( ReiCG-WADLIT, Ver 1.0 [ Paget of22 Date of issue: February, 2015 ‘EMI No. RDSO/2014/CGICMI-04 INDIAN RAILWAYS. © Ser Deals [lamar PROCEDURE FOR CORROSION REPAIR OF HEAD STOCK ASSEMBLY OF BG MAINLINE PASSENGER COACHES OF ICF DESIGN S.No._| MonthiYear of issue | Revision /Amendment | Page No. | Reason for Amendment 1 February, 2015 First issue Issued By: Research Designs and Standards Organization vp Manak Nagar, Lucknow - 226014, Seams Aa a Reeve dergmon | Se ancurage | Wc Distr su levrge | Dect Sto/Cara? Preparedby: | ___-Checked by: | Approved by:Ref. CG-WIAD.I-1, Ver. 10 | Page? of 22_| Date of issue: Fe sy, 2015 | CMI No, RDSO/BOIACCICMTOG INDEX SNO. DESCRIPTION PAGE NO. 1 INTRODUCTION, 03 2. ‘SCOPE, 03, 3. EXAMINATION OF HEAD STOCK ASSEMBLY DURING POH/MLR| 03 IN WORKSHOPS. a REPAIR PROCEDURE __ _ 05 5. (GENERAL WELDING GUIDELINES 07, 6. QUALITY CHECK OF WELD JOINTS OF OUTER HEAD STOCKI| 08 HEAD STOCK ASSEMBLY 7. FABRICATION OF HEAD STOCK ASSEMBLY 08 "ANNEXURE| | CRITICAL LOCATIONS OF WELD JOINTS FOR DYE PENETRANT | 11 TEST (DPT) ANNEXURE-I| | ICF'S WORK INSTRUCTIONS NO. SMM: Wi-012, REV.NO.02FOR| 12-15 INHOUSE FABRICATION OF HEAD STOCK ASSEMBLY ANNEXUREA [ICFs STR No. ICF/MDISPEC-147, Rev. No.02 FOR| 16-22 PROCUREMENT OF HEAD STOCK ASSEMBLY FROM TRADE be ‘Signature A "Name & designation ‘Se Direeloristds Carriage | Director/Stds/Carriage ‘Checked by: Approved by:(Re CCWEARIA, Ver. 10] Page Tof73_| Date afinone: Febraary, 2015 | CMI No. RDSOAUTACGICMI-GT | 22 23 24 32 33 34 35 PROCEDURE FOR CORROSION REPAIR OF HEAD STOCK ASSEMBLY OF BG MAINLINE PASSENGER COACHES OF ICF DESIGN INTRODUCTIOF Indian Railways have reported the cases of en-route detachment of coaches of ICF design due to weld failures of head stock and these failures of head stock were also discussed during 14" CMG held at Puri (ECoR). These failures have occurred primarily due to working out of head stock, draw bar assembly and sole bar cracks etc. The quality of corrosion repair at the ‘coach ends has a direct bearing on the safe running of coaches. Accordingly, previous instructions issued vide RDSO letter no. MC/CRN/REH dated 21.12.2010 for corrosion repair of head stock have been reviewed considering precautions to be taken during welding, requirements of inspection after welding to specifically assess the quality of the weld joints, necessity of Dye Penetrant Test (DPT) of critical weld joints of head stock assembly, to ensure crack free joints in service and to detect discontinuities open to ‘surface. SCOPE: This Carriage Maintenance Instruction (CMI) covers corrosion repair of head stock assembly of BG mainline passenger coaches of ICF design. This CMI covers procedure of inspection, repair of buffer base, replacement of outer head stock, and replacement of complete head stock assembly including fabrication of complete head stock assembly during corrosion repairs of ICF design coaches during POHIMLR. This CMI also cover precautions to be taken during welding, requirements of inspection after welding to assess the quality of the weld joints, Dye Penetrant Test (OPT) on critical weld joints to ensure crack free joints in service. This CMI covers corrosion repair/replacement of head stock assembly of ICF design coaches fitted with screw coupling and side butfers. EXAMINATION OF HEAD STOCK ASSEMBLY DURING POH/MLR IN WORKSHOPS: Head stock assembly shall be thoroughly examined during every POH/MLR as stipulated in Para 2.25.1 of IRCA PartlV. ‘As per Para ‘S' 4.22.3 of IRCA-IV, displacement of céntre of buffer face in any direction by more than 38 mm from its normal position of centre of the buffer face is a rejectable defect. Coaches received for POH/MLR in workshop shall be examined for head stock bent prior to dismantiing of buffers. This defect may be occurred due to misalignment of outer head stock/head stock assembly at the time of new fitmentreplacement, oblong/ cracks in buffer bolt holes, packing in between buffer casing plate and buffer base, unusual impacts etc. However, packing plate in between buffer casing plate, as per Para ‘S’ 4.22.3 of IRCAV of head stock, is not permissible. Run out the coach bogies and support the body on trestles of equal height so that the body weight is borne equally by the trestles. Measure and record the cambers of the coach as stipulated in Para 2.25.3 of IRCAIV by “Piano Wire System" and as per procedure issued vide this office letter no. MC/CRN/REH dated 12.04,2008, Record the camber measurement readings and height of the outer head stock from rail level. In case of replacement of complete head stock assembly, before cutting of head stock assembly, height of the bottom flanges of inner head stock, outer head stock and at sole bar ‘Signature, a y gav 1 ‘Name & designation | SSEAStUs/Carviage | Jt DirecbrStds.Carriage | DirectoriStda Carriage Prepared by: Checked by ‘Approved by:(RERCG-WIADI-1, Ver 1.0 | Page 4 of | Date of sues February, 2015 | CMI No. RDSOR0ISCG/ICMI-O | 3.6 37 38 3.9 3.10 3.1 3.12 3.13 3.134 3.13.2 3.13.3 3.44 3.15 3.16 347 cutting location shall also be measured on both sides from the rail