HCC Bogie

Ref: CGW 0001 (Rev. – 4)

of 24 Date of issue February, 2011 Spec. No.RDSO/2011/CG-01

Signature

Name & Designation

Prepared By- Amit Kumar /SE/D

Checked By- P.K.Srivastava /ADE/VDG

Approved By- Shivendra Singh /Jt. Director/VDG

INDIAN RAILWAYS

Technical Specification for Higher Carrying Capacity (HCC) EMU/DMU Bogie with Pneumatic Suspension.

(Broad Gauge: 1676mm)

S No. Date/month of Issue

Revision /Amendment

Page no.

Reasons of Revision

1. Feb 2011 Nil Nil New

Issued by:

Research Designs & Standards Organisation Manak Nagar, Lucknow – 226 011.

Ref: CGW 0001 (Rev. – 4)


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Name & Designation




Technical Specification for Higher Carrying Capacity (HCC) 20.32 t

EMU/DMU Bogie with Pneumatic Suspension 1. Scope: 1.1 This specification covers the technical requirements to be complied by the

tenderer for manufacture, testing and supply of HCC (20.32t) EMU/DMU Fabricated Bogie with pneumatic suspension at secondary stage of suspension.

1.2 Definition

Wherever “Inspecting Agency has been mentioned” it shall be taken as “Authorised Inspecting Agency of Purchaser”.

1.3 Purchase of Drawings: All ICF drawings with latest Revision / Amendment required for manufacturing shall be obtained from ICF Chennai as per usual terms and conditions of ICF.

2. Eligibility Criteria: The manufacturer shall have the following:-

i) Adequate fabrication, heat treatment, machining and shot blasting facilities.

ii) ISO-9001-2000 certification. iii) Experience in manufacture of fabricated bogies or other large

fabrications subjected to dynamic loading and vibration and shall furnish the complete details of fabrications done in the past to RDSO for appraisal.

iv) Well-equipped laboratory for various tests required for a quality product of fabricated bogie.

v) Adequate technically trained staff including welders and non-destructive testing operators for radiographic, ultrasonic and magnetic particle inspection, qualified to approve ISI/international standards.

vi) Employing a minimum work force of at least 50 persons including supporting personnel. Since bogie frames are also required to be heat treated, the manufacturer shall have adequate capacity both in regard to heating (furnace) and cooling under controlled condition.

Ref: CGW 0001 (Rev. – 4)


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Name & Designation




The manufacturer shall submit evidence in support of the above requirements along with the tender. The manufacturer shall also submit detailed list of machines available for manufacturing the bogies.

3. Scope of Supply: 3.1 The HCC (20.32t) fabricated bogie duly assembled is to be supplied

conforming in all respects to the relevant drawings as indicated in Annexure-III.

3.2 The tenderer is required to coordinate and liaise with RDSO, Lucknow and

the purchaser during manufacture of the first two bogies, which shall be the prototype bogies.

3.3 This is a general specification required for manufacturing of all types of

HCC (20.32t) bogies used in EMU/DMU coaching stock. 4. Governing Specifications: IS:2062 - Weldable Structural Steel IS:813 - Scheme of symbols for welding IS:817 - Code of Practice training and testing of welders IS:2102 - General locations for linear and angular dimensions IS:2074 - Ready mixed paint, air drying, red oxide, zinc chrome priming IS:2932 - Enamel, synthetic exterior (a) under-coating (b) finishing ASTM - Straight beam ultrasonic examination of steel plates A:435 IS:3658 - Code of Practice for liquid penetrant flaw detection IS:5334 - Code of Practice for magnetic particle flaw detection of welds AWS D1.1 - Structural Welding Code (1983)Blue Std. International Institute of Welding IS:9595 - Metal arc welding of carbon and manganese. IS:7307 - Approval tests for welding procedure.

Wherever reference to standards, IS or any other Standards/code, appears in this specification it shall be taken as a reference to the latest version of the Standard/code.

