REVISION OF SPECIFICATION / STR Bearing) & 6326 (Non-Drive ...

REVISION OF SPECIFICATION / STR

Item Name: Functional Requirement Specification (FRS) for Bearings N/NU 332 (Drive End

Bearing) & 6326 (Non-Drive End Bearing) used on3-Phase Induction Motors for

4000 HPAC-AC (WDG4 & WDP4) and4500 HP AC-AC (WDG4D, WDP4B&WDP4D)

Diesel Electric Locomotives.

Specification No. : MP-0.2402.27 (Rev.00), Ferbuary’2021.

1. RDSO is reviewing the specification/STR to cater to the latest technological developments in

the field, modify clauses not relevant in the present context and making them more enabling

with focus on functional requirements.

2. It is requested that your comments / suggestions with regard to improvements /modifications in

specification / STR of the above mentioned item may be submitted in the following format along

with the justification for the changes required.

Part A: Basic Information

SN Particulars Information

1 Name

2 Designation

3 Professional Qualification

4 Organization / Firm’s Name

5 Address for Correspondence

6 Contact No.

7 Email ID

8 Whether firm is registered with RDSO for the subject item. If yes, details like date of registration, current status etc. If no, firm’s experience in manufacturing of subject item or similar item

9 Whether any technical document/Report/Study to support suggested changes is available / enclosed for better appreciation

Part B: Comments / Suggestions on the specification

SN Clause No. of RDSO STR/ Spec

Clause, as it exists in RDSO STR/ Spec

Clause , as it should read after incorporation of comments /suggestions in the RDSO Spec / STR

Justification for changes

Comments may be sent to following address within 15 days from the date of publication on

rdso.indianrailways.gov.in

Director/Motive Power

Research Designs and Standards Organization

Manak Nagar, Lucknow – 226011

Email: [email protected], [email protected]

mailto:[email protected]

FRS NO. MP-0.2402.27 (Rev.00), FEB.‟2021 Page 1 of 12

भारत सरकार

रेल मंत्रालय

GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

बबयररंग्स N/NU 332 (बेलनाकार रोलर बेयररंग) और 6326 (डीप गू्रव बॉल बेयररंग) के बलए कायाात्मक

आवश्यकता बवबिष्टता (FRS) 4000 HP AC-AC (WDG4 और WDP4) और 4500 HP AC-AC (WDG4D,

WDP4B और WDP4D) डीजल इलेक्ट्रि क लोकोमोबिव

Functional Requirement Specification (FRS) for Bearings N/NU 332 (Cylindrical Roller Bearing) & 6326 (Deep Groove Ball Bearing) used on 3-Phase Induction

Motors for 4000 HPAC-AC (WDG4 & WDP4) and 4500 HP AC-AC (WDG4D, WDP4B &WDP4D) Diesel Electric Locomotives

आवश्यक कायाात्मक बवबिबष्ट नं0 एम0पी0-0-24-02-27 (ररवीजन-00)

फरवरी 2021

Functional Requirement Specification (FRS) No. MP-0.2402.27 (Rev. - 00), February’2021

अनुसंधान अबभकल्प एवं मानक संगठन

मानकनगर, लखनऊ- 226011

RESEARCH DESIGNS & STANDARDS ORGANISATION MANAK NAGAR, LUCKNOW-226 011


LIST OF AMENDMENTS

Sl. No. Amendment date Revision Details

1 --- Rev.00 --

2


Contents

1. FOREWORD: .........................................................................................................................................4

2. SCOPE: ..................................................................................................................................................4

3. OBJECTIVE: ...........................................................................................................................................4

4. VENDOR CHANGES IN APPROVED STATUS: .........................................................................................4

5. PREFERENCE TO MAKE IN INDIA: .........................................................................................................4

6. GENERAL REQUIREMENTS: ..................................................................................................................4

7. QUALITY ASSURANCE PLAN (QAP): ......................................................................................................4

8. METHODOLOGY OF DEVELOPMENT: ...................................................................................................5

9. BASIC DETAILS OF BEARINGS: ..............................................................................................................5

10. DETAILS OF BEARINGS TO BE FURNISHED BY VENDOR: ..................................................................6

11. TESTING AND INSPECTION: ..............................................................................................................6

12. FIELD TRIAL: ................................................................................................................................... 11

13. MARKING: ..................................................................................................................................... 11

14. PROTECTION AGAINST CORROSION: ............................................................................................ 12

15. PACKING: ....................................................................................................................................... 12

16. FIELD TRIAL SCHEME: .................................................................................................................... 12


Functional Requirement Specification (FRS) for Bearings N/NU 332 (Drive End Bearing) & 6326 (Non-Drive End Bearing) used on3-Phase Induction Motors for 4000

HPAC-AC (WDG4 & WDP4) and4500 HP AC-AC (WDG4D, WDP4B&WDP4D) Diesel Electric Locomotives.

1. FOREWORD:

At present, 3-phase induction motors are used in diesel electric locomotives of type WDG4 & WDP4B. These traction motors have been provided with bearings N/NU332 (DE) &6326 (NDE). With this Functional Requirement Specification; it is intended to develop the additional sources for procurement of these bearings.

2. SCOPE:

This Functional Requirement Specification (FRS) covers design, development and manufacturing for bearings (N/NU332 & 6362) of 3-phase induction motors for 4000 HPAC-AC (WDG4 & WDP4) and 4500 HP AC-AC (WDG4, WDG4D, WDP4B & WDP4D) Diesel Electric Locomotives and shall be used for developing additional sources for these bearings.

3. OBJECTIVE:

The objective of the FRS is to lay down general, functional and testing requirement for

development of sources for these bearings.

4. VENDOR CHANGES IN APPROVED STATUS:

All the provisions contained in RDSO‟s ISO procedures laid down in Document No. QO-D-

8.1-11 dated 01.07.2020 (Title “Vendor-Changes in approved status”) and subsequent

versions/amendments thereof, shall be binding and applicable on the successful

vendor/vendors in the contracts floated by Railways to maintain quality of products supplied

to Railways.

5. PREFERENCE TO MAKE IN INDIA:

The Government of India policy on make in India shall apply.

6. GENERAL REQUIREMENTS:

The firm shall have valid ISO-9001 certification issued by an approved agency with the activity desired clearly mentioned in the scope of certification. The firm shall have a Quality Manual indicating the extent of control over production.

7. QUALITY ASSURANCE PLAN (QAP):

The firm shall prepare a Quality Assurance Plan (QAP) for all items for which approval is

sought and submit the same as a part of compliance of this Specification. The QAP shall be

a comprehensive document covering the following aspects including all the parameters in

accordance with ISO Document No. QM-RF-8.1-3, Version No. 1.0 or latest - Guidelines for

preparing QAP during registration.


Followings are the salient points for preparing the QAP.

i. Details of Quality Control Organization of the firm along with key personnel engaged in

the QC function.

ii. Quality Assurance Process of incoming materials used for the subject items.

iii. Process Flow Chart indicating process of manufacture of an individual product or for a

family of products, if the process is same.

iv. List of plant, machinery, measuring and Testing Equipment.

v. Quality Assurance System – Inspection & Testing Plan including stage inspection.

vi. Calibration scheme and status of calibration of equipment‟s used in the quality process.

vii. The firm shall have a system of documentation with respect to rejection at customer

end, warranty replacement and failure of item supplied by them during service.

viii. Details of In-house manufactured and items Outsourced.

8. METHODOLOGY OF DEVELOPMENT: I. Development of bearings will be as per Functional Requirement Specification (FRS). II. Vendors shall offer the broad design parameters and dimensional drawings of bearings.

III. Prototype unit of above bearings shall be type tested and got approved by RDSO. IV. After successful prototype testing by RDSO, bearings shall be cleared for fitment on traction

motors for field trial. The Quantity and period of Field trials shall be governed by RDSO Document no. MP-M-8.1-1(Latest).

