reasoned document for str no. rdso/pe/str/ac/0027 … · 2018-12-07 · house. earlier cnc machine...

Claus

e No

Existing provisions in

Rev-0

Proposed in Revision 1 Proposed changes Commnets

of

M/s.Amit

Engineers

Commnets of M/s.

Rishab Industries

Comments

ofM/s. Hind

Rectifiers

Ltd

Comments of

M/s.

Bhavitron

powertech

Pvt.Ltd.

Commnets of M/s.

Light Enginenring

corporation

RDSO

Remark

s

Accepte

d/Reject

ed

Reason of

acceptance/R

ejection

The firm seeking

approval for

manufacture and supply

of Switch Board Cabinet

for LHB type AC

coaches and other

panels of AC coaches,

should meet the

technical requirements,

as laid down in this

STR.

The firm seeking approval

for manufacture and

supply of Switch Board

Cabinet for LHB type AC

coaches and other panels

of AC coaches, should

meet the technical

requirements, as laid

down in this STR.

Power/Control Panel

included

Agreed Agreed Agreed Agreed Agreed

Capability of personnel

in design,

manufacturing & testing

in the field of electrical

panels( Switch Board

Cabinet/ Power/control

Panel) is mandatory

requirement.

The clause has been

proposed to add to

improve the design

and manufacturing

workmanship.


Reasoned document for STR no. RDSO/PE/STR/AC/0027-2009(Rev-1)-2009 (draft) of

Switch board cabinet on the basis of comments received from manufacturers

SCHEDULE OF TECHNICAL REQUIREMENTS (STR) FOR MANUFACTURE OF ALL

TYPE OF SWITCH BOARD CABINET AND ALL TYPE OF POWER PANEL OF AC AND

NON AC COACHESTECHNICAL REQUIREMENTS (STR) FOR MANUFACTURE OF ALL TYPE OF SWITCH

BOARD CABINET /CONTROL PANELS OF AC AND NON AC COACHES

The firm should have

manufactured and

supplied minimum 100

Switch Board

Cabinet/Power

Panel/Control Panel of

at least 25 kW load

capacity to Indian

Railways/Public

sector/Electricity

Authority/State

Government/Central

Government bodyin last

3 years from the date of

application for vendor

registration.

The clause has been

proposed to ensure

that the proposed

vendor has

established credential

for similar items

before being

approved switch

board cabinet.

Agreed We have designed &

manufactured

microprocessor based

servo voltage

corrector upto

140kVA ACDB with

isolation transformers

upto 350kVA to our

corporate clients like

Vertiv( Emerson

Network India) &

Consul Neowatt

Power solutions

Private Limited. Our

products have been

exported. We have till

date manufactured &

supplied more than

300 numbers in last 3

years.

Agreed Agreed This clause should be

minimum 100 Switch

Board Cabinet/Power

amended to max. 50

Panel/Control Panel

of at least 25 kW load

Switch board cabinet/

capacity Government

body in last 3 years

from the date of load

capacity Electricity

Authority/ State

Government/ Central

panel of at least 20

KW to Indian

Railways/ Public

sector/ Power

Panel/Control

Rejected only one firm

requetsed to

reduce the

criterial all

other firms are

agreed

A MEASURING AND

TESTING

INSTRUMENTS

MEASURING AND

TESTING

INSTRUMENTS

Zonal Railways have

reported problems of

poor quality of SBC.

FRPCPY of Switch

board cabinet is more

than 40% which

requires the

immediate

improvement in the

quality;Elaborate

testing arrangement

for the switch gears

and sub assemblies

provided in the Switch

Board Cabinet are

therefore proposed to

be includedin the STR

.Following


1. 3 Phase Power

Analyzer of Fluke or

equivalent make for

measuring required

electrical parameters

simultaneously. 1no.


2. HV tester

2 Nos

Agreed Agreed Following

added

instruments

minimum

Agreed Agreed

3. Insulation tester

2 nos.

1. 3 Phase

Power Analyzer of

Fluke or equivalent

make for measuring

required electrical

parameters

simultaneously.

1no.

Agreed Agreed i) 3 phase

power

analyserof

fluke or

equivalent

make for

measuring

reviewed

electrical

parameters

simultaneou

sly. 1 no.