Ref: CGW 0001 (Rev. – 4)


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Name & Designation




5. Deviation: When deviations from original design, material specifications, dimensions

etc. are desired specific proposals with reason shall be submitted for prior approval of RDSO/Lucknow before commencement of manufacture.

6. Infrastructure facilities:

The manufacturer shall have following infrastructure facility at their works for manufacturing of bogie. (i) Degreasing/Derusting plant (ii) Profile cutting machine (oxy-acetylene/plasma) for cutting plates

upto thickness 25mm) (iii) Submerged arc welding plants (iv) Edge preparation facility (planer/shapers) (v) Shot blasting plant (vi) Load testing machine for load testing of bogies. (vii) Radiographic testing facility /Ultrasonic testing machine. (viii) Furnace for stress reliving of bogie components (ix) Hydraulic press for straightening of components (x) Fixtures for fabrication and assembly of bogie components (xi) Manipulator for down hand welding of bogie components (xii) Plate bending machine (xiii) MIG welding set with CO2/Argon as shielding media. (xiv) Apparatus to check chemical composition of steel. (xv) Hardness testing machine. (xvi) Lab for chemical & mechanical testing having –

a) Universal testing machine of 400 KN or have tie up with reputed lab/agency for carrying out testing which should be ISO 9001:2000 certified.

b) Impact testing machine or have tie up with reputed lab/agency for carrying out testing, which should be ISO 9001:2000 certified.

(xvii) Oven for drying electrodes (0-500 degree C) (xviii) MPI & DP testing facility. (xix) 1t/2t/5t EOT Cranes. (xx) Level surface table of size 4000 mm X 2600 mm.

Ref: CGW 0001 (Rev. – 4)


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Name & Designation




7. Bogie: Bogie consists of the following assemblies: 7.1 Bogie frame assembly and Bogie Bolster assembly: As per RDSO

Specification C-9202 Latest Revision.

7.2 Primary Suspension (Helical coiled springs ) The primary suspension consists of oil resisting rubber pads and helical spring mounted between axle box and bogie frame. The axle box guide arrangement shall be as per drg. no. given in attached annexure-III. The items required to be fitted on the axle guide shall be supplied duly fitted and suitably packed. The items of primary suspension i.e. primary spring, upper and lower washers, compensating rings, lower spring seat shall be supplied loose in packed condition.

7.3 Secondary Suspension (Air suspension assembly)

The pneumatic suspension system for the secondary stage of MC and TC stock shall confirm to RDSO specification No. C-K406 (Latest rev.) for air spring assembly and C-K407 (Latest rev.) for their control equipments with latest revision. The air spring bogies shall have two vertical and two lateral hydraulic shock absorbers (conforming to Spec. C-8703 Latest Rev.) with one lateral rubber bump stop provided at each side of bogie between bolster and bogie frame.

7.4 Assembly of Bogies

The bogies shall be supplied by the contractor in duly assembled condition, as per the requirements by the railways, containing all the items as listed in Annexure III of this specification except wheel & axle with axle box assembly. The latest drawing shall be procured as per para. 1.3 above.

8. Raw Material: 8.1 The chemical composition and mechanical properties of steel shall

conform to IS: 2062 Fe 410 WC with Cu. 8.2 The standard steel plates conforming to IS: 2062 Gr.C Fe 410 WC with Cu

shall be procured from SAIL/TISCO or other reputed manufacturers, having the essential facilities, along with their test certificates. These test

Ref: CGW 0001 (Rev. – 4)


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certificates shall be co-related with the stamping on the plates to be taken up for manufacture prior to commencement of work.

8.3 Wherever test certificates are not available, sample from each shall be

drawn and tested both for chemical composition and physical properties in the presence of Inspecting Agency.

8.4 All records of physical, chemical including impact tests shall be made

available to Inspecting Agency. All plates to be taken up for manufacture shall be visually checked for surface defects such as cracks, dents, pittings, bend, rust, scales etc. and they shall be free from all these defects. Straightening of the plates can be done with the help of either straightening machine or Hydraulic press. Hammering shall not be resorted to straighten the plates.

