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GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

SCHEDULE OF TECHNICAL REQUIREMENTS FOR VENDOR APPROVAL FOR MANUFACTURE AND SUPPLY OF DYNAMIC BRAKE HATCH

ASSEMBLY (Complete Assembly Including Grid, Motor & Fan) FOR 4000/4500hp HHP LOCOMOTIVES

STR No. – MP.STR.EM.02.02.12 (Rev.- 00 01 ) May’ 2015

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RESEARCH DESIGNS & STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW-226 011

STR No. MP.STR.EM.02.02.12(Rev.-01) May‘2015

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SCHEDULE OF TECHNICAL REQUIREMENTS FOR VENDOR APPROVAL FOR MANUFACTURE & SUPPLY OF DYNAMIC BRAKE HATCH ASSEMBLY (Complete

assembly including Grid, Motor & Fan) FOR 4000/4500hp HHP LOCOMOTIVES 1. Scope:

This Schedule of Technical Requirements (STR) is issued to determine the qualification criteria for the manufacturers of Dynamic Brake Hatch Assembly (Complete Assembly Including Grid, Motor & Fan) for 4000/4500hp High Horse Power (HHP) Diesel Electric Locomotives to Indian Railways. This STR is also applicable as qualification criteria for manufacturers offer who wish to supply Roof Mounted Forced Cooled DBR hatch Assembly with Short Hood for ALCO Locomotives complying to DLW Purchase Specification No. DEL/SPN/217(Rev.-01) and relevant drawings indicated therein.

2. General Requirement

The qualifying firm should be an ISO certified company and should have a well structured system for the following:

a) A system of regular submission of rejection details of material giving rejection rate,

cause of rejection, corrective action taken etc. on quarterly basis. b) The firm shall have a system of documentation with respect to rejection by the

customer, warranty replacement and failure of items supplied by them during service.

c) The firm shