Ref: CGW (Rev.– 4) 0001 Page 1 of 24 Date of issue February, 2011 Spec. No.RDSO/2011/CG-01 INDIAN RAILWAYS Technical Specification for Higher Carrying Capacity (HCC) EMU/DMU Bogie with Pneumatic Suspension. (Broad Gauge: 1676mm) S No. 1. Date/month of Issue Feb 2011 Revision /Amendment Nil Page no. Nil Reasons of Revision New Issued by: Research Designs & Standards Organisation Manak Nagar, Lucknow – 226 011. Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP.K.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt. Director/VDG Ref: CGW (Rev. – 4) 0001 Page 2 of 24 Date of issue February, 2011 Spec. No.RDSO/2011/CG-01 Technical Specification for Higher Carrying Capacity (HCC) 20.32 t EMU/DMU Bogie with Pneumatic Suspension 1. 1.1 Scope: This specification covers the technical requirements to be complied by the tenderer for manufacture, testing and supply of HCC (20.32t) EMU/DMU Fabricated Bogie with pneumatic suspension at secondary stage of suspension. Definition Wherever “Inspecting Agency has been mentioned” it shall be taken as “Authorised Inspecting Agency of Purchaser”. Purchase of Drawings: All ICF drawings with latest Revision / Amendment required for manufacturing shall be obtained from ICF Chennai as per usual terms and conditions of ICF. 1.2 1.3 2. Eligibility Criteria: The manufacturer shall have the following:i) Adequate fabrication, heat treatment, machining and shot blasting facilities. ii) ISO-9001-2000 certification. iii) 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. iv) Well-equipped laboratory for various tests required for a quality product of fabricated bogie. v) Adequate technically trained staff including welders and nondestructive testing operators for radiographic, ultrasonic and magnetic particle inspection, qualified to approve ISI/international standards. vi) Employing a minimum work force of at least 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. Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP.K.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt. Director/VDG – 4) 0001 Page 3 of 24 Date of issue February.3 4. air drying.1 Scope of Supply: The HCC (20. IS or any other Standards/code.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt. The manufacturer shall also submit detailed list of machines available for manufacturing the bogies. IS:9595 IS:7307 - Code of Practice for liquid penetrant flaw detection Code of Practice for magnetic particle flaw detection of welds Structural Welding Code International Institute of Welding Metal arc welding of carbon and manganese. The tenderer is required to coordinate and liaise with RDSO. Governing Specifications: IS:2062 IS:813 IS:817 IS:2102 IS:2074 IS:2932 Weldable Structural Steel Scheme of symbols for welding Code of Practice training and testing of welders General locations for linear and angular dimensions Ready mixed paint. Approval tests for welding procedure.32t) bogies used in EMU/DMU coaching stock.2 3. zinc chrome priming Enamel. No. which shall be the prototype bogies. 3. 3.K. 2011 Spec.32t) fabricated bogie duly assembled is to be supplied conforming in all respects to the relevant drawings as indicated in Annexure-III. red oxide. Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP.1 (1983)Blue Std. Lucknow and the purchaser during manufacture of the first two bogies. ASTM A:435 IS:3658 IS:5334 - - AWS D1. Wherever reference to standards. synthetic exterior (a) under-coating (b) finishing Straight beam ultrasonic examination of steel plates 3. This is a general specification required for manufacturing of all types of HCC (20.RDSO/2011/CG-01 The manufacturer shall submit evidence in support of the above requirements along with the tender. Director/VDG . appears in this specification it shall be taken as a reference to the latest version of the Standard/code.Ref: CGW (Rev. Infrastructure facilities: The manufacturer shall have following infrastructure facility at their works for manufacturing of bogie. (xiv) Apparatus to check chemical composition of steel.K. No.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt. Director/VDG . (xv) Hardness testing machine. – 4) 0001 Page 4 of 24 Date of issue February. Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP. (xx) Level surface table of size 4000 mm X 2600 mm. dimensions etc. material specifications.Ref: CGW (Rev.RDSO/2011/CG-01 5. (xvii) Oven for drying electrodes (0-500 degree C) (xviii) MPI & DP testing facility. (vii) Radiographic testing facility /Ultrasonic testing machine. 6. which should be ISO 9001:2000 certified. (xvi) Lab for chemical & mechanical testing having – a) Universal testing machine of 400 KN or have tie up with reputed lab/agency for carrying out testing which should be ISO 9001:2000 certified. b) Impact testing machine or have tie up with reputed lab/agency for carrying out testing. 2011 Spec. (xix) 1t/2t/5t EOT Cranes. (viii) Furnace for stress reliving of bogie components (ix) Hydraulic press for straightening of components (x) Fixtures for fabrication and assembly of bogie components (xi) Manipulator for down hand welding of bogie components (xii) Plate bending machine (xiii) MIG welding set with CO2/Argon as shielding media. (i) Degreasing/Derusting plant (ii) Profile cutting machine (oxy-acetylene/plasma) for cutting plates upto thickness 25mm) (iii) Submerged arc welding plants (iv) Edge preparation facility (planer/shapers) (v) Shot blasting plant (vi) Load testing machine for load testing of bogies. Deviation: When deviations from original design. are desired specific proposals with reason shall be submitted for prior approval of RDSO/Lucknow before commencement of manufacture. 7. primary spring. along with their test certificates.1 Raw Material: The chemical composition and mechanical properties of steel shall conform to IS: 2062 Fe 410 WC with Cu. C-8703 Latest Rev. 1.) with one lateral rubber bump stop provided at each side of bogie between bolster and bogie frame. Director/VDG . lower spring seat shall be supplied loose in packed condition. 8. The axle box guide arrangement shall be as per drg. These test 8. given in attached annexure-III. upper and lower washers.3 Secondary Suspension (Air suspension assembly) The pneumatic suspension system for the secondary stage of MC and TC stock shall confirm to RDSO specification No. No.) for air spring assembly and C-K407 (Latest rev. having the essential facilities. The air spring bogies shall have two vertical and two lateral hydraulic shock absorbers (conforming to Spec. 7. C-K406 (Latest rev.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt. 2011 Spec.2 7. no. compensating rings.RDSO/2011/CG-01 7.K. The latest drawing shall be procured as per para. The items required to be fitted on the axle guide shall be supplied duly fitted and suitably packed.Ref: CGW (Rev. containing all the items as listed in Annexure III of this specification except wheel & axle with axle box assembly. The items of primary suspension i.1 Bogie frame assembly and Bogie Bolster assembly: As per RDSO Specification C-9202 Latest Revision.) for their control equipments with latest revision. – 4) 0001 Page 5 of 24 Date of issue February. Bogie: Bogie consists of the following assemblies: 7.3 above.e. 8. as per the requirements by the railways. Primary Suspension (Helical coiled springs ) The primary suspension consists of oil resisting rubber pads and helical spring mounted between axle box and bogie frame.4 Assembly of Bogies The bogies shall be supplied by the contractor in duly assembled condition. The standard steel plates conforming to IS: 2062 Gr.C Fe 410 WC with Cu shall be procured from SAIL/TISCO or other reputed manufacturers.2 Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP. scales etc. 8.K. chemical including impact tests shall be made available to Inspecting Agency.3 Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP. Straightening of the plates can be done with the help of either straightening machine or Hydraulic press. Director/VDG . bend.2 9. Unaccepted plates shall be suitably stamped/painted and segregated and records shall be kept in proper way.1 9. – 4) 0001 Page 6 of 24 Date of issue February.3 Wherever test certificates are not available. Hammering shall not be resorted to straighten the plates.5 8. No. All plates to be taken up for manufacture shall be visually checked for surface defects such as cracks.6 8. Plates shall be cut either by oxy-acetylene plasma or by machine. dents. in accordance with ASTM-A 435” The tested and accepted plates shall be painting suitably at several places for easy verification at the time of tack welding.4 8. internal lamination etc. All records of physical.Ref: CGW (Rev. sample from each shall be drawn and tested both for chemical composition and physical properties in the presence of Inspecting Agency. Cleaning. and they shall be free from all these defects.