8.5 Ultrasonic Test:

All the plates shall be subjected to ultrasonic test on the entire surface for detection of sub-surface defects or internal flaws, such as cracks, internal lamination etc., in accordance with ASTM-A 435”

8.6 The tested and accepted plates shall be painting suitably at several places

for easy verification at the time of tack welding. 8.7 Unaccepted plates shall be suitably stamped/painted and segregated and

records shall be kept in proper way. 9. Cleaning, Marking and Cutting 9.1 All the plates shall be degreased and derusted before commencing

manufacturing operations. 9.2 All the plates shall be marked properly to achieve the specified dimensions

given in the drawing keeping the required allowances for proper welding and margin for machining.

9.3 Plates shall be cut either by oxy-acetylene plasma or by machine. All

nicks/cuts on the plates during cutting shell be welded and finish ground before using them for sub-assembly/assembly.

Ref: CGW 0001 (Rev. – 4)


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Name & Designation




10. Edge preparation 10.1 All edge preparation shall be done by machining. 10.2 The weld joint dimensions/edge preparation shall be as per the relevant

drawing/IS specification. 10.3 The surfaces and edges to be welded shall be ground smooth and uniform

and shall be free from cracks, undercuts, slags, gauges etc. that would adversely affect the quality and the strength of the weld.

10.4 The roughness of oxygen cut surfaces shall be no greater than 25

microns. 10.5 Plates shall be inspected for dimensional accuracy. Any distortion that

occurs during cutting shall be straightened before tack welding. 11. Fixtures and Manipulators

The manufacturer should have the fixtures and manipulators for the following: i) Transom ii) Side frame iii) Air suspension cradle iv) Bogie frame assembly v) Bolster vi) Headstock (vii) Fixture for guide fitment (viii) Lower spring seat

12. Tack welding of Assemblies 12.1 The welding surfaces and the surrounding area shall be free from loose or

thick scale, slag, mill scale, moisture, grease, oil, rust etc. that would prevent proper welding.

12.2 All members to be welded shall be brought into correct alignment and held

in position by clamps, wedges, strong backs, fixtures etc. until welding is completed. Tack welds shall be made with the same electrodes that meet the requirements of the final welds and shall be cleaned thoroughly.

12.3 The length of tack weld and the distance between two consecutive tacks

shall be suitably selected by the manufacturer to avoid defects like distortions, warpage etc.

Ref: CGW 0001 (Rev. – 4)


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12.4 Procedure for tack welding as specified in IS:9595 should be followed 13. Welding Procedure:

13.1 Filler metal

MIG welding process using CO2 gas as shielding media shall be used for curved areas where as submerged arc welding shall be used for straight areas. RDSO approved brand of filler wire shall be adopted.

13.2 Welders qualification

Qualified welder as per IS: 817 shall be employed for fabrication work and Radiographic test shall be carried out. The edge preparation shall be in accordance with the thickness of the plates. The welding shall reveal high standard of workmanship. However, if welders employed are qualified to any other international approved standards, prior approval of Inspecting Agency is necessary.

13.3 Joints

.1 Gaps and fit-ups shall be checked before starting the welding.

.2 Use of Backing plates below the gaps of the joints is not permitted. 13.4 Position

As far as possible, all the weld joints shall be welded in down hand position, if necessary by using manipulators.

13.5 Weaving bead Technique and Interpass cleaning technique shall be

adopted by grinding and using wire brushes. 13.6 Welding parameters as recommended by the electrode manufactures may

be followed. 13.7 Pre-Heat

.1 Inter pass temperature of 1500 C to 2000 C shall be maintained throughout the welding.

.2 Electrodes shall be pre-heated, in the electric ovens, to a temperature of 1500 C to 2500 C for 2 hours before they are used.

14. Quality of Weld joints 14.1 Visual (By using magnifying glass if required)

.1) Weld joints shall have uniform beading and smooth change over from weld deposit to the parent metal and thorough fusion between adjacent layers of weld metal and between weld metal and parent metal.