Agreed Agreed

1. HV

tester2

nos

4. Ammeter 1000

Volts,5 Ampere. 6 nos.

2. Ammeter 1000

Volts,5 Ampere. 6

nos.

Agreed Agreed ii)

Ammeter

1000 Volts,

5 Ampere. 2

Agreed Agreed

2.

Insulatio

n tester2

nos.

5. Voltmeter 1000 Volts,

6 nos.

3. Voltmeter

1000 Volts, 6 nos.

Agreed Agreed iii)

Voltmeter

1000V. 2

no’s

Agreed Agreed

3.

Ammeter

2 nos.

6. Wattmeter 1000

Volts. 3 nos.

4. Wattmeter

1000 Volts. 3 nos.

Agreed Agreed iv)

Wattmeter

500 watts, 2

no’s

Agreed Agreed

4.

Voltmete

r2 nos

7. Frequency meter. 2

nos.

5. Frequency

meter. 2 nos.


5.

Wattmet

er2 nos.

8. Multi

meter/Multifunction meter.

1 no.

6. Multi

meter/Multifunction

meter. 1 no.


6.

Frequen

cy

meter2

nos.

9. 9. Variable voltage

transformer 3 Phase (0-

1000 Volts) AC. 1 no.

7. Variable

voltage transformer

3 Phase (0-1000

Volts) AC. 1 no.


7.

Multimet

er1 no.

10. Measuring tape. As

required

8. Current

injection/loading

facility for

temperature rise


8.

Variable

voltage

transfor

mer 1

no.

11. Micrometer. 2 nos. 9. Power

supply 24 V dc

110 V ac/dc230 V

ac 415 V ac and

750 V ac

Agreed Acceptable and will be

complied.

Agreed Agreed Agreed

12. Vernier caliper. 2 nos. 10. Power factor

meter 1 no.


9.

Measurin

g tap As

required

13. MMR setting test

bench1 no.

11. Tongue

tester.

1 no.


10.

Micromet

er2 nos.

14. Test bench for

Disconnecting

&Earthing device1 no

12. IMR

(Insulation

Monitoring relay)

setting test bench 1

no.


11.

Varnier

caliper2

nos

15. Test bench for

DC-DC converter1 no.

13. Standard

measuring

gauges/instruments-

As required


12.

MMR

setting

test

bench1

no.

16. Test bench for

MCB/MPCB1 no.

Test bench for battery

charger has been

deleted as this is not

in scope of SBC

manufacturer.


13. Test

bench

for

Disconn

ecting

&Earthin

17. Test bench for

regulated battery

charger


14. Test

bench

for DC-

DC

converter

18. Current

injection/loading

facility for

temperature rise


15. Test

bench

for

MCB/MP

CB1 no.

19. Milli volt drop

meter for measuring

volt drop across

contactor & relays. 2

nos

Agreed Agreed xvi) test

bench for

MCB/MPCB

: Not

mandatorily

required

because

MCB and

Agreed Agreed rejected MCB MPCB is

necessary to

check before

use

16. Test

bench

for

regulated

20. Arrangement for

pick up & dropout

voltage of relay1 no.


17. Milli

volt drop

meter for

measurin

g volt

drop

21. Powder coating

thickness checking

meter. 1 no.


18.

Arrange

ment for

pick up &

dropout

voltage

22. Thermal image

camera for

checking of loose

connection during

load test and

general wiring. 1


19.

Powder

coating

thicknes

s


20.

Thermal

image

camera

for

checking

of loose

connecti

23. Power supply 24

V dc 110 V ac/dc


21.

Power

supply

24 V

dc110 V

230 V ac 415 V ac

and 750 V ac


Agreed Agreed Agreed Agreed

230 V

ac415 V

ac

24.

Thermometers/therm

ocouple. 1 no


Test room Agreed Agreed Agreed Agreed

22.

Thermometers/thermoc

ouple. 1 no.

25. Fire extinguishers. As

required


23. Test room 26. Power factor meter.

1 no.


24. Fire extinguishers.

As required

27. Tongue tester.

1 no.


28. IMR (Insulation

Monitoring relay)

setting test bench 1 no.


