Online Vendor Registration System

26th May 2015

Key enabling features of new system:

• Online Submission of VA form

• System generated acknowledgement to Vendor and

DLW officials at every stage

• Paperless transaction

• Smart tracking of document / Timeline Monitoring

of complete process / Status of application visible to
vendor
www.dlw.indianrailways.gov.in
New Online Vendor Registration
&
Process Monitoring system
Troubleshooting & System Maintenance

• 9 to 5 Call centre will be functional for next 3 months

to assist vendors on any issue related to working of
portal

• Continuous Software refinement based on experience

gained
dlwadedev@gmail.com
Other advantages of new system:

• Scaleable model , lateral additions possible

• Other web based modules planned:

1. Web based updation of DLW Vendor Directory

2. Monitoring of developmental POs
3. Monitoring of Prototype inspections

• Timeline : 6 months
Fast-tracking
Indigenization
&
Multisourcing
Turbo Lube Oil soak back Pump Motors (DC)
 Capacity: 0.75 HP,
 Rated Voltage : 74 V
 Speed : 1200 RPM
 Rotation : CCW Commentator end
 Type : DC Compound motor
 Cost: Rs. 132000.00 (Approx.)
 Approved Source:
Part-I : EMD/USA & DPG/USA Part-II : Nil
 Developmental Orders already placed on following firms:
I. M/s IEC/Bangalore
II.M/s DRESPL/ Raisen
III. M/s Elgi Electric/ Coimbatore respectively.
Double Idler Stub Shaft (PL No. 16030473)
• Critical cast component made from SAE-
J431, Gr. 4000 high strength cast iron.

Main Requirement for manufacturing:

• Induction furnace of at least 1 ton capacity.
CO2 / No-bake sand molding facility.
Outsourcing is permitted.
• VTL of size 56”dia. Or feedout head
arrangement on adequate capacity CNC
VMC, CNC VMC of adequate size, CNC
turning center for Sleeve, Cylindrical
Grinding for Sleeve, I.D. Grinding machine
for Sleeve & Surface Roughness machine.
• Case Carburizing, hardening & tempering
facility. Outsourcing is permitted.

Quantity per loco : 01 no.

Present Cost : Rs. 94500.00/PC

Lube Oil Strainer Asm (PL No. 16060118)

• It is large box-shaped cast and

machined aluminum housing.
• Weight – 65 Kg approx.
• Lube oil strainers are also the child parts
of this assembly.

Main Requirement for manufacturing:

• Aluminum casting facility having CO2/
No-bake sand moulding .
• Horizontal boring machine & radial
drilling machine or CNC vertical
machining centre or CNC horizontal
machining centre.

Quantity per loco : 01 no.

Present Cost : Rs. 149999.00/PC

Piston (PL No. 16120073)
• Cast iron alloy.
• Bowl shape (piston crown) – toroidal
• Piston cooling – oil cooled – cocktail
shaker
Main Requirement for manufacturing:

• Proper casting facility with at least one

ton melting furnace.
• CNC turning centre, CNC non cylindrical
grinder, induction hardening, universal
drilling machine/HMC, MPI, Tin plating &
ultrasonic cleaning facility.
• Precision measurement facility including
CMM capable of all measurement of
machined Piston.

Quantity per loco : 16 nos.

Present Cost : Rs. 28042.00/PC

 Carrier Piston Pin (PL No. 16141430)
• Basic function of this component is to
accommodate the piston-pin in its bore and
support the piston on its platform.
• In operation, it creates a rotational degree of
freedom for the piston, thereby permitting it
to rotate and take the optimum position. This
reduces the tendency of localized wear of
piston skirt caused by the phenomenon of
piston slap.
Main Requirement for manufacturing:
• Forging facility. Outsourcing is peremitted.
• Turning Centres, Horizontal machining
center, Cylindrical grinding machine with
Quantity per loco : 16 nos. double wheel angular plunge mechanism,
surface grinding machine, special purpose
Present Cost : Rs. 17700.00/PC machine for drilling angular holes, shot
peening machine, broaching machine,
honing machine and inspection facilities.
Cylinder Liner Stud Asm (PL No. 19110017)
• This component is for fully machined
cylinder liner stud assembly.
• It consists of Cylinder liner, deflector &
eight nos. studs.
Main Requirement for manufacturing:
• Casting facility.
• Induction brazing facility.
• CNC horizontal machining centre, CNC
vertical machining centre, Broaching
machine, laser hardening, honing & leak
testing facility.
• Precision measurement facility including
CMM capable of all measurements of
cylinder liner stud Asm.