Ref: CGW 0001 (Rev. – 4)


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.2) They shall be free from cracks, craters, undercuts, overlaps,

porosities, inclusions, blow-holes etc. .3) The fillet weld profile shall be made concave by grinding so that

smooth transition occurs at the toe of weld maintaining correct size of the welds.

.4) The slags shall be thoroughly removed and cleaned after each

interpass. .5) The welds shall be ground to eliminate stress raisers and to improve

fatigue life. .6) Members distorted by welding shall be straightened by carefully

supervised application of heat. The temperature of heating areas shall not exceed 6500 C. Mechanical method may also be used with application of heat. All the rework and straightening operations shall be completed before stress relieving.

14.2 Magnetic Particle Test/Dye Penetrant Test

.1) All the fillet weld joints shall be subjected to Dye Penetrant Test on all critical areas, as indicated in relevant Drawings listed in Annexure-I and all the butt weld joints (100%) shall be subjected to Magnetic Particle Test/Dye Penetrant Test for detection of weld flaws. The procedure and acceptance standard shall be as per IS specification no.5334/3658 respectively.

.2) Evaluations Discontinuities and defects shall be indicated by retention of the

magnetic particles and rise of Dye Penetrating after applying developer on the surface of welds shall indicate discontinuities and defects. All such indications are not necessarily the defects, since excessive surface roughness, and the heat-affected zones etc. may produce similar indications. Even if indications are believed to be non-relevant, each type of indication shall be explored to determine if linear discontinuities are present.

Ref: CGW 0001 (Rev. – 4)


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Name & Designation




14.3 Acceptance Standard .1) All linear discontinuities are un-acceptable and shall be

removed and repaired by chipping or grinding and subsequent welding.

.2) When defects appear, they shall be rectified and the area shall be re-examined by the same method to verify that they have been rectified completely.

.3) All test reports of Magnetic particle inspection/Dye Penetrant Test will be submitted for review to the Inspecting Agency.

14.4 Radiographic/Ultrasonic Examination

.1) All the Butt weld Bevel joints shall be subjected to 100% Radiographic Tests at 2% sensitivity and 2.0-2.2 film density conforming to Blue Standard of International Institute of Welding (IIW). Locations for radiography in frame assembly shall be done as per Annexure-I.

.2) As per the specified standards IIW Weld joints having cavities,

undercuts and porosities shall be within the acceptable limits as per the specified standards.

.3) The Radiographic examination shall be carried out by qualified

personnel and radiographs shall be submitted to the inspecting agency for interpretation. In case of difference of opinion, the interpretation of Inspecting Agency will be final.

.4) Alternatively Ultrasonic testing of welded joints shall be carried

out as per M&C dte’s Code of Practice No. MC-4 of November 1994 (Reaffirmed in March 2005).

15. Stress Relieving:

The stress relieving of the bogie frame/bolster shall be carried out in an oil-fired furnace equipped with thermocouples and recorders. Adequate measures shall be taken to avoid any appreciable distortion of the bogie/bolster during heat treatment. If any resetting is required to be done after heat treatment in order to achieve required dimensions, the bogie frame/bolster shall be again suitably heat treated after such re-setting. The heat treatment shall be carried out as specified in annexure-II.

Ref: CGW 0001 (Rev. – 4)


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Name & Designation




16. Gauging: List of gauges used for axle guide fitment and checking of Bolster

Suspension Spring hangers is following:

i) Longitudinal gauge for axle guide. (As per ICF Drawing No J&T/G0296/01 –latest rev.)

ii) Transverse gauge for axle (As per ICF Drawing No J&T/G0384/01–latest rev.) iii) Diagonal gauge for axle guide.

(As per ICF Drawing No J&T/G0300/01–latest rev.) 16.1 Square ness of the bogie frame, axle guides and BSS brackets shall be

checked with the help of transverse, longitudinal and diagonal gauges and straight edge. Axle box alignment shall be checked with reference to the BSS brackets with the following gauges.