level and recorded for reference during fitment of new head stock assembly. Dismantle side buffers prior to intensive inspection of head stock assembly. Dismantle screw coupling and draw gear assembly prior to intensive inspection of head stock assembly. All accessible weld joints of head stock assembly including interfacing area of head stock assembly with the sole bars shall be cleaned with the help of wire brush, spike hammer etc. Examine visually outer head stock, inner head stock, stiffeners immediately behind the buffers, draw bar assembly housing and the joints of the sole bar and head stock for incidence of corrosion, Al critical weld joints as mentioned in Annexure-| shall be thoroughly inspected visually to the ‘extent possible in sufficient light. Any suspected crack in weld joints and loss of thickness of head stock assembly due to corrosion should be confirmed by stripping off the flooring and other members. Check visually the buffer base periphery for corrosion and the buffer bolt holes for wear and oblongivity/cracks. Examine the buffer base of head stock by chalk test or sound test for cracks and dents. Check thickness of head stock assembly members at various locations with the help of suitable thickness measurement method and/or visually. Examine each head stock assembly of the coach for the following Examine buffer bolt holes for securing of buffers (worn out / cracks/ oblong). Extent of corrosion on outer head stock (i.e. loss in section is more than 20% of original thickness and/ or cracks at any location). Extent of corrosion on inner head stock (i.e. loss in section is more than 20% of original thickness and /or cracks at any location). If the extent of corrosion below the buffer base, on outer head stock, on inner head stock is insignificant and the buffer bolt holes are not worn out and no cracks have been noticed, clean and paint the head stock assembly. If the buffer bolt holes for securing of buffers are worn out / have become oblong and the extent of corrosion is insignificant on outer head stock (i.e. loss in section is not more than 20% of original thickness and no cracks at any location) and also the extent of corrosion is insignificant on inner head stock (i.e. loss in section is not more than 20% of original thickness ‘and no cracks at any location) then repair procedure as detailed in Para 4.1 shall be followed. If the extent of corrosion is significant on outer head stock (i.e. loss in section is more than 20% of original thickness, cracks at any location), worn out buffer bolt holes or otherwise and the extent of corrosion is insignificant on inner head stock (.e. loss in section is not more than 20% of original thickness and no cracks at any location) then repair procedure as detailed in Para 4.2 shall be followed, If the extent of corrosion Is significant on inner head stock (ie. loss in section is more than 20% of original thickness, cracks at any location) and the extent of corrosion on outer head ‘stock is insignificant (ie. loss in section is not more than 20% of original thickness, no cracks at any location, no oblong buffer bolt holes etc.) or otherwise then repair procedure as detailed in Para 4.3 shall be followed. ‘Signature: Ed iE Name & daignation | SSE/Site/Carriage | Jt DieWorkas.c Direcovistds Carriage Prepared by: Checked ‘Approved by:(RefiCG-WI-42.1-1, Ver. 1.0 | Page 5 of 22 | Date of issue: February, 2015 | CMI No. RDSO/2014/CG/CMI-04 | 4 41 42 424 422 423 424 425 426 427 428 429 4.2.10 REPAIR PROCEDURE: INSTRUCTIONS FOR REPAIR OF OBLONG HOLES FOR SECURING OF BUFFERS: The oblongiworn out holes for securing of buffers on outer head stock should be filed up by welding. Re-dill holes as required for securing of buffers, ground the repaired buffer bolt holes and neighboring area for ensuring proper seating of buffer casing base plate. ‘The repaired buffer bolt holes shall be rechecked for free from porosity, cracks and for proper alignment of the holes. After thorough cleaning, paint the outer head stock beam arrangement and all other visible members by high performance anticorrosion epoxy coating to RDSO Specification No. M&CIPCN/123/2006. Alternatively, paint the outer head stock beam arrangement and all other visible members with two coats of primer to IS: 2074-1992 to a minimum Dry Film Thickness (OFT) of 50 microns followed by one coat of ant-corrosive Black Japan Type-B to IS: 341 toa DFT of 35 microns, after which entire outer head stock beam arrangement and all other visible members is to be given one coat of Black Japan Type-B to IS: 341 to a minimum DFT of 35 microns. INSTRUCTIONS FOR REPLACEMENT OF OUTER HEAD STOCK: Remove the floor molding, end wall panel, lavatory, stainless steel inlay flooring! compreg PVC flooring up to a distance of 300mm in lavatory gang way and supporting member of ‘compreg flooring jin the gangway. ‘Support the anti-telescopic stanchions at the bottom and sole bar on suitable standsitrestles, Gas cut the outer head stock beam along with the vestibule sill and other corroded components and the end wall sheet, ensuring that no