Ref: CGW 0001 (Rev.

4)

Page 1 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

INDIAN RAILWAYS

Technical Specification for Supply of Fabricated Bogie to IR for Mainline Coaches, EMU/MEMU/DMU Coaches and 40,000 lts. capacity VVN type Milk Tank Van. (Broad Gauge: 1676mm)
S No. 1 Date/month of Issue November 2006 Revision /Amendment Rev. 01 Page no. 2 Reasons of Revision Change in Cl.11: Number of Employees changed from 200 to 50 nos Added new Cl. 6: Infrastructure Facilities at manufacturers work place. Added new Cl. 7: Fabrication of bogie frame/bolster components has been given. Details of components fitted in ICF bogie has been given. Added new Cl. 11: Details of Fixtures & Manipulators has been given. Added new Cl 16:, Details of Gauging has been given. 14 Added new Annexure-3 Reference drg. Nos.of all the components/parts fitted in ICF bogie of various coaching/ Suburban stock provided.

4.

10

28 & 29 2 October 2008 Rev.02 -

(a) Amendment 01 of Nov. 2007 has been incorporated in C-9202 (Rev 02) (b) Annexure III at page 30 has been updated by incorporating latest drawing nos. in AC EMU (ASR), DC EMU, AC/DC EMU, and MEMU & DMU stock. (c) Detailed drawing list for the main line ASR coaches of 13t, 16.25t Self Generating & End On Generating mainline coaches, 16.25t trailer coaches required for retro fitment from coiled suspension to ASR coaches, MEMU (ASR) motor & trailer coaches furnished in Annexure IV at page 31 & 32 in the specification. (d) Amendment in clause 2.1, clause 6 and 17 specifying shot blasting in place of grit/garnet blasting.

Issued by:

Research Designs & Standards Organisation Manak Nagar, Lucknow 226 011.

Ref: CGW 0001 (Rev. 4)

Page 2 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

Technical Specification for Supply of Fabricated Bogie to IR for Mainline Coaches, EMU/MEMU/DMU Coaches and 40,000 lts. capacity VVN type Milk Tank Van. 1. 1.1 Scope: This specification covers the technical requirements to be complied by the tenderer for manufacture, testing and supply of Fabricated Bogie duly assembled to IR for Mainline Coaches, EMU/MEMU/DMU Coaches and 40,000 lts. capacity VVN type Milk Tank Van. This specification supercedes the earlier specification No.C-9202 (Rev.0) issued in 1992. It also supercedes the bogie technical specification for 40,000 lts. VVN type Milk Tank Van to CONTR-BGMV-8401 of Aug 1984. Definition Wherever Inspecting Agency has been mentioned it shall be taken as Authorised Inspecting Agency of Purchaser. Eligibility Criteria: The manufacturer shall have adequate fabrication, heat treatment and machining and shot blasting facilities. The manufacturer shall be an ISO9001-2000 certified company. The manufacturer shall have prior 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. A wellequipped laboratory for various tests required for a quality product of fabricated bogie must be available with the tenderer. They shall have adequate technically trained staff including welders and non-destructive testing operators for radiographic, ultrasonic and magnetic particle inspection, qualified to approved ISI/international standards. The manufacturers shall normally be 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. The manufacturer shall submit evidence in support of these requirements along with the tender. The manufacturer shall also submit detailed list of machines available for manufacturing the bogies.

1.2

1.3

2. 2.1

Ref: CGW 0001 (Rev. 4)

Page 3 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

3.

Scope of Supply:

3.1

The fabricated bogie duly assembled is to be supplied conforming in all respects to the relevant drawings as indicated in annexure-3. The tenderer is required to coordinate and liaise with RDSO, Lucknow and the purchaser during manufacture of the first two-bogie frame/bolster, which shall be the prototype bogies. This is a general specification required for manufacturing of all types of bogies used in mainline coaching stock, EMU/DMU/MEMU coaching stock, Self Propelled vehicles and for 40,000lts., capacity VVN type Milk tank van. Governing Specifications: IS:2062 Weldable Structural Steel IS:813 Scheme of symbols for welding IS:817 Code of Practice training and testing of welders IS:2102 General locations for linear and angular dimensions IS:2074 Ready mixed paint, air drying, red oxide, zinc chrome priming IS:2932 Enamel, synthetic exterior (a) under-coating (b) finishing ASTM A:435 IS:3658 IS:5334 Straight beam ultrasonic examination of steel plates

3.2

3.3

4.

