pape INSPECTION & TEST PLAN | DOC. NO: GAERICEW.34 MALTES ISSUE NO: 01 RITES LTD BOGIE FRAME ARRANGEMENT | PAGENO. Sorte i (QA DIVISION) FOR NON-AC COACHES CPPROVED BY: GGMAUER ‘Case No.: Book No: ‘Set No: ] 1. Specification /Drawing 2. Date of Inspection 3. Place of Inspection 4, Size of lot 5. Size of Sample 6. Document Verification . Tests/Checks (to be wi ICF Drg. No. T-0-3-804 Alt. /2 Coll * ICF/MD/SPEC-147 Rev.02 & RDSO Specn. C-9202 Rev.02 {*Note-15) a) Internal’ External test certificate for raw material »b) Internal test and dimensional check report. ©) Calibration record of gauges, measuring instruments & test equipment, 4) RDSO Approval of firm, approval of QAP by Design office/ICF before manufacture of prototype is essential itnessed/conducted by inspector) Parameter Value Specified Observations | : All plates shall be free from surface Ref Cl. No. 8.4 of defects such as cracks, dents, €-9202 Rev.2 piting, bend, rust, scales etc. As per Note of Drg. No. Straightening of T-0-3-804 Alt. q/2 Col plates can be done with the help of i) Tri-axial welds shall be avoided. | either straightening All sharp edges to be rounded off. | machine or Hydraulic press. il) In case of box sections, gaps Hammering shall shall be filed with sealing not be resorted fo compound to 1S:1580 to avoid straighten the moisture creep. plates. (a) | Visual a il) tem-46 (M-16 Hexagon Head eo Screw) shall be galvanized to obese 1S:1673 Service Grade No. 2 of ican ei) hace Tab.-2 & shall be hand tightened ae iv) Item-25 (Boss) thread shall not ee be damaged due to welding. eas ¥) Aluminium rivets & the holes in Need aA the bogie coming in contact shail Bre Caner be adequately treated for bimetallic nui Bracket) a ‘action with Zinc Chromium primer Bi 0 ea before riveting e jig welded, Prepay Thema Fowadea oy (ERAS FecinatGa RAS cuesINSPECTION & TEST PLAN | DOC. NO: GA/ERICaW-34 PAGE NO: 2of 16 BOGIE FRAME ARRANGEMENT FOR NON-AC COACHES Fee area ea Ro.| Parameter Value Specified Observations | Remarks As per ICF Dig. Ne | Dimension sheet | T.0-3-804 Alt. ¢/2 Coll enclosed | Tolerance for untoleranced | dimensions shall be as per (by | Dimensions | ICFISTD-9.0-001 Ref Cl. No. 21.3 & Calibrated measuring gauge, 21.4 of C-9202 vernier caliper, throat gauge, Rev.2 straight edge, level bed, Go No-go gauges shall be used. ‘The standard steal plates Ref Gi No. 828 conforming to 1S:2062 Gr. C/ 8.3 of C-9202 Rev.2 e410 WC with Cu shall be | procured from SAILITISCO or other These test | reputed manufacturers alongwith cerlfcates shall be | their test certificates. correlated withthe stamping on the (c} | Raw Material | Whenever test certificates are a not available, samples from each up for manufacture shall be drawn & tested both prior to chemical composition & Commencement of physical properties in presence work: Ef inspecting Agency. z Ref Gl, No. 85 of Allthe plates shall be subjected to €-9202 Rev.2 ultrasonic test on the entire surface {@) | Ultesonic Test | for detection of sub surface defects of plates or intemal flaws, such as cracks, internal lamination etc. in 7 | accordance with ASTM Ad35 i) Side Frame Complete (Item-1) Drg. No. T-0-3-808 Col.-t ii) Headstock Complete (Item-2) Drg. No. T-0-3-665 ltem-2 ili) Longitudinal Complete LH & RH (Item 3 & 4) Drg. No. T-0-3-806 Col-2 & Col-1 iv) Transom Part (Item-5) Drg. No. T-0-8-805 Col.-1 ©) |) Transom Top Flange (em) Org. No. 1-0-3604 em2 PLATE THICKNESS 8, 10, 12mm 2062 Feat 0CUWC &/or IRS M-61/97 | | As per Note-11 of Drg. No. T-0-3-804 Alt, ¢/2 Cotill, alternatively Steel to 1S:2062 E250 Cu C may be used in lieu of Stee! to IRS M-41/7, where ever specified for the items pertaining to this Drg. Brapared Chasked bp Fawarded IesRAs. ‘echneal Cl: RAS. chestINSPECTION & TEST PLAN DOG. NO! QATERICEW.34 ISSUE NO: 01 RITES LTD. BOGIE FRAME ARRANGEMENT | PAGENO: 30616 jin (QADIVISION) FOR NON-AG COACHES APPROVED BY: COMMER B,,| Parameter Value Specified Observations Remarks ‘As per IS:ZO62Z0TI EZ50CUC Tost method Plale thickness 8, 10 & 12 mm ‘As per relevant ; 18: 228 oF {i Permissible parts of variation for any other | Product established ; Analysis instrumental Material : Srv | 21 | arene ion [%C- 020max. | %C- +0.02 chemical method sphdn 1.50 max. | 96NIn- +0.05 %Si- O40 max. | %Si- +0.03 S6P- 0.040max. | %P- +0.005, %S- 0.040 max. | %S- — +0.005 %Cu-0.20100,35 | %Cu- 40.03 %CE-0.39max 2 Mechanical Properties As per 18:2062/2011 E250CuC Tensile Test UTS (MPa)- 410 min, YS (MPa)- 250 min.