29. Standard

measuring

gauges/instruments- As

required


Other hand tools like

spanner, pipe bending

machine etc. As

required.


NOTE: NOTE: 1) Agreed Agreed Agreed Agreed Agreed

1) One set of each

instrument shall be kept

as standby. Firm shall

submit calibration

status of each

instrument along with a

copy of calibration

certificate.

Firm shall submit

calibration status of each

instrument along with a

copy of calibration

certificate.


2) Test room shall be

equipped with all the

testing & measuring

instruments

as mentioned above.

2)Test room shall be

equipped with allthe

testing & measuring

instruments as mentioned

above.


B. Plant and Machinery MACHINARIES &

PLANTS CAPABLE FOR

PROCESSING STEEL

USED DURING

MANUFACTURIN

Zonal Railways have

reported problems of

poor quality of

paint/powder coating

which requires the

immediate

improvement in the

quality of Switch

Board Cabinet hence

plant and machinery

has been kept in-

house. Earlier CNC

machine and powder

coating was allowed

to be outsourced.

Now firm has to

arrange in-house

manufacturing as well

as testing facility.

Following instruments

have been added: -


1. CNC punching

machine

1. CNC Machines

required for process like

shearing, punching,

cutting and bending for

fabrication of Stainless

steel structure

Agreed Fabrication is a

specialized & core

field by itelf and even

if the plants and

machineries are

purchased, ensuring a

good quality cannot

be guaranteed. We

have a strong tie set

up with M/s Yash

Lasertek India private

limited located very

close to us. The

technology used by

M/s Lasertek is 3 axis

laser cutting machine.

This technology gives

much better finish and

quality as compared

to the CNC turret

punching machines.

The bending is also

done on CNC bending

machines. M/s Yash

lasertek are single

source for companies

like atlas copco for

their compressor and

Performanc

e of switch

board

cabinet is

directly

depended

on quality of

electrical

knowledge

and skill set

of

manufacture

r.

In Clause No.

B, Plant and

Machinery, S.

No.1 to 12 was

allowed for

outsourcing

before and now

has been

changed to

have the

facilities in-

house. We are

in the process

of arranging

the

requirements

(Fabrication

and Powder

coating

process) as per

your new STR.

So, we request

you to keep our

Case Pending

till we make

necessary

arrangements.

For fabrication of

Switch Board

Cabinet, punching

job is very

restricted, as such

this job should be

allowed to be

outsourced.

Rejected CNC inhouse

will lead to

good quality

fabrication

enclosure .

2.

Hydraulic/Pneumatic/Pow

er press

Agreed We can assure

excellent quality with

very cloase

monitoring through

our lean

manufacturing &

control systems which

has been

implementaed at M/s

Yash lasertek India

Private Limited & M/s

Rishabh through a

program jointly

conducted under

ministry of MSME.

National Productivity

council and MCCIA

Mechanical

portion

should not

directly

involve in

performance

but need to

maintain

high quality

and

standards

because it is

use in LHB

coaches

and it is also

matter of

public

Agreed 7tank treatment and

powder coating

facilities may be

outsourced as from

environmental point

of view it is not

desirable that every

factory should have

this facility. We will

keep all quality

checks so that

quality is

maintained.

7 tank inhouse

will lead to

good quality

fabrication

enclosure .

2. CNC shearing

machine

3. Drill machine 1. Jigs & Fixture

suitable for welding,

leveling and

mounting

Agreed We are located in

Bhosari, MIDC Pune

which has got all the

possible facilities,

required for

fabrication and

powder coating. The

total cost of this kind

set up will be around

8-9 crores.

An electrical

organization

don’t have

own

expertise to

maintain

this quality

as per their

present

technical

skills and

Agreed Agreed

4. Spot

welding

machine/TIG &

MIGwelding

machine

suitable SS

2.

Hydraulic/Pneumatic/

Power press against

Power Press.

Agreed Agreed Therefore, it

is always

unmatched

with the

quality of a

standard

Agreed Agreed

3. CNC cutting

machine

5. Grinding

machine and

portable grinder

3. Spot welding

machine/TIG & MIG

welding machine

against spot welding

machine

Agreed Agreed In view of

above, MOU

with an ISO

mechanical

organization

who have

vast

Agreed Agreed

6. Seven tank treatment

for full structure of switch

board cabinet/power

panel/control panel.

