qms-09:2009 - indian railwayrdso.indianrailways.gov.in/works/uploads/file/qms-09.pdf ·...

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.


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.


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.


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.


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.


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.


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.


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).


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.


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.


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.


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.


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 .


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.


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


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


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.


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.


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.


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.


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.


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.


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


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.


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.


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.


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.


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.


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.)


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


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.


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


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.


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.


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.


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.


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.


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’).


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.


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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