S.No. Gauges HCC (20.32 t) bogies

1 Longitudinal gauge for axle guide 630 mm 2 Transverse gauge for axle guide 2210 mm 3 Diagonal gauge for axle guide

3643±1 mm 4 Longitudinal gauge for BSS brackets 800±1 mm

5 Transverse gauge for BSS brackets 2140±1 mm

6 Diagonal gauge for BSS brackets 2285±3.0 mm 7 Distance between BSS bracket and

adjacent axle guide 733± 1.0 mm

8 Transverse Gauge for Brake beam hanger bracket.

875±1.0 mm equidistant from centre line of axle

16.2 If the BSS brackets do not lie within the tolerances relocate one or more

BSS brackets with correct alignment after ensuring correct alignment of the BSS brackets. Measure the location of axle guide from BSS bracket. If these measurements deviate from the standard measurements, relocate this aligned plane of axle guides.

Ref: CGW 0001 (Rev. – 4)


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Name & Designation




17. Shot Blasting: 17.1 The entire bogie frame/bolster shall be subjected to shot blasting after

heat-treatment for cleaning of rust, scales, spatters etc. Special care shall be taken to protect the threads of Axle box guide during shot blasting.

17.2 Immediately after shot blasting and inspection the bogie frame/bolster

shall be coated with one coat of anti-corrosive paint to spec. no. IS: 2074 in order to arrest rusting and corrosion.

18. Marking of Bogie Frame/Bolster

The bogie frame/bolster shall be placed on the marking table in order to ensure the following:

.1) Profile and Geometry .2) Absence of distortion

Record of above checks and Dimension Control Chart shall be submitted to the inspecting agency on demand.

19. Painting

The bogie frame/bolster shall be given one coat of Red Oxide Zinc Chromate to IS: 2074 followed by two coats of black synthetic enamel paint to IS: 2932.

20. Stages of Inspection: 20.1 The inspection shall be carried out by inspecting agency as indicated

below: 1) Stage inspection of major sub-assemblies consisting of:

a) Side frames b) Bolsters c) Axle box guides d) Air suspension cradle e) Headstock f) Transoms g) Longitudinal Members

2) Inspection after the above parts are assembled and tack welded. Special care shall be taken to maintain the centers of Axle box guides and bolster spring suspension brackets.

Ref: CGW 0001 (Rev. – 4)


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3) Inspection of complete bogie frame/bolster after complete welding.

20.2 After completion of the First Two Bogie Frames/Bolster, waiving of any or

all items of the stage inspection may be considered by RDSO/Purchaser on request by the manufacturer. This will depend upon the experiences gained at the time of inspection of first two bogies/bolsters and the level of confidence built-up. The manufacturer will proceed further in manufacturing the bogies only after taking clearance at each stage as specified above.

20.3 The Purchaser/Inspecting Agency shall have access at all reasonable

times to the works where bogie frame/bolster is manufactured and material is stored and the right to inspect die, jig and fixtures and measuring instruments being used by the manufacturer. All the facilities including labour, appliances, gauges, measuring instruments etc. necessary for testing and inspection shall be provided by the manufacturer free of cost.

20.4 Dimensional Control Charts, Chemical and Mechanical properties test

certificates, Magnetic Particle Test Certificates, Radiography Test Reports, Heat Treatment records etc. shall be supplied along with the Bogie Frames/Bolster to the purchaser.

21. Dimensions and Tolerances 21.1 All dimension/tolerances shall be as per details given in the drawings.

However, special attention shall be given to check the centers of axle box guides and bolster spring suspension brackets in longitudinal, lateral and diagonal directions.

21.2 Detailed dimension control charts/ sheets shall be prepared for each bogie

frame in which measurements of critical dimensions shall be recorded and kept for evaluation and verification by the inspecting agency.

21.3 All the un-tolerance dimensions shall be in accordance with IS: 2102-1980

(Medium) as indicated in the drawing. 21.4 Gauges, fixtures and templates and accurate measuring instruments shall

be used to ensure the correctness of the dimensions.

