‘Spetification ‘Technical Specification for Fabricated and Machined | MOTS-204001 Revi Bogie Bolster for FIAT Bogie Page ety mT =a me ‘Aman Bhardwaj ‘SSEIBogie Design Wa We 18.02.2013 Joginder Singh SME cig” | te0oanis | Aine Lalt Kishore Dy CMEND-3 uy 18.02.2013 ‘Agreed Pamanand Sigh | CDE an 18022013 | Approved Rev. No. Detais of Changes Date oF ‘Typologicalerorsreciied Bogie Fame replaced with bogie bolslerin clause -| 108.022013 16,17 and 22. Weave Prepared by Reviewed by“Specification | Technical Specification for Fabricated and Machined WTS 20004 Rava ‘Bogle Bolster for FIAT Bogle en 4. General: This specification covers the technical requirements to be complied by the tenderer for manufacture, testing and supply of bogle botster for FIAT bogie used in mainline coaching stock. 2. Scope of supply: The fabricated and machined bogie bolster is to be supplied conforming in a respects to the relevant drawings & specication of tender and this technical schedule, 3. Eilgllity Criteria: i. The manufacturer shall be an 1S0-9001-2000 cetifed company. ii, The manufacturer shall have prior experience in heavy fabrications end shell furnish the complete details of febieetions done inthe pas for appraisal at landering S206. a ii The terderer shal submit pare-vise comments on this speciation In his offer. He shal bring out the deviations, if any from the specticaton & drawing with adequate justfication, Failure to do so ‘may resutin offer being regarded as technically unsuitable. |v. Firm shall provide list of MBP, past performance, source of steel plate, and sources of steel castings! forging ints ofr. v. The manufacturer shall have adequate manufacturiig facities mentioned in para # 4, a well ‘equipped laboratory with equipments mentioned in para #5, also ready fr testing of desired tests by inspecting agency from a reputed NABL certified laboratory at his own expenses and technically trained skied sta mentioned in para #6 ofthis specication. 4. Availability of infrastructure facility at manufacturer's premises In working order: i. Minimum 3-axis CNC Machining centr with probing facity (or reference and inspection), ‘minimum bed size 1.5Mx3,5M suitable for machining of bogie bolster in single setting. Machine ‘should have 3-ax’s movement in X,Y, Z-axis of miling head for dling and facing. Pg welding for welding major straight welds of boster. High defniton Plasma or Laser profle cuting machine with capacty upto thickness of 14mm. ‘least one roll bending machine for spring dome. Universal Miling and Beveling Machining facility for edge preparation. ‘Press brake of suitable capacity. Hydraulic press / straightening machine for plates and components. Hinimum two MAG welding sets (400A or more) & suitable shielding media, ‘Shot blasting lant or equivalent fatty for surface preparation in house. Painting facity in house. Level surface table of size 3500 mmX1500mm, Bax KBSsere 5 Availability of testing equipments at manufacturers premises in working order: | Apperais fo check chemical composition of steel. Universal testing machine of 40. ‘Impact testing machine Hardness testing machine. PT facity Welding gauges ‘Vernier caliper size 0.5 M with dial gauge accuracy 0.01mm. ‘Bore gauge fr diferent holes in bolster Height gauge Digital surface roughness tester. Dry fim thickness tester. ‘Thread gauges Bax wbSs<2Be-R.C.F. ‘Specification | Technical Specification for Fabricated and Machined. | MDTS-204001 Bogie Bolster for FIAT Bogie Cae ee Page: Sot 6 (Facilities mentioned at (), {2 8 above, may not bo fm promises, but manufacturer should be ready for carrying out testing from NABL certified laboratory at their own expense as and when required) 6 Requiem of tececal tied she tat Fin should have cetiied welders for precision & heavy fabrication from Govt. approved ‘accredited labs. {Welder qualfications: Quaified welders as per EN-287-1 shall be employed for fabrication work a per FIAT's welding procedure specication 22.026 part document 100 03. The welding shall reveal high standard of workmanship. However, if welders employed are qualified to any other ~ intamattonal approved stenxdard, prior approval of RF is to be taken. material: |. The chemical composition and