AWS D1.1 (1983)Blue Std. 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. Approval tests for welding procedure.

Wherever reference to standards, IS or any other Standards/code, appears in this specification it shall be taken as a reference to the latest version of the Standard/code.

Ref: CGW 0001 (Rev. 4)

Page 4 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

5.

Deviation: When deviations from original design, material specifications, dimensions etc. are desired specific proposals with reason shall be submitted for prior approval of RDSO/Lucknow before commencement of manufacture.

6.

Infrastructure facilities: The manufacturer shall have following infrastructure facility at their works for manufacturing of bogies. (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 (vii) Radiographic testing facility /Ultrasonic testing machine. (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. (xiv) Apparatus to check chemical composition of steel. (xv) Hardness testing machine. (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, which should be ISO 9001:2000 certified. (xvii) Oven for drying electrodes (0-500 degree C) (xviii) MPI & DP testing facility. (xix) 1t/2t/5t EOT Cranes. (xx) Level surface table of size 4000 mm X 2600 mm. Bogie: Bogie consists of the following assemblies: Bogie frame assembly Bolster assembly Suspension Air suspension assembly in secondary suspension

7. 7.1 7.2 7.3 7.4

Ref: CGW 0001 (Rev. 4)

Page 5 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

7.1

Bogie frame assembly: Bogie frame assembly consists of following sub-assemblies, (i) Headstock assembly (ii) Side frame assembly (iii) Transoms assembly (iv) Longitudinal members

7.1 (i) Headstock a) All parts/members shall be first degreased and derusted in a degreasing/derusting plant b) All the parts/members shall be placed into the fixtures and tack welded. c) Weld the straight portion of the parts/members by submerged arc welding and weld the curved contour by down hand MIG welding in the manipulator. d) Stress relieving shall be done by putting the component along with fixture into oil fired furnace equipped with thermo- couples and recorders and allow to be heated between the temperature of 380 to 420C and later allowed to cool down in furnace. e) The assemblies shall be checked for its dimensions and inspected for its straightness. f) In case the component is not straight, straightening of component shall be carried out followed by stress relieving process. g) The above process of straightening followed with the stress relieving process shall be repeated till complete straightness is achieved. 7.1. (ii) a) b) c) Side frame: All parts/members shall be first degreased and derusted in a degreasing/derusting plant All the parts/members shall be placed into the fixtures and tack welded. Weld the straight portion of the parts/members by submerged arc welding and weld the curved contour by down hand MIG welding in the manipulator. Stress relieving shall be done by putting the component along with fixture into oil fired furnace equipped with thermo- couples and recorders and allow to be heated between the temperature of 380 to 420C and later allowed to cool down in furnace. The assemblies shall be checked for its dimensions and inspected for its straightness.

d)

e)

Ref: CGW 0001 (Rev. 4)

Page 6 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

f) g)

In case the component is not straight, straightening of component shall be carried out followed by stress relieving process. The above process of straightening followed with the stress relieving process shall be repeated till complete straightness is achieved. Transom: All parts/members shall be first degreased and derusted in a degreasing/derusting plant All the parts/members shall be placed into the fixtures and tack welded. Weld the straight portion of the parts/members by submerged arc welding and weld the curved contour by down hand MIG welding in the manipulator. Stress relieving shall be done by putting the component along with fixture into oil fired furnace equipped with thermo- couples and recorders and allow to be heated between the temperature of 380 to 420C and later allowed to cool down in furnace. The assemblies shall be checked for its dimensions and inspected for its straightness. In case the component is not straight, straightening of component shall be carried out followed by stress relieving process. The above process of straightening followed with the stress relieving process shall be repeated till complete straightness is achieved. Nose suspension bracket, shall be welded in the transom for Motor bogies using necessary fixture (For powered bogies only). Longitudinal members: All parts/members shall be first degreased and derusted in a degreasing/derusting plant All the parts/members shall be placed into the fixtures and tack welded. Weld the straight portion of the parts/members by submerged arc welding. Stress relieving shall be done by putting the component along with fixture into oil fired furnace equipped with thermo- couples and recorders and allow to be heated between the temperature of 380 to 420C and later allowed to cool down in furnace. The assemblies shall be checked for its dimensions and inspected for its straightness.