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt.7 9.RDSO/2011/CG-01 certificates shall be co-related with the stamping on the plates to be taken up for manufacture prior to commencement of work. Ultrasonic Test: All the plates shall be subjected to ultrasonic test on the entire surface for detection of sub-surface defects or internal flaws. 2011 Spec. 9. 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. rust. such as cracks. pittings. 8. All nicks/cuts on the plates during cutting shell be welded and finish ground before using them for sub-assembly/assembly. Marking and Cutting All the plates shall be degreased and derusted before commencing manufacturing operations.. Director/VDG .Srivastava /ADE/VDG Approved ByShivendra Singh /Jt. warpage etc.2 Edge preparation All edge preparation shall be done by machining. that would adversely affect the quality and the strength of the weld. 10. All members to be welded shall be brought into correct alignment and held in position by clamps. gauges etc. grease.RDSO/2011/CG-01 10.K.3 Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP. Plates shall be inspected for dimensional accuracy. fixtures etc. slag. Tack welds shall be made with the same electrodes that meet the requirements of the final welds and shall be cleaned thoroughly. 2011 Spec. 12.1 10. wedges. strong backs.1 12. 12. undercuts. oil. slags.4 10. that would prevent proper welding. 10. The surfaces and edges to be welded shall be ground smooth and uniform and shall be free from cracks. until welding is completed. Fixtures and Manipulators The manufacturer should have the fixtures and manipulators for the following: i) Transom ii) Side frame iii) Air suspension cradle iv) Bogie frame assembly v) Bolster vi) Headstock (vii) Fixture for guide fitment (viii) Lower spring seat Tack welding of Assemblies The welding surfaces and the surrounding area shall be free from loose or thick scale. mill scale.Ref: CGW (Rev. – 4) 0001 Page 7 of 24 Date of issue February. Any distortion that occurs during cutting shall be straightened before tack welding. The weld joint dimensions/edge preparation shall be as per the relevant drawing/IS specification. moisture.5 11. No.2 12.3 10. The length of tack weld and the distance between two consecutive tacks shall be suitably selected by the manufacturer to avoid defects like distortions. The roughness of oxygen cut surfaces shall be no greater than 25 microns. rust etc. prior approval of Inspecting Agency is necessary. – 4) 0001 Page 8 of 24 Date of issue February. No.K. Joints .2 Use of Backing plates below the gaps of the joints is not permitted. .1 Procedure for tack welding as specified in IS:9595 should be followed Welding Procedure: Filler metal MIG welding process using CO2 gas as shielding media shall be used for curved areas where as submerged arc welding shall be used for straight areas.1 Inter pass temperature of 1500 C to 2000 C shall be maintained throughout the welding. 14. if necessary by using manipulators. 13.RDSO/2011/CG-01 12. The edge preparation shall be in accordance with the thickness of the plates.1 Gaps and fit-ups shall be checked before starting the welding. The welding shall reveal high standard of workmanship. if welders employed are qualified to any other international approved standards.7 14.4 13. Position As far as possible.4 13.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt.2 Electrodes shall be pre-heated. RDSO approved brand of filler wire shall be adopted.5 13. Welding parameters as recommended by the electrode manufactures may be followed. all the weld joints shall be welded in down hand position.1 Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP. to a temperature of 1500 C to 2500 C for 2 hours before they are used. Director/VDG . However.6 13.2 13. in the electric ovens. Pre-Heat . 