damage is caused to the anti-telescopic stanchions, sole bar and the stiffener tube behind the buffers. Grind sole bar flanges, stiffener tubes behind buffer (center stiffener) and floor stiffener stanchions for matching with the outer head stock and for edge preparation for welding, Remove all existing paint of visible area by steel wire brush etc. to bare metal & prepare the visible surfaces for welding. Prepare a new outer head stock with 8 mm steel plate to drg. No. ICF/STD-1-2-002 or RCF drg. No. C1229, Before fitment, ensure correctness of buffer bolt holes in outer head stock beam. Carry out welding of (Item 5, 15, 6, 16 of ICF drg. No. ICF/STD-1-2-002 or Item no. 2 of RCF drg. No. CC12229) as applicable with the new outer head stock. Align new outer head stock beam arrangement with the stiffeners and draw gear assembly and carry out tack welding, Full weld the new outer head stock beam arrangement to the sole bars, stiffener tubes, anti telescopic stanchions, floor stiffeners, draw gear assembly, and guide angles. Weld a new vestibule sill over the headstock. Follow the general welding guidelines for fitment of outer head stock as detailed in Para (5) of this CMI ‘Welded outer head stock beam arrangement should be cleaned again by steel wire brush etc. to bare metal. Inspect critical weld joints, at location no. 1, 2, 3, 4, 5 & 6 as indicated in Annexure-I, of outer head stock to assess the quality of the weld joints as per procedure detailed in Para (6) of this CMI. All other weld joints shall be visually examingd and shall be free from gefects. Some Ets ya ‘Name & designation | SSE/St4s/Carrlage ate irecowtaolCariage | Director/Stds Carriage Prepared by: eee Checked by: ‘Approved by:([Reef:CG-WI-42.1-1, Ver. 1.0 | Page 6 of 22 | Date of issue: February, 2015 | CMI No. RDSO01WCGICMI-04 | 4244 4.242 42.13 4244 42.45 43 434 4344 4312 431.3 43.14 4345 43.16 43.4.7 43.1.8 43.1.9 43.2 43.24 43.22 43.23 43.24 43.25 4.3.26 Dimensions and straightness as per applicable drawings of the outer head stock beam arrangement shall be checked. Paint the head stock beam arrangement and all other visible members by high performance anticorrosion epoxy coating to RDSO Specification No. M&C/PCN/123/2006. Alternatively, paint the head stock beam arrangement and all other visible members with two coats of primer to IS: 2074-1992 to a minimum Dry Film Thickness (DFT) of 50 microns followed by ‘one coat of ant-corrosive Black Japan Type-B to IS: 341 to a DFT of 35 microns, after which entire outer head stock beam arrangement and all other visible members is to be given one coat of Black Japan Type-B to IS: 341 to a minimum DFT of 35 microns. ‘Weld new end wall sheets as required, Clean and paint the end wall as per applicable paint scheme. Measure the final camber of the furnished coach at the ends and compare with the initial readings. PROCEDURE FOR CORROSSION REPAIR AND REPLACEMENT OF HEAD STOCK: CUTTING OF HEAD STOCK ASSEMBLY: Remove the floor mouldings, end wall panel, stainless steel inlay flooring from lavatory, ‘compreg/PVC flooring up to doorway and supporting members of compreg/PVC flooring, Gas cut the vestibule sill and the end wall sheet up to required height. Provide support props at the body bolster and at bottom portion of sole bar flange from Rail level. Cut the end wall panel by gas cutting up to required height. Remove the draw gear assembly and cut the end stanchion pillar by gas cutting. Cut the corroded complete head stock assembly by gas cutting the sole bars near door pillar, sole bar boxing and body side pillars. Cut the lavatory tube/ trough floor welded with inner head stock by gas cutting Grind sole bar edges, body pillar etc. to match with the head stock and for edge preparation for welding. Remove all existing paint of visible area by steel wire brush etc. to bare metal & prepare the visible surfaces for welding. FITTING OF HEAD STOCK ASSEMBL' Place the head stock assembly by EOT crane on the lifting platform Move the loaded lifting platform for fitment to a place where old one was removed by gas cutting Fully weld the support props of the bottom flange of old sole bars to the inner head stock on both sides. Finish cut the outside end stanchion pillar as per the required height. Place the lifting platform in proper place and lft it up to the required height. Push it forward so that the inner head stock support is welded with the old sole bars. The lifting platform shall be provided with leveling gauge in order to ensure proper alignment of head stock assembly to be fitted. Tack weld two end stanchion at both end with the old one and weld two angles at bottom portion of it to provide support to the head stogkwportion of the assembly. ‘Signature, aay ‘Name & designation | SSE/Stds/Carriage | Jt. Direclok/Stds/Carriage | DirectoriSt Prepared by: ‘Checked by: ‘Approved by(RehiCG-WI42.