thermocouples shall be fixed at the four corners and tw0 at the centre of the side beams. Soaking temperature shall be between 600 degree centigrade and 650 degree centigrade. On reaching the temperature, the assembly shall be held within specified limits for a time not less than 1 hour per 25mm thickness ofthe plates. In addition, for determining the soaking time, the thickness of the thickest part of the assembly shall be considered. During the soaking period, the difference between the highest and lowest temperature of the assembly shall not be greater than 50 degree centigrade. During cooling eycle upto 315 degree centigrade cooling of the job shall be done in a closed furnace at a rate not greater than 100 degree centigrade per hour. From 315 degree centigrade, the assembly may be cooled in still Suitable tie-bars shall be provided during stress relief operation for maintaining the critical dimensions. The assembly shall be kept in the furnace, bottom side up (inverted position) during the heat treatment ‘The assembly shall be suitably supported while loading in the furnace to avoid any permanent deformation during stress relieving operation. ‘The heat-treating furnace temperature shall be effectively controlled by using thermocouples having associated recording equipment.IN BOLSTER ASSEMBLY (TRAMER BOGISime SCHEER Sie Sather T058 | Spee Te: reir | = | a _ : hb Eq woe OFF IF oe STOc: LOCATIONS OF OYE PENETRATION To 1 ; IN BOGIE FRAME (MOTOR CORCH;mone | Tee tba“)J6na) s0¥LN| conn ante awed sa ea ost ato aug (= yew) coo 99 8Ret EW G00 Page 31 of Date ot isaue Oawber ZOE] Spee. No. C-B202 (Rev.2) (Rev_-4) S [bane No Maite Bogies (ASR) « MEMU (ASR) ofexising coaches) | 86 boa is2se Toler 16.251 163 Tea aooe0! | WEAC O07 Provo? | ACEMUICASICOO0HE a a lea Wwrac E30 cone | WIAG-OTI0F CABSTOS | CRISTO | WHA TARE ACEC? AS03003 TATEIOF WINGS EMU 05-055 FU WIntEOTaI EMCO = BOSE WIACEO-05 EMU O5057 ‘RBOTI06 WTACH-SaDe EMUCSOTO RBOSI64 107 ogi WAG TOT RCEMUCT ese | Asr-n4.006 ory TacaoT [eEMrson [ears [EMU MURS | DMUIDRCEOS30F 05.505 (600 Ka) (600 Ks)_| DOEMUINI DOE MNTASROS- SR0.5.005 SR05.005. | 05 100g) i NATa OTTO OT a ATO HHI TROL TOT EARE aeons TIONS [—SIOHHS | 91s eodOeUSY micas Dina 0006 rounwa sooo6v9 | _o0s6¥9 sooecnwaoa__| izes wrecovun | cizemy | zezet0 “ue oem aon | oy | POSS POMWNEOY | _ozisma sorsaovan | onisova | ooisoyo | sotsudins nos | 24 soe-o-rwavoa | ootoua zorreovin | roomy | 62t1039 | sus 2x082ny | 9b ] = ea) (2:new) 2026-9 ON “20d | 2002 3890}90 nss1 Jo 8180 zewoze obes }o00_ ANB yeu