Quantity per loco : 16 nos.

Present Cost : Rs. 68250.00/PC

Cylinder Head (PL No. 16120127)
• Alloy cast iron with integrated cast
passages for water and exhaust gases
for better heat transfer characteristics.
Main Requirement for manufacturing:
• Foundry facility equipped with Induction
furnace at least 2 Ton.
• Shell core shooting machine for making
core.
• Lab capable for doing spectro analysis &
metallographic examination.
• CNC VTL, CNC HMC, Washer, Valve
Seat cutting facility and Pneumatic
testing facility.

Quantity per loco : 16 nos.

Present Cost : Rs. 24863.00/PC

Turbo Wheel Impeller Bal. Asm (PL No. 16080385)
• Critical assembly consisting of turbine and
compressor on a common shaft and
accurately balanced to enable its rotation
at rotational speeds as high as 22000
RPM.
• Consists of Impeller assembly, Spacer-
Impeller outer, Spacer-Impeller inner, nut,
Turbo wheel shaft, Washer-special, screw
& Weight balance.
Main Requirement for manufacturing:
• Forging facility and shell casting facility.
• CNC VMC five axis machining centre.

Quantity per loco : 01 no. • Broaching machine or wire cutting

machine.
Present Cost : Rs. 1076084.00/PC • Press machine to bend tap lock.
• Dynamic balancing machine.
• Surface roughness tester & CMM
 Clutch Drive Asm (PL No. 16060490)
• Consists of five major child parts –
Support drive, Clutch dowelling asm, Plate
cam, Gear upper idler and Gear turbo
drive.

Main Requirement for manufacturing:

• Forging hammers (8 Ton or more).
• Billet heating furnace, Trimming presses &
Heat treatment facility.
• CNC Turning centre, CNC VMC with 4-
axis, Super Cooling facility, Induction
hardening, Case Carburizing, hardening,
Tempering, Chrome Plating facility, I.D.
Grinding machine, Center-less Grinder for
Roller, Polishing facility for roller and cam
Quantity per loco : 01 no.
plate, Surface Roughness testing
machine, Gear Hobbing for Gear turbo
Present Cost : Rs. 641092.00/PC
drive & Upper Idler,
• Balancing machines for Gear turbo drive &
Upper Idler and bearing pressing facility.
Lash Adjuster Asm (PL No. 16040144)
• Used in valve bridge assembly on HHP
engines.
• Consists of seven components viz.
Body-lash adjuster (40118614), Plunger-
lash adjuster (40118615), Spring-plunger
(40105761), Retainer-ball (40115266),
Spring-ball (40105763), Snap ring
(8052320) and Ball-lash adjuster
(40105765).

Main Requirement for manufacturing:

• CNC turning centre,
• Centre-less grinding facility, Internal
grinding facility and hydraulic “leak-
down” test arrangement.

Quantity per loco : 64 nos.

Present Cost : Rs. 478.00/PC

Manifold Asm Fuel Line-RB (PL No. 16050216)
Manifold Asm Fuel Line-LB (PL No. 16050198)

• It provides passage of fuel oil to be

supplied to each injector through fuel oil
line.
• It is made of AISI MT-1010/1015 steel
tubing & SAE-1117 steel.
Main Requirement for manufacturing:
• CNC pipe bending.
• Zn plating, brazing & pickling.

Quantity per loco : 01 no.

Present Cost : Rs. 16988.00/PC

Fuel Manifold (PL No. 16050162)

• It provides passage of fuel oil inlet to

spin on filter as well as return of excess
fuel and return of fuel in case of plugged
filter.
• It is made of SAE-1020, SAE-1117 steel
forging & welded cold drawn steel
tubing.
Main Requirement for manufacturing:
• CNC pipe bending.
• Zn plating, brazing & pickling.

Quantity per loco : 01 no.

Present Cost : Rs. 4353.00/PC

 Inlet Tube Asm (PL No. 16050253)
• It is fabricated sub assembly of flange,
elbow-saddle and tube.
• It is made of AISI-8620 H steel tubing,
malleable iron (ASTM A47 casting) & IS-
2004 class-II steel forging
• Flange & saddle are made by forging
and casting respectively and both the
components are precision machined
before welding with tube. Shot Peening
is to be done of this tube assembly after
welding.
Main Requirement for manufacturing:
• Forging, casting facility. Outsourcing is
Quantity per loco : 16 nos. permitted
• CNC turning centre & CNC VMC.
Present Cost : Rs. 2940.00/PC
• CNC tube bending.
• Induction brazing.
• Shot peening & pickling
Piston Cooling Tube (PL No. 16060271)
• It is made of Silicon bronze casting,
sintered powder child part & AISI NT-
1010/1015 tubing.

