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Government of India Ministry of Railways
QMS-09:2009 (Revision 0)
Infrastructure, manufacturing, testing & quality control requirements for
(i) Cast steel Casnub & CONCOR Bogies (ii) Casnub Bogie – Bolster (iii) Casnub Bogie – Side Frame
Inspection & Liaison Directorate
Research Designs & Standards Organisation Manak Nagar Lucknow – 226011
February’2009 (Price Rs. 1100/ -)
STR Clause No.QMS 09 (Existing)
Firm,s name Remarks/ suggestion by firm’s, if furnished
Recommendation by committee based on feedback from firm’s & discussion
2.1 Vendors seeking approval shall satisfy the
requirements for category “A” foundry as
per IS:12117 (1996) or latest.
Brand Alloy Vendors seeking approval shall
satisfy the requirements for class
“A” foundry as per IS:12117
(1996) or latest.
Besco FASL,Kanpur FASL, HP BECO,Bhilai Titagarh Wagon,KOl Raneka, Dhar Texmaco Rail
A D Electro CLW Siena Jupiter Alloy Titagarh Wagon HED) Braithwaite HEI Burn Standard Orient Steel, HWH Besco Foundry Div Simplex
2.2 The firm should have acquired ISO 9000
series certification or QS certification
Brand Alloy No Change
Besco FASL,Kanpur FASL, HP BECO,Bhilai Titagarhwagon,KOl Raneka, Dhar Texmaco Rail A D Electro CLW Siena
Jupiter Alloy Titagarh Wagon HED) Braithwaite HEI Burn Standard Orient Steel, HWH Besco Foundry Div Simplex
3.1 Covered shed with sufficient height and
space provided with at least one number EOT
Crane in each bay covering the below
mentioned activities:
I) Melting, Moulding , Fettling
II) Heat Treatment
III) Gauging & assembly
IV) Load testing area.
Brand Alloy No Change.
Besco FASL,Kanpur FASL, HP BECO,Bhilai Titagarhwagon,KOl Raneka, Dhar Texmaco Rail A D Electro CLW Siena Jupiter Alloy Titagarh Wagon HED) Braithwaite HEI Burn Standard Orient Steel, HWH Besco Foundry Div Simplex
3.2 Covered area with sufficient space for
handling raw material like Sand, Scrap etc
provided with EOT crane and conveyor,
magnetic chuck.
Brand Alloy No Change.
Besco FASL,Kanpur FASL, HP BECO,Bhilai Titagarhwagon,KOl Raneka, Dhar Texmaco Rail
A D Electro CLW Siena Jupiter Alloy Titagarh Wagon HED) Braithwaite HEI Burn Standard Orient Steel, HWH Besco Foundry Div Simplex
3.3 Ensure that at least one number tilting type
electric arc furnace having laddle refining
facility with minimum 5t capacity is available.
Brand Alloy NO change
Besco FASL,Kanpur FASL, HP BECO,Bhilai Titagarhwagon,KOl Raneka, Dhar Texmaco Rail For induction furnace melting ladle
refining facility is required to reduce P&S.
A D Electro CLW Siena Option of induction furnace can also
be added as it has better and faster melting technology.
Jupiter Alloy Titagarh Wagon HED) Braithwaite HEI Burn Standard Orient Steel, HWH Besco Foundry Div Simplex
3.4 Minimum three numbers of Charging Brand Alloy Besco
buckets of suitable capacity for scrap and
foundry returns should be available.
FASL,Kanpur NO Change. FASL, HP
BECO,Bhilai Titagarhwagon,KOl Raneka, Dhar Texmaco Rail A D Electro CLW Siena Jupiter Alloy Titagarh Wagon HED) Braithwaite HEI Burn Standard Orient Steel, HWH Besco Foundry Div Simplex
3.5 Facilities for preheating of laddle should
be available. Laddle lining should be of
Kaltex or of High Alumina bricks. In case of
use of cold laddle board, it should be
ensured that there is no drop in temperature of
molten metal and it is one time used
only.
Brand Alloy No Change.
Besco FASL,Kanpur FASL, HP BECO,Bhilai Titagarhwagon,KOl Raneka, Dhar Texmaco Rail A D Electro CLW Siena Jupiter Alloy Titagarh Wagon HED) Braithwaite HEI Burn Standard Orient Steel, HWH Besco Foundry Div
Simplex
3.6 Separate identified area for different grade
of scrap and foundry returns should be
available for avoiding wrong charging.
Brand Alloy No Change.