mechanical properties of steel plates to be used shall conform to applicable drawings. {i The steal plates to correct chemical composition shall be procured ffom SAIL or other reputed manufacturers along wit their tot coticaes. These test cetficates shall be co-rlatod with the ston on ep be taken vo fr else pr cormercane of wok fi test cetfcates ae not available, sample shall be drawn and tasted both for chemical jv. Al records of physical, ‘properties tests shall be made avaliable to Inspecting Agency. All plates to be taken up for manufacture shall be visualy checked for surface defects such as cracks, denis, rust, scales etc. and they shall be free from all these 8 Procurement of Major Bought outs: [Lf required, forging, casting or sub components may be procured / bought out only from approved sources of RDSO/ RCF, Kapurthala. a Cleaning, Cling, Ege reparation and atelier ‘Any distorion that oocurs during cutting shail be straightened before i a rae ha bo teprensd stdout bore conmencng nandacing operators. jv. All nicksicuts on the plates during cutting shail be finish ground before using them for sub- assemblyiassembly. \v. The surfaces and edges to be welded shall be ground smooth and uniform and shall be free from racks, ‘undercuts, slags, gauges etc. that would adversely affect the quality and the strength of the w ‘howe int menslosledgepropren shal be as per he relevant crewing specication, 410. Fixtures and Manipulators: The manufacturer shall prepare at least folowing fiures for fabrication & ‘machining and snd mani o down end welding of og ble tile lngos Delors tg the anfcig (Tr nay be mqemens of fia ite an arpa, ao) 1. Bolster top, bottom and web tack welding. i Bott tl wed rue hevng tag ty fr down hand wee. Bolster machining foture. o Prepared by ‘greed byR.C.F. padlication |" Technical Specification for Fabricated and Machined MOTS 2040 ‘Bogie Bolster for FIAT Bogie Pane are. 11, Welding procedure: k Shielding gas: MAG welding process using shielding media gas mixture es par EN 430 M2t {(BZ%Ar #18 % COZ) OR EN 439 N11 ( 50 % Ar+ 25% He + 25 % C02). i. Fler metal: Filer material chould be used as per spec. EN440-G3Si1. ii. As far 2s possible, all the weld joints shall be welded in down hand positon, manipuators to be used if necessary. iv. Weaving beed Technique and Intr-pass cleaning technique shall be adoptad by grinding and using wire brushes. Pug welding to be used wherever possible. Manual MAG welding may be done for the erees which are pot sccassible ee 12, Quality of Weld Joints: 1 Visual (By using magnifying glass If required) ‘i ‘a. Weld joints shall have uniform beadings and smooth change over from weld deposit to the parent metal and thorough fusion between adjacent layers of weld metal and Between weld metal end parent metal. 'b. They shal be free from cracks, craters, undercuts, ovetaps, porosities, Inclusions, blow-holes etc, cc. Members distorted by welding shall be straightened by carefully supervised application of heat. ‘The temperature of heating areas shall not exceed 650 degree centigrade. Mechanical method ‘may also be used with application of heat. Dye Penetrant Test : ‘Al the filet weld joints shall be subjected to Dyé Penetrant Test and al the butt weld joints (100%) shall be subjected to Dye Penetrant Test for detection of weld flaws. The procedure and ‘acceptance standard shall be as per specification no. 1S: 5334/3658 respectively. 13, Acceptance Standard i. Allineardiscontinues are unacceptable and shal be removed and repaired by chipping OF gfnding and subsequent welding. i. When defects appear, they hal be rectifed and the area shall be re-examined by the seme method to verity that they have been rectified completely. ii Altes reports of Dye Penetrant Test wil be submited for review to the Inspecting Agency. 44, Shot Blasting: The entire bogle bolster shall be subjected fo shot blasting for clearing of rust, scales, sspatters etc. before painting ofthe bogie bolster 415. Painting: Immediately after shot basting, the bogie bolstar shall be coated with epaxy primer & painted with High Build Epony paint as per RCF spectication no, MOTS-166. 