-1, Ver. 1.0 | Page Tof22_| Date of issue: February, 2015 | CMI No. RDSO72014/ 4.3.2.7 Place the assembly properly and setit as per dimensions by measuring tape & plumb, 4.3.2.8 Prop the head stock assembly and sole bar at three locations i.e. at lower flanges of inner head stock, outer head stock and sole bar cutting location from rail level on each side. Adjust the height of head stock assembly as per camber requirement andfor to the initial reading taken before cutting of head stock assembly in order to minimize twist, misalignment and drooping of head stock assembly. 4.3.29 Check all the dimensions and tack weld the head stock assembly with the stanchion pillars, sole bar and sole bar boxing. Remove the welded support from the end stanchions. 4.3.2.10 Tack weld the middle stanchion pillars. 4.3.2.11 Release the lifting platform and pull it out 4.3.2.12 Weld two nos. of vertical support with the lower portion of the head stock on both sides, to provide support of the front portion of head stock assembly from rail line. 4.3.2.13 Tack-weld the head stock bottom strengthening plate at proper place and carry out full weld. 4,3.2.14 Fully weld the outside stanchion pillar with the outer head stock. 4.3.2.16 Follow the general welding guidelines for fitment of head stock assembly as detailed in Para (5) of this CMI. 4.3.2.16 Fabricate the new sole bars and boxing section etc. as per requirement. 4.3.2.17 The vertical support of the head stock assembly should be removed after completion of the fitment of newly fabricated sole bars and boxing section etc. on both sides. 4.3.2.8 Welded head stock shall be cleaned again by steel wire brush etc. to bare metal 4.3.2.19 Inspect the critical weld joints, at location no. 1, 6, 7, 8, 9 & 10 as indicated in Annexure-1, of head stock assembly to assess the quality of the weld joints as per procedure detailed in the Para (6) of this CMI. All other weld joints shall be visually examined and shall be free from defects. 4,3.2.20 Dimensions and straightness as per applicable drawings of the head stock assembly shall be checked. 4.3.2.21 Paint the head stock assembly and all visible members by high performance anticorrosive ‘epoxy coating to RDSO Specification No. M&C/PCN/123/2006. Alternatively, paint the head stock assembly and all visible members with two coats of primer to IS: 2074-1992 to a ‘minimum Dry Film Thickness (DFT) of 50 microns followed by one coat of ant-corrosive Black Japan Type-B to IS: 341 to a DFT of 35 microns, after which entire head stock assembly and all other visible members is to be given one coat of Black Japan Type-B to IS: 341 to a imum DFT of 35 microns. 4,3.2.22 Weld new end wall sheets as required. 4,3.2.23 Clean and paint the end wall as per applicable paint scheme. 4,3.2.24 Measure the final camber of the furnished coach at the ends and compare with the initial readings. 5 ELINES: 5.1 MIGIMAG welding with Class-IV welding wites as per specification IRS-M46 (atest Rev.) shall be used for repair and fabrication of head stock assembly. However, in Railway Workshops repair and fabrication of head stock assembly can be done by MMAW with 'D’ Class electrodes to IRS ~ M 28 (latest Rev.) as a short term measure. [Signature Cee pene DirectoriStds Carriage ‘Name & designation | SSE/Stds/Carriage | Jt, Direttor/Stds./Carriage Prepared ‘Checked by: __ Approved by:[RefiCG-WI42.1-1, Ver. 1.0 | Page & of 22 | Date of issue: February, 2015 | CMI No, RDSOROI4ICGICMI-OT] B44 52 53 54 55 61 62 While welding with MIG/MAG flux cored wires under Class-IV to IRSM-46 (latest Rev.), the following must be ensured: |) that the consumables are free from moisture/rust. |i) that if consumable is not consumed fully, the rest consumable wire shall be kept carefully for next welding operation and cut the operation end about 2 meter to minimize the initial weld defects. ili)” that Shielding gas flow rate is in between 12 to 20 liters/minute. While welding with MIGIMAG solid wires under Ciass-IV to IRSM-46 (latest Rev.), the following must be ensured: that wire/consumabies are free from moisture/rust. ii) that shielding gas flow rate is in between 15 to 25 liters/minute. While welding with ‘D' Class electrodes, the following special care should be taken as these are basic coated electrodes: ‘@) The electrode must be preheated to about 250°C for two hours or as recommended by electrode manufactures before use. b) While welding with AC, the welding transformer must have minimum OCV-80 volts for its smooth running, ©) If welding with DC equipment, the electrode must be connected with positive terminal of ‘equipment. ) During positional welding, 4 mm or less diameter electrodes to be preferred for better control of bead. Welding may be carried out in all position except vertical-down position. Suitable welding parameter as recommended by manufacturers must be used. Welding electrode and MIG/MAG welding wire for welding of different types of steels are: ‘S.No. Description MMAW Electrode | MIG/MAG welding wire | as per a3 p IRS M.2B- 2012 IRs M46-2018 [RSNA wih TRSMEAT "O'class Class 1V 2. IRSM-41with AISI 307 ‘M, Class Class Vil 3. [AISI SO%7AISI 304 with S206 E250_| Wires Clase Vil 41S 2062 €-250 to 1S: 2062 E-250 of | Ay, Class Cass] 1S: 4239 PL Tab.3 : 5 [RSM wih IS: 2062-250 Dts | as ITY CHECK OF WELD ITS_OF Ot