7.1 (iii) a) b) c)

d)

e) f) g)

h)

7.1 (iv) a) b) c) d)

e)

Ref: CGW 0001 (Rev. 4)

Page 7 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

f) g)

In case the component is not straight, straightening of component shall be carried out followed by stress relieving process. The above process of straightening followed with the stress relieving process shall be repeated till complete straightness is achieved. Bogie Frame Assembly: The sub assemblies of the bogie frame shall be placed in a fixure for final assembly of the bogie frame. The joints between side frames with Transom, Headstock and Longitudinals shall be welded properly for non-powered bogies. The joints between side frames with Transom, Head stock shall be welded properly for powered bogies The welded joints between side frames with Transom and Headstock shall be cleared by Radiographic Test. The other bogie components eg. brake block hanger, brackets, brake pipe brackets, Shock absorber brackets, Lateral damper brackets(for Air Suspension), Brake cylinder brackets ,BSS brackets, Wire Rope brackets etc. shall be fabricated as per relevant drawings. The components shall be placed in the fixures for fitment on bogie frame and full welding shall be done. Axle guides shall be welded in the bogie side frame with the help of axle guide welding fixture. Alignment of the axle guide shall be checked by using master gauges and straight edge. Any slight discrepancy in location can be rectified by suitable local heating of the frame After proper fixing of guide, the dimensions shall be recorded.

7.1 (v) a) b) c) d) e)

f) g) h) i) j) 7.2

Bolster Assembly: a) All parts/members shall be first degreased and derusted in a degreasing/derusting plant b) All the parts/members shall be placed into the fixtures and tack welded. c) Weld the straight portion of the parts/members by submerged arc welding and weld the curved contour by down hand MIG welding in the manipulator. d) Stress relieving shall be done by putting the component along with fixture into oil fired furnace equipped with thermo- couples and recorders and allow to be heated between the temperature of 380 to 420C and later allowed to cool down in furnace.

Ref: CGW 0001 (Rev. 4)

Page 8 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

e) f) g)

The assemblies shall be checked for its dimensions and inspected for its straightness. In case the component is not straight, straightening of component shall be carried out followed by stress relieving process. The above process of straightening followed with the stress relieving process shall be repeated till complete straightness is achieved.

7.2.1 Following are the assemblies/parts, which shall be fitted on bolster arrangement: a) Centre Pivot Arrangement: Centre Pivot arrangement with rubber silent block bushes shall be provided as per drawing nos. given in attached annexure-3. b) Side Bearers Arrangement: The side bearer arrangement shall be provided as per drawing nos. given in attached annexure-3. c) Anchor links (For Non Powered Bogies & Non HCC Bogies): One Anchor Link in each side of the bolster diagonally across shall be provided to connect bolster & transom as per drawing nos. shown in Annexure-3. d) Silent block: Silent block as per RDSO specification no. C-9406 (latest revision) shall be provided in Anchor links. Silent block shall also be provided in center pivot assembly. e) Air vent screws: Tapped holes above dashpot shall be provided for replenishing oil in dashpot. Special screw with Cu asbestos washers shall be provided in the dashpot hole to make it air tight. f) Shock absorber: Shock absorber as per RDSO Specification No. C-8703 (latest revision) shall be provided as per details given in annexure-3. g) Equalizing stay: Equalizing stays as per drawing no. given in annexure-3 shall be provided in the bogie between the lower spring plank and the bolster. h) Lower Spring Plank: The lower spring plank shall be manufactured in a proper fixture as per drawing no. shown in the attached annexure-3. Proper stress relieving shall be done by putting the component along with fixture into oil fired furnace equipped with thermo- couples and recorders and allow to be heated between the temperature of 380 to 420C and later allowed to cool down in furnace. i) Brake Beam load Test: a). Brake beam load test, for Bogie mounted brake system coaches shall be carried out according to the procedure laid down in ICF drg. No. T-3-2-624.

