schedule of technical requremennts for traction motor end ... - rdso

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Jan 1, 2012 ... 5.1 For materials: IS: 1387-1993 (Second Rev.) ..... with IS: 1387 – 1967 (First revision) 'General requirements for the supply of metallurgical ...

STR No. MP.STR.EM.01.01.12 (Rev-00), January-2012 SCHEDULE OF TECHNICAL REQUIREMENTS FOR TRACTION MOTOR ROLLER SUSPENSION BEARING TUBE (ALCO & GM) OF BG_DIESEL ELECTRIC LOCOMOTIVES WITH COMPONENTS 1.0

SCOPE:

The Motor Suspension Unit (MSU) tubes are vital parts of traction motors used on conventional (WDM3A, & WDG3A) and three phase GM diesel electric locomotives (WDP4 & WDG4) on Indian Railways. These components are procured by DLW, DMW and Zonal railways from RDSO approved sources as per DLW/ DMW drawings. In addition, a number of assembly components are also procured as per DLW/ DMW drawings. The schedule of technical requirement (STR) mentioned hereunder is issued to serve as a guide to manufacturers and should be read in conjunction with the relevant drawings. The firm should satisfy themselves having complied with the requirements of the drawings and STR. 2.0

GENERAL REQUIREMENTS:

2.1 The firm should have currently valid ISO-9000 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 should be followed by the firm. 2.3 The firm shall have a system of documentation in respect of 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 should be current and verified by physically checking the calibration certificate issued by the Calibration Agency from whom it was calibrated. 2.6 The firm shall have a system of easy traceability of the product from manufacturing stage to finished product stage. Stamped identification marking with serial number of beam should be used for this purpose.

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STR No. MP.STR.EM.01.01.12 (Rev-00), January-2012 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 part of compliance of this STR. The QAP shall be a comprehensive document covering the following aspects: i) ii) iii) iv) v)

Details of Quality Control Organization of the firm along with key personnel engaged in the QC function. Quality Assurance Process of incoming materials used for the subject items. Process Flow Chart indicating process of manufacture for an individual product or for a family of products if the process is same. Quality Assurance System – Inspection & Testing Plan including the stage inspection. 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. 4.0

QUALITY CONTROL ORGANISATION:

4.1 The complete organizational setup of the quality control key personnel and officials along with their qualification and experience should be furnished. 4.2 The Quality Control Organization should be headed by a senior level official having adequate technical qualification who shall directly report to plant in-charge. 5.0 5.1

GOVERNING SPECIFICATIONS: For materials: IS: 1387-1993 (Second Rev.) – “General requirements for the supply of metallurgical materials”. Carbon Steel- IS: 1030-1998 (Fifth Rev.)- “Carbon steel castings for general engineering purposes- specification”. Carbon Steel- IS: 5517-1993, Gr. 45 C8. Steel Plate- IS: 2062, Gr- B, 1992 IS: 2269- 1981, P 12.9 BS: 1486 Part-II 1961, Zinc Plate EMS 15 2

STR No. MP.STR.EM.01.01.12 (Rev-00), January-2012 MS 4361 Steel tube ASTM A 513 Type 5 Pin alloy steel- Quenched & Tempered to Surface Hardness of Rockwell 46- 53RC ASTM A513 Type 5 (DOM) Steel Tubing Non-Metallic Steel Alloy Steel- Quenched & Tempered to Surface Hardness of Rockwell C3745 IS: 12117 – 1996 5.2.1 For tests: Tolerances on cast un-machined dimensions- IS: 4897, CL-II Radiography test- ASTM E446, Level- III for central portion and Level- II for both side housing bores of tube. (Sl- 2566, TMB 3.1) Chemical Test- IS: 228 Tensile Test- ASTM A370/05 Ultrasonic Test- ASTM A388, 2007 IS: 1608- 1995 (Second Rev.) ‘Method for tensile testing of steel products’ IS: 1500 – 1983 ‘Method for brinell hardness test for metallic materials (second revision)’ IS: 1757- 1988 (Sencond revision) ‘Method for Charpy impact test (V-Notch) for metallic materials’. IS: 1599- 1985 (Second Rev.) ’Method for bend test for steel products other than sheet, strip, wire and tube).’ 5.3

For dimensional tolerances: IS: 3739-1987 (First Rev.) - Dimensional tolerances for carbon and constructional steel products.