R_HEAD STOCK/HEAD STOCK ASSEMBLY: Inspection after welding shall be carried out to assess the quality of the weld joints. Carry out visual inspection at welded portion, Macro etch test of weld joints as per procedure detailed in Para (7) of Annexure-III, measurement of weld size, Dye Penetrant Test (DPT) of weldments ‘on all critical areas so as to ensure crack free joint in service, detection of weld flaws and discontinuities open to surface. IS: 3658 (Code of Practice for Liquid Penetrant Flaw Detection) may be used for guidance for DPT of weldments. All the weld joints shall be free from welding defects such as blow holes, porosities, cracks, excessive undercuts and overlaps. t vary Satie at — Nine a Segaion | ~SSWSACcarage | ac inborlCringe [ Bere | Prepared by: Checked by Approved by(ReiCG-WI42.1-1, Ver. 10 | Page 9 of 22 | Date of is 63 64 65 66 67 68 69 6.10 611 6.12 TA TAA = Febranry, 2013 [ CMI No, RDSORUISCGICMI-GT) Weld joints shall be uniform, weld slag shall be thoroughly removed and cleaned after each pass. Overiaps if any shall be ground. Welding shall not be intermittent and incomplete finish. Misalignment shall not be acceptable. To avoid any misalignment, component shall be tack weld property before fabrication. To minimize distortion, component shall be tack weld properly before fabrication, weld size shall be uniform and intermittent weld shall be avoided. ‘The welds shall be ground to eliminate stress raisers and to improve fatigue life of weld joints. All linear discontinuities. shall be removed and repaired by chipping or grinding and subsequent welding, Proper welding sequence shall be followed to minimize distortion of members during fabrication. Members distorted, if any due to welding shall be straightened by application of heat by flame heating and/or by cold straightening carefully. The temperature of the heating areas shall not exceed 650°C. If any defect or crack is detected during DPT on critical locations of weld joints, the defect shall be removed by gouging and repaired by welding, The repaired portion shall be re-checked for free from welding defect by the methods of visual inspection and DPT. After DPT, all the dye must be washed out. FAI F HEAD STOCK ASSEMBL) Fabricate in-house complete head stock assembly with 8mm outer beam (outer head stock) to RCF Drawing No CC12230 or ICF drawing No. ICF/STD-1-2-001 on a welding manipulator for facilitating down-hand welding or procure from trade. IN-HOUSE FABRICATION OF HEAD STOCK ASSEMBLY: Fabricate the complete head stock assembly, as per guidelines given in ICF Work Instructions No. SMM: WI-012 (Rev. No.02) for in-house fabrication of head stock assembly (Annexure-I!) and also after considering availabilty of required infrastructure for fabrication of head stock assembly as detailed in Para (4) of Annexure-Il, in workshops. Inspection before the commencement of in house fabrication of head stock assembly should be done and it should cover all the aspects of the fabrication with a view to eliminate all Potential sources of defects. This can be achieved by: i. Taking of specified material for fabrication of head stock assembly and its components, ii, Inspecting the head stock members visually for surface defect (corroded, pitted, bent, cracked etc.). li, Proper cleaning of the components to be welded to ensure that welding process is free from dust, dirt and grease etc. Follow the general welding guidelines for fabrication of head stock assembly as detailed in Para (5) of this CMI Quality of all critical weld joints except at location no. 1, 6, 7, 8, 9 & 10 of Annexure-l, of fabricated head stock assembly shall be checked as per procedure detalled in Para (6) of this CM. All other weld joints of fabricated head stock assembly shall be visually examined and Signature: "Name & designation | SSE/Stds/Cari shall be free from defects. sre Cag Dina | ‘Checked by: ‘Approved t([ReECG-WI-AZ.LA, Ver. £0] Page 10 of 23 | Date of fsue: February, 2015 | CMI No. RDSOROSCGICMED | TAS TAS 72 724 7.22 a ‘The newly fabricated head stock assembly after thorough cleaning shall be checked for straightness, alignment and dimension as per applicable drawings. Protect the welding edges of fabricated head stock assembly by suitable tape. Paint the fabricated head stock assembly by high performance anticorrosive epoxy coating to RDSO ‘Specification No. M&C/PCN/123/2006. Alternatively, paint the fabricated head stock assembly with two coats of primer to IS: 2074-1992 to a minimum Dry Film Thickness (DFT) of 50 microns. PROCUREMENT OF HEAD STOCK ASSEMBLY FROM TRADE: For procurement of complete head stock assembly to RCF Drawing No CC12230 or ICF drawing No. ICF/STD-1-2-001, ICF Schedule of Requirements No. ICF/MD/SPEC-147 (Rev. No.02) with Amendment Slip No. 01 (Annexure -IIl) can be followed for guidance. Alternatively, head stock assembly can be procured from ICF/RCF approved vendors. All test reports as per Schedule of Requirements No. ICF/MD/SPEC-147 (Rev. No.02) with ‘Amendment Slip No.01 including Dye Penetrant Test (DPT) shall be submitted for review of the