Besco FASL,Kanpur FASL, HP BECO,Bhilai Titagarhwagon,KOl Raneka, Dhar Texmaco Rail A D Electro CLW Siena Jupiter Alloy Titagarh Wagon HED) Braithwaite HEI Burn Standard Orient Steel, HWH Besco Foundry Div Simplex
3.7 Facilities should be available for oxygen
lancing and Argon purging for removal of
entrapped gases.
Brand Alloy No Change.
Besco FASL,Kanpur FASL, HP BECO,Bhilai Titagarhwagon,KOl Raneka, Dhar Texmaco Rail A D Electro CLW Siena Argon purging can be made optional,
as it is technically more suitable for steel industries than for casting foundries.
Jupiter Alloy
Titagarh Wagon HED) Braithwaite HEI Burn Standard Orient Steel, HWH Besco Foundry Div Simplex
3.8 Material handling facilities like mobile
crane, Pay loader, Fork lifter, Tram beam,
Piller crane, Magnetic chuck should be
available.
Brand Alloy Adequate material handling equipment viz. Mobile crane/EOT crane/Fork lifter/Payloader/Magnetic crane/Tractor Trolley/Loading Tempo/Tram beam/Piller crane should be available for handling of
material at all stages of production.
Besco FASL,Kanpur EOT Crane, fork Lifter is sufficient
for work, if required mobile cranes & pay loaders can be outsourced.
FASL, HP BECO,Bhilai Titagarhwagon,KOl Raneka, Dhar Texmaco Rail A D Electro CLW Siena Making all optional;- mobile crane/
Pay loader/ Fork lifter/ Tram beam/ Piller Crane/ Magnetic chuck and more applicable irrespective to its location
Jupiter Alloy Titagarh Wagon HED) Braithwaite HEI Burn Standard Orient Steel, HWH Besco Foundry Div Material handling facilities like
mobile crane/Pay loader/Fork lifter/Tram beam/ Piller Crane, Magnetic chuck should be available.
Simplex
3.9 Weighing machine of 1T capacity for
ferro alloys charge and finished casting
weighment
Brand Alloy Weighing machine of minimum
500 Kg. capacity for ferro alloys
charge and of minimum 1T
capacity for finished casting
Weighment
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena Can be mentioned as minimum I T or at least IT
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div Weighing machine of 500 Kg. capacity fo ferro alloys charge and 1 Ton for finished casting weighment.
Simplex
3.10 Ensure that refractory pouring cups &
downspruce are used.
Brand Alloy No Change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl Refraction/Co2 Pouring cup with proper painting
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
4.0 SAND PREPARATION
4.1 Ensure that Sand drier of 1t/hr capacity
with conveyor and cooling arrangement are
provided with intermediate hopper.
Brand Alloy
Automatic sand drier and cooling arrangement of adequate capacity with intermediate hopper for drying incoming sand with suitable automatic transportation arrangement.
Besco
FASL,Kanpur If dry sand is procured, the need of the facilityis not required.
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail For core making sand Dryer must be available for NO-Bake core
A D Electro
CLW
Siena Instead of specific 1t/hr capacity, it can be made as adequate capacity, Conveyor & hopper arrangement can be made optional depending on the location of sand storage area
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div Ensure that Sand drier of 1 t/hr capacity with conveyor are provided with intermediate Hopper.
Simplex
4.2 Automatic sand continuous mixer machine
for making ‘Mould’ and ‘Core’ should be
available. The mixer should be intensive type
with calibrated dozing of important
ingredients.
Brand Alloy NO Change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl Core sand preparation with muller
may also be allowed for core making. Timer based intensive type sand mixer for mould making sand to be allowed.
Raneka, Dhar
Texmaco Rail In continuous mixture at a certain intervals testing is to be done for process control
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div May be deleted, as covered under 4.5 & 4.7
Simplex
4.3 Ensure that the system exist for testing of
prepared sand as per the following
frequency:
i) Moulding sand 1 in every 5 batch.
ii) Core sand 1 in every 20 batch.
Brand Alloy
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
4.4 Whenever the sand is tested the following
properties of prepared sands shall be
checked. Green Compressive Strength, Green
Shear Strength, Moisture, Permeability,
Shatter Index flowability, hardness etc. The
acceptance value for each test must be clearly
specified and any sand not meeting the above
parameters must not be used for mould/core
making.
Brand Alloy No Change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
4.5 Jolt and Squeeze machine or machanised
moulding line should be available for
moulding.
Brand Alloy No Change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail Hand moulding may not be accepted as there s no consistance in quality of each mould.