4. Fork lifter of at

least 3 Ton.


4. Bending machine 5. Mobile trolley

and hoist.


7. Powder coating

arrangement


5. Power press Agreed Agreed Agreed Agreed Agreed

8. Electric Dryer/oven Agreed Agreed Agreed Agreed Agreed

6. Drill machine Agreed Agreed Agreed Agreed Agreed

9. Cable handling fixture Agreed Agreed Agreed Agreed Agreed

7. Spot welding

machine

10. Cable cutting tools Agreed Agreed Agreed Agreed Agreed

11. Hydraulic Crimping

tools of various size


8. Welding machine 12. Zig and fixture for

structure


13. Mobile trolley and

hoist.


9. Grinder/sander 14. Jigs & Fixture

suitable for welding,

leveling and mounting


15. Fork lifter of at

least 3 Ton.

Note 2 deleted. Agreed Agreed Agreed Agreed Agreed

10. Seven tank

treatment for structure

of switch board cabinet

NOTE: 1) S.No., Rating,

date of purchase along

with purchase bills and

quantity of each items

shall be furnished by

the firm in tabulated

for..


11. Powder coating

arrangement



12. Electric Dryer/oven Agreed Agreed Agreed Agreed Agreed


13. Cable handling

fixture



14. Cable cutting tools Agreed Agreed Agreed Agreed Agreed


15. Crimping tools of

various size



16. Zig and fixture for

structure



17. Trolleys for carrying

material


Agreed Agreed Agreed Agreed Agreed NOTE: Agreed Agreed Agreed Agreed Agreed

1) S.N, Rating, date of

purchase along with

purchase bills and

quantity of each items

shall be furnished by

the firm in tabulated

for..


2) The work related to

S.N. B 1) to 12) may be

outsourced, provided

that the firm (sub-

vendor) should have

plant and machineries

mentioned against

S.No. B 1) to 12). The

sub-vendor shall also

have ISO 9001-2008.

Quality Management

System confirming the

requirements

mentioned in clause

No. D) of STR.


6.4 POWDER COATING

FACILTY

Agreed Agreed Agreed Agreed Accpted

A. The firm should have

powder coating testing

facilities for which ISO

9001-2008 certification

is mandatory.

Agreed For powder coating,

we may request to

allow shot blasting

technique for clearing

of structures surface

to ensure excellent

quality of powder

coating. We are

located in Bhosari

MIDC in Pune which

has got all the

Agreed may be allowed to

outsourced.

Accpted

Similar to

above

reason,

MOU with

an ISO

mechanical

organization

who have all

the facilities

in powder

coating

should be

allowed.

And at last,

setting up

an in house

Many of the

prospective

vendors have

requested for

outsourcing

seven tank

treatment and

powder

coating facility.

It has been

agreed to

promote

competition.

Sub vendor

should,

however, have

all stipulated

facilities /M&P

/ Certification

i.e. Red or

applicable

category. It is

agreed as

electrical panel

manufacturing

units are

generally

located in

green

zone/corridor.

B. Phosphate coating

Tank used for treatment

of SBC/panel shall be of

adequate size to

accommodate the

entire SBC in one go.

Agreed Lower

volume of

business

cannot run

the plant

continuously

therefore;

maintenanc

e cost of

plants would

be high

during

noncooperat

ion. Our

factory is

stipulated in

green zone

of industrial

area

therefore

setting up

environment

al hazards

plants also

Agreed Agreed Accpted

C. Firm should have the

pollution control board

certificate for Red

category.


D. The machine

operators should have

minimum one-year

experience of operating

for each machine


E. Powder coating

process with necessary

gauges & control for

accurate coating

thickness shall be


Firm should have the

facility of checking of

quality of powder

coating in terms of

abrasion, corrosion,

hardness,

inflammability, finishing



Many of the

prospective

vendors have

requested for

outsourcing

seven tank

treatment and

powder

coating facility.

It has been

agreed to

promote

competition.

Sub vendor

should,

however, have

all stipulated

facilities /M&P

/ Certification

i.e. Red or

applicable

category. It is

agreed as

electrical panel

manufacturing

units are

generally

located in

green

zone/corridor.