Inspecting Agency. = / Checked Prepared by: ‘Approved by:(ReiCG-WH2.15, Ver. [ Page 11 of 22 | Date of haul: February, 2013 | OMI No, RDSOROTUCCICMTEOS) ANNEXURE: CRITICAL LOCATIONS OF WELD JOINTS FOR DYE PENETRANT TEST (DP’ 9 —— ero) =m remem aa wea ons rc 08 es ssc FIGURE:— CRITICAL LOCATIONS OF WELD JOINTS FOR DYE PENETRANT ‘OCK COMPLETE WW HEAD Signature: ‘Name & designation | SSE/Stds/Carriage mhz ge ee Prepared by: Checked by: ‘Approved by:(ReGCG-WEA2.17, Ver. 10 | Page 12 of 2 | Date ofasu: February, 2013 [ CMI No, RDSORUTAICCICMI-OT] ANNEXURE-II INTEGRAL COACH FACTORY, CHENNAI-38|SMM: WI0I2___| E __ WORK INSTRUCTION REV. NO: 02 4/10/2012 SUB: UNDER FRAME HEAD STOCK ASSE| E: 0 Contd.in 1 PROCEDURE PAGE CONTROL SHEET SHEET NO, REVISION STATUS OF DOCUMENT PAGES 00 oO 7 02 ane (03) _| on 04.03.96 14.08.06 24/10/2012 _ 7 2 04.03.96 [14.08.06 24/10/2012 B = 14.08.06 [2ano201i2 id ISSUE STATUS ot ____ [SIGNATURE a ] PREPARED BY WwiMiS | ‘APPROVED BY ~~: DY CME/BOGIE L any Te Dire stds Carriage | Divectonstas/Carringe ‘Checked by: “Approved by:(ReiCG-WIAZI-T, Ver. 10 | Page 15 of | Date of tue: February, 2018 | CMINo, RDSOROIICCICMER | INTEGRAL COACH FACTORY, CHENNAI-38 | SMM: _WI012_ WORK INSTRUCTION REV.NO: 02 DATE: 24/10/2012 SUB: UNDER FRAME HEAD STOCK ASSEMBLY:) | PAGE: 1 OF 3 UNDER FRAME HEAD STOCK ASSEMBLY: {CONVENTIONAL COACHES) HEAD STOCK ASSEMBLY 4.INNER HEAD STOCK BEAM ASSEMBLY 4. Collect the RC and relevant drawing from the J.E. 2. Ensure the details are conformed in the previous stage of work. 3. Grind the mating surface of welding-ie center plate edges and its butting location with the Channel 4. Use JIG NO W 0040 and assemble as per drawing 5. Weld alll the joints using automatic CO2 welding. 6. Ensure the sample piece is sent to CMT for Micro Etching Test after welding as per the procedure. 7. Assemble center stiffener tube halves and web plate. ‘8. Weld as per Drawing 2.QUTER HEAD STOCK ASSEMBLY 1. Ensure the details are conformed in the previous stage of work 2. Assemble as per drawing 3. Weld the assembly. 4. Check the straightness 3.DRAFT GEAR BRACKET ASSEMBLY 1. Assemble the collar with the draft gear bracket using JIG NO - W0122 /, 02 Weld as per drawing HEAD STOCK ASSEMBLY 1. Collect inner head stock assembly, draft gear assembly, outer head stock assembly and other details. Using JIG NO - W0052 , assemble as per drawing . Remove the assembly from the Jig . First piece inspection done by section supervisor. . Weld the assembly completely, . Follow weld sequence to minimise distortion. - Remove the distortions if any by flame heating and hand straightening. . Maintain over all dimensions. Final inspection done by section supervisor. OPNBALON ISSUE STATUS: 01 = 7 SIGNATURE _ PREPARED BY: SME/MRVC/ S$ be APPROVED BY: DY.CME/ Bogie yteeed 7 cs AS ‘Signature x yao ‘Name & designation a r/Stds Carriage Checked by:(RefiCG-WE431-1, Ver. 10 | Page 14 of 2 | Date offasue: February, 2015 | CMI No. RDSOMOIACGICMI-D4 ] INTEGRAL COACH FACTORY, CHENNAI-38 [swim WIO12 _ WORK INSTRUCTION | REV. NO: 02 DATE: 24/10/2012 SUB: UNDER FRAME HEAD STOCK ASSEMBLY: | PAGE: 2 OF 3 EMU HEAD STOCK ASSEMBLY 4.CROSS BEARER ASSEMBLY 1. Collect the confirmed details 2. Assemble as per drawing 3. Weld the assembly completely. 4. Check the straightness and remove bend if necessary 2. LONGITUDINAL ASSEMBLY AND BEND ANGLE ASSEMBLY 4. Collect the conformed details 2. Assemble as per drawing 3. Weld the assembly completely 4. Check the straightness and remove bend if necessary HEAD STOCK ASSEMBLY 1. Collect the confirmed details and sub assembly 2. Assemble using welding Jig No. W 0352 or 0352/1 3. Remove the assembly from the Jig 4. Assemble the other details with the Head stock 5.First piece inspection done by section supervisor. 6. Weld the assembly duly following the sequence 7. Mark and punch the drilling locations (modified buffer arrangement of side - buffer) as per drawing 8. Drill as per drawing 9. Check the overall dimensions 10. Firtal inspection done by section supervisor. EAD STOCK ASSEMBLY ( Dri End 41.CROSS BEARER ASSEMBLY 1. Collect the confirmed details 2. Assemble as per drawing 3. Weld the assembly completely ISSUE STATUS: 01 SIGNATURE PREPARED BY: SME/MRVC/S APPROVED BY: DY.CME/ Bogie el — iam ———}>— “JE Directorfstds. [Carriage | Direcior/Stds Carriage | Checked by: ‘Approved by: Signature Name & designation([Ret:CG-WI-AZI-I, Ver. 1.0_| Page 15 of 22 | Date of issue: February, 2015 | CMI No, RDSOROTAICGICMTO4 ) INTEGRAL COACH FACTORY, CHENNAL-38 WORK INSTRUCTION SUB: UNDER FRAME HEAD STOCK ASSEMBLY: 2.COUPLING BEAM ASSEMBLY 1. Collect the confirmed details 2. Assemble as per drawing 3. Weld the assembly completely S3.BUFFER STUD LH/RH 1. Collect the confirmed details 2. Assemble as per drawing 3. Weld the assembly completely 4.DIAGONAL CPL, _LH/ RH 4. Collect the confirmed details 2. Assemble as per drawing 3. Weld the assembly completely S.MODIFIED ARRANGEMENTS FOR SIDE BUFFER BASE Collect the confirmed details Marking & punching of base plate. Drilling & Tapping of base plate with radial drilling machine. Assemble as per drawing Weld the assembly completely HEAD STOCK ASSEMBLY ( Driving End ) 1. Collect the confirmed details and sub assembly 2. Ensure the details are conformed to the Drawing 3. Assemble using welding Jig No. W 0353 4. Assemble as per drawing 5. Remove the assembly from the Jig 6. Assemble the modified arrangements for side buffer base with the Head stock 7.Weld the assembly. 