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
4.6 Mould cavity & core must be painted with
mould wash Alkalic base in nature to reduce
mould metal reaction.
Brand Alloy Mould cavity & core must be
painted with mould wash Alkali
base / Zircon base in nature to
reduce mould metal reaction
Besco
FASL,Kanpur Zircon base mould wash used.
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail Co2 system should not be used as there is very less collapsibility property and crack defect may come.
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
4.7 Ensure that the facilities are existing for
preparation of cores by ‘No bake’ method.
Brand Alloy NO Change
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div Ensure that the facilities are existing for preparation of cores by ‘No bake’ method & Co2 method.
Simplex
5.0 HEAT TREATMENT
5.1 Heat treatment facilities capable of
handling the entire production must be
available in house. Heat treatment furnace
should be of continuous type either oil fired
or electric
type.
Brand Alloy Heat treatment facilities capable
of handling the entire production
must be available in house. Heat
treatment furnace should be
either oil fired or Gas fired or
electric type.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar Bogie hearth oil fired furnace available.
Texmaco Rail Continuous type furnace is used in rolling mill or for forging shop where continous heating and production is required.
A D Electro
CLW
Siena Instead of just continues tunnel type more options can be introduced (like batch type) and gas fired can also be allowed. Additional suggestion: Equipment for surgace hardening can also be added as an requirement in STR as for center Pivot it is one of the very important process and is mandatory.
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div Heat treatment facilities capable of handling the entire production must be available in House. Heat treatment
furnace should be either oil fired or electric type.
Simplex
5.2 Heat treatment furnace should be provided
with multi point automatic continuous
temperature recording arrangement with
digital indicators for each point (one point at
every five feet length).
Brand Alloy No Change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div Heat treatment furnace should be provided with multi point automatic continuous temperature recording arangement with digital indicators for each point. (one point at every five feet length) Maximum.
Simplex
5.3 The heat treatment furnace must be
calibrated using sufficient no of thermocouple
for
assessing temperature at different zones at
various temperature ranges. The calibration
is to be done at least once in a year.
Brand Alloy NO Change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
5.4 Thermocouples, temperature indications
should be calibrated at least once in 6 month.
Brand Alloy No Change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
5.5 Serial nos. of castings under heat
treatment should be recorded in a register for
traceability with temperature time curve and
date. Display of temperature curve near
the furnace for the guidance of the operator
should be ensured.
Brand Alloy NO Change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
5.6 Arrangement of proper sealing of doors of
HT furnace should be available to avoid
oxidation / scale formation on the surface of
the casting. There should be positive
pressure inside to avoid entry of air from
outside.
Brand Alloy No Change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
5.7 The Heat Treatment recorder/Graph
should have sealing arrangement to avoid
tampering .
Brand Alloy No Change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
5.8 Positioning of the nozzles of oil fired
furnace should be such that the flame does not
come in direct contact with the castings.
Brand Alloy Positioning of the nozzles of oil
fired/Gas fired furnace should be
such that the flame does not
come in direct contact with the
castings.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
5.9 The burners of HT furnace should be
calibrated at every three months.
Brand Alloy NO Change.
Besco
FASL,Kanpur Calibration of burner once in six month is sufficient.
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div Not required.
Simplex
6.0 SHOT BLASTING MACHINE
6.1 Suitable shot blasting machine conveyor
monorail type or Twin table type should be
available.
Brand Alloy
Besco Suitable shot blasting machine
conveyor monorail type/ Twin
table type/Hanger type should
be available.
FASL,Kanpur Roatatory Table & hanger type avalable are sufficent.
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena Option of hanger type shot blasting machine can also be introduced which are also very popular
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div Suitable shot blasting machine conveyor monorail type or Twin table type or equivalent should be available.
Simplex
6.2 Casting to be given shot blasted before
and after heat treatment using steel shot of
size SS 1000, IS 4606.
Brand Alloy No change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
7.0 SAND TESTING
7.1 All incoming sand must be tested before
acceptance as per frequency set by QC
Department. The following must be checked
i) AFS grain size.
ii) Clay content.
iii) Moisture content.
iv) Loss of Ignition
Brand Alloy No Change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
7.2 For testing incoming virgin sand,
moulding sand, core sand the following
equipment at
Brand Alloy No Change.
Besco (f) Sand Muller 4 kg.
