é) | ge Heanrege | Gama issued on | ware aMeA STR yerTafea/Rev 0 | 1of 13 (August- 2018) No.CLW/2018/ELDO/M/STR/0SO SCHEDULE OF TECHNICAL REQUIREMENTS FOR MANUFACTURING AND SUPPLY OF “STAINLESS STEEL PIPE FITTINGS” FOR THREE PHASE ELECTRIC LOCOMOTIVES art wat ISSUED BY faaqa sort afteey erator fata facataer ELECTRIC LOCO DESIGN OFFICE CHITTARANJAN LOCOMOTIVE WORKS CHITTARANIAN-713331 WEST BENGAL septa wall/approven By _BECTEUSIGNATURE, © Rerwfter arcvReCoMMENDED BY s 1aTR/SIGNATURE } ae —— — | | _ ARs awe 8.1 CEE/D&D = | Smet Prem arar sissuep ay ~~ SEEYD/CON \_ DY.CEE/D-I60 Ts Homage | Garieia/ issued on | wae. IA STA yarafen/revo eas | (August- 2018) No.CLW/2018/ELDO/M/sTR/050 SCHEDULE OF TECHNICAL REQUIREMENTS FOR MANUFACTURE AND SUPPLY OF FOLLOWING STAINLESS STEEL PIPE FITTINGS REQUIRED FOR THREE PHASE ELECTRIC LOCOMOTIVEs:- 1.0 NAME OF THE ITEM: Stainless Stee! Pipe Fittings for three phase electric locomotives 2.0 APPLICATION: This STR prescribes the requirements for stainless steel fittings with double ferrule for compressed air transmission for braking purpose in three-phase electric locomotives (WAG-SWAG-SHIWAG-SHC, WAP-7 & WAP-5), Operating air pressure may be as high as 14.5 kg/emsqr. Normal air pressure is 10 Ko/Cmsqr 3.0 SCOPE: The Schedule of Technical Requirements (STR) is issued to serve as a guide to manufactures (called the ‘firm’ hereafter) and should be read in conjunction with the relevant drawings and specifications with latest Revisions / Alterations. The technical requirements are meant {0 serve as guidelines only and are not exhaustive The firm should satisfy themselves having complied with the requirements of drawings and STR. List of relevant Drawings / Specifications is listed as Annexure -| Wherever lacking, existing CLW approved sources must also upgrade their facilities to fulfil the requirements of this STR within a period of One year from date of issue of thie STR 4.0 GENERAL REQUIREMENTS 42 The firm should have currently valid |S0-9000 certification issued by an approved agency of the International Accreditation Forum (IAF) with the activity desired clearly mentioned in the scope of certification 42. A system of regular submission of rejection details of material giving rejection rate, cause of ‘election, corrective action taken etc. on quarterly basis should be followed by firm 43 The fim must have system of documentation in respect of rejection at customer end warranty replacement and failure of item supplied by them during service 44° The firm shall have ail latest relevant Standards like IS, DIN, BS etc. pertaining to product specification 48 The firm shall have system of recording the plant, machinery and control equipments remaining out of service, nature of repairs done etc 46° The testing & measuring equipments shall be duly calibrated and the validity of calibration Should be current and verified by physically checking the calibration certificate issued by warm an Prepared By sian aren «| ane Par aren ssuep ay ZART/Checked By | SSE/DRG SEE/D/CON | DY.CEE/D-I| TS weaiPage | semfa issued on 30f13, cs) GeRTaTe/Rev 0 wHEIRA/STR No.CLW/2018/ELD0/Mm/sTR/O50 | (august- 2028) Calibration Agency from whom it was calibrated. Calibration shall be done by NABL accredited labs whose accreditation is valid on the date of calibration 47° Firm should have adequate trained personnel for after sales network 48 Whenever there is any change with respect to approved QAP. the same shall be promptly submitted to CLW for approval 5.0 QUALITY ASSURANCE PLAN (QAP: The firm shall prepare a Quality Assurance Plan (QAP) before approval is sought and Submit the same as part of compliance of this STR. The QAP shai be a comprehensive document covering the following aspects i Details of Quality Contro! Organization of the firm along with key personnel engaged in the QC function. ‘Qualification log sheet of the personne! manning the quality control set up. ") Process flow chart indicating process of manufacture of an individual product or for a family of products for which the process is same v) Details of Sub-Vendors: > The