Schedule of Technical requirements for Traction Motor Roller Suspension Bearing Tubes (ALCO, DEMU & HHP)
SCHEDULE OF TECHNICAL REQUIREMENTS FOR
TRACTION MOTOR ROLLER SUSPENSION BEARING TUBES (FOR ALCO & HHP
LOCOS AND DEMU) WITH COMPONENTS OF BG DIESEL- ELECTRIC LOCOMOTIVES
1.0
SCOPE:
The Motor Suspension Unit (MSU) tubes are vital parts of traction motors used on
Alco and HHP diesel electric locomotives as well as DEMU of Indian Railways.
These components are procured by DLW, DMW and Zonal railways from RDSO
approved sources as per DLW, DMW & BHEL/CGL drawings. In addition, a number
of assembly components are also procured as per DLW, DMW & BHEL/CGL
drawings. The schedule of technical requirement (STR) mentioned hereunder is
being issued to serve as a guide to manufacturers and shall be read in conjunction
with the relevant drawings. The firms shall satisfy themselves to having complied
with, all the requirements of the drawings and STR. Approval shall be granted to a
firm that has the capability to supply fully machined suspension tube as per the
STR.
2.0
GENERAL REQUIREMENTS:
2.1
The firm shall have valid ISO-9001 certification issued by an approved agency with
the activity desired clearly mentioned in the scope of certification. The firm shall
have a Quality Manual indicating the extent of control over production.
2.2
A system of regular submission of rejection details of material giving rejection rate,
cause of rejection, corrective action taken etc. on quarterly basis shall be followed
by the firm.
2.3
The firm shall have a system of documentation with respect to rejection at customer
end, warranty replacement and failure of item supplied by them during service.
2.4
The firm shall have a system of recording the plant, machinery and control
equipments remaining out of service, nature of repairs done etc.
2.5
The testing and measuring equipment shall be duly calibrated and the validity of
calibration shall be current and verified by physically checking the calibration
certificate issued by the Calibration Agency from where it was calibrated.
2.6
The firm shall have a system of easy traceability of the product from manufacturing
stage to finished product stage.
2.7
At the time of application, the firm must submit clause wise compliance of this STR.
3.0
QUALITY ASSURANCE PLAN (QAP):
The firm shall prepare a Quality Assurance Plan (QAP) for all items for which
approval is sought and submit the same as a part of compliance of this STR. The
QAP shall be a comprehensive document covering the following aspects including
all the parameters in accordance with Para 5.1.8 - Quality Assurance Plan (QAP) of
latest MP- G-7.1-1: Guidelines of RDSO for Vendor Approval.
STR No. MP.STR.EM.01.01.12 (Rev-00), July’2012
Page 1 of 14
Schedule of Technical requirements for Traction Motor Roller Suspension Bearing Tubes (ALCO, DEMU & HHP)
(i)
Details of Quality Control Organization of the firm along with key personnel
engaged in the QC function.
(ii) Quality Assurance Process of incoming materials used for the subject items.
(iii) Process Flow Chart indicating process of manufacture of an individual product
or for a family of products, if the process is same.
(iv) Quality Assurance System – Inspection & Testing Plan including stage
inspection.
(v) Calibration scheme and status of calibration of equipments used in the quality
process.
Details of the above aspects are described in the following paragraphs. The QAP
shall be approved by RDSO and shall form basis of approval process.
3.1
Firm shall have to declare details of the manufacturing operations to be conducted
in house or by outside agencies. Details of the outside agencies shall be indicated
and prior approval shall be taken from RDSO, which reserves the right to inspect
these firms also.
A general format for guidance is given below:
Product /
Name of
the
process
and
details of
machine
used
indicating
their
capacities
/ accuracy
limit
4.0
Acceptance
limit of the
parameters
to be
inspected
during
different
operations
of
MSU
Tube
and
components
Standards
followed for
acceptance
of the test
parameters
Sample
size & its
frequency
of
inspection
Format
no. for
recording
for
traceability
Action
taken on
rejection,
if any
Calibration
scheme
and status
of
calibration
of
equipments
used in the
quality
control
process
QUALITY CONTROL ORGANIZATION:
4.1
The complete organizational setup of the quality control key personnel and officials
along with their qualification and experience shall be furnished.
4.2
The Quality Control Organization shall be headed by a senior level official having
adequate technical qualification who shall directly report to plant in-charge.