Ref: CGW 0001 (Rev. 4)

Page 9 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

7.3

For coaches equipped with Underframe mounted brake system, Brake beam load test required to be carried out according to the procedure laid down in ICF drg. No. T-3-2804. Suspension (for coiled spring bogies) c) The primary suspension consists of oil resisting rubber pads and helical spring mounted between axle box and bogie frame. The axle box guide arrangement shall be as per drg. no. given in attached annexure. The items required to be fitted on the axle guide shall be supplied duly fitted and suitably packed. The items of primary suspension i.e. primary spring, upper and lower washers, compensating rings, lower spring seat shall be supplied loose in packed condition. d) For Main Line bogies ,upper & lower washer will be of Hytrel material to RDSO Specification No. C-K409 (latest Revision) and as per Drg. No.CG-K4058 & CG-K4059 respectively. e) In case where coiled springs are provided in secondary suspension, these coiled springs shall be mounted in between upper bolster and bolster lower spring plank which is turn is supported on the bogie frame through swing hanger/links as per drg. no. given in the attached annexure-3. f) Bolster springs of helical type shall be manufactured as per RDSO Specification No. WD-01-HLS-94 (Rev.02). Air suspension assembly The pneumatic suspension system for the secondary stage of MC and TC stock shall confirm to RDSO specification No. CK-106 for air spring assembly and CK-407 for their control equipments. The air spring bogies shall have two vertical and two lateral hydraulic shock absorbers with one lateral rubber bump stop provided at each side of bogie between bolster and bogie frame. Assembly of Bogies The bogies shall be supplied by the contractor in duly assembled condition, as per the requirements by the railways, containing all the items as listed in Annexure III of this specification except wheel & axle with axle box assembly.

b).

7.4.

7.5

Ref: CGW 0001 (Rev. 4)

Page 10 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

8. 8.1

Raw Material: The chemical composition and mechanical properties of steel shall conform to IS: 2062 Fe 410 WC with Cu. 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, having the essential facilities, along with their test certificates. These test certificates shall be co-related with the stamping on the plates to be taken up for manufacture prior to commencement of work. Wherever test certificates are not available, sample from each shall be drawn and tested both for chemical composition and physical properties in the presence of Inspecting Agency. All records of physical, chemical including impact tests shall be made available to Inspecting Agency. All plates to be taken up for manufacture shall be visually checked for surface defects such as cracks, dents, pittings, bend, rust, scales etc. and they shall be free from all these defects. Straightening of the plates can be done with the help of either straightening machine or Hydraulic press. Hammering shall not be resorted to straighten the plates. Ultrasonic Test: All the plates shall be subjected to ultrasonic test on the entire surface for detection of sub-surface defects or internal flaws, such as cracks, internal lamination etc., 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. Unaccepted plates shall be suitably stamped/painted and segregated and records shall be kept in proper way. Cleaning, Marking and Cutting All the plates shall be degreased and derusted before commencing manufacturing operations. 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.

8.2

8.3

8.4

8.5

8.6

8.7

9. 9.1

9.2

Ref: CGW 0001 (Rev. 4)

Page 11 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

9.3

Plates shall be cut either by oxy-acetylene plasma or by machine. All nicks/cuts on the plates during cutting shell be welded and finish ground before using them for sub-assembly/assembly. Edge preparation All edge preparation shall be done by machining. The weld joint dimensions/edge preparation shall be as per the relevant drawing/IS specification. The surfaces and edges to be welded shall be ground smooth and uniform and shall be free from cracks, undercuts, slags, gauges etc. that would adversely affect the quality and the strength of the weld. The roughness of oxygen cut surfaces shall be no greater than 25 microns. Plates shall be inspected for dimensional accuracy. Any distortion that occurs during cutting shall be straightened before tack welding. 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, slag, mill scale, moisture, grease, oil, rust etc. that would prevent proper welding. All members to be welded shall be brought into correct alignment and held in position by clamps, wedges, strong backs, fixtures etc. until welding is completed. Tack welds shall be made with the same electrodes that meet the requirements of the final welds and shall be cleaned thoroughly.

10. 10.1 10.2

10.3

10.4 10.5

11.

12. 12.1

12.2

Ref: CGW 0001 (Rev. 4)

Page 12 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

12.3

The length of tack weld and the distance between two consecutive tacks shall be suitably selected by the manufacturer to avoid defects like distortions, warpage etc. 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. RDSO approved brand of filler wire shall be adopted. Welders qualification Qualified welder as per IS: 817 shall be employed for fabrication work and Radiographic test shall be carried out. The edge preparation shall be in accordance with the thickness of the plates. The welding shall reveal high standard of workmanship. However, if welders employed are qualified to any other international approved standards, prior approval of Inspecting Agency is necessary. Joints .1 Gaps and fit-ups shall be checked before starting the welding. .2 Use of Backing plates below the gaps of the joints is not permitted. Position As far as possible, all the weld joints shall be welded in down hand position, if necessary by using manipulators. Weaving bead Technique and Interpass cleaning technique shall be adopted by grinding and using wire brushes. Welding parameters as recommended by the electrode manufactures may be followed. Pre-Heat .1 Interpass temperature of 150 degree C to 200 degree C shall be maintained throughout the welding. .2 Electrodes shall be pre-heated, in the electric ovens, to a temperature of 150 degree C to 250 degree C for 2 hours before they are used.

