R.D.S.

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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

SCHEDULE OF TECHNICAL REQUIREMENT

FOR FABRICATED BOGIE FRAME & BOLSTER ASSEMBLY
FOR LOCOMOTIVES

STR No. MP.STR.VL- 02.02.11 (Rev-01)

July 2015

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RESEARCH DESIGNS & STANDARDS ORGANISATION
LUCKNOW - 226 011
Cost (Rs).
 INDEX

Para Description Page

1.0 General 1

2.0 Reference Documents and Standards 1,2

3.0 General Infrastructures & Manufacturing Facilities 2

4.0 Manufacturing Facilities 3

5.0 Inspection & Testing Facilities 5

6.0 Quality Control Requirements 6

7.0 Qualification of Man Power 6

 MINIMUM INFRASTRUCTURE, MANUFACTURING, TESTING AND QUALITY
CONTROL REQUIREMENTS FOR THE FIRM FOR RDSOS APPROVAL OF
VENDORS

1.0 General
The firm shall have acquired ISO: 9000 series certification for steel fabrication.
The firm shall have a system of documentation for the following:
a) Test results of incoming raw material with reference to Test Certificate
issued by the supplier and the results of internal tests carried out by the firm
for verification.
b) Stage inspection and test results
c) Calibration records
d) Records of heat treatments indicating charge-wise & loading serial numbers
wise details and time- temperature graph

2.0 Reference Documents and Standards

The firm shall have a copy of latest versions of following specifications & Standards
/codes:

Sl No. Specification Description

Technical Specification for Fabricated Bogie Frame &
1. VL.Spec.-6
Bolster Assemblies for locomotives.
2. IS : 813 Scheme of Symbols for Welding.
Code of Practice for Training and Testing of Metal Arc
3. IS : 817
Welders.
4. IS : 2062 Steel for General Structural Purposes.
Ready Mixed Paint, air-drying, red oxide zinc chrome,
5. IS : 2074
Priming.
General Tolerances
6. IS : 2102
(For Un-tolerance Linear and Angular Dimensions).
7. IS : 3658 Code of practice for liquid penetrant flaw detection
Recommended Practice for Straight Beam Ultrasonic
8. IS : 4225
Testing of Steel Plates.
9. IS : 5334 Code of Practice for Magnetic Particle Flaw Detection of
welds.
Approval tests for Welders working to Approved Welding
10. IS : 7310 (Part1) Procedures.
Enamel, Synthetic, Exterior (a) Under Coating (b)
11. IS: 8662
Finishing for Railway Coaches.
Metal-Arc Welding of Carbon and Carbon Manganese
12. IS: 9595
Steels-Recommendations.
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 13. ASM E-Sec IX Welding Procedure Specification.
14. ASTM E-164 Practice for Ultrasonic Contact Examination of Weldment.
Straight Beam Ultrasonic Examination of Steel Plates for
15. ASTM A: 435
Pressure Vessels.
16. AWS- D.1.1 Structural Welding Code.
Classification, Testing and Approval of Metal Arc
17. IRS: M 28
Welding Electrodes used and Gas Welding Rods.
Procedure for welding of manganese steel liners with mild
18. RDSOs MC - 29
steel.
Code of procedure of Ultrasonic Testing Technique for
19. RDSOs MC - 4
butt welded joints of bogie frames for railway rolling stock.
Metallurgical Requirements for the Qualification of
20. EMDs ETI 827
Castings for General Usage
Quality requirements for fusion welding of metallic
21. ISO 3834 - 2
materials - Comprehensive quality requirements.
Thermal Cutting classification of thermal cuts
22. ISO 9013
Geometrical product specification and quality tolerances.
23. ISO 14731 Welding coordination Tasks and responsibilities.
Qualification test of welders Fusion welding Part 1:
24. EN 287 -1
Steels

3.0 General Infrastructures & Manufacturing Facilities

The firm shall have a covered shed with sufficient height and space provided with
material handling facility of adequate capacity like Crane, Chain-Pulley Block etc. in
each bay covering the following activities:
.1 Raw Material Storage
.2 Laboratories for material testing
.3 Heat Treatment (for items requiring heat treatment)
.4 Shot Blasting
.5 Grinding
.6 Machining Facilities
.7 Storage of Finished Items
.8 Painting facility
.9 Weighing facility for weighment of bogie frame with bolster and bolster sub-
assembly (Capacity should be at least 6 T)
.10 Degreasing / De-rusting plant for cleaning of plates used for manufacturing of
bogie frame.