13.3 13.1) 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 metal and parent metal. Quality of Weld joints Visual (By using magnifying glass if required) . 2011 Spec.Ref: CGW (Rev. Welders qualification Qualified welder as per IS: 817 shall be employed for fabrication work and Radiographic test shall be carried out. Weaving bead Technique and Interpass cleaning technique shall be adopted by grinding and using wire brushes. . 5334/3658 respectively. may produce similar indications. undercuts. No.RDSO/2011/CG-01 .2 Magnetic Particle Test/Dye Penetrant Test .5) . as indicated in relevant Drawings listed in Annexure-I and all the butt weld joints (100%) shall be subjected to Magnetic Particle Test/Dye Penetrant Test for detection of weld flaws. All the rework and straightening operations shall be completed before stress relieving. porosities.K.3) . Even if indications are believed to be non-relevant. 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.1) All the fillet weld joints shall be subjected to Dye Penetrant Test on all critical areas. The slags shall be thoroughly removed and cleaned after each interpass. .2) Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP. The temperature of heating areas shall not exceed 6500 C. Director/VDG . The welds shall be ground to eliminate stress raisers and to improve fatigue life. 2011 Spec. . – 4) 0001 Page 9 of 24 Date of issue February.2) They shall be free from cracks. inclusions. The fillet weld profile shall be made concave by grinding so that smooth transition occurs at the toe of weld maintaining correct size of the welds. The procedure and acceptance standard shall be as per IS specification no. All such indications are not necessarily the defects. craters. each type of indication shall be explored to determine if linear discontinuities are present.4) .6) 14. since excessive surface roughness. overlaps.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt. and the heat-affected zones etc. Members distorted by welding shall be straightened by carefully supervised application of heat. blow-holes etc.Ref: CGW (Rev. Mechanical method may also be used with application of heat. undercuts and porosities shall be within the acceptable limits as per the specified standards. the interpretation of Inspecting Agency will be final.1) All the Butt weld Bevel joints shall be subjected to 100% Radiographic Tests at 2% sensitivity and 2.4 .RDSO/2011/CG-01 14. The heat treatment shall be carried out as specified in annexure-II.0-2. Alternatively Ultrasonic testing of welded joints shall be carried out as per M&C dte’s Code of Practice No.2) . Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP. Radiographic/Ultrasonic Examination .K. The Radiographic examination shall be carried out by qualified personnel and radiographs shall be submitted to the inspecting agency for interpretation. If any resetting is required to be done after heat treatment in order to achieve required dimensions. In case of difference of opinion. Adequate measures shall be taken to avoid any appreciable distortion of the bogie/bolster during heat treatment. MC-4 of November 1994 (Reaffirmed in March 2005).3) . Stress Relieving: The stress relieving of the bogie frame/bolster shall be carried out in an oil-fired furnace equipped with thermocouples and recorders.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt.4) 15.2 film density conforming to Blue Standard of International Institute of Welding (IIW). .2) When defects appear.1) All linear discontinuities are un-acceptable and shall be removed and repaired by chipping or grinding and subsequent welding. Director/VDG . No. – 4) 0001 Page 10 of 24 Date of issue February. the bogie frame/bolster shall be again suitably heat treated after such re-setting. 14. As per the specified standards IIW Weld joints having cavities. 