12.4 13. 13.1

13.2

13.3

13.4

13.5

13.6

13.7

Ref: CGW 0001 (Rev. 4)

Page 13 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

14. 14.1

Quality of Weld joints Visual (By using magnifying glass if required) .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. .2) They shall be free from cracks, craters, undercuts, overlaps, porosities, inclusions, blow-holes etc. .3) 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. .4) The slags shall be thoroughly removed and cleaned after each interpass. .5) The welds shall be ground to eliminate stress raisers and to improve fatigue life. .6) 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. All the rework and straightening operations shall be completed before stress relieving.

14.2

Magnetic Particle Test/Dye Penetrant Test .1) All the fillet weld joints shall be subjected to Dye Penetrant Test on all critical areas, 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. The procedure and acceptance standard shall be as per IS specification no.5334/3658 respectively. .2) 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. All such indications are not necessarily the defects, since excessive surface roughness, and the heat-affected zones etc. may produce similar indications. Even if indications are believed to be

Ref: CGW 0001 (Rev. 4)

Page 14 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

non-relevant, each type of indication shall be explored to determine if linear discontinuities are present. 14.3 Acceptance Standard .1) All linear discontinuities are un-acceptable and shall be removed and repaired by chipping or grinding and subsequent welding. .2) When defects appear, they shall be rectified and the area shall be re-examined by the same method to verify that they have been rectified completely. .3) All test reports of Magnetic particle inspection/Dye Penetrant Test will be submitted for review to the Inspecting Agency. Radiographic/Ultrasonic Examination .1) All the Butt weld Bevel joints shall be subjected to 100% Radiographic Tests at 2% sensitivity and 2.0-2.2 film density conforming to Blue Standard of International Institute of Welding (IIW). .2) As per the specified standards IIW Weld joints having cavities, undercuts and porosities shall be within the acceptable limits as per the specified standards. .3) The Radiographic examination shall be carried out by qualified personnel and radiographs shall be submitted to the inspecting agency for interpretation. In case of difference of opinion, the interpretation of Inspecting Agency will be final. .4) Alternatively Ultrasonic testing of welded joints shall be carried out as per M&C dtes Code of Practice No. MC-4 of November 1994 (Reaffirmed in March 2005). 15. Stress Relieving: The stress relieving of the oil-fired furnace equipped measures shall be taken bogie/bolster during heat done after heat treatment bogie frame/bolster shall setting. bogie frame/bolster shall be carried out in an with thermocouples and recorders. Adequate to avoid any appreciable distortion of the treatment. If any resetting is required to be in order to achieve required dimensions, the be again suitably heat treated after such re-

14.4

Ref: CGW 0001 (Rev. 4)

Page 15 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

The heat treatment shall be carried out as specified in annexure-2. 16. Gauging: List of gauges used for axle guide fitment and checking of Bolster Suspension Spring hangers is following:

16.1

Longitudinal gauge for axle guide. (As per ICF Drawing No J&T/G0296/01) ii) Transverse gauge for axle (As per ICF Drawing No J&T/G0384/01) iii) Diagonal gauge for axle guide. (As per ICF Drawing No J&T/G0300/01) Square ness of the bogie frame, axle guides and BSS brackets shall be checked with the help of transverse, longitudinal and diagonal gauges and straight edge. Axle box alignment shall be checked with reference to the BSS brackets with the following gauges. Gauges 13 t bogies 16 t bogies Main Line & EMU/ME DMU Stock MU Stock 5701.0mm equidistant from centre line of axle 21591.0mm 20.32 t bogie s 5701.0mm 630 equidistant mm from centre line of axle 21591.0m 2210 m mm 36121.0m m 13401.0m m(6700.5 mm from longitudin al centre line) 21591.0 mm

i)

S.No.