Ref: CGW 0001 (Rev. – 4)


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22. Periodic Calibration of Gauges and Fixtures

The gauges, fixtures and templates shall be calibrated/checked for its correctness and accuracy after every six months and records shall be kept in proper way as per ISO: 9001 requirements.

23. Quality Assurance Plan (QAP)

A Quality Assurance Plan which outlines the various processes including inspection in order to obtain a Quality product shall be submitted to RDSO for approval and QAP shall be prepared on the lines as indicated in ISO: 9001 document, CGG 0001(Rev 01) Vendor approval guidelines.

24. Code of Practice for Quality Control and Inspection 24.1 The system

The manufacturers shall furnish to the purchasing/inspecting authorities information in respect of quality control systems in force at their works on various materials used in the manufacture of components.

24.2 Records, Tests & Sampling

The manufacturers shall furnish the Purchasing/Inspecting authorities the details of tests and inspection records and other relevant records as required under the quality control systems in force. These records and reports shall be maintained by the Competent Technical Authority of the manufacturer and shall be open to examination by the Purchasing/Inspecting Authorities at all reasonable time. The Purchasing/Inspecting Authorities at their discretion may draw samples of materials referred to in para 8 and products at any stage of production for conformity tests either at the works of the manufacturer or in an approved laboratory. In case the samples do not conform to the requirements of the specification, double the number of samples from the same lot/batch shall be drawn for re-tests. Should any of the re-test samples do not conform to the requirements, the entire lot/batch shall be rejected.

24.3 Approved Manufacturers 24.3.1 For reasonable quality assurance, it is desirable that the components are

procured from manufacturers approved by Research Designs & Standards Organisation (RDSO), Lucknow or by any other agency as assigned by the Purchasing Authority, based on evaluation of the components as per

Ref: CGW 0001 (Rev. – 4)


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the specification, manufacturing and quality control facilities and quality/assurance programme. However, such approval does not guarantee the supply of consistent quality of material/components and therefore every lot/batch offered shall be subjected to inspection and testing as per the specification.

24.3.2 The approved manufacturers shall be subjected to periodical re-appraisal

(periodicity for each components shall be assigned by the approving authority). The consignee may also periodically arrange testing if so desired, in an approved laboratory for conformatory tests within six months from the date of receipt of the supplies.

25. Identification Marking:

Each bogie frame/bolster shall be provided with an easily visible identification plate indicating the bogie frame/bolster serial number year of manufacture and manufacturer’s name to facilitate identification/correlation with the inspection/test results.

26. Packing: 26.1 All machined surfaces shall be protected from oxidation and corrosion by

applying two coats of rust preventive oil to IS spec. No.493 Pt.I viscosity grade 46.

26.2 The packing shall be such that all the machined surfaces shall be properly

protected against rubbing/impact/scratches with other bogies or with mode of transportation i.e. wagon/truck/trailers etc.

27. Warranty:

The manufacturer shall warrant the bogie frame for a period of 5 years from the date of commissioning into service for material, manufacture and workmanship as regards trouble-free and satisfactory service performance. If any defects are noticed during service with regards to manufacture/welding quality of the bogie fame, action shall be taken by the supplier to carry out any repairs/rectification or replacement, as may be considered appropriate, which shall be done at his own cost. The decision of the purchaser in this regard shall be final.

Ref: CGW 0001 (Rev. – 4)


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28. Submission of Tender Offer:

The tenderer shall submit parawise comments on this specification in his offer. In the absence of parawise comments, his offer will stand rejected. He shall bring out the deviations, if any from the specification with adequate justification for such deviations. Unless otherwise stated in his offer, it will be presumed that there are no deviations.

29. Static Load Test :

1. The static load test on bogies shall be conducted on level plane for first

two prototype bogies of every order. 2. Bogie frame along with bolster assembly shall be placed on test rig.

Axle box springs and bolster springs of the bogie shall be replaced by providing solid cylindrical spacers of 300mm height at axle guide (Location at a b c & d) and also at secondary suspension (Location at P & Q).