8. First piece inspection done by section supervisor. 9.Check the overall dimensions and correct if necessary. 9. Final inspection done by section supervisor. gaeNs ISSUE STATUS: 01 a _ SIGNATURE _ PREPARED BY: SME/MRVC/S by APPROVED BY: DY.CME/ Bogie - C KES eeny - - aa 4 wot Signature oD) Sige : "Name & designation | SSE/Stds/Carriage | Jt. Director/Stds Carriage _Prepared by: Checked by:(ReefiCG-WI-42.1-1, Ver. 1.0 | Page 16 of 22 | Date of issue: February, 2015 | CMI No. RDSOAUIAICGICMI-OG | ANNEX INTEGRAL COACH FACTORY, CHENNAI33 TCR/MD/SPEC-147 ISSUE STATUS:01 ‘SCHEDULE OF REQUIREMENTS TO MANUFACTURE | Date : 21-07-2006 HEAVY FABRICATION ITEMS OF MILD STEEL AND. REV. No.02 CORTEN STEEL ‘AMENDMENT SLIP NO.: 01 DATED.12-02-07 No. of Pages: 1 PAGE CLAUSE EXISTING REVISED T Lt “This schedule covers infrastractural | This schedule covers infrastructural requirements formanufsetire and | requirements for manufacture end supply of frished mad steland | supply offished mid steel and ‘ore steel eavy fibration tems. | eortn sel heavy faction items, such as Doge Frame, Bogle holster, Body bolster, Head stock et z 43 > Stress relieving | Stress releiving afler welding as per_ aferwelding | relevant specication > Shotit blasting | shot blasting t get surface finish euivalent to $a 2.5 of 180 speciation | Nes501-1-88. Itshall be moted tat the Primer should be applied immediatly, | : ster grit blasting. i i z Tea | eal ave RSG tg Th rn bal ave a oe esting fies forthe folowing and’ ‘| tates for Macro ech test for tasion of supply rin outpiece withthe | fillet weld und Die penetration tet and frithd components, supply run out pce withthe finished Chemica! and | Somponents, The firm stall produce tat Mechanical "| certicats from Government or NABL Properties of raw | spprovedlaborsory for chemical and icra ‘Mechanical properdesof raw material > Maso etch txt for ison of filet weld > Die penetration i i ! CONTROLLED BY | PREPARED BY | VERIFIED BY | APPROVED BY SSE/D/MS AME/BD DY.CME /DESIGN CDE/MECH ‘Signature —T ‘Name & designation Der oe ae] 1 DirectoriStdsiCarviage ecked by: | UIapproved by:(RefiCG-WI42.E, Ver. 1.0 [Page 17 of 2 | Date of asue: February, 2013 | CMINo. RDSORULACGICMIAT] INTEGRAL COACH FACTORY, CHENNAT-38. ICF/MD/SPEC-147 ISSUE STATUS:01 SCHEDULE OF REQUIREMENTS TO REV. No.02 MANUFACTURE HEAVY FABRICATION ITEMS OF MILD STEEL AND CORTEN STEEL eee IDENTIFICATION SHEET No. OF PAGES 4 & ANNEXURE-A’ NATURE OF DOCUMENT COPY NUMBER ISSUED TO ISSUED BY DY.CME/DESIGN. RETURN OF COPIES In case of transfer / retirement, the holder of controlled copies shall return the same either to SSE/D/MS or to his/her successor under intimation to SSE/D/MS. NOTE 1. Controlled copy holders of this DOCUMENT are expected to bring the content of this document to the knowledge of the concerned officials who are working in his / her department /section. 2. Unauthorised copying of this document is prohibited. Prepared, verified and approved Page No.4 OF 4 CONTROLLED COPY HOLDERS C.COPY No. 1. CME/INSP ol 2. Dy.CC&M 02 3. AME/MPO/Fur : 03 4, Design Library 04 CONTROLLED BY | PREPARED BY VERIFIED BY APPROVED BY TE | sea Ae tot ae SSE/D/MS SME / DEV. DY.CME/ Design. | CDE/MECH Same 1 uz ‘Name & designation ‘SSE/Stds/Carriage | Jt. Director/Stds./Carriage Director/Stds./Carriage Prepared by: Checked by: ‘Approved by:[RefsCG-WI-42.1-1, Ver. 1.0 | Page 18 of 22 | Date of issue: February, 2015 | CMI No, RDSO/014/CGIOMI-04 J ‘SCHEDULE OF REQUIREMENTS FOR MANUFACTURE OF HEAVY FABRICATION ITEMS OF MILD STEEL AND CORTEN STEEL ICE, sPEC-147 Issue status :01 Rev.02 Page 1 of 4 1.0 SCOPE 1.1 This schedule covers infrastructural requirements for manufacture and supply of finished mild steel and corten steel heavy fabrication items 2.0 REQUIREMENTS 2.1, All vendors seeking registration with ICF must fulfil the requirements of this schedule. 3.0 COVERED AREA The firm shall have adequate covered area for storage of raw material, finished products and work in progress. 4.0 MACHINERY AND INFRASTRUCTURE REQUIRED 4.1 The firm shall have the following machinery and infrastructure with them as a requirement for manufacture of heavy fabricated items. SL | MACHINERY CAPACITY ‘ACCEPTANCE/ No. ALTERNATE PROCESS 1 | Shearing machine | Thickness 16 mm PUG gas cutting, plasma, Length 3000 mm laser, equal capacity 2 | Straightening Thickness 16 mm Hydraulic straightening, machine width 600 mm ‘equal capacity Length 3000 mm 3 _| Press brake 400Tons capacity Hydraulic press, equal length of bed 3000 mm__| capacity 4” | Hydraulic press for | 60 tons. No alternative bush pressing. 