Longitudin al gauge for axle guide Transverse gauge for axle guide Diagonal gauge for axle guide Longitudin al gauge for BSS brackets

5701.0mm equidistant from centre line of axle 21591.0mm

36121.0mm

36121.0mm

14001.0mm(700 0.5mm from longitudinal centre line)

15001.0mm( 7500.5mm from longitudinal centre line) 21591.0 mm

3643 1 mm 8001 mm

Transverse gauge for BSS brackets

21591.0 mm

2140 1 mm

Ref: CGW 0001 (Rev. 4)

Page 16 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

Diagonal gauge for BSS brackets Distance between BSS bracket and adjacent axle guide Transverse Gauge for Brake beam hanger bracket.

25731.0 mm

25731.0 mm

25411.0 mm

2285 3.0 mm

4631.0mm

4131.0mm

4931.0mm 733 1.0m m

8761.0mm equidistant from centre line of axle

8761.0mm equidistant from centre line of axle

8751.0mm equidistant from centre line of axle

8751. 0mm equid istant from centre line of axle

16.2

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. Measure the location of axle guide from BSS bracket. If these measurements deviate from the standard measurements, relocate this aligned plane of axle guides. Shot Blasting: The entire bogie frame/bolster shall be subjected to shot blasting after heat-treatment for cleaning of rust, scales, spatters etc. Special care shall be taken to protect the threads of Axle box guide during shot blasting. Immediately after shot blasting and inspection the bogie frame/bolster shall be coated with one coat of anti-corrosive paint to spec. no. IS: 2074 in order to arrest rusting and corrosion. 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 .2) Absence of distortion

17. 17.1

17.2

18.

Ref: CGW 0001 (Rev. 4)

Page 17 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

Record of above checks and Dimension Control Chart shall be submitted to the inspecting agency on demand. 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. 20. 20.1 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. Special care shall be taken to maintain the centers of Axle box guides and bolster spring suspension brackets. .3) Inspection of complete bogie frame/bolster after complete welding. 20.2 After completion of the First Two Bogie Frames/Bolster waivel of any or all items of the stage inspection may be considered by RDSO/Purchaser on request by the manufacturer. This will depend upon the experiences gained at the time of inspection of first two bogies/bolsters and the level of confidence built-up. The manufacturer will proceed further in manufacturing the bogies only after taking clearance at each stage as specified above. 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, jig and fixtures and measuring instruments being used by the manufacturer. All the facilities labour,

20.3

Ref: CGW 0001 (Rev. 4)

Page 18 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

appliances, gauges, measuring instruments etc. necessary for testing and inspection shall be provided by the manufacturer free of cost. 20.4 Dimension Control Charts, Chemical and Mechanical properties test certificates, Magnetic Particle Test Certificates, Radiography Test Reports, Heat Treatment records etc. shall be supplied along with the Bogie Frames/Bolster to the purchaser. Dimensions and Tolerances All dimension/tolerances shall be as per details given in the drawings. However, special attention shall be given to check the centers of axle box guides and bolster spring suspension brackets in longitudinal, lateral and diagonal directions. 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. All the un-toleranced dimensions shall be in accordance with IS: 2102-1980 (Medium) as indicated in the drawing. Gauges, fixtures and templates and accurate measuring instruments shall be used to ensure the correctness of the dimensions. Periodic Calibration of Gauges and Fixtures The gauges, 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. 23. Q.A.P 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, CGG 0001(Rev 01) Vendor approval guidelines.

21. 21.1

21.2

21.3

21.4

22.

Ref: CGW 0001 (Rev. 4)

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Spec. No. C-9202 (Rev.2)

24.

Code of Practice for Quality Control and Inspection

24.1 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. 24.2 Records, 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. 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. 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. In case the samples do not conform to the requirements of the specification, double the number of samples from the same lot/batch shall be drawn for re-tests. Should any of the re-test samples do not conform to the requirements, the entire lot/batch shall be rejected. 24.3 Approved Manufacturers

24.3.1 For reasonable quality assurance, it is desirable that the components are procured from manufacturers approved by Research Designs & Standards Organisation (RDSO), Lucknow or by any other agency as assigned by the Purchasing Authority, based on evaluation of the components as per the specification, manufacturing and quality control facilities and quality/assurance programme. However, such approval does not guarantee the supply of consistent quality of material/components and therefore every lot/batch offered shall be subjected to inspection and testing as per the specification. 24.3.2 The approved manufacturers shall be subjected to periodical re-appraisal (periodicity for each components shall be assigned by the approving authority). The consignee may also periodically arrange testing if so desired, in an approved laboratory for conformatory tests within six months from the date of receipt of the supplies.

Ref: CGW 0001 (Rev. 4)

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Spec. No. C-9202 (Rev.2)

25.