3. Arrangement shall be made for measuring load deflection at the center of the side frame (Location at A&B) by providing dial indicator gauges with suitable fixing arrangement, initial setup at 00.

4. The predetermined load, required for this test, which is given in the table below according to the type of bogie, shall be applied simultaneously at the side bearer on the bogie bolster (location at X & Y).

5. The deflection of the side frame at location A & B shall be observed and recorded as per the proforma below. This should not be more than 1mm.

6. The applied load shall than be removed from the side bearer and the residual deflection (if any) is observed and recorded. This residual deflection should be nil.

7. The sketch of the load testing equipment is given on page 23 of this specification

S. No.

Axle load (t)

Max. load applied on side bearer (t)

Deflection under Max. load at the center of side frame location at

Residual deflection (if any) after removal of load at location

Remarks

A (mm)

B (mm)

A (mm)

B (mm)

1. 20.32 9.600

Ref: CGW 0001 (Rev. – 4)


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ANNEXURE - I

Location of Radiographic and Dye Penetrating Test on Bogie frame and Bolster

Type of Bogie Drawing References

Radiographic Examination

Dye penetrant test

Bogie frame

Bolster Bogie frame

Bolster

HCC bogie of EMU SK-92078 (At page no.-23)

SK-92063 (At page no.-21)

SK-92076 (At page no.-22)

---

Ref: CGW 0001 (Rev. – 4)


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ANNEXURE -II

RECOMMENDED STRESS RELIEVING PROCEDURE 1) The temperature of the furnace shall not exceed 315 degree centigrade at

the time the welded assembly is placed in it. 2) Above 315 degree centigrade, the rate of heating shall not exceed 160

degree centigrade per hour. During the heating period, variation in temperature through the portion of the part being heated shall not be greater than 50 degree centigrade. The same shall be monitored by measurement of temperature using suitable thermocouples. For bogie frame, 4 thermocouples shall be fixed at the four corners and two at the centre of the side beams.

3) Soaking temperature shall be between 600 degree centigrade and 650

degree centigrade. On reaching the temperature, the assembly shall be held within specified limits for a time not less than 1 hour per 25mm thickness of the plates.

In addition, for determining the soaking time, the thickness of the thickest part of the assembly shall be considered. During the soaking period, the difference between the highest and lowest temperature of the assembly shall not be greater than 50 degree centigrade.

4) During cooling cycle upto 315 degree centigrade cooling of the job shall be

done in a closed furnace at a rate not greater than 100 degree centigrade per hour. From 315 degree centigrade, the assembly may be cooled in still air.

5) Suitable tie-bars shall be provided during stress relief operation for

maintaining the critical dimensions. The assembly shall be kept in the furnace, bottom side up (inverted position) during the heat treatment.

6) The assembly shall be suitably supported while loading in the furnace to

avoid any permanent deformation during stress relieving operation. 7) The heat-treating furnace temperature shall be effectively controlled by

using thermocouples having associated recording equipment.

Ref: CGW 0001 (Rev. – 4)


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ANNEXURE-III

S.No. Description AC/DC EMU 700 HP DMU

1400 HP DMU

DHMU AC EMU (ASR)