Main Requirement for manufacturing:

• CNC pipe bending machine facility.
• CNC machining facility for Bracket.
• Sintering powder metallurgy facility.
• Silicon bronze casting facility.
• Brazing facility & Pickling facility.

Quantity per loco : 16 nos.

Present Cost : Rs. 4247.00/PC

Elbow Lower (PL No. 16191171) &
Elbow Upper (PL No. 16191183)

• These are pressed components.

• These are made of MS 4361 semi killed or
killed steel
Main Requirement for manufacturing:
• Hydraulic press upto 200 tons required.
• Shearing machine/laser cutting facility
required.
• Magnaflux/DP test facility for surface quality.

Quantity per loco : 16 nos. each

Present Cost : Rs. 1600.00/PC

Base Rail (PL No. 16191778)

• MS 4361 semi killed or killed steel rolled

section.

Main Requirement for manufacturing:

• Rolling mill with Roller dia of 14” or more

alongwith billet heating furnace to suit this
job for carrying out preheating of Billet at
minimum 1150ºC.
• Straightening facility.
• Testing facilities for destructive and non-
destructive testing like Megna flux &
Ultrasonic Testing facilities.

Quantity per loco : 02 nos.

Present Cost : Rs. 35709.00/PC

Channel air Box (PL No. 16191780)
• MS 4361 semi killed or killed steel
rolled section.

Main Requirement for manufacturing:

• Rolling mill with Roller dia of 28” or

more alongwith billet heating furnace to
suit this job for carrying out preheating of
Billet at minimum 1150ºC.

• Straightening facility.

• Testing facilities for destructive and

non-destructive testing like Megna flux &
Ultrasonic Testing facilities.

Quantity per loco : 04 nos.

Present Cost : Rs. 154689.00/PC

Gasket Chamber To Crankcase (PL No. 16170489)

• It is made of non asbestos filler material

with steel core bounded by SS-304 &
teflon coating on outer surface.
• Used between exhaust manifold leg
flange & top deck (exhaust) & working
under high temperature (600̊C).
Main Requirement for manufacturing:

• Design facility.
• Laser cutting facility, Press and testing
facility for tensile, hardness,
compressibility resistance, leak/seepage
test & oil absorption test etc..

Quantity per loco : 08 nos.

Present Cost : Rs. 2257.00 /PC

Gasket Cylinder Head (PL No. 16170039)
• It contains gasket and seal assembly.
Gasket is of stainless steel with copper
layer on upper portion and seal
assembly consists of seal made of
silicon and insulator seal is of glass filled
Teflon.
• It has got 20 holes punched. Twelve nos.
for water passage to enter water from
Cylinder liner to Cylinder Head and eight
nos. for passing stud of Cylinder liner
stud assembly. Location of all holes are
very important in this assembly.
Main Requirement for manufacturing:

• Design & validation facility.

• Press, assembly & testing
facility.

Quantity per loco : 16 nos.

Present Cost : Rs. 1874.00/PC

Brake Head ASM ( PL No. 17020440)

• Brake Head Body - Nodular cast iron to

EMS-9
• Steel Bushing – EMS-85

Main Requirement for manufacturing:

• Nodular cast iron casting facilities (can
be out sourced)
• Drill machine
• Milling /shaping/planning machine
• Press for bushing fitment

Per loco Requirement : 12 no.

Present Cost : Rs. 1869 /PC

Ring Wear (PL No. 17271162)
Material
Material Nylon alloy –Non metallic, wear
resistance & self lubricated like
Polyamides PA6. to RDSO specification
no. MP.0.40.99.02
Main Requirement for manufacturing:
• Manufacturing facilities should be as per
RDSO STR No. MP.STR.VL-04.09.11
(Rev-00). Mainly following facilities
should be there-
• Nylon alloy molding or casting
• Lathe machine
• Grinding wheel

Per loco Requirement : 02 no.

Present Cost : Rs. 216 /PC

Wear Plate (PL No. 17084374 )
Material
Nylon alloy –Non metallic, wear
resistance & self lubricated like
Polyamides PA6 to RDSO specification
no. MP.0.40.99.02
Main Requirement for manufacturing:
• Manufacturing facilities should be as per
RDSO STR No. MP.STR.VL-04.09.11
(Rev-00). Mainly following facilities
should be there-
• Nylon alloy molding or casting
• Lathe machine
• Grinding wheel

Per loco Requirement : 24 no.

Present Cost : Rs. 90 /PC

THANKS