5.0
GOVERNING SPECIFICATIONS:
The latest revisions as applicable to the specification referred below shall be
followed.
STR No. MP.STR.EM.01.01.12 (Rev-00), July’2012
Page 2 of 14
Schedule of Technical requirements for Traction Motor Roller Suspension Bearing Tubes (ALCO, DEMU & HHP)
5.1
For materials:
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
(xi)
(xii)
(xiii)
5.2
For tests:
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
5.3
IS: 1500 – 1983 ‘Method for Brinell hardness test for metallic materials
(Second revision)’.
IS: 1599 - 1985 (Second Rev.) ’Method for bend test for steel products other
than sheet, strip, wire and tube).’
IS: 1608 - 1995 (Second Rev.) ‘Method for tensile testing of steel products’.
IS: 1757 - 1988 (Second Rev.) ‘Method for Charpy impact test (V-Notch) for
metallic materials’.
ASTM A370/05 - Tensile Test.
ASTM A388, 2007- Ultrasonic Test for steel forgings.
ASTM A609/A609M- 91 (Reapproved 2007) - Ultrasonic Test for steel
castings.
ASTM E446 - Radiography test Level- III for central portion and Level- II for
both side housing bores.
ETI 827- Metallurgical requirements for the qualification of casting for general
purpose.
For dimensional tolerances:
(i)
(ii)
5.4
IS: 1030-1998 (Fifth Rev.) - “Carbon steel castings for general engineering
purposes- specification”.
IS: 1387-1993 (Second Rev.) - “General requirements for the supply of
metallurgical materials”.
IS: 2062-1999, Steel for general structural purposes – Specification (Fifth
Rev.).
IS: 2269- 1995, Specification for Hexagon socket head screws.
IS: 5517-1993, Steels for hardening and tempering – Specification.
IS: 12117 – 1996: Norms for classification of Steel Foundries for quality
assurance (First Rev.), Feb.2002.
ISO: 9001- 2000: Purchasing Procedure.
BS: 1486 Part-II 1961 for Zinc Plated Grease Nipple.
ASTM A513 - Steel Tubing.
ASTM A519 – Hot finished seamless tubing.
HHP Loco (EMD) Spec. no. EMS 9 Rev. E for Nodular Iron Medium Strength.
HHP Loco (EMD) Spec. no. EMS 15 for Cast Steel.
HHP Loco (EMD) Spec. no. MS 4361- Steel plate.
IS: 3739-1987 (First Rev.) - Dimensional tolerances for carbon and
constructional steel products.
IS: 4897- 1994: Deviations on untoleranced dimensions and mass of steel
castings.
For welding:
A.I 1651- EMD welding, brazing and soldering specification.
STR No. MP.STR.EM.01.01.12 (Rev-00), July’2012
Page 3 of 14
Schedule of Technical requirements for Traction Motor Roller Suspension Bearing Tubes (ALCO, DEMU & HHP)
6.0
INCOMING MATERIAL:
6.1
A complete Bill of Material (BOM) indicating all input material required for
manufacturing of the product, governing specification and their sources of supplies
as approved by the firm in accordance with clause 7.4.1 of ISO:9001 (2000) shall be
furnished.
6.2
Test results of incoming raw material with reference to test certificate issued by the
supplier and the results of internal tests carried out by the firm for verification shall
be submitted as a part of QAP.
7.0
DIMENSIONS AND TOLERANCES:
The MSU tube and components shall conform to the respective drawings indicated
for dimensions, tolerances, finish and material etc.:
7.1
List of drawings of Suspension Tube & Accessories (10 Components) for
traction motor type TM 4907 application (Class of locos WDM3A & WDG3A):
Sl.
no.
1
2
3
4
5
6
7
8
9
10
11
7.1.1
Description
DMW Drawing
Material Specifications & Tests
no.
Suspension
Tube 1/DCW/M/TM- Casting - Carbon Steel- IS: 1030-1998
398, Alt- x
(Machined) for TM
(Fifth Rev.), Gr. 280-520W.
4907
Bearing Housing for 1/DCW/M/TM- Forging - IS: 5517-1993 for Carbon Steel,
TM 4907
414, Alt- Nil
Gr. 45 C8.
End Cover (RWE) 1/DCW/M/TM- Forging - IS: 5517-1993 for Carbon Steel,
for TM 4907
416, Alt-Nil
Gr. 45 C8.