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4.0 Manufacturing Facilities

The following manufacturing facilities shall be available with the firm:

4.1 Fabrication Facilities

.1 Automatic Flame / Laser / Plasma computerised controlled Cutting machines
with sufficient bed size to cut steel plates of required thickness (thickness not
less than 40 mm) and size to the desired profile.
High definition Plasma or Laser profile cutting machine with sufficient bed size
to cut steel plates up to 32 mm thickness and size to the desired profile. For
thickness above 32 mm, automatic Flame cutting machine may be used.
.2 Edge preparation through machining
CNC beveling machining facility or Plasma cutting with beveling facility for edge
preparation covering entire profile of the plate.
.3 Robotic welding for welding of major straight welds of bogie frame.
.4 MIG / MAG MIG welding facilities (Argon / CO2) and welding gauges.
.5 Electrode drying ovens.
.6 Specially designed welding manipulator by professional agencies for down
hand welding of bogie frame assembly and sub-assemblies.
.7 Facilities of specially designed Jigs & fixtures by professional agencies required
for fabrication, machining and all type of measurement of bogie frame at
different stages.
.8 Facilities for making manufacture and periodic calibration and validation of jigs
and fixtures.

4.2 Machining and Bending Facilities

.1 Plate straightening machine

.2 Portable Grinding machine
.3 Drilling machine
.4 Milling / Slotting Machine for cutting slots
.5 Plate bending machine of adequate capacity for bending of plates
.6 Computer Controlled Plano-Miller with horizontal and vertical boring and with
probing facilities. The machine must have at least three axes (preferably 5 axis)
machining facility and adequate size and stroke length to machine bogie
frames of size 6.4m x 3m x 1.3m in single setting. (If any existing RDSO
approved supplier is presently not having this facility, he shall have to install the
same within nine months of coming into existence of this specification). If any
existing RDSO approved supplier is presently not having this facility, he must
install and commission the same within 15 months of coming into existence of
this specification .However documentary proof for procuring such facility shall
be provided by the supplier within 12 months.
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 .6 Surface Table of size adequate for inspection & taking measurement of bogies
of dimension upto 6.4 m x 3 m. It should be at sufficient height to facilitate
taking measurements.
.7 Facilities for stamping of identification markings as per specification.
.8 Vernier calipers ( Minimum 0 to 50 mm range), Inside , outside and centre
Calipers, height gauges (0-500mm), measuring tapes 10000mm, Go, No Go
and template gauges required during machining operations and dimensional
checks.
.9 Facility for checking Surface roughness

4.3 Facility for Proof Load Test

Hydraulic press of minimum 125 t capacity with suitable arrangement for carrying
out proof load test of bogie frame and bolster assemblies.

4.4 Facility for Material Handling

Over head crane of minimum 6 t capacity for handling of bogie frame and bolster
sub-assemblies.

4.5 Heat Treatment Furnace

.1 A heat treatment furnace for stress relieving capable of handling the entire
production shall be available. The furnace shall be of continuous type either oil
fired preferably gas fired or electrically heated type, having minimum operating
space of 7 m x 4 m x 2 m.
.2 The furnace shall have automatic temperature controller, and shall be fitted with
thermo-couples or temperature sensors to measure temperature of different
regions of the furnace. There shall be multi point computer controlled continuous
temperature recording arrangement for each point. These temperature recorders
shall have the facility of getting sealed for making them tamper-proof.
.3 Serial numbers of item under stress relieving shall be recorded in a register for
traceability with time-temperature curve and date.
.4 Proper Sealing arrangements of heat treatment furnace shall be provided to avoid
oxidation / scale formation on the surface of beams being heat-treated. There shall
be positive pressure inside the furnace to avoid entry of air from outside.
.5 Positioning of the nozzles of oil-fired furnace, if used, shall be such that the flames
do not make direct contact with the beams.
.6 The heat treatment furnace shall be calibrated using thermocouples for assessing
temperatures at different zones at various temperature ranges. The calibration
shall be done at least once in a year & proper records shall be maintained.
.7 Thermocouples and temperature indicators shall be calibrated at least once in 12
months.