9. BASIC DETAILS OF BEARINGS:

PARAMETERS BEARINGS Governing

Specification/

Drawing

DE Side (N/NU332) NDE Side (6326)

Type Cylindrical Roller

Bearing

Deep Groove Ball

Bearing

As per firm‟s drawings

Basic dynamic load

rating (C)

860 KN (minimum) 212 KN(minimum) 225 KN (minimum)

As per IS: 3824- 2002/

ISO: 281 - 1990

Basic static load

rating (Co)

1060 KN(minimum) 225 KN (minimum) 212 KN (minimum)

As per IS: 3823-1988/

ISO: 76 - 1987

ID (nominal) mm ø160 ø130

As per firm‟s drawings

OD (nominal) mm ø340 ø280

Over all width mm 68 58

Radial clearance mm 0.340 to 0.370 mm

(N type) / 0.115 to

0.165 mm (NU type)

0.132 to 0.160 mm

(N type) / 0.071 to

0.114 mm (NU

type)


Maximum operating

temperature

100 °C 100 °C

L-10 life - - To be submitted by firm

Lubrication Oil-lubrication Grease lubrication List of approved

lubricants as

mentioned in MP.MI-15

(latest version)

Special feature Insulated bearing Insulated bearing As per firm‟s drawings

10. DETAILS OF BEARINGS TO BE FURNISHED BY VENDOR:

i. Two sets of signed dimensional drawings of bearings with significance of each suffix/prefix, accuracy class, tolerances & suitability of application are to be submitted.

ii. Details of bearings i.e. number of roller and size, pitch circle diameter, type of cage guidance, cage material (brass/bronze), riveted or rivets less, gap between cage and rollers, radial & axial clearance etc. to be submitted.

iii. Details mentioned in Para 8.0, for the bearings to be submitted.

iv. Details of Heat treatment process including stage wise like heating, quenching, tampering, hardening etc. to be submitted.

v. Material specification, hardness and surface finish level for inner ring, outer ring, cage & rollers.

vi. Detailed calculation of L-10 life as well as dynamic & static load capacity of proposed bearing.

vii.QAP as mentioned in Para 7.0

viii. Any other relevant information.

11. TESTING AND INSPECTION:

11.1 Type Test:

Type tests are required on initial approval, change of design and change of manufacturing processes.

11.2 Acceptance Test:

This test is to be conducted for the system other than prototype for purchase inspection.

This is the subset of type test mentioned above. Following test is required to be conducted

for Acceptance test plan.

The sampling plan as per IS: 2500, Pt.I, General Inspection Level-II should be adopted for

selecting the samples against the lot and determining the acceptance/rejection of lot based

on Acceptance test result.


11.3 The table given below lists the summary of parameters/tests to be conducted during Type Test and Acceptance Test.

A. For Drive End Bearing:

SN PARAMETERS DRIVE END (DE)

Type Tests (Bearing in

dis-assembled

Condition)

Routine Tests (Bearing

in assembled

Condition)

1 Outer Ring

OD size OD roundness*

OD taper/Difference*

OD square ness w.r.t. face*

Width

Face parallelism

Face flatness*

Raceway roundness X

Raceway taper X

Eccentricity of OD w.r.t.

Track*

X

Surface finish on track X

Surface finish on face*

Surface finish on OD*

Track width* X

Track roundness X

Track taper X

Hardness (HRC)*

Insulated coating on the outer ring face and external diameter coating thickness*

Corner Radius-

Axial direction

Radial direction

2 Inner Ring

Bore size Bore roundness

Bore taper

Bore square ness w.r.t. face

Width

Face parallelism

Face flatness

Track roundness

Track taper

Eccentricity of bore w.r.t.

Track




dis-assembled

Condition)


in assembled

Condition)

Surface finish on track

Surface finish on face

Surface finish on bore

Hardness (HRC)

Corner Radius

Axial direction

Radial direction

3

Roller

OD size X

OD roundness X

Lot dia. variation in bearing X

Length X

Surface finish OD X

Hardness (HRC) X

4 Cage

Outer dia. X

Inside dia. X

Width X

Pocket width X

Surface finish

Pocket dia. Pocket face

X

Hardness (HB) X

5 Bearing in assembled condition Radial clearance Radial run out- OR X

Radial run out- IR X

Interchangeability (OR & Roller cage assembly with IR)

Weight 6 Other Special Test

Magnetic Particle Test (MPT)/Ultrasonic Test (UT)

X




dis-assembled

Condition)


in assembled

Condition)

Destructive tests including chemical analysis of materials of different elements and microstructure of rings & rollers etc. #

Note : Before conducting Destructive Test on the bearing, * marked test indicated in Sl. No.1 above will be conducted on the bearing earmarked for Destructive Test during type test.