2011 Spec.3) All test reports of Magnetic particle inspection/Dye Penetrant Test will be submitted for review to the Inspecting Agency. . they shall be rectified and the area shall be re-examined by the same method to verify that they have been rectified completely.Ref: CGW (Rev. Locations for radiography in frame assembly shall be done as per Annexure-I.3 Acceptance Standard . RDSO/2011/CG-01 16. Director/VDG . Measure the location of axle guide from BSS bracket. Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP. Axle box alignment shall be checked with reference to the BSS brackets with the following gauges. (As per ICF Drawing No J&T/G0296/01 –latest rev.No.K. axle guides and BSS brackets shall be checked with the help of transverse. Gauging: List of gauges used for axle guide fitment and checking of Bolster Suspension Spring hangers is following: i) ii) iii) Longitudinal gauge for axle guide. HCC (20. 2011 Spec.1 Square ness of the bogie frame.2 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.) Transverse gauge for axle (As per ICF Drawing No J&T/G0384/01–latest rev.0 mm equidistant from centre line of axle S. Gauges Longitudinal gauge for axle guide Transverse gauge for axle guide Diagonal gauge for axle guide Longitudinal gauge for BSS brackets Transverse gauge for BSS brackets Diagonal gauge for BSS brackets Distance between BSS bracket and adjacent axle guide Transverse Gauge for Brake beam hanger bracket.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt.) 16. – 4) 0001 Page 11 of 24 Date of issue February. If these measurements deviate from the standard measurements. relocate this aligned plane of axle guides.32 t) bogies 630 mm 2210 mm 3643±1 mm 800±1 mm 2140±1 mm 2285±3.) Diagonal gauge for axle guide.Ref: CGW (Rev.0 mm 733± 1. longitudinal and diagonal gauges and straight edge.0 mm 875±1. No. (As per ICF Drawing No J&T/G0300/01–latest rev. 1 2 3 4 5 6 7 8 16. 1 Stages of Inspection: The inspection shall be carried out by inspecting agency as indicated below: 1) Stage inspection of major sub-assemblies consisting of: a) Side frames b) Bolsters c) Axle box guides d) Air suspension cradle e) Headstock f) Transoms g) Longitudinal Members 2) Inspection after the above parts are assembled and tack welded.1 Shot Blasting: The entire bogie frame/bolster shall be subjected to shot blasting after heat-treatment for cleaning of rust. 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 . Special care shall be taken to protect the threads of Axle box guide during shot blasting.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt. 19. Painting The bogie frame/bolster shall be given one coat of Red Oxide Zinc Chromate to IS: 2074 followed by two coats of black synthetic enamel paint to IS: 2932.2) Absence of distortion Record of above checks and Dimension Control Chart shall be submitted to the inspecting agency on demand. 17. Special care shall be taken to maintain the centers of Axle box guides and bolster spring suspension brackets. No.RDSO/2011/CG-01 17. IS: 2074 in order to arrest rusting and corrosion. 20.Ref: CGW (Rev.K. Director/VDG . spatters etc. no. Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP.2 18. Immediately after shot blasting and inspection the bogie frame/bolster shall be coated with one coat of anti-corrosive paint to spec. 2011 Spec. 17. 20. – 4) 0001 Page 12 of 24 Date of issue February. scales. Dimensional Control Charts. Dimensions and Tolerances All dimension/tolerances shall be as per details given in the drawings. Radiography Test Reports. – 4) 0001 Page 13 of 24 Date of issue February. 2011 Spec.4 21. Heat Treatment records etc.2 21. Chemical and Mechanical properties test certificates.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt.2 After completion of the First Two Bogie Frames/Bolster.1 21. lateral and diagonal directions. special attention shall be given to check the centers of axle box guides and bolster spring suspension brackets in longitudinal. 