3” | Profile gas cutting | Thickness 25 mm PUG cutting Mie, machine Bed length 3 mtrs. X 1.5 | equal capacity mrs. Widh 6 | Radial drilling ‘60 mm capacity Any drilling machine of 36 machine mm capacity or plasma cuttin 7 | Submerged auto 3 mers. Length MIG welding welding Saas - —— ‘Name & designation | SSE/Stds/Carriage | Jt Director/Stds/Carriage | Director/STs Carriage Prepared by: Checked by: ‘Approved by:SCHEI (ReiCGWIA2I, Ver. 1.0 | Page 19 of 22 | Date of issue: February, 2015 | CMI No, RDSODOI/CGICMI-O | DULE OF REQUIREMENTS FOR MANUFACTURE OF HEAVY FABKICANIUW. ITEMS OF MILD STEEL AND CORTEN STEEL Issue status :01 Rev.02 Page 2 of 4 4.2 The firm shall have facilities for edge preparation and also have adequate jigs & fixtures as per the requirements to ensure dimensional _ controls. 43 The firm shall have in house facility or tie up with other firms for the following > Stress relieving after welding > Shot/grit blasting 5.0 ELECTRODES Required electrodes shall be procured from RDSO approved sources only. 6.0 MAN POWER 6.1 welders qualified with ITI or equivalent qualification shall be only employed. 6.2 Supervisors with minimum qualification of diploma in mechanical engineering, shall be employed for monitoring production and quality control. 7.0 INSPECTION & TESTING FACILITIES 7.1 The firm shall have calibrated measuring gauge, Vernier calliper, throat gauge, straight edge, level bed, GO & NO GO GAUGES etc. 7.2 The firm shall have in house testing facilities for the following and supply run out piece with the finished components. > Chemical and Mechanical properties of raw material » Macro etch test for fusion of fillet weld > Die penetration test 7.3. The firm shall have in house facility or tie up for radiographic test conforming to Blue standard of ITW (International Institute of Welding) 1A PROCEDURE MACRO ETCH TEST 7.4.1 The run-out sample shall be cut perpendicularly and the cross section of the welded area shall be ground to smooth finish without any tool/file marks. The welded area shall be etched using dilute nitric acid about 15% v/v for about one minute and washed throughly in running water. After washing it shall be dried. The etched welded zone shall be viewed either by naked eye or using magnifying lence of 40X. for fusion level and other weld defects. =e ee ‘Name & designation TBireetrfStas/Carriage | 1 Checked by: i(REECG-WIA2.1, Ver. 0 | Page 30 of 2 | Date of sue: February, 2015 | CMINo. RDSO/OLA/CGICMI.O4 | SCHEDULE OF REQUIREMENTS FOR MANUFACTURE OF HEAVY FABRICATION 18 TSA 182 183 154 155 38.0 81 82 83 ITEMS OF MILD STEEL AND CORTEN STEEL ICE/MD/SPEC-147 Tssue status :01 Rev.02 Page 3 of 4 ACCEPTANCE FOR MACRO ETCH TEST Fillet welds shall have fusion to the root of the joint. Shall have complete fusion between a adjecent layers of weld metal and with base metal. Shall have no cracks. Shall have no under-cut exceeding 1 mm in depth. Shall have weld profiles as shown in the ANNEXURE-A. QUALITY CONTROL REQUIREMENTS ‘The manufacturer shall have ISO: 9000 series certification, ‘There shall be a system to ensure traceability of the product from raw material stage to finished product stage. Quality Assurance Plan (QAP) for the following aspects shall be ensured. v Process flow chart Stage inspection details from raw materials stage to finished product stage. vv Various parameters to be checked and level of acceptance of such parameters indicated and method to ensure and control over them, > Disposal system of rejected raw material and components ‘Signature Sa ee | ee Prepared by: ‘Checked by: ‘Approved by7 (ReECG-WIA2.T1, Ver. £0 | Page 21 of 2 | Date of fisue: February, 2015 | CMI No, RDSOOLICGICMIO] SCHEDULE OF REQUIREMENTS FOR MANUFACTURE OF HEAVY FABRICAIIUN ITEMS OF MILD STEEL AND CORTEN STEEL I /SPI Issue status :01 Rev.02 Page 4 of 4 47 8.4 DOCUMENTATION v Incoming raw material register, v Stage inspection results including finished products results as approved by QAP. Records of internal rejection and its analysis vis ~a - vis action plan Records of final products inspection by external agencies. Records of maintenance schedule of machinery and Plant vvvyv Records of training imparted in Production, quality assurance, safety parameters and maintenance of machinery etc. 9.0 MARKING Manufacturers name or initial with month and year of manufacture shall be available in the finished products as specified in the relevant drawings. Share — 1 — be ‘Tt Director/Stas./¢ Director/$fds/Carriage ‘Checked by “Approved by: Signature, ‘Name & designation: (RefCG-WI42.1-1, Ver. 1.0 | Page 22 of 22 | Date of issue: February, 2018 [ CMI No, RDSO/2014/CGICMI-O4 ANNEXURE-A (A) Desirable fillet wold profiles (8) Acceptable fillet weld profiles Note: Convexity, C, of @ weld or individual surface bead shall not exceed 0.07 times the actual face width of the weld or individual bead respectively, plus 0.06 in. (1.5 mm) unless otherwise specified in the applicable section. Rn a Insufficient Excessive Excessive Overlap Insufficient Incomplete throat convexity undercut leg fusion (C) Unacceptable fillet weld profiles sn Tae eo ahaa ‘Name & designation ‘SSE/Stds/Carriage It. Director/Sids./Carriage Director/Stds./Carriage aa Ee —