Note 2: Item no. 6,7 &8

are only required for

SBC/Power

panel/control panel


7 PERSONNEL &

EXPERIENCE


7.1 Firm should have

atleast one graduate

engineers in electrical

discipline having not

less two-year

experience in the field

of panel designing,

cable layout and full-

fledged knowledge of

protection devices.

They shall be able to

understand the

requirement and

importance of the

product with relevant

standards including

electricity rules. The

experience details in

similar field shall be

submitted by the firm.

Firm should have at least

oneGraduate Engineers in

Electrical Engineering

discipline having not less

two-year experience in the

field of panel designing,

cable layout and full-

fledged knowledge of

protection devices. They

shall be able to

understand the

requirement and

importance of the product

with relevant standards

including electricity rules.

The experience details in




7.2 There should be quality

control set up headed

by minimum graduate

engineer having 5

years’ experience in

similar field. The




There should be Quality

Control set up headed by

minimum Graduate

Engineer of

Mechanical/Electrical/Elec

tronics/instrumentation

having5years’ experience

in similar field. The






7.3 There should be a

testing department

headed by at least

diploma engineer in

electrical engineering

with at least two years’

experience in testing of

electrical control panel.

7.1 There should be a

testing department

headed by at least

Diploma Engineer in

Electrical Engineering in

firm with at least 02 year

experience in Testing of

Electrical Control Panel

Wiring .



7.4 One mechanical

engineer is also

required, working with

firm having experience

in fabrication of different

structure. The engineer

shall have full fledge

knowledge of welding,

brazing and riveting

works along with

relevant

Indian/International

One Graduate Mechanical

Engineer in firm shall also

be required, working with

firm having experience of

minimum 02 years in

fabrication of different

structure. The mechanical

engineer shall have full

fledge knowledge of

welding, brazing and

finishing works along with

relevant

Agreed Agreed Agreed Agreed Graduate

Mechanical

Engineer with

Experience of 01

year should be

allowed

REJECTED 02 YEARS

EXPERIENCE IS

NECESSARY

7.5 Firm should also have

well trained manpower

conversant with switch

gear and protection

system. In this regard,

firm shall submit details

of manpower along with

their qualification and

experience of

personnel.

Well trained

manpower

conversant with

switch gear and

protection system

has been specified

to improve the

quality of design

and manufacturing

of switch board

cabinet.


7.6 Firm should also have

website for logging

complaints of their

product as after sales

service. It shall include

details of complaints

number, date & time of

complaints login and

man deputed to attend

complaints alongwith

their mobile number

etc. Firm should have

their maintenance

service engineers at

major cities of India and

they should attend the

failure within 24 hours

Website with for

logging complaints

of their product as

after sales service

has been added to

improve the

promptness of

servicing and to

avoid the delay in

service of

passengers.

Agreed Agreed Single

window

complain

logging

facilities

should be

available

with firm in

PAN India

basis which

is either

website or

telephone.

Agreed Agreed

7.7 D. ISO AND QUALITY

ASSURANCE PLAN

FOR SWITCH BOARD

CABINET

7.1 Quality assurance

plan is corrected in

line with specified

QAP format by ISO

cell.



1. Firm intended to

manufacture & supply

of switch board panel

for Indian Railways

should have ISO 9001-

2008. The certifying

agency of ISO shall be

accredited with NABCB.


ISO 9001-2008

certification or better

for manufacture &

design of Power

panel/Control

panel/Switch board

cabinet or similar item

in quality management





2. ISO certificate shall

contain design,

manufacturing,

fabrication, testing &

supply of switch board

cabinet as scope of

work.

Firm should produce

their proposed quality

assurance plan (QAP) in

respect of procurement

of raw material,

manufacturing and in-

house inspection and



The Quality Assurance

Plan shall cover the



3. Firm should

produce their proposed

quality assurance plan

(QAP) in respect of

procurement of raw

material, manufacturing

and in-house inspection

a) Organizational chart

clearly bringing out the

quality control set up.



b) Qualification log

sheets of the personnel

meaning the quality



4. The Quality

Assurance Plan shall

cover the following:

c) Process flow chart

indicating the process

of manufacture of an

item or a family of items

for which the process is


d) Details of sub-

vendors:


• Name of the item for

which sub-vendor is

approved.


a)

Organizational

chart clearly

bringing out the

• Inspection criteria of

the sub-vendor.


b)

Qualification

log sheets of

the personnel

• The sub-vendor has

ISO:9001 certifications.