FASL,Kanpur
FASL, HP
least one number each should be available.
a) Permeability tester.
b) Sand Rammer
c) Quick moisture teller
d) Chemical balance
e) Sand sieve shaker
f) Sand Muller 25 kg.
g) Shatter Index tester.
h) Dry compression strength tester.
i) Sand mouldability / Compatibility tester
j) Sand flowability tester
k) Mould/Core hardness tester
l) Methylene blue test equipment for clay.
m) Portable hardness tester other than poldy
BECO,Bhilai
Titagarhwagon,KOl Methylene blue test equipment for clay may be alternated by wet analysis method.
Raneka, Dhar
Texmaco Rail Gas checking M/cmay be used to check the Gas content by using NO bake send in mould/core because gas in excess can ceat pinhole/gashole defect in casting.
A D Electro
CLW
Siena m) Portable hardness tester other than poldy- is not required for sand testing. It can be removed.
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
7.3 Ensure that the calibration of the above
equipments is done once in a year.
Brand Alloy NO Change
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
8.0 CHEMICAL LABORATORY
8.1 Computerised emission spectrometer with
automatic printer should be available for
analysis and recording of steel composition at
different stages of manufacturing.
Brand Alloy No Change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
8.2 Wet analysis facilities including
Strohelien apparatus for carbon analysis,
conducting chemical test of incoming
rawmaterials, refectories, ferro alloys should
be available in addition to spectro.
Brand Alloy NO Change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
8.3 Metalographic polishing equipment, Belt
polisher etc. should be available.
Brand Alloy Metalographic polishing
equipment viz. cut off machine, belt polishing/rotary polishing Machine etc. should be available.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
9.0 PHYSICAL LABORATORY
9.1 Universal testing machine of 40T capacity
with graphical recording facilities for
conducting tensile test of sample from each
heat should be available. The machine is to
be calibrated once in a year.
Brand Alloy Universal testing machine of 40T
capacity with graphical
recording/ Computer recording & printing facility for
conducting tensile test of sample
from each heat should be
available. The machine is to
be calibrated once in a year.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
9.2 Direct reading hardness testing machine
capacity 95-500 BHN should be available.
Brand Alloy No Change.
Besco
FASL,Kanpur BHN & HRC Machines are required.
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
9.3 Impact testing machine 0-300J capacity
for conducting impact test at room
temperature and sub zero temperature should
be available. Liquid Nitrogen container and
stainless steel bath with digital temperature
indicator for sub zero test arrangement
must be available.
Brand Alloy Impact testing machine 0-300J
capacity for conducting Impact Test at room temperature and Sub-zero temperature with cold chamber with digital temperature indicator for sub-zero test arrangement should be available.
Besco Impact testing machine 0-300J capacity for conducting impact test at room temperature and sub zero temperature should be available. Liquid Nitrogen container and stainless steel bath with digital temperature indicator or Refrigeration system for sub zero test arrangement must be available.
FASL,Kanpur Liquid Nitrogen Container should not be mandatory, other process may also be accepted i.e. Cold bath with acetone as a medium.
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena Instead of just liquid nitrogen container & stainless steel bath, option cold chamber can also be introduced which can hold the temperature upto(-70)degree C
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
9.4 Shadowgraph facilities for assuring
correct notch profile and dimension for impact
test specimen.
Brand Alloy NO Change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
9.5 Liquid penetrant test facilities for
checking surface welding cracks.
Brand Alloy No Change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
9.6 Magnetic particle Inspection facilities for
crack detection should be available.
Brand Alloy No change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
9.7 Radiographic examination facilities with
well equipped standard room should be
available
Brand Alloy No change.
Besco Radiographic examination facilities with well equipped standard room to be available.
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
9.8 Relevant ASTM E-446 reference
radiograph for comparing level of
radiographic quality should be available.
Brand Alloy NO change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
9.9 Metallurgical micro scope with 1000 x
magnification.
Brand Alloy No change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI 500x max magnification is sufficient to determince ASTM grain size NO. 4 or better.
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
9.10 SCRATA comperator for assessing
surface quality.
Brand Alloy No change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI SCRATA comparator not specified in
bogie’s specification.
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
9.11 Person in charge of the metallurgical area
is at least Graduate in metallurgical with not
less than 5 years experience.
Brand Alloy No change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl Diploma holder with 15 years experience in metallurgy/in relevant field may be allowed.
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
9.12 Staff conducting test like chemical
analysis, Sand testing of mechanical
properties have adequate skill and competence
and have under gone training to give the
reasonable reliability.
Brand Alloy No change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
9.13 Skill of such staff is periodically
qualified by making them carry out test on
blind samples.