Motor Coach

Trailer Coach

DPC DPC Motor Coach Trailer Coach

1 Axle load 20.32t 20.32t 20.32t 20.32t 20.32 t 20.32t 20.32t

2 Bogie genl. arrgt.

AC/DC EMU/M2 0-0-201

AC/DC EMU/C2 0-0-001

DMU/DP C 0-0-001

DMU/DP C 10- 0-0 -001

DHMU/ DPC 0-0001

AC/ EMUM/ASR-0-0-001


3 Axle box guide arrgt.


ACDC/E MU/M2 0-1-201

EMU/M 0-1-033

DHMU/ DPC 0-1-001

DHMU/ DPC 0-1001

DHMU/DPC 0-1-001

AC/DC EMU/M2-0-1-201

4 Roller bearing axle box

EMU/M 0-2-001

EMU/M 0-2-001

EMU/M 0-2-001

EMU/M 0-2-001

DHTC 0-2-001

EMU/M- 02-001

EMU/M-02-001

5 Bogie frame arrgt.



DMU/ DPC -0-3-009

DMU/DP C10-0-3-001

DHMU/ DPC 0-3001

DMU/DPC1 0-0-3-001

AC/DC EMU/M2 03-201

6 Bogie side frame

DMU/DPC 5 0-3-515

DMU/DPC 5 0-3-515

DMU/ DPC -0-3-002

DMU/DPC 5 0-3-515

DMU/ DPC -0-3-002

DMU/DPC5-0-3-515

DMU/DPC 5- 0-3-515

7 Head stock EMU/M -0-3-004

EMU/M 0-3-004

EMU/M -0-3-004

EMU/M 0-3-004

EMU/M -0-3-004

EMU/M- 0-3-004

EMU/M- 03-004

8 Transom DC/EMU /M/ASR 0-3-003

DC/EMU /M/ASR 0-3-003

DHMU/ DPC -0-3-002

DC/EMU /M/ASR0-3-003

DHMU/ DPC 0-3002

DC/EMU/M/ ASR-0-3-003

DC/EMU/ M/ASR-0-3-003

9 Bogie bolster arrgt.

DMU/DP C10- 0-4-001

DMU/DP C10-0-4-001

DMU/DP C 0-4-001

DMU/DP C10- 0-4-001

DMU/DP C 0-4-001

DMU/DPC1 0-0-4-001

DMU/DPC 10-0-4-001

10 Centre pivot arrgt.

EMU/M 0-6-001

EMU/M 0-6-001

EMU/M-0-6-001

EMU/M0-6-001

EMU/M-0-6-001

EMU/M-0-6-001

EMU/M-0-6-001

11 Shock absorber drg. / capacity

DMU/DP C5-0-5-503/ V-300Kg, DC/EMU M/ASR-0-5-005/ L-100Kg


ICF/SK-0-5-015/ V900Kg


ICF/SK-05-015/ V900Kg

DMU/DPC5-0-5-503/ V-300Kg, DC/EMUM/ ASR-0-5-005/ L200Kg

DMU/DPC 5-0-5-503/ V-300Kg, DC/EMU M/ASR-0-5-005/ L-200Kg

Ref: CGW 0001 (Rev. – 4)


Signature

Name & Designation




12 Axle box coil spring

DC/EMU /M2 0-1-203

DC/EMU /M2 0-1-203

DMU/ DPC-0-1-001

DMU/ DPC5-0-1-501

EMU/M-0-1-024

DC/EMU/M 2-0-1-203

DC/EMU/ M2-0-1-203

13 Bolster suspension arrgt.

DMU/DP C10-0-5-001

DMU/DP C10-0-5-001

DMU/DP C 0-5-001

DMU/DP C10-0-5-001

DMU/DP C- 0-5-001

DMU/DPC1 0- 0-5-001

DMU/DPC 10- 0-5-001

14 Bogie brake arrgt.

EMU/M 3-2-064

EMU/M 3-2-064

EMU/M 3-2-064

EMU/M 3-2-051

EMU/M 3-2-064

EMU/M- 3-2-064

EMU/M 3-2-064

15 Suspension diagrammatic arrgt.



DMU/DP C-9-0-010

DMU/DP C5 9-0510

DHMU/ DPC 9-0003

AC/ EMU/M/AS R- 9-0-003

AC/DC EMU/C2 90-203

16 Wheel & axle arrgt.

AC/DC EMU/B0-2-001

DC/EMU /H2-0-1-202

EMU/M-0-1-027

DMU/DP C5 0-2504

DHTC -0-2-002

EMU/M-0-1-027

DC/EMU/ H2-0-1-202

Ref: CGW 0001 (Rev. – 4)


Signature

Name & Designation




Ref: CGW 0001 (Rev. – 4)

of 24 Date of issue January, 2011

Spec. No. RDSO/2011/CG-01

Signature

Name & Designation




HCC Bogie

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Transcript of HCC Bogie