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 manufacturers name to facilitate identification/correlation with the inspection/test results.

26. 26.1

Packing: All machined surfaces shall be protected from oxidation and corrosion by applying two coats of rust preventive oil to IS spec. No.493 Pt.I viscosity grade 46. 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. wagon/truck/trailers etc. Warranty: The manufacturer shall warrant the bogie frame for a period of 5 years from the date of commissioning into service for material, manufacture and workmanship as regards trouble-free and satisfactory service performance. If any defects are noticed during service with regards to manufacture/welding quality of the bogie fame, action shall be taken by the supplier to carry out any repairs/rectification or replacement, as may be considered appropriate, which shall be done at his own cost. The decision of the purchaser in this regard shall be final.

26.2

27.

28.

Submission of Tender Offer: The tenderer shall submit parawise comments on this specification in his offer. In the absence of parawise comments, his offer will stand rejected. He shall bring out the deviations, if any from the specification with adequate justification for such deviations. Unless otherwise stated in his offer, it will be presumed that there are no deviations.

29.

Purchase of Drawings: i) All ICF drgs. mentioned in the specification shall be obtained from ICF Chennai. The drgs. and technical details would be provided by ICF free of cost, but incidental charges connecting with preperation and printing of drgs. and cost of booking of staff would be paid to ICF at actuals.

Ref: CGW 0001 (Rev. 4)

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Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

ii) All ICF drgs. pertaining to VVN type Milk Tank Van shall be obtained from RDSO Lucknow. 30. Static Load Test : 1.The static load test on bogies shall be conducted on level plane for first two prototype bogies of every order. 2.Bogie frame along with bolster assembly shall be placed on test rig. 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). 3.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, initial setup at 00. 4.The predetermined load, required for this test, which is given in the table below according to the type of bogie, shall be applied simultaneously at the side bearer on the bogie bolster (location at X & Y). 5.The deflection of the side frame at location A & B shall be observed and recorded as per the proforma below. This should not be more than 1mm. 6.The applied load shall than be removed from the side bearer and the residual deflection (if any) is observed and recorded. This residual deflection should be nil. 7.The sketch of the load testing equipment is given on page 29 0n this specification
Max. load applied on side bearer Deflection under Max. load at the center of side frame location at A (t) 1 2 3 13 16.25 20.32 (t) (mm) 6.530 8.547 9.600 (mm) (mm) (mm) B Residual deflection (if any) after removal of load at location A B Remarks

S. Axle load No.

Ref: CGW 0001 (Rev. 4)

Page 22 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

Annexure-I Location of Radiographic and Dye Penetrating Test on Side frame and Bolster
Type of Bogie Drawing References Radiographic Examination Dye penetrant test Bogie frame Bolster Bogie frame Bolster SK-92064 SK-92063 SK-92077 ---

Trailer bogies of MEMU/DMU and Mainline bogies (all coiled type) Motor bogie & HCC bogie of EMU (all coiled type)

SK-92078

---

SK-92076

---

Ref: CGW 0001 (Rev. 4)

Page 23 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

Annexure-2 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. Above 315 degree centigrade, the rate of heating shall not exceed 160 degree centigrade per hour. During the heating period, variation in temperature through the portion of the part being heated shall not be greater than 50 degree centigrade. The same shall be monitored by measurement of temperature using suitable thermocouples. For bogie frame, 4 thermocouples shall be fixed at the four corners and two at the centre of the side beams. Soaking temperature shall be between 600 degree centigrade and 650 degree centigrade. On reaching the temperature, the assembly shall be held within specified limits for a time not less than 1 hour per 25mm thickness of the plates. In addition, for determining the soaking time, the thickness of the thickest part of the assembly shall be considered. During the soaking period, the difference between the highest and lowest temperature of the assembly shall not be greater than 50 degree centigrade. 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. From 315 degree centigrade, the assembly may be cooled in still air. Suitable tie-bars shall be provided during stress relief operation for maintaining the critical dimensions. The assembly shall be kept in the furnace, bottom side up (inverted position) during the heat treatment. The assembly shall be suitably supported while loading in the furnace to avoid any permanent deformation during stress relieving operation. The heat-treating furnace temperature shall be effectively controlled by using thermocouples having associated recording equipment.