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. However. Director/VDG .RDSO/2011/CG-01 3) Inspection of complete bogie frame/bolster after complete welding. waiving of any or all items of the stage inspection may be considered by RDSO/Purchaser on request by the manufacturer. Magnetic Particle Test Certificates. jig and fixtures and measuring instruments being used by the manufacturer. No. All the un-tolerance dimensions shall be in accordance with IS: 2102-1980 (Medium) as indicated in the drawing. necessary for testing and inspection shall be provided by the manufacturer free of cost. This will depend upon the experiences gained at the time of inspection of first two bogies/bolsters and the level of confidence built-up. All the facilities including labour. 20. 20. 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. Gauges.3 21. shall be supplied along with the Bogie Frames/Bolster to the purchaser. fixtures and templates and accurate measuring instruments shall be used to ensure the correctness of the dimensions. 21. appliances.K. measuring instruments etc.Ref: CGW (Rev. The manufacturer will proceed further in manufacturing the bogies only after taking clearance at each stage as specified above. gauges.3 20.4 Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP. 2011 Spec. 23.K.RDSO/2011/CG-01 22. Periodic Calibration of Gauges and Fixtures The gauges.3 Approved Manufacturers 24. the entire lot/batch shall be rejected. based on evaluation of the components as per Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP.1 The system 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. double the number of samples from the same lot/batch shall be drawn for re-tests.2 Records.Ref: CGW (Rev. No.1 For reasonable quality assurance. Should any of the re-test samples do not conform to the requirements. 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 or in an approved laboratory. 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.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt. 24. 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. Director/VDG .3. In case the samples do not conform to the requirements of the specification. Code of Practice for Quality Control and Inspection 24. 24. – 4) 0001 Page 14 of 24 Date of issue February. it is desirable that the components are procured from manufacturers approved by Research Designs & Standards Organisation (RDSO). 24. CGG 0001(Rev 01) Vendor approval guidelines. Lucknow or by any other agency as assigned by the Purchasing Authority. These records and reports shall be maintained by the Competent Technical Authority of the manufacturer and shall be open to examination by the Purchasing/Inspecting Authorities at all reasonable time. Quality Assurance Plan (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. manufacture and workmanship as regards trouble-free and satisfactory service performance.3. such approval does guarantee the supply of consistent quality of material/components therefore every lot/batch offered shall be subjected to inspection testing as per the specification.RDSO/2011/CG-01 the specification. 2011 Spec. in an approved laboratory for conformatory tests within six months from the date of receipt of the supplies. Warranty: The manufacturer shall warrant the bogie frame for a period of 5 years from the date of commissioning into service for material.493 Pt. Identification Marking: Each 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.I viscosity grade 46. However.1 Packing: All machined surfaces shall be protected from oxidation and corrosion by applying two coats of rust preventive oil to IS spec. 26. The decision of the purchaser in this regard shall be final. and not and and 24. The consignee may also periodically arrange testing if so desired. as may be considered appropriate. The packing shall be such that all the machined surfaces shall be properly protected against rubbing/impact/scratches with other bogies or with mode of transportation i.e. 26.2 27. which shall be done at his own cost. wagon/truck/trailers etc.K. manufacturing and quality control facilities quality/assurance programme. Director/VDG .Srivastava /ADE/VDG Approved ByShivendra Singh /Jt. 26.2 The approved manufacturers shall be subjected to periodical re-appraisal (periodicity for each components shall be assigned by the approving authority). 25. Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP. No. action shall be taken by the supplier to carry out any repairs/rectification or replacement.Ref: CGW (Rev. – 4) 0001 Page 15 of 24 Date of issue February. If any defects are noticed during service with regards to manufacture/welding quality of the bogie fame. No. Axle No. load 1. it will be presumed that there are no deviations. – 4) 0001 Page 16 of 24 Date of issue February. The deflection of the side frame at location A & B shall be observed and recorded as per the proforma below. 2.32 Max.600 Residual Remarks deflection (if any) after removal of load at location A B (mm) (mm) Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP. 6. The applied load shall than be removed from the side bearer and the residual deflection (if any) is observed and recorded. required for this test. Static Load Test : 1. 29. initial setup at 00. He shall bring out the deviations. which is given in the table below according to the type of bogie. (t) 20. Unless otherwise stated in his offer. 7. load at the side bearer center of side frame location at A B (t) (mm) (mm) 9. 2011 Spec.RDSO/2011/CG-01 28. load Deflection under applied on Max. No. Bogie frame along with bolster assembly shall be placed on test rig. The sketch of the load testing equipment is given on page 23 of this specification S. shall be applied simultaneously at the side bearer on the bogie bolster (location at X & Y). 3. if any from the specification with adequate justification for such deviations. 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). This residual deflection should be nil. Director/VDG . The predetermined load.Ref: CGW (Rev. 4. In the absence of parawise comments.K. Submission of Tender Offer: The tenderer shall submit parawise comments on this specification in his offer. 5. his offer will stand rejected. Arrangement shall be made for measuring load deflection at the center of the side frame (Location at A&B) by providing dial indicator gauges with suitable fixing arrangement.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt. This should not be more than 1mm. The static load test on bogies shall be conducted on level plane for first two prototype bogies of every order. I Location of Radiographic and Dye Penetrating Test on Bogie frame and Bolster Type of Bogie Drawing References Radiographic Examination Bogie Bolster frame SK-92078 SK-92063 (At page (At page no. Director/VDG .-23) no. – 4) 0001 Page 17 of 24 Date of issue February.RDSO/2011/CG-01 ANNEXURE . No.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt.Ref: CGW (Rev. 2011 Spec.-21) Dye penetrant test Bogie Bolster frame SK-92076 --(At page no.-22) HCC bogie of EMU Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP.K. Suitable tie-bars shall be provided during stress relief operation for maintaining the critical dimensions. During the heating period. the assembly may be cooled in still air. In addition. for determining the soaking time. Director/VDG . 2) 3) 5) 6) 7) Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP. For bogie frame. the difference between the highest and lowest temperature of the assembly shall not be greater than 50 degree centigrade. the thickness of the thickest part of the assembly shall be considered. 2011 Spec.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt. 4 thermocouples shall be fixed at the four corners and two at the centre of the side beams. Above 315 degree centigrade. The same shall be monitored by measurement of temperature using suitable thermocouples. the assembly shall be held within specified limits for a time not less than 1 hour per 25mm thickness of the plates. On reaching the temperature. bottom side up (inverted position) during the heat treatment. No. The heat-treating furnace temperature shall be effectively controlled by using thermocouples having associated recording equipment. 