• QAP of the sub-vendor

is approved by the

primary vendor.


c) Process

flow chart

indicating the

process of

manufacture of

an item or a

• Sub-vendor has

submitted the quality

manual to the primary

vendor.


• Sub-vendor has all the

requisite infrastructure

of manufacturing and

testing facilities,

preferably under one


d) Details of

sub-vendors

• Periodical inspection

schedule for sub-

vendor is being

followed strictly by the


e) Quality Assurance

System - Inspection &

Testing Plan. This shall


• Incoming material Agreed Agreed Agreed Agreed Agreed

Name of

the item for

which sub-

vendor is

• In Process control Agreed Agreed Agreed Agreed Agreed

The

name of the

approving

• Final inspection. Agreed Agreed Agreed Agreed Agreed

Inspection

criteria of the

f) Calibration plan

for measuring

instruments


The sub-

vendor has

ISO:9000

g) Customer

complaint system as

per ISO norms.


QAP of

the sub-vendor

is approved by

the primary

h) Any additional

information


Sub-

vendor has

submitted the

quality manual


Sub-

vendor has all

the requisite

infrastructure of

manufacturing

and testing


Periodical

inspection

schedule for

sub-vendor is


e) Quality

Assurance

System-

Inspection &

Testing Plan


Incoming material Agreed Agreed Agreed Agreed Agreed

Process control Agreed Agreed Agreed Agreed Agreed

System control Agreed Agreed Agreed Agreed Agreed


Gauging scheme-

in the format of each

operation gauges

should be maintained.


7.8 NOTE: 1. Firm shall

keep all the records

related to internal

quality control,

stage/process

inspection, routine and

final testing of the

product/individual

equipment/component

for easy traceability of a

particular job, in

addition to the

inspection of brought

out material. In addition,

firm should maintain all

the records of test done

on various

part/components on

respective test bench

as per QAP.

Firm shall keep all the

records related to

internal quality control,

stage/process

inspection and final

testing of the

product/individual

equipment/component

for easy traceability of a

particular job.

Performa ‘A’is now

replaced by online

application form.


2. The firm shall

furnish

documentary

evidence for

information already

submitted to RDSO


The firm shall furnish

documentary evidence

for information already

submitted to RDSO in

online application form.



7.9 R & D FACILITIES R & D FACILITIES Failure investigation

with suitable



The firm should have R

& D facilities to

investigate into the

various types of failures

and evolve necessary

remedial measures to

avoid failures in future.


set up to investigate the

various types of line

failures of Switch Board

Cabinet/Power/Control

Panel and evolve

necessary remedial

measures to avoid

failures in future.

Agreed System exists. We do

analysis through why

why analysis methods.

fish bone diagrams, BD

methods for root causes

analysis and improve by

Kaizen and pokayoke to

avoid failures.

Agreed Agreed Agreed

8 1. DG set of

adequate capacity as

stand/by power supply.

Diesel Generator set of

adequate capacity as

standby power supply

shall be available with

firm

Agreed Agreed Agreed Agreed Agreed It is further

clarified that

incoming

power supply

connection and

DG set capacity

shall be

adequate to

conduct

temperature

rise at 125

Amp at 415 V 3

phase AC 50 Hz


2. Firm should

have valid digital

signature certificate for

e-


3. Following power

supply arrangement for

testing Switch Board

Cabinet



1. 24 V dc Agreed Agreed Agreed Agreed Agreed


2. 110 V ac/dc Agreed Agreed Agreed Agreed Agreed


3. 230 V ac Agreed Agreed Agreed Agreed Agreed


4. 415

V ac



4. The firm should have

the capacity for

manufacturing at least

200 Switch Board

Cabinet in one year.


1. Firm should also

furnish the qualification

and experience of the

operator of various

machines.


reasoned document for str no. rdso/pe/str/ac/0027 … · 2018-12-07 · house. earlier cnc machine...

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