name of item for which sub-vendor is approved ~The name of approving agency > Quality manual submitted by sub-vendor to primary vendor ~The sub-vendor to have all the requisite infrastructure of manufacturing and {esting facilities, preferably under one roof. The sub-vendor to broadly meet with all the technical requirements laid down in this STR ~The primary vendor is following periodical inspection schedule for sub-vendor strictly, ~ 180 Certification details of sub-vendor also ~The sub-vendoris also liable for assessment by CLW. ¥) Inspection and testing plan of 2) Incoming Material as per format in Annexure ~ IV. Clause -2 ») Process (stage inspection) as per format in Annexure ~ IV, Clause - 3 ©) Product (Final inspection) as per format in Annexure ~ IV. Clause. 5 ware ar Siar ar a ae far ara ssueo ey | | ZART)/Prepared By @ART/Checked By SSE/DRG. “f ] SEE/R/CON | BV EEDA a de i[a5 ¥eatPoge Tyan issued on | wa ama /sTR se Fragiearevo | sands (August- 2018) No.CLW/2018/ELDO/M/STR/OSO ea | Se a = vi) All the formats used for recording inspection results 54 544 bag 5.2 521 wil) System of traceabilty, traceability diagram linking traceability from raw material stage {o internal check and finally lot offered for inspection vil) All internal checks to be carried out during manufacturing shall be summarized and furnished ix) QAP Format submitted in duplicate. Details of the above aspect are described in the following paragraphs. The QAP shall be approved by CLW and shail form basis of approval process QUALITY CONTROL ORGANISATION The complete organizational setup of the Quality Control Key personnel and official along ‘with their qualification and experience should be furnished The Quality Control Organization should be headed by a senior level official having degree in engineering who shall directly report to plant in charge INCOMING MATERIAL ees | = sitar ara | 38) fara are vissueD By | ZARI)/Prepared By ZaIT)/Checked By "FART Tarn = SSE/ORG. =| seeypjepn DY.CEE/D-|_ : e he el we 7 ne ee — a _ J| BS Semrage | werfita issued on ew. AaasTe | argieayrevo ele (August- 2018) | No.CLW/2018/ELDO/M/STR/OSO 5.2.3 Record of each sub-supplior clearly showing the quantity purchased and rejected as well as 5.2.4 Incoming raw material shall be 100% Inspected by Quality Control Department of the firm for any defect and verification may be submitted as part of QAP. 5.3 PROCESS OF MANUFACTURING 531 Complete process flow chart covering all steps of process of manufacture for an individual Product (or for a family of product if the process is Same), including the process flow of Cutsourced activities along with its integration with main Process, shall be clearly enlisted as Part of QAP. 53.2 The following details of machine used for all the steps of machining operations should be included 2 Make, model and commissioning date of the machine, b. Accuracy, © Details of machining operations 53.3 Machining process should be such that all critical dimensions are final. Vague language like available or will install is not acceptable 5.3.4 Details of jigs and fixtures used during manufacture should be furnished along with the ‘Manufacturing process wherever used $3.5 List of typical Machinery & Plant {esting and measuring instruments required for manufacture is mentioned in Annexure ~ Il & Ill The lst is for general guidance only and manufacturing operation shall be submitted and got approved by the firm as a part of QAP. ARN/Prepared By ZARD/Checked By | SSE/DRG, | SEE/R/CONst | 385 teamPage | gantfara/ issued on | THALHITCE/STR Wugicc/Revo [6 of 13 | (August- 2018) No.CLW/2018/ELDO/M/sTR/0S0 5.4 INSPECTION AND TESTING PLAN 5.4.1 Testing setup should be available in the fim’s own premises capable of testing the equipments as specified in the relevant technical specification, 5.42 Complete Inspection and Testing Chart covering all steps of Process of manufacture for an individual product including final inspection should be clearly enlisted as part of QAP 5.4.3. The following details of Testing / measuring instruments / equipments / tools / jigs / fixtures used