End Cover (GWE) 1/DCW/M/TM- Forging - IS: 5517-1993 for Carbon Steel,
for TM 4907
417, Alt-Nil
Gr. 45 C8.
Abutment Piece for 1/DCW/M/TM- Forging - IS: 5517-1993 for Carbon Steel,
TM 4907
418, Alt-Nil
Gr. 45 C8.
Enclosure for TM 1/DCW/M/TM- Forging - IS: 5517-1993 for Carbon Steel,
4907
419, Alt-Nil
Gr. 45 C8.
Adjustment Washer 1/DCW/M/TM- IS: 2062- 1999 for Steel Plate
for TM 4907
415, Alt-Nil
Gr- B.
Socket Head Screw 1/DCW/M/TM- IS: 2269- 1995, P 12.9
M10 x 30 long
421, Alt-Y
Socket Head Screw 1/DCW/M/TM- IS: 2269- 1995, P 12.9
M12 x 70 long
423, Alt-Y
Socket Head Screw 1/DCW/M/TM- IS: 2269- 1995, P 12.9
M12 x 90 long
422, Alt-Y
Grease Nipple
1/DCW/M/TM- BS: 1486 Part-II 1961
420, Alt-Y
(Zinc Plated).
In case cast components (i.e. item at sl. no. 2 to 6 mentioned above) are chosen as
per clause 11.2, then the material shall be Carbon Steel- IS: 1030-1998 (Fifth Rev.),
Gr. 280-520W.
STR No. MP.STR.EM.01.01.12 (Rev-00), July’2012
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Schedule of Technical requirements for Traction Motor Roller Suspension Bearing Tubes (ALCO, DEMU & HHP)
7.1.2
Hardware’s as per item no. 8 to 11 of clause 7.1 if not manufactured by the supplier
itself, shall be out sourced from reputed brand / manufacturers to be declared in the
QAP. (If sources are not specified in the relevant drawings).
7.2
Housing Bearing Kit for HHP Loco (consisting of 11 items) as per DLW Part
No. 17454499:
S.
No.
1
Description
Housing
Bearing
Machine
EMD Drawing
No. / Part No.
GM Pt. No.
40075563
2
Cap (CE) Axle
Bearing Mach.
GM Pt. No.
40086808
3
Cap PE Axle
Bearing Mach.
GM Pt. No.
40076796
4
Seal PE
GM Pt. No.
40076794
5
Spacer CE
6
Seal
7
Seal
8
Plug 1/8” PT
9
Plug 3/8” NTP
10
Screw 1/2”- 13
HS Cap
GM Pt. No.
40076798
GM Pt. No.
40076990
GM Pt. No.
9084265
GM Pt. No.
8348617
GM Pt. No.
8348619
GM Pt. No.
138293
11
Screw 1/2”- 13
HS Cap
GM Pt. No.
138299
Material Specifications and Tests
EMS 15 – Cast Steel as per casting drawing
no. 40075432.
A.I 1651- Weld Braze Specification mentioned
in drawing no. 40075563.
Material as per casting drawing no. 40076800:
Casting- EMS 9 Nodular Iron and ETI 827 or
Plate - MS 4361 steel.
Material as per casting drawing no. 40076797:
Casting- EMS 9 Nodular Iron and ETI 827 or
Plate - MS 4361 steel.
Material as per casting drawing no. 40076795:
Tubing- ASTM A519 Hot finished seamless
tubing or
Plate - MS 4361 steel.
ASTM A513 Type 5 (DOM) Steel Tubing as
per drawing no. 40076798.
Nitrile (Buna-N) as per drawing no. 40076990.
Nitrile (Buna-N) as per drawing no. 4084265.
Steel as per drawing no. 8348617.
Steel as per drawing no. 8348619.
Alloy Steel- Quenched & Tempered to Surface
Hardness of Rockwell C37- 45 as per drawing
no. 138293.
Alloy Steel- Quenched & Tempered to Surface
Hardness of Rockwell C37- 45 as per drawing
no. 138299.
7.2.1
Hardware’s as per item no. 8 to 11 of clause 7.2, if not manufactured by the supplier
itself, shall be out sourced from reputed brand / manufacturer as recommended in
the DLW drawing no. K- 1745037 of Housing Bearing Kit.
7.2.2
Nitrile seals as per item no. 6 & 7 of clause 7.2, if not manufactured by the supplier
itself, shall be out sourced from reputed manufacturers already approved with
RDSO for similar items. The sources shall be declared in the QAP.