2)

3)

5)

6)

7)

Ref: CGW 0001 (Rev. 4)

Page 24 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

Ref: CGW 0001 (Rev. 4)

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Spec. No. C-9202 (Rev.2)

Ref: CGW 0001 (Rev. 4)

Page 26 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

Ref: CGW 0001 (Rev. 4)

Page 27 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

Ref: CGW 0001 (Rev. 4)

Page 28 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

Ref: CGW 0001 (Rev. 4)

Page 29 of 32

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Spec. No. C-9202 (Rev.2)

Ref: CGW 0001 (Rev. 4)

Page 30 of 32

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Spec. No. C-9202 (Rev.2)

Ref: CGW 0001 (Rev. 4)

Page 31 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

Annexure-IV
S. No . Description Mainline Bogies (ASR) 16.25t(ASR)

* MEMU (ASR)
Motor 20.32t ACEMU/M/ ASR-0-0-001althR EMU/M-0-1 -033 col-III EMU/M-0-2 -001 col-IX EM03100 DMU/DPC0-3-002 EMU/M-0-3-004 EM03117 N.A. EM04110 EMU/M-0-6-001 col-IV N.A. DMU/DPC5-05-503 (900 Kg) DC/EMU/M/AS R-0-5-005 (100Kg) N.A. DMU/DPC-0-1001 Trailer 16.25t ET00002

Trailer (For retrofitment

of existing coaches) 16.25t AC EMU/C/ASR-0-0002

1 2

Axle load Bogie genl. arrgt.

SG (13t) 13t CA00002

SG (16.25t 16.25t CA00001

EOG (16.25t) 16.25t WTAC4-0-0-401

3 4 5 6 7 8 9 10 11 12 13

Axle box guide arrgt. Roller bearing axle box Bogie frame arrgt. Bogie side frame Head stock Transom Longitudinal members Bogie bolster arrgt. Centre pivot arrgt. Anchor link Shock absorber Vertical capacity Shock absorber Lateral capacity BSS hangers Axle box coil spring

CC01100

AW01100

WTAC3-0-1-304 WTAC3-0-2-304

ET01100 CC02100 ET03150 ET03181 ET03101 ET03106 ET03100 ET03143 ET04130 CC06100 ET07104 DMU/DPC50-5-503 (600 Kg) DC/EMU/M/A SR-0-5-005 (100Kg) N.A. ET01001

EMU 0-1-018 WTAC3-0-2-304 ACEMU/C/ ASR-0-3-003 EMU 0-3-069 EMU 0-3-068 EMU 0-3-067 EMU 0-3-070 ACEMU/C/ ASR-0-4-004 EMU 0-6-001 EMU 0-7-001 DMU/DPC5-0-5-503 . DC/EMU/M/ASR-0-5005 . NA DC/EMU2-0-1-203

CA03105 CA03104 RB03104 RB03146 RB03106 RB03164 CA04100 CC06100 CC07130 DMU/DPC50-5-503 (600 Kg) DC/EMU/M/A SR-0-5-005 (100Kg) N.A. CC01129

CA03100 CA03101 AW03226 AW03125 AW03221 AW03127 CA04100 CC06100 CC07130 DMU/DPC50-5-503 (600 Kg) DC/EMU/M/A SR-0-5-005 (100Kg) N.A. AW01101

WTAC3-0-1-402 WTAC4-0-3-408 WTAC3-0-3-314 WTAC4-0-3-403 WTAC4-0-3-404 WTAC5-0-4-501 T-0-6-601 WTAC5-0-7-501 Chair car- 600kg. Power car- 900kg. Chair car- 100kg. Power car- 400kg. NA WTAC3-0-1-202

14

15 16

Ref: CGW 0001 (Rev. 4)

17 18 19 20 21. Bolster suspension arrgt. Bogie brake arrgt. Suspension diagrammatic arrgt. Wheel & axle arrgt. Remarks

Page 32 of 32

Date of issue October, 2008

Spec. No. C-9202 (Rev.2)

CA05100 CC32272 CA90001 CG-K6016

CA05100 AW32122 CA90001 CG-K6016

WTAC3-0-5-305 WTAC4-3-2-401 DMU/TC2 9-0-204 CG-K6016

EM05102 EMU/M-3-2-064 Col- I EM90003 EMU/M-0-1-027

ET05120 ET32111 ET90003 ET02102

ACEMU/C/ ASR-0-5-004 DC/EMU 3-2-006 ACEMU/C/ ASR-9-0-003 EMU-0-2-007

* To be applicable only after issue of speed certificate.