for all the steps of measurement and testing operations should be included * Make and Model of the equipment + Name of the manufacturer + Accuracy * Capacity or Range * Date of Calibration * Due date of calibration * Agency of Calibration Vague language like available or will install is not acceptable 5.4.4 The accuracy and capacity of the testing and measuring equipments shall be adequate to meet the requirements of the specification and drawing, 545° Stage inspection detailing inspection procedure, inspection parameters and method of testing / test procedure including sample sizes for destructive and non-destructive testing Record of test results of stage inspection should be available and furnished 546 List of typical Testing and measuring instruments required for manufacture is mentioned in Annexure ~ Ill The list is for general guidance only. However, the specific Testing & measuring instruments, gauges used by the firm will also form part of QAP and shall be submitted | ‘Se ara (a ‘Sant far aM /IssuED By @€RT)/Prepared By @aNT)/Checked By | SSE/DRG. | SEE/D/CO) | DY.CEE/D-1[83 FeavPace | waft issued on | wa Aamaiista 7 of 13 | (August- 2018) No.CLW/2018/ELD0/M/sTR/O50 L 5.5 FORMAT TO BE SUBMITTED WITH QAP Format to be submitted with QAP is enclosed as Annexure — IV. Firms shall fill these formats keeping in view Para 5.0, STORAGE FACILITY * Adequate Dust free, clean and non - humid environment for storage of raw material and finished product separatcly + Adequate Dust tree, clean and non-humid environment for product assem bly area * Adequate Stacking / Handiing tables and racks in above storage area ar ara (& aif fara arar /issuED ay @aNT) Prepared By | @aI1)/Checked By | SSE/DRG. ] SeE(DICON | \ DV.CEE/DIL 1 rt | Ni aoe FS HowPoge | varia issued on | cua LaMeaSIR qaragiea/rev 0 Sofds =| (August- 2018) No. CLW/2018/ELDO/M/sTR/050 ANNEXURE -1 LIST OF DRAWINGS, SPECIFICATIONS AND STANDARDS 1. CLW Specification/Drawings: CLWWIMS/3/053 alt. latest for WAG-SHCIWAP-7. CLWIMS/10/015 A alt. latest for WAP-S. 2. Relevant Standard: | ASTM A108 Gr.1018 I. ASTMA276 Ss 316 lI ASTM A269 SS316 IV. ASTM A105/ Vv. Iso7/1 Vi. 180 28/1 Vil. CLW Spec MS/3/029 * All Specification of Raw Materials and Testing should be as per current version. aaren aren a oT eT sit féar ara /ASsuED By |___BART/Prepared By GAN /Checked By SSE/DRG SEE(D/CON | DY.cEE/t Ee a irTe HearPage | varia issued on | CRALMEASTR —aERTGFER/Rev 0 aot | (August- 2018) No.CLW/2018/ELD0/M/STR/O50 | ANNEXURE ~ 11 LIST OF MACHINERY AND PLANT: LIST OF MACHINERY AND PLANT: | Name of Machinery & Plant ST Capacity / Rating Essential / Optional CNC Lathe MiG [Standard ___| Essential CNC Milling WG | Standard ____| Essential | ‘Shearing WC “Standard a [Essential Buffing MIC me _| Standard Bes _| Essential 1 Grinding M/C sae ___| Standard can __| Essential Thread Cutting Machine ‘Standard _____] Essential | Air delivery compressor | Standard [Essential = Bh Vices tees ree a Standard Essential _[ Swaging Machine ‘Standard ____| Essential aser Marking Machine sential ation/Ultrasonic cleaning machine __TEssential 1 Forging facility aes Stand: = | Optional Zaplatng facility Standard | Optional -_ and Case Hardening facility | Standard J Optional DRAWING & DESIGN SETUP: [SI] Details Sie es | Capacity Rating | Essential Optional] pAoet si 1. | Drafting Software AutoCAD, Latest version | Essential 2. | Solid Modeling Software SOLIDWORKS — or | Essential equivalent software, Latest [ | version si - 3 1 ints Element Analysis Software | ANSYS or equivalent Optional __| software. Latest version Note: All optional activity or Machinery & Plant facility may be outsourced. | aware ara & sian are sre fear star /ssuED BY |__BBrET/Prepared By | ZART/Checked By SSE/DRG. | SEE/D/CON ae |gre | 985 erage | waste issued on WHER AISTR wuafed/Rev 0 | 10 0r a3 (August- 2018) No.CLW/2018/ELDO/M/STR/050 1 ANNEXURE - Ill LIST OF MEAS| IG EQUIPMENTS: | SLNo. | Name of Measuring & Testing Equipments | Capacity / Rating | Essential/ Optional 1 Inside Micrometer & Outside Micrometer Standard Essential [ | Vernier Caliper Standard