16. Machining of Bolster: i ‘Machining of bogie bolster shall be done on 3-axs CNC machining centre as indicated in para 4 (). i, Bogle bolster should be suitably fied on Machining certr using proper fixture in such @ way that machining shall be done in single sating to achieve the dimension tolerances and the surface rughness 2s per drawing of tender. Tolerance for ur-toleranced dimensions should be folowed as por 18.2102 (medium). Single seting means that a paricuer reference is taken by probe and machining is completed according to that referenca taken are the program fed without any change i bogie bolster postion. 0 Mee read by rt ih reRF Specification |” Technical Specification for Fabricated and Machined MOTS-204001 Bogie Bolster for FIAT Bogie See He Page: Sot 6 17, Stage Inapection: The stage Inspecton shal be caried cut by manufacturers Ida below and Ti, Dimension Conivol Charts, Chemical end mechanical properties test certhcates, Magietc Paricios ‘Test Cortficates, DPT and stage inspection report etc. shall be supplied slong with the Bogle bolster - to the purchaser. 418, Dimensions and Tolerances: |. Alldimensionttolerances shal be 2s per detals given inthe drawings, ii. Detailod dimengion control charts/sheets shall be prepared for each bogie bolster in. which measurements of crfical dimensions shall be recorded and kept for evaluation and verification by fi. Allthe un toleranced dimensions shall be in accordance with IS: 2102 (Medium). iv. Gauges, ices and fempltes and accurate messurnginsumets shal be used to ensue the 19, Quality Assurance Plan: A Qually Assurance Plan which outines the various stages and processes inducing inspection in oder to obtain a Quality product shal be submited lo RCF. Kapurthala or Purchaset for approval QAP shal be prepared on the ines as indicated in MDFOQ014, Tis shal be done and got ‘approved by CDEIRCF, Kepurthala before undertaking manufacture of plot sample, 20, Pilot sample approval: Manufacturer shoul! gt two samples approved fom CDE/RCF, Kapurthaa before start of series manufacture and butk supply. 214, Code of Practice for Quality Control and Inspection: iL The manufacturers shal fuish to the purchasinginspectng authories infomation in respect of {ually contol systems in force at their works on various mates used inthe manufac of components. i. The manufacturers shal furish tothe Purchasing/nspecting autores the deta of tests and inspection records and other relevant records as required under the quay con systems in force. These records and reports shall be maintained by the Competent Technical Autry of the Tranufacturer end shal be open to exarintion by the Purchasing/nspecting Authorities at all ime. tu. Purchasinglnspeding Autores alter discretion may draw samples of products at any stage of pradutn for confomiy tess efor at the wors ofthe manufacture rn an approved aborsoy, sree the samples do not conform tothe requirements ofthe specication, double the numberof ‘amples fom the sane belch shall be crave for re-tess. if any of th r-tst samples do not“ g a ‘pediication | Technical Specification for Fabricated and Machined | MOTS-206001 Rev Bogie Bolster for FIAT Bogie tae co 22. Wdentification Marking: Each bogie bolster shall be stamped with an easily visible identification indicating the bogie bolster seri number, year of manufacture and manufacture’s name to facitate ‘dentiicaliontoorrelation with the inapeation/test results. 23, Packing: 1. All machined surfaces shall be epplied with suitable rust preventive, which shall prevent it from ‘corrosion & oxidation fora minimum period of one year of storage. i. The packing shall be such that all the machined surfaces shell be properly protected against rubbingimpactscratches with other bogies or with mode of transportation Le. otc, ‘4, Warranty: The menufachrer hall wairani the bogie bolstatfor a parod ofS years fromthe date of supply, {or material, manufacture and workmanship 8s regards trouble-free and service Ht any defects are noticed during service with regards to manufacturetwelding qualty of the bogie bolster, ‘action shall be taken by the supplier to cany out any repairsirectfcation or replacement at his cost .The decision of the purchaser in this regard shall be final. es Prepared by Reviewed! ‘Agreed by