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4.6 Shot Blasting
Shot Blasting Chamber shall be available with Shot Blasting Machine of
appropriate capacity to accommodate bogie frame and bolster assemblies.

5.0 Inspection & Testing Facilities

Following inspection & testing facilities shall be available with the firm:
.1 Inspection Facilities
.1 Surface Table of size adequate for inspection & taking measurement of bogies
of dimension upto 6.4 m x 3 m. It should be at sufficient height to facilitate
taking measurements.
.2 Vernier calipers (Minimum 0 to 500 mm range, preferably digital type), Inside,
Outside and Centre Calipers, height gauges (0-1000mm), measuring tapes
10000mm, Bore Gauges, Thread gauges, Go, No Go and template gauges
required during machining operations and dimensional checks.
.3 Firm shall have CMM capability for dimensional inspection and verification.
Alternatively, firm shall have dedicated full-sized bogie check fixture for use
with conventional precision gauging equipment.
.4 Facility for checking Surface roughness through Digital surface roughness
tester.
.5 Dry film thickness tester (Elcometer) for checking of paint thickness.
.6 Facilities for stamping of identification markings as per specification.

.2 Testing Facilities

.1 Metallurgical and Chemical Laboratory

.1 Availability of Spectrometer with necessary standard and automatic printer
shall be preferred for verification of chemical composition of material.
Alternatively, Wet Analysis facilities including Strohelien Apparatus for carbon
analysis shall be available.
.2 Dye Penetrant Test (DPT) facilities for checking of surface cracks.
.3 Magnetic Particle Inspection (MPI) facilities for checking sub-surface flaws.
.4 Metallurgical Microscope with magnification power up to 500X &
metallographic sample preparation facilities with appropriate accessories to
take photographs of slides.
.5 Ultrasonic testing of weld joints

.2 Physical Laboratory
.1 Universal Testing Machine of adequate capacity with graphical recording
facilities for conducting tensile tests.
.2 Direct reading Hardness Tester of required capacity.

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 .3 Impact Testing Machine (Charpy V-notch) of 0-300 Joules capacity for
conducting impact test with facilities for notch cutting and undertaking the test
at sub-zero temperatures as per the specified standards.
.4 Shadowgraph facilities for assuring correct notch profile and dimension for
impact test specimen.

6.0 Quality Control Requirements

.1 The firm shall have a system of easy traceability of the product from
manufacturing stage to finished product stage. Stamped Identification marking
with serial number of bogie frame / bolster should be used for this purpose.
.2 The firm shall submit a Quality Assurance Plan (QAP) in the standard format, for
the product detailing various manufacturing aspects for RDSOs approval. Quality
control requirements, as mentioned below, shall be the part of QAP.
a) Calibration of the Testing / Measuring Equipments shall be done at least once in a
year unless stated otherwise.
b) A system of regular submission of rejection details of material giving rejection
rate, cause of rejection, corrective action taken etc. on quarterly basis shall be
followed by the firm.
c) The firm shall have a system of documentation in respect of rejection at customer
end, warranty replacement and failure of item supplied by them during service.

7.0 Qualification of Man Power

.1 Diploma or Engineering Degree with 5 years experience qualified Technical staff to

carry out quality control requirements

.2 Firm shall have a welding coordinator with comprehensive technical knowledge

(Level A) according to ISO 14731 for coordination of manufacturing requirements
for all welding and welding-related activities.

.3 Welders shall be qualified in accordance with AWS Structural Welding Code

D.1.1 or IS 817 / IS 7310 with radiographic test or EN 287-1.