STR No. MP.STR.EM.01.01.12 (Rev-00), July’2012
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Schedule of Technical requirements for Traction Motor Roller Suspension Bearing Tubes (ALCO, DEMU & HHP)
7.3
S.
No.
1
2
Housing Bearing Kit for HHP Loco (consisting of 4 items) as per DLW Part
No. 17454487:
Description
Seal Gear
3
Cover
Assembly
Tube
4
Ring
7.4
S.
No.
1
2
2
3
4
5
6
7
8
9
10
11
12
EMD Drawing
No. / Part No.
GM Pt. No.
40009050
GM Pt. No.
40012764
GM Pt. No.
40076189
GM Pt. No.
40076190
Material Specifications
and Tests
MS 4361 Steel as per drawing no. 40009050
MS 4361 Steel as per drawing no. 40012026
for Cover-GR Case AY- Mach.
ASTM A513 Type 5 (DOM) Steel Tubing as
per drawing no. 40076189.
MS 4361 Steel as per drawing no. 40076190.
List of drawings of Suspension Tube & Accessories for traction motor type
TM 4303 / C1005TM application (Class of loco 1400 HP DEMU):
Description
BHEL Drg. No.
CGL Drg. No.
Qty.
General
Arrangement
Axle Suspension Unit.
Roller
bearing
suspension tube
Bearing Housing
Adjustment Washer
End Cover- RWE
End Cover- GWE
Abutment Piece
Enclosure
Socket Head Screw
(M10 x 30 Long)
Socket Head Screw (M12
x 70 Long)
Socket Head Screw (M30
x 110 Long)
Grease Nipple
Spring Washer A30
04391580002 (Latest)
CGM/106001 (Latest)
1
04391158000 (Latest)
CGM/106801 (Latest)
1
14451575001 (Latest)
14451575002 (Latest)
14451575003 (Latest)
14451575005 (Latest)
14451575004 (Latest)
14391580001 (Latest)
44391560001 (Latest)
CGM/206803 (Latest)
CGM/206805 (Latest)
CGM/206806 (Latest)
CGM/206802 (Latest)
CGM/206804 (Latest)
CGM/206801 (Latest)
CGM/42201 (Latest)
1
1
1
1
1
1
6
44391560003 (Latest)
CGM/42202 (Latest)
16
CGM/406801 (Latest)
8
CGM/42203 (Latest)
CGM/32204 (Latest)
2
8
34394028003 (Latest)
The manufacturer shall supply suspension tube & components for DEMU
application as per the details & drawings provided above or by the purchaser.
Quality control aspects of the tube & components shall conform to this STR.
7.4.1
Hardware’s as per item no. 8 to 12 of clause 7.4 if not manufactured by the supplier
itself, shall be out sourced from reputed brand / manufacturers to be declared in the
QAP. (If sources are not specified in the relevant drawings).
STR No. MP.STR.EM.01.01.12 (Rev-00), July’2012
Page 6 of 14
Schedule of Technical requirements for Traction Motor Roller Suspension Bearing Tubes (ALCO, DEMU & HHP)
8.0
PROCESS OF MANUFACTURE:
8.1
Complete process flow chart covering all steps of process of manufacture for an
individual product (or for a family of products, if the process is same) shall be clearly
enlisted as a part of QAP.
8.2
The following details of machines used for all the steps of machining operations
shall be included:
Make and Model of the machine
Accuracy.
Details of machining operations.
8.3
Machining process shall be such that all critical dimensions are final machined on
CNC machining centers, preferably in single setting.
8.4
Details of Jigs and Fixtures used during manufacture shall be furnished along with
the manufacturing process, wherever used.
8.5
List of typical machinery & plant (M&P) required for manufacture is furnished in
Annexure- I. The list is for general guidance only and actual manufacturing
operations shall be submitted and got approved by the firm as a part of QAP.
9.0
QUALITY ASSURANCE PROCESS – INSPECTION & TESTING PLAN:
9.1
Complete inspection and testing chart covering all steps of process of manufacture
for an individual product including final inspection shall be clearly enlisted as a part
of QAP.
9.2
The following details of measuring instruments / equipments / jigs / fixtures used for
all the steps of measurement operations shall be included:
Make and Model of the measuring equipment
Accuracy
Value to be measured and acceptable value range
9.3
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 shall be available and furnished
where needed.