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STR No. MP.STR.EM.01.01.12 (Rev-00), January-2012 6.0 INCOMING MATERIAL 6.1 A complete Bill of Material indicating all input material items 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) should 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 may be submitted as part of QAP. 7.0

DIMENSIONS AND TOLERANCE:

The tube and components shall conform to the following drawings for dimensions, tolerances, finish and material etc.: List of drawings of Suspension Tube & Components for TM 4907 application: S. Description DMW No. Drawing No. 1/DCW/M/TM1 Suspension 398, Alt- x Tube (Machined) for TM 4907

Material Specifications Carbon SteelIS: 1030-1998 (Fifth Rev.), Gr. 280-520W.

1/DCW/M/TM414, Alt- Nil

Carbon SteelIS: 5517-1993, Gr. 45 C8. Carbon SteelIS: 5517-1993, Gr. 45 C8. Carbon SteelIS: 5517-1993, Gr. 45 C8. Carbon SteelIS: 5517-1993, Gr. 45 C8. Carbon SteelIS: 5517-1993, Gr. 45 C8. Steel Plate- IS: 2062, Gr- B, 1992 IS: 2269- 1981, P 12.9

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4 5

Bearing Housing for TM 4907 End Cover (RWE) for TM 4907 End Cover (GWE) for TM 4907 Abutment Piece for TM 4907

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Enclosure TM 4907

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Adjustment Washer for TM 4907 Socket Head Screw M10 x 30

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1/DCW/M/TM416, Alt-Nil 1/DCW/M/TM417, Alt-Nil 1/DCW/M/TM418, Alt-Nil

for 1/DCW/M/TM419, Alt-Nil 1/DCW/M/TM415, Alt-Nil 1/DCW/M/TM421, Alt-Y

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Standard for Tests • Tolerances on cast unmachined dimensions- IS: 4897, CL-II • Radiography test- ASTM E446, Level- III for central portion and Level- II for both side housing bores of tube.

STR No. MP.STR.EM.01.01.12 (Rev-00), January-2012 9 10 11

long Socket Head Screw M12 x 70 long Socket Head Screw M12 x 90 long Grease Nipple

1/DCW/M/TM423, Alt-Y

IS: 2269- 1981, P 12.9

1/DCW/M/TM422, Alt-Y

IS: 2269- 1981, P 12.9

1/DCW/M/TM420, Alt-Y

BS: 1486 Part-II 1961, Zinc Plate

Housing Bearing Kit (consisting of 11 items) as per DLW Part No. 17454499: S. Description No. 1 Housing Bearing Machine

EMD Drawing Material No. Specifications GM Pt. No. EMS 15 40075563

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Cap CE Axle GM Pt. Bearing Mach. 40086808

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Cap PE Axle GM Pt. Bearing Mach. 40076796

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Seal PE

GM Pt. 40076794

No. MS 4361 Steel tube ASTM A 513 Type 5 Pin alloy steelQuenched & Tempered to Surface Hardness of Rockwell 46- 53 RC No. MS 4361 Steel tube ASTM A 513 Type 5 Pin alloy steelQuenched & Tempered to Surface Hardness of Rockwell 46- 53 RC No. MS 4361 Steel tube ASTM A 513 Type 5 Pin alloy steelQuenched & Tempered to Surface Hardness of 5

Standard for Tests • Chemical Test- IS: 228 • Tensile Test- ASTM A370/05 • Radiography testASTM E446, Level-III • Chemical Test- IS: 228 • Tensile Test- ASTM A370/05 • Ultrasonic Test- ASTM A388, 2007

• Chemical Test- IS: 228 • Tensile Test- ASTM A370/05 • Ultrasonic Test- ASTM A388, 2007

• Chemical Test- IS: 228 • Tensile Test- ASTM A370/05 • Ultrasonic Test- ASTM A388, 2007

STR No. MP.STR.EM.01.01.12 (Rev-00), January-2012

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Spacer CE

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Seal

7 8 9 10

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GM Pt. 40076798

GM Pt. 40076990 Seal GM Pt. 9084265 Plug 1/8” PT GM Pt. 8348617 Plug 3/8” NTP GM Pt. 8348619 Screw 1/2”- 13 GM Pt. HS Cap 138293