X

Insulation Resistance of Outer ring (Between OD and Face)

Note : Vendor shall carry out in-process test and inspection before insulation for those parameters which are not measurable in final product in order to prevent damage to Insulation of outer race. Vendor shall furnish internal reports on measurement and inspection to the routine inspecting agencies. B. For Non-Drive End Bearing:

SN PARAMETERS NON-DRIVE END (NDE)


disassembled

Condition)


in assembled

Condition)

1 Outer Ring

OD size OD roundness*

OD taper/Difference*

OD square ness w.r.t. face*

Width

Face parallelism

Face flatness*

Raceway roundness X

Raceway taper X

Eccentricity of OD w.r.t.

Track* X

Surface finish on track X

Surface finish on face*

Surface finish on OD*

Track width* X

Track roundness* X




disassembled

Condition)


in assembled

Condition)

Track taper* X

Hardness (HRC)*

Insulated coating on the outer ring face and external diameter coating thickness*

Corner Radius-

Axial direction

Radial direction

2 Inner Ring

Bore size Bore roundness

Bore taper/Difference

Bore square ness w.r.t. face

Width

Face parallelism

Face flatness

Track roundness

Track taper

Eccentricity of bore w.r.t.

Track

Surface finish on track

Surface finish on face

Surface finish on bore

Hardness (HRC)

Corner Radius-

Axial direction

Radial direction

3

Ball

Size (Dia./Length) X

Lot dia. variation in bearing X

Surface finish on OD X

Hardness (HRC) X

4 Cage

Outer dia. X

Inside dia. X

Width size X

Pocket Length Width X

Surface finish-

Pocket dia. Pocket face

X

Hardness (HB) X

5 Bearing in assembled condition




disassembled

Condition)


in assembled

Condition)

Radial clearance Radial run out- OR X

Radial run out- IR X

Interchangeability (OR & Roller cage assembly with IR)

Weight 6 Other Special Test

Magnetic Particle Test (MPT)/Ultrasonic Test (UT)

X

Destructive tests including chemical analysis of materials of different elements and microstructure of rings & rollers etc.

Note : Before conducting Destructive Test on the bearing, * marked test indicated in Sl. No.1 above will be conducted on the bearing earmarked for Destructive Test during type test.

X

Insulation Resistance of Outer ring (Between OD and Face)

Note: Vendor shall carry out in-process test and inspection before insulation for those parameters which are not measurable in final product in order to prevent damage to Insulation of outer race. Vendor shall furnish internal reports on measurement and inspection to the routine inspecting agencies.

12. FIELD TRIAL:

On successful Prototype tests and fitment in the locomotive, the specified number of Quantity of bearings will be subjected to field trials for specific period as indicated at Para 8(iv).

13. MARKING:

13.1 Packed containers shall be marked with the following. a) Manufacturer‟s name or trade mark b) Code or direct indication of month and year of manufacture. c) Designation of the bearing defining the type and dimensions, radial internal clearance

etc. d) Quantity.


13.2 Each bearing shall carry on the side face of its inner and outer rings visibly and indelibly the following markings –

a) Manufacturer‟s name/ code/ trade mark. b) Complete Designation of the bearing. c) Date code of manufacturing of the production lot.

14. PROTECTION AGAINST CORROSION:

The type of protection against corrosion shall be decided by the manufacturer depending

on the packing material used. Under proper storage conditions the anti-corrosive

treatment shall be effective for at least 12 months in order to ensure a satisfactory

functioning of the rolling bearings, unless otherwise required by the RDSO.

15. PACKING:

The complete bearing assembly in unit shall be packed individually in suitable card board carton and several pieces may be packed together in suitable wooden containers depending on the size. The packing shall carry company„s trademark, part number and Packaging date, and shall conform to international norms so as to protect the product during the transit handling and storage. In the event of supply to various sheds, the bulk packing must not be opened and bearings in multiple of bulk packing should only be supplied.

16. FIELD TRIAL SCHEME:

Field trial of bearings (DE & NDE) shall be carried out and performance to be monitored

as per following format:

SN Loco No.

TM Make & Model No.

TM No./ Location

Date of fitment of TM in Loco

Date of failure, if any

Remarks

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