9.4
The list of measuring machines / instruments & testing facilities are furnished in
Annexure- II & III respectively for general guidance only. However, the specific
testing and measuring instruments, gauges used by the firm will also form part of
QAP, which shall be submitted and got approved by the firm.
9.5
Dimensional measurements shall be made on three-dimensional co-ordinate
measurement machines as mentioned in Annexure – II on prototype & on sample
lots. Periodicity of measurement shall be as indicated in clause 17.0 (Sl. no.4) of the
STR. Measurements shall be included as a part of QAP.
STR No. MP.STR.EM.01.01.12 (Rev-00), July’2012
Page 7 of 14
Schedule of Technical requirements for Traction Motor Roller Suspension Bearing Tubes (ALCO, DEMU & HHP)
10.0
CHEMICAL COMPOSITION:
The permissible variation in chemical composition and ladle analysis of steel shall
conform to the respective requirements given in Clause 7.0 of this STR.
11.0
MATERIAL SPECIFICATION:
11.1
General requirements relating to the supply of material shall conform to IS: 13871993 (Second Rev.) ‘General requirements for the supply of metallurgical materials’,
as per Clause 5.1 (ii) of this STR.
11.2
The material used for cast or forged components shall be so chosen that none of
the specified properties in this STR is compromised.
11.3
The suspension tube shall only be manufactured from castings supplied by RDSO
approved Class “A” foundries.
11.4
The suspension tube components i.e. accessories or any other components shall be
manufactured from normalized carbon steel castings or forgings as applicable &
mentioned in Clause 7.0 of this STR.
11.5
In case the manufacturer proposes to supply forged suspension tube components
instead of cast components, the same can be accepted only with the prior approval
of RDSO. The forging shall be manufactured from killed steel produced by open
hearth furnace, electric furnace or any other approved process.
11.6
Rough machining of the forgings shall be carried out in case of procurement of
forgings by the purchaser & forging shall be supplied to the dimensions specified in
the drawing of rough machined components to be provided by the purchaser.
11.7
In case, finished component is procured by the purchaser, machining shall be done
in suitable sequence approved by the purchaser.
12.0
REQUIREMENT FOR CASTINGS:
12.1
It would be preferred that the approved sources of suspension tubes & other cast
components shall have their own RDSO approved captive foundries meeting Class
‘A’ requirements as per IS:12117 – 1996 and machining units.
12.2
In case, where the firms don’t have their captive foundries, they shall fulfill the
following conditions:
They shall use castings from foundries certified Class ‘A’ as per IS: 12117 –
1996 only.
The certification of foundry shall be, by RDSO and currently valid.
The machinist firm shall furnish undertaking from casting manufacturer
showing long term commitment to supply castings to the machinist vendor.
The Quality Assurance Plan (QAP) of the foundry shall formulate part of
approval process for the individual machinist vendor.
STR No. MP.STR.EM.01.01.12 (Rev-00), July’2012
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Schedule of Technical requirements for Traction Motor Roller Suspension Bearing Tubes (ALCO, DEMU & HHP)
12.3
12.4
The QAP of the component shall clearly include the stipulation that “each cast
component shall have individual distinct number embossed by the foundry so as to
ensure its traceability”. A sample marking on suspension tube is given below:
At least two letter initial of the foundry + 2 digits of year of manufacturing code + 4
digits of unique serial number + at least 2 digits of customer code for the foundry.
(Example: SMP/06/3991/SMP).
Stage inspection of all cast components shall be mandatory by the Inspecting
Authority at the foundry premises. The QAP of the component shall clearly include
such provision.
13.0
REQUIREMENT FOR FORGINGS:
13.1
Source of forging components shall be intimated to RDSO with infrastructure details.
Tenderers shall have to furnish it’s guidelines / standard regulations against which they
have approved the forging units as well as the units where manufacturing of the subject
components takes place.
13.2
Heat treatment:
Forgings shall be supplied in ‘As forged’ or ‘As forged normalized’ condition
(880ºC - 910ºC) to give the mechanical properties as per respective specification
given in Clause 7.0 of this STR.
13.3
Freedom from defects:
The steel forgings shall be free from internal and surface defects such as seams,
laps and injurious imperfections etc.