Screw 1/2”- 13 GM Pt. HS Cap 138299

Rockwell 4653RC No. ASTM A513 Type 5 (DOM) Steel Tubing

• Chemical Test- IS: 228 • Tensile Test- ASTM A370/05 • Ultrasonic Test- ASTM A388, 2007

No. Non Metallic No. Non Metallic No. Steel No. Steel No. Alloy SteelQuenched & Tempered to Surface Hardness of Rockwell C3745 No. Alloy SteelQuenched & Tempered to Surface Hardness of Rockwell C3745

Housing Bearing Kit (consisting of 4 items) as per DLW Part No. 17454487 S. Description No. 1 Seal Gear

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Cover Assembly

EMD Drawing Material No. Specifications GM Pt. No. MS 4361 Steel 40009050 tube ASTM A 513 Type 5 Pin alloy steelQuenched & Tempered to Surface Hardness of Rockwell 4653RC GM Pt. No. MS 4361 Steel 40012764 tube ASTM A 6

Standard for Tests • Chemical Test- IS: 228 • Tensile Test- ASTM A370/05 • Ultrasonic Test- ASTM A388, 2007

• Chemical Test- IS: 228 • Tensile Test- ASTM

STR No. MP.STR.EM.01.01.12 (Rev-00), January-2012

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Tube

GM Pt. 40076189

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Ring

GM Pt. 40076190

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513 Type 5 Pin alloy steelQuenched & Tempered to Surface Hardness of Rockwell 4653RC No. MS 4361 Steel tube ASTM A 513 Type 5 Pin alloy steelQuenched & Tempered to Surface Hardness of Rockwell 4653RC No. MS 4361 Steel tube ASTM A 513 Type 5 Pin alloy steelQuenched & Tempered to Surface Hardness of Rockwell 4653RC

A370/05 • Ultrasonic Test- ASTM A388, 2007

• Chemical Test- IS: 228 • Tensile Test- ASTM A370/05 • Ultrasonic Test- ASTM A388, 2007

• Chemical Test- IS: 228 • Tensile Test- ASTM A370/05 • Ultrasonic Test- ASTM A388, 2007

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 should be included: o o o

Make and Model of the machine Accuracy Details of machining operations

8.3 Machining process should 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 should be furnished along with the manufacturing process wherever used. 7

STR No. MP.STR.EM.01.01.12 (Rev-00), January-2012 8.5 List of typical 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 should 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 should be included: o o o

Make and Model of the measuring equipment Accuracy Quality 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 nondestructive testing. Record of test results of stage inspection should be available and furnished. 9.4 The list of testing and measuring instruments 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 open bridge type co-ordinate measurement machines on prototype and on sample lots. The firm should have three dimensional co-ordinate measurement machines of requisite accuracy in accordance with the dimensions of the jobs to be measured. Measurements shall be included as a part of QAP. 10.0

MATERIAL SPECIFICATION:

10.1 The suspension tube and components shall be manufactured from normalized carbon steel castings/ forgings as per Clause 7.0 of this specification. 10.2 In case the manufacturer proposes to supply cast or forged tube/ components, the same can be accepted with the prior approval of the RDSO. The material used for cast or forged components shall be chosen so that none of the specified properties in this specification are compromised. The forging shall be manufactured from killed steel produced by the open hearth, electric or any other approved process. 10.3 General requirements relating to the supply of material shall conform to IS: 1387-1993 (Second rev) ‘General requirements for the supply of metallurgical materials ’. as per Clause 5 of this specification. 8

STR No. MP.STR.EM.01.01.12 (Rev-00), January-2012 10.4 Rough machining of the forgings shall be carried out in case of procurement of forgings by the purchaser. In case finished component is procured by the purchaser, machining shall be done in suitable sequence approved by the purchaser. 10.5 steel forging shall be supplied to the dimensions specified in the drawing of rough machined components to be provided by the purchaser. 10.6 In case finished components are procured by the purchaser, the supplier shall ensure that forgings used for manufacture shall confirm to all the clauses of this specifications. 11.0

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 specification. 12.0

HEAT TREATMENTS:

Forgings shall be supplied in ‘As forged’ or ‘As forged normalized’ condition (880 – 910 deg.C) to give the mechanical properties as per respective specification given in clause 7.0 of this specification. 13.0