Brand Alloy NO change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
9.14 Muffle furnace 0-1200 degree C with
temperature recorder should be available for
chemical analysis and Jominy test with
calibration on yearly basis.
Brand Alloy No change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail Muffle furnace of 100 degree C capacity is sufficient for any Test in Lab
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI Jominy test not required as per Cast Steel Bogie’s specification.
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
9.15 Hot air oven, Hot plate, Electrical oven
and other accessories and chemical agents
necessary for wet analysis should be available
including platinum crucibles (atleast 2
nos.)
Brand Alloy No change.
Besco
FASL,Kanpur 1 no is sufficient.
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail Only one type oven with crucible is sufficient for any chemical test.
A D Electro
CLW
Siena Can be mentioned as Hot air oven/Hot plate/electrical oven as not all necessarily required as roles are same
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
10. STATIC LOAD TESTING
10.1 Load testing arrangement for Bogie with
100t hydraulic power pack should be
available
Brand Alloy No change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
10.2 Proof load and destructive load testing
arrangement for side frame and bolster with
hydraulic power pack of 300tonnes capacity
should be available.
Brand Alloy No change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
11.0 MACHINING FACILITIES
11.1 The firm should have a machine shop
equipped with the following machine.
Plane miller machine of suitable capacity for
Brand Alloy No Change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
machining bolster surface.
Lathe machine.
Air Compressor.
Drilling machine.
Sawing grinder.
Welding transformer DC
Welding rectifier DC
Power saw for sectioning sides frame/Bolster
Titagarhwagon,KOl Outsourcing of sectioning jobs may be allowed.
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
11.2 Firm should have gauges as detailed in
RDSO’s specification number WD-31-Misc-
99 & use these during & after machining
operations.
Brand Alloy No Change.
Besco Firm should have gauges as detailed in RDSO’s specification number WD-31-Misc-99 & use these during & after machining operations.
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
12. QUALITY CONTROL Brand Alloy No Change.
REQUIREMENTS
12.1 There exists system of easy tracibility of
the product from casting stage to finished
product stage.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
12.2 Quality assurance plan for the product
detailing various aspects like
a) Organisation chart
b) Flow process chart
c) Stage Inspection details
d) Various parameters to be maintained to
ensure control
e) Policy of disposal of rejected castings.
should be implemented and record is
maintained for documentary evidence.
Brand Alloy No change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
12.3 A graduate Engineer with at least 5 years Brand Alloy No Change.
experience or a Diploma holder must head
the inspection/final quality control section
with 10 years experience exclusively for
inspection of castings.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
12.4 Inspection staff conducting non
destructive testing is adequately trained and
qualified by recognised agency and has
adequate experience.
Brand Alloy No change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
12.5 There exists quality manual of the firm Brand Alloy No change.
indicating the extent of control over
production
and testing.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
12.6 To ensure regular submission of foundry
returns detailing rejection rate, cause of
rejection corrective action taken on quarterly
basis.
Brand Alloy No change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
12.7 There exists a system of documentation Brand Alloy No change.
in respect of rejection at customer end,
warranty replacement, on line service failure
of castings.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
12.8 There exists system of recording plant,
machinery control equipments remaining out
of service, nature of repair done etc.
Brand Alloy No change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
12.9 Welders engaged in welding Brand Alloy No change.
works/reclamation works of castings must be
qualified as per IS:7318 must be revalidated at
least once in 2 years.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
13 GAUGING
13.1 Ensure that minimum three sets of
gauges as per the stipulated specifications are
available (Annexure ‘A’).
Brand Alloy No change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
14 TRAINING Brand Alloy No change.
14.1 Training need for all personnel to be
identified. Regular training should be
organized covering personnel identified for a
particular period.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
15 DOCUMENTATION
15.1 System should exists for documentation
of the following:
a) Incoming raw-material register with TC
reference of supplier as well as internal
test result.
b) Stage inspection and test result
c) Calibration records
d) Casting records sl.no. wise, components
wise, month wise.
e) Register for heat treatment indicating
charge wise, loading serial no.wise
Temperature graph must be pasted on the H.T
register.
f) Weighment records of one side frame and
bolster at least once in a month.
Brand Alloy No change.
Besco
FASL,Kanpur
FASL, HP
BECO,Bhilai
Titagarhwagon,KOl
Raneka, Dhar
Texmaco Rail
A D Electro
CLW
Siena
Jupiter Alloy
Titagarh Wagon HED)
Braithwaite
HEI
Burn Standard
Orient Steel, HWH
Besco Foundry Div
Simplex
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