14.0
INSPECTION:
14.1
General inspection of the tube and components shall be in accordance with IS:
1387 – 1993 (Second Rev.) ‘General requirements for the supply of metallurgical
materials ‘
14.2
Upon pre-arrangement, the purchaser shall have free entry at all time when work on
the contract of the purchaser is being performed to all parts of the manufacturer’s
works which concern the manufacture of the material ordered under the
specification. The manufacturer shall afford the inspector, free of charge, all
reasonable facilities and necessary assistance to satisfy him that the material is
being furnished in accordance with referred specifications. Final acceptance of all
purchased material shall be made at purchaser’s premises.
15.0
SAMPLING FOR MECHANICAL TESTS:
15.1
Unless otherwise agreed, for the purpose of mechanical tests, the sample shall be
tested for each cast and heat treatment batch.
15.2
If the product is continuously heat treated, the sampling for mechanical tests shall
be as agreed to between the purchaser and the manufacturer.
STR No. MP.STR.EM.01.01.12 (Rev-00), July’2012
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Schedule of Technical requirements for Traction Motor Roller Suspension Bearing Tubes (ALCO, DEMU & HHP)
16.0
MECHANICAL TESTS:
The test piece after being heat treated as per Clause 13.2 shall meet the following
tests in the longitudinal direction upto a ruling section of 300 mm. Properties for
thicker sections shall be subjected to agreement between the purchaser and the
supplier.
16.1
Tensile Test:
The tensile test shall be carried out in accordance with IS: 1608- 1995 (Second
Rev.) ‘Method for tensile testing of steel products’ or ASTM A370/05.
16.2
Hardness:
The test pieces shall have Brinell hardness in accordance with IS: 1500 - 1983
‘Method for brinell hardness test for metallic materials (Second Rev.)’.
16.3
Charpy Impact Value (V-Notch):
The test pieces shall show the minimum Charpy Impact values when tested as per
IS: 1757- 1988 (Second Rev.) ‘Method for Charpy impact test (V-Notch) for metallic
materials’.
16.4
Bend Test:
Bend test shall be carried out in accordance with IS: 1599- 1985 (Second Rev.)
’Method for bend test for steel products other than sheet, strip, wire and tube).’
17.0
OTHER SPECIAL TEST FOR SUSPENSION TUBE & ACCESSORIES:
The tests to be carried out along with periodicity as mentioned below for ALCo &
DEMU as well as HHP (EMD) tube & components;
S.No.
1
Radiography test
2
Ultrasonic test
3
Chemical analysis &
Mechanical test
Dimensional measurements
on CMM
4
17.1
Testing Parameters
Incoming
Finished
Incoming
Finished
Incoming
Finished
Incoming
Finished
Periodicity
Type test
Acceptance
Firm’s to declare
10% (Min.)
100%
Firm’s to declare
Firm’s to declare Firm’s to declare
100%
100%
Firm’s to declare
4% (Min.)
100%
Firm’s to declare
Firm’s to declare Firm’s to declare
100%
20% (Min.)
Radiography test for Alco Loco & DEMU tube:
As per ASTM E446, Level- III for Central portion & Level- II for both side housing
bores of tube & as mentioned in the casting drg. no. 1/DCW/M/TM-397, Alt.- latest.
17.2
Radiography test for HHP (EMD) Loco tube:
As per ETI 827 mentioned in casting drawing no. 40075432.
STR No. MP.STR.EM.01.01.12 (Rev-00), July’2012
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Schedule of Technical requirements for Traction Motor Roller Suspension Bearing Tubes (ALCO, DEMU & HHP)
17.3
Ultrasonic test (UT):
This test shall be conducted as per ASTM A388, 2007- for steel forgings & ASTM
A609/ A609M-91 (Reapproved 2007) for steel castings.
17.4
Magnaflux / Dye- Penetrant Test (DPT) shall be conducted by the manufacturer/
supplier.
17.5
Magnetic Particle Inspection (MPI) shall be conducted by the manufacturer/
supplier.
18.0
TEST CERTIFICATES:
Three copies of test certificates shall be supplied unless otherwise stated on the
order. The following details shall be furnished in the test certificate:
(i)
(ii)
(iii)
(iv)
(v)
19.0
Dimensional inspection
Detail of heat treatment
Chemical composition
Results of mechanical tests
Results of additional tests called for in the drawing / order.
PACKING AND MARKING:
Suitably marked and finished MSU tube & components shall be packed to prevent
corrosion and damage during transit. Machined surface shall be properly protected
with anti-corrosive compounds.