REQUIREMENT FOR FOUNDRY FACILITIES

13.1 It is preferable if the approved sources of suspension tubes and other cast components have their own RDSO approved captive foundries meeting Class ‘A’ requirements as per IS:12117 – 1996 and machining units. 13.2 In case where the firms don’t have their captive foundries, they should fulfill the following conditions: They should use castings from foundries certified Class ‘A’ as per IS: 12117 – 1996 only. The certification of foundry should be by RDSO and currently valid. The machinist firm should 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. 13.3 The QAP of the component should clearly include the stipulation that “each cast component should have individual distinct number embossed by the foundry 9

STR No. MP.STR.EM.01.01.12 (Rev-00), January-2012 so as to ensure its traceability”. A sample marking on suspension tube is given below: 13.4 At least two letter initial of the foundry + two digits of year of manufacturing code + 4 digits of unique serial number + at least two digits of customer code for the foundry. (Example: SMP/06/3991/SMP). 13.5 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. 14.0

FREEDOM FROM DEFECTS:

The steel forgings shall be free from internal and surface defects such as seams, laps and injurious imperfections. 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. 16.0

MECHANICAL PRTOPERTIES:

The test piece after being heat treated as per clause 6.0 shall show the following properties 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’.

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 revision)’. 16.3

Charpy Impact Value (V-Notch):

The test pieces shall show the following minimum charpy impact values when tested as per IS: 1757- 1988 (Second revision) ‘Method for Charpy impact test (V-Notch) for metallic materials’.

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STR No. MP.STR.EM.01.01.12 (Rev-00), January-2012 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).’ 16.5 If required by the purchaser, the following tests shall be conducted as per relevant standard subject to approval by purchaser; 17.0

INSPECTION:

Upon prearrangement 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 these specifications. Final acceptance of all purchased material shall be made at purchaser’s premises. In general inspection of the tube and components shall be in accordance with IS: 1387 – 1967 (First revision) ‘General requirements for the supply of metallurgical materials ‘ 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:

Finished tube and components shall be suitably packed to prevent corrosion and damage during transit. Machined surface shall be properly protected with anticorrosive compounds.

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STR No. MP.STR.EM.01.01.12 (Rev-00), January-2012 ANNEXURE - I MACHINERY & PLANT (M&P) FOR MANUFACTURING The following is the indicative list of machining facilities to be available with the firm: 1. The manufacturer shall have suitable CNC machine capable of meeting the requirement of drawings mentioned in para 7.0 in respect of dimensions and accuracy. The manufacturer shall also submit documents in this regard at the time of offer. 2. Marking / Measuring Table of suitable size. 3. Facilities for stamping of identification markings as per specification

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STR No. MP.STR.EM.01.01.12 (Rev-00), January-2012 ANNEXURE - II LIST OF TESTING FACILITIES: 1.0 Calibration of the Testing / Measuring Equipments should 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. Following testing facilities should be available with the firm; METALLURGICAL AND CHEMICAL LABORATORY: 1. Availability of Emission Spectrometer with necessary standard and automatic printer shall be preferred for verification of chemical composition of material. 2. Suitable Radiography 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 up to 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. Shadowgraph facilities for assuring correct notch profile and dimension for impact test specimen. If the testing facilities for any test are not available at the manufacture’s premises, the manufacture shall make necessary arrangements for carrying out that test at out side laboratories, either reputed or Government Approved. 13

STR No. MP.STR.EM.01.01.12 (Rev-00), January-2012 ANNEXURE - III LIST OF MEASURING INSTRUMENTS: Calibration of the Testing / Measuring Equipments should be done at least once in a year unless stated otherwise. 1. The manufacturer shall have suitable CMM machine capable of meeting the requirement of drawings mentioned in para 7.0 in respect of dimensions and accuracy. The manufacturer shall also submit documents in this regard at the time of offer. 2. Vernier Calipers, Micrometers, Inside and Outside Calipers and all other Gauges required during matching operations and dimensional checks. 3. Micrometer (200 – 500 mm. Outside) 4. Bore Micrometer ( one meter Inside) 5. Bore Dial Gauge (100 – 500 mm.) 6. Vernier Height Gauge (600 mm.) 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 should be available To check accuracy of axle bore, co-axiality, Parallelity, perpendicularity in respect of rotor fixing end shields bore along with GWE side bore, RWE side bore. To check and prove air-gap has been maintained for all the pole faces. The fixture should be fitted along with a dial gauge to prove the same in respect of GWE side and RWE side bore. The gauges should 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.

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