(<20mm thk,) %Elongation- 23 % min, Bend Test The test piece shall withstand bending through 180° to an intemal diameter not greater than 2t (for $25mm thk,) without cracking. Charpy Impact Test (at -20° C) The average value of 03 test specimens shall be 27J min, and Test method ~ As per 1S:1608 Test method — As per IS:1599 The V-notch test pieces shall be in conformity with 03 Material Composition To individual value shall be less 1s1757 than 70% of the specified value, ‘As per IRS M-41/97 Tesi method- Plate thickness &, 10 & 12 mm Taddle Analysis | Permissible variation for Product Analysis %C- O40max. | %C- +0.02 SpMin- 0,25 100.45 | %NMn- 0.05 %Si- 028 100.72 |%S- £0.03, %@Ni- 0.2010 0.47 | %NI- 20.03 %Cu- 0.30 100.60 | %Cu 40.05 %Cr- 0.35100.60 | %Cr- £0.05 %S- 0.03max, | %S- +0.005 %P- 0.075 10 0.140 | %P- £0.05, 6Mo- 0.05 max.” %V- 0.05 max." Al 0.08 max." ShNb- 0.04 max.* *Total Incidental Elements-0.16% max As por relevant parts of IS: 228 or any other established instrumental’ chemical method. Bropares crecea By TERAS Tecnrieal Gt: RAS Forwarded o cust(75 | WSPECTIONSTESTPLAN /DOC.NO: GAERICEW-34 RITESLID BOGIE FRAME ARRANGEMENT | PAGENO: 4 of 16 (QA DIVISION) FOR NON-AC COACHES —_| ‘APPROVED BY: GGMAIER) Ro.| Parameter Value Specified Observations Remarks Fe per RSMEATST T Tensile Test Test method Tat Gold As per 1S:1608 Rolled | Rolled _ || UIS(MPS) | 480 min | 440 in|) ai "YS (MPa) | 340-min. | 300 min. oa | Noman *EElong | 22% min. | 26% min Bend Test Test method | Bond through 180° around a former : | of diameter equivalent to the As per IS:1599 thickness of the material without cracking on the outside of the bent portion MAJOR COMPONENTS ON BOGIE FRAME |, | MASTER ITEM LIST in IBS to be referred for component's check sheets (duly linked with ( | brg. & Spec.) NOTE: Inspection/tests may be conducted as per the respective Inspection & Test plan (hyperlinked) & detailed observations may also be recorded in the relevant check sheets. ‘AS por [OF Dig, No. -0-3-670 Alt-12 Col. | As per Note-10 of Drg. No. Shook Shoot (ltem-7) ‘welding of Guide with side frame, ee the manufacturer's initial should be placed outside of the frame, to facilitate easy identification. Check Sheet: Doc. No. B.S.S. Bracket | As per IGF Dra. N i: per ICF Drg. No. QNERICEWI31 | (Item-8) T-0-3-622 Alt-a/15 Col.1 (hyperiinked) | Check Sheet: Anchor Link Doc. No. 13 | Bracket Fearne cal QNERICaWi2t (ltem-9) ae (hyperlinked) Check Sheet: Suspension | As per ICF Drg. No. Doc. No. 14 | Strap WTAG:-0-3-317 Alta Item-t QNERICAWI24 {{tom-10) (hyperiinked) Rapa oe Thee Fanvardea oy TERA. ‘Tesneleal Gali RAS ousINSPECTION & TEST PLAN — [ DOG. NO: GATERICRW-34 ERUES ISSUE NO: 01 RITES LTD. BOGIE FRAME ARRANGEMENT | Prcsctiye pares (1. (QA DIVISION) FOR NON-AC COACHES APPROVED BY: GGM-VER i Parameter Value Specified Observations. Remarks ‘As per ICF Dig. No. cee “ICE/STD-0-3-001 Col.-1 | Brake Block | (Casting Design) £5 aaa on | Fabricated bracket may be used as Headstock | Per Note -2 of Dro." as alternate. {Item-11) ee mene Check Sheet: Doc. No. QA/ERICRWI23 As par IGF Dig. No. seu “ICFISTD-0-3-001 Col-2 trypetinked) Brake Block | (Casting Design) yp Hanger Fabricated bracket may be used as 18 | Bracketon | serNote 2 of Dg. as alternate (torn-12) Conforming to ICF Drg. No. ICE-SK-0-3-220 Alt. biNil (Fabricated Design) Check Sheet: Brake Cylinder | Doc. No. 7 | Fixing Bracket | S5°° or V9. RO 4 QNERICRWI25 item-20) aes (hyperlinked) ce | Check Sheet: sou wie As per ICF Drg. No. Doc. No. ta | Satet 03-673 Alt4/2 lem-1 QWERICAWI33 (item-22) Se Modified Bett Check Sheet: Tensioning | Doe. No. 19 | Bracket feloer Cea Ne QAERICAWI26 1-0-3678 Alt Col.2 : Arrangement (hyperiinked) {Item-40) ‘As per ICF Drg. No. ce ee ICE/MRVCIM-7-1-074 AIL-Ni oe Check Sheet: Earthing Lug Doc. No. 1.10] Complete tee QMERICRWI32 {Item-45) EO 808 AIL gle Colt, (hyperlinked) meant for earthing of Bogie with the Body & hence painting of the item shail be strictly avoided. aredbp SSCS Cn ] Fowarded by] Teeirieal Cl: RAS oust