STR No. MP.STR.EM.01.01.12 (Rev-00), July’2012
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Schedule of Technical requirements for Traction Motor Roller Suspension Bearing Tubes (ALCO, DEMU & HHP)
ANNEXURE - I
MACHINERY & PLANT (M&P) FOR MANUFACTURING
The following is the list of typical machining facilities mandatory with the firm:
1.
The manufacturer shall have CNC Horizontal Machining Center (HMC) and CNC
turning center of requisite accuracy suitable for the suspension tube & components
as per drawings mentioned in clause 7.0
2.
Marking / measuring table of suitable size.
STR No. MP.STR.EM.01.01.12 (Rev-00), July’2012
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Schedule of Technical requirements for Traction Motor Roller Suspension Bearing Tubes (ALCO, DEMU & HHP)
ANNEXURE - II
LIST OF MEASURING MACHINES & INSTRUMENTS:
The following is the mandatory list of measuring facilities to be available with the firm:
1.
Calibration of the Testing / Measuring Equipments shall mandatorily be done at least
once in a year unless stated otherwise for Vernier Calipers, Micrometers, Inside &
Outside Calipers and all other Gauges required during matching operations and
dimensional checks.
2.
It shall be mandatory for the new manufacturers to have open bridge type Coordinate Measuring Machine (CMM) of requisite accuracy in accordance with the
dimensions of the jobs i.e. suspension tube & components etc. to be measured in a
single set up. However, the existing manufacturers can continue with the facilities as
available at the time of prototype test.
3.
Micrometer (outside).
4.
Bore Micrometer (one meter inside).
5.
Bore Dial Gauge.
6.
Vernier Height Gauge.
7.
Thread plug gauges for checking threading portion duly calibrated.
8.
Hard and ground pins to check accuracy of hole dia. of pole shoes fixing bolts.
9.
Fixtures shall be available (mandatory):
Facilitate to check accuracy of GWE & RWE side bores, co-axiality, parallelity,
perpendicularity in respect of rotor fixing end shields bore along with GWE &
RWE side bores.
Facilitate to check and prove that air-gap has been maintained for all the pole
faces. The fixture shall be fitted along with a dial gauge to prove the same in
respect of GWE side and RWE side bore.
The gauges shall be hard and ground to avoid any lapses of accuracy.
10.
Calibrated template to check the centre of both poles.
11.
Infra-red thermometer for checking temperature of material at standard room before
dimensional checking.
STR No. MP.STR.EM.01.01.12 (Rev-00), July’2012
Page 13 of 14
Schedule of Technical requirements for Traction Motor Roller Suspension Bearing Tubes (ALCO, DEMU & HHP)
ANNEXURE - III
LIST OF TESTING FACILITIES:
1.0
Calibration of the Testing / Measuring Equipments shall be done at least once in a
year, unless stated otherwise.
2.0
Inspection Staff conducting non-destructive testing shall be adequately trained and
qualified by recognized agency and shall have adequate experience.
3.0
Staff conducting tests like Chemical Analysis and Mechanical Properties shall have
adequate skill & competence and shall have under gone sufficient training. Skill of
such staff shall periodically be qualified by making them carry out tests on blind
samples.
4.0
Following testing facilities shall be available with the firm; alternately the test can
also be conducted through NABL approved lab. This same shall be indicated in the
QAP.
4.1
METALLURGICAL AND CHEMICAL LABORATORY:
4.2
1.
Availability of Emission Spectrometer with necessary standard and automatic
printer shall be preferred for verification of chemical composition of material.
2.
Suitable Radiography / Ultrasonic testing facilities.
3.
Magnaflux / Dye-Penetrant Test (DPT) facilities for checking of surface cracks.
4.
Magnetic Particle Inspection (MPI) facilities for checking sub-surface flaws.
5.
Metallurgical Microscope with magnification power upto 500x & metallographic
sample preparation facilities with appropriate accessories to take photographs
of slides.
PHYSICAL LABORATORY:
1.
Universal Testing Machine of 40 tonne capacity with graphical recording
facilities for conducting tensile tests.
2.
Direct reading Hardness Tester of capacity 95-500 BHN.
3.
Impact Testing Machine (Charpy V- Notch) of 0-300 Joules capacity for
conducting impact test with facilities for notch cutting and undertaking this test
at sub-zero temperatures as per the specified standard.
4.
Shadow graph facilities for assuring correct notch profile and dimension for
impact test specimen.
STR No. MP.STR.EM.01.01.12 (Rev-00), July’2012
Page 14 of 14