4) During cooling cycle 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. The assembly shall be kept in the furnace. – 4) 0001 Page 18 of 24 Date of issue February. the rate of heating shall not exceed 160 degree centigrade per hour.RDSO/2011/CG-01 ANNEXURE -II RECOMMENDED STRESS RELIEVING PROCEDURE 1) The temperature of the furnace shall not exceed 315 degree centigrade at the time the welded assembly is placed in it. variation in temperature through the portion of the part being heated shall not be greater than 50 degree centigrade. From 315 degree centigrade.K. During the soaking period. Soaking temperature shall be between 600 degree centigrade and 650 degree centigrade.Ref: CGW (Rev. The assembly shall be suitably supported while loading in the furnace to avoid any permanent deformation during stress relieving operation. Bogie side frame Head stock AC/DC EMU/M2 0-0-201 AC/DC EMU/M2 0-1-201 EMU/M 0-2-001 AC/DC EMU/M2 0-3-201 DMU/DPC 5 0-3-515 EMU/M 0-3-004 DC/EMU /M/ASR 03-003 DMU/DP C10. arrgt.32 t 20.32t 1 Axle load 2 Bogie genl.32t Trailer Coach 20. DC/EMU M/ASR-05-005/ L200Kg 3 4 5 6 7 8 Transom 9 Bogie bolster arrgt.0-3004 DC/EMU/M/ ASR-0-3003 DMU/DPC1 0-0-4-001 EMU/M-0-6001 DMU/DPC50-5-503/ V300Kg.02001 DMU/DPC1 0-0-3-001 DMU/DPC50-3-515 EMU/M.Ref: CGW (Rev. 2011 Spec.No. Description AC/DC EMU Motor Coach 20. Axle box guide arrgt. / capacity 10 11 Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP.K.32t 1400 HP DMU DPC 20. DC/EMU M/ASR-05-005/ L200Kg DHMU/ DPC 00001 DHMU/ DPC 01001 DHTC 02-001 DHMU/ DPC 03001 DMU/ DPC -03-002 EMU/M 0-3-004 DHMU/ DPC 03002 DMU/DP C 0-4001 EMU/M0-6-001 ICF/SK05-015/ V900Kg AC/ EMUM/ASR0-0-001 DHMU/DPC 0-1-001 EMU/M. Centre pivot arrgt.0-4001 EMU/M 06-001 DMU/DP C5-0-5503/ V300Kg. DC/EMU M/ASR-05-005/ L100Kg AC/DC EMU/C2 0-0-001 ACDC/E MU/M2 01-201 EMU/M 02-001 AC/DC EMU/M2 0-3-201 DMU/DPC 5 0-3-515 EMU/M 03-004 DC/EMU /M/ASR 03-003 DMU/DP C10-0-4001 EMU/M 06-001 DMU/DP C5-0-5503/ V300Kg. DC/EMU M/ASR-05-005/ L200Kg DMU/DP C 0-0001 EMU/M 0-1-033 EMU/M 0-2-001 DMU/ DPC -03-009 DMU/ DPC -03-002 EMU/M 0-3-004 DHMU/ DPC -03-002 DMU/DP C 0-4001 EMU/M0-6-001 ICF/SK0-5-015/ V900Kg DMU/DP C 10.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt.RDSO/2011/CG-01 ANNEXURE-III S. DC/EMUM/ ASR-0-5005/ L200Kg AC/DC EMU/C2 0-0-201 AC/DC EMU/M20-1-201 EMU/M02-001 AC/DC EMU/M2 03-201 DMU/DPC 5.0-3-515 EMU/M03-004 DC/EMU/ M/ASR-03-003 DMU/DPC 10-0-4001 EMU/M-06-001 DMU/DPC 5-0-5-503/ V-300Kg.32t 700 HP DMU DPC 20.0-0 -001 DHMU/ DPC 0-1001 EMU/M 02-001 DMU/DP C10-0-3001 DMU/DPC 5 0-3-515 EMU/M 03-004 DC/EMU /M/ASR03-003 DMU/DP C10.0-4001 EMU/M06-001 DMU/DP C5-0-5503/ V400Kg. – 4) 0001 Page 19 of 24 Date of issue February. Director/VDG .32t Trailer Coach 20.32t DHMU AC EMU (ASR) Motor Coach 20. Roller bearing axle box Bogie frame arrgt. Shock absorber drg. No. RDSO/2011/CG-01 Axle box coil spring Bolster suspension arrgt. 2011 Spec. DC/EMU /M2 0-1203 DMU/DP C10-0-5001 EMU/M 32-064 AC/DC EMU/M5 9-0-203 AC/DC EMU/B02-001 DC/EMU /M2 0-1203 DMU/DP C10-0-5001 EMU/M 32-064 AC/DC EMU/C2 9-0-203 DC/EMU /H2-0-1202 DMU/ DPC-01-001 DMU/DP C 0-5001 EMU/M 3-2-064 DMU/DP C-9-0010 EMU/M0-1-027 DMU/ DPC5-01-501 DMU/DP C10-0-5001 EMU/M 32-051 DMU/DP C5 9-0510 DMU/DP C5 0-2504 EMU/M0-1-024 DMU/DP C.0-5-001 EMU/M.9-0-003 EMU/M-0-1027 DC/EMU/ M2-0-1203 DMU/DPC 10.Ref: CGW (Rev. – 4) 12 0001 Page 20 of 24 Date of issue February.0-5001 EMU/M 32-064 AC/DC EMU/C2 90-203 DC/EMU/ H2-0-1202 13 14 15 16 Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP. Bogie brake arrgt. Director/VDG .3-2064 AC/ EMU/M/AS R. No. Wheel & axle arrgt.0-5001 EMU/M 3-2-064 DHMU/ DPC 90003 DHTC 0-2-002 DC/EMU/M 2-0-1-203 DMU/DPC1 0. Suspension diagrammatic arrgt.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt.K. – 4) 0001 Page 21 of 24 Date of issue February. 2011 Spec. Director/VDG .K.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt.Ref: CGW (Rev.RDSO/2011/CG-01 Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP. No. Srivastava /ADE/VDG Approved ByShivendra Singh /Jt. 2011 Spec. Director/VDG . No.K. – 4) Page 22 of 24 Date of issue January.Ref: CGW 0001 (Rev. RDSO/2011/CG-01 Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP. Director/VDG .Srivastava /ADE/VDG Approved ByShivendra Singh /Jt. – 4) Page 23 of 24 Date of issue January. No.Ref: CGW 0001 (Rev. RDSO/2011/CG-01 Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP.K. 2011 Spec. 2011 Spec.Ref: CGW 0001 (Rev. No. RDSO/2011/CG-01 Signature Name & Designation Prepared ByAmit Kumar /SE/D Checked ByP.Srivastava /ADE/VDG Approved ByShivendra Singh /Jt. Director/VDG .K. – 4) Page 24 of 24 Date of issue January.