sential 3._| Scale = | Standard Essential _4. | Thread gauge 7 _T Standare Essential 5. _| Profile Projector - __| Standard ___| Essential 6. | Dial gauge ‘Standard Essential ‘Surface roughness te test m machin i. dard SS Essential 8._| Plating thickness gauge - Essential |_9. [Surface hardness testing equipment | As per CLW specification | Essential LIST OF TESTING FACILITY: SINo. | Name of Measuring & Testing Equipments | Capacity / Rating __| Essential/ Optional 10._| Pneumatic pressure test setup As per CLW specification | Essential 11._| Hydrostatic test setup ____| As per CLW specification | Essential 12. _| Vacuum test setup As per CLW specification | Essential _ 13._| Temperature cycling test setup | As per CLW specification | Essential 14. Test es As per CLW specification | Essential | Hydrostatic Burst Test Setup a v tion | Essential Vibration test setup - As per CLW specification | Optional | Pressure Impulse cum Vibration test setup | As per CLW specification | iptional Flexure Fatigue Test As per CLW specification | Optional | Neutral Salt spray test Setup ‘As per CLW specification | Optional Salt Mist Test Setup [As per CLW specification | Optional Raw material test facility ____ [As per CLW specification | Optional | Intra-Granular Corrosion Test Setup ‘As per CLW specification | Optional (23. | Repeated assembly test setup ___|As per CLW specification | Optional) 24__| Case hardness test facil ‘As per CLW speaffcatior LW speci Optional Note: All optional measuring & testing facility may be outsourced to Govt. Approved / RDSO Approved Lab, i warn aT a J Ser aren Sin (8 aa ISSUED BY GaRT)/Prepared By FaNT)/Checked By SSE/DRG. “h =| yesy [es Femrhege | saftey issuedon [waeiaaste | gagiyRevo Motls | (August- 2018) | No.CLW/2018/ELD0/M/sTR/OS0 @ 7 a dae ~=t- Design in — charge Production in — charge = | Quality Inspection in-charge] Te | 2._Incoming Material Control 4 de _ ‘Subject / ‘Sample size & | Parameter for | Mode of Inspection Acceptance Product / ne eneY | inspection | / Equipments used | Limtlertera/speciied Process___| of inspection | | value as per DrgiSpec._| @) (b) Co) @ (e) | | ae = 6 = = as = ae [ Document | Record | Action in case] Reference | Format No. of rejection 6 @) ) ee ee 3. Process Control: (i) Proposed Map = - Si | Process) | Work Machine Details Ji house] No. | Activity | instruction [Téa ] Make | Model | Comm] Accuraey | Out source (a) |) | {c) @ Te a | | | lee | Sea Fray Sa are (& Zam Prepared By aRN/Checked By SSE/DRG. SEE/| IN “ae[ 353 FeaPage | sara issued on | of 13 (August- 2018) | wadiamea.ste | No.CLW/2018/EL00/M/sTR/050 4. Stage Inspection /Test Play Subject7" | insirument /Tinspection | Parameter ~ | Sample size | Document] Product/ | Jig & Fixture | stage for & its | Reference Process test bench | inspection | frequency of | | __| used | Inspection __| (a) | (b) == I ~ 1 2 = = Acceptance Inspection Agency | Record Format No | Action in case of | Limit/criteria/specified rejection value as per | Drg./Spec a _ ——- @ o @ | ® | | L = . a 5. Product Control: Subject “7 instrument / Jig | Parameter Sample | Document | Acceptance Product //& Fixture test | for Size Gils | Reference | Limitferteria/speci | Process bench used inspection frequency fied value as per of | Drg/Spec, : | Inspection I =I (a) 3) © | @ ) oH } Inspection Agency Record | Action in] |Format | case of | No. rejection | oT, w# o | J [ waren ara & Siar ara @ Sire rar ara ssueo ev | GART)Prepared By | ZaRT)/Checked By L SSE/ORG. [ ake FP ~ \DY.CEE/D-1 | Ja | wera issued on [vadsnedste | qrrrafea/revo (August- 2018) No.CLW/2018/ELD0/m/sTR/OS0 ar of | Capacity | Accuracy | Periodicity procurement | /Range | of Calibration @ | mH | [Instrument | Serial | Make | Mode! Description | No fe) f) @ Te bet @ [Calibration | Record] Agency | Format No. a) i) =| ones 7. Approved Sources for Raw Materials / Consumables [Raw Material 7] Specification 7 Source with | Whether Source is | Consumable Standard Address controlled by CLW / | RDSO / Others (@ “(b) ) @ cs a me | ~ om far are issueD ey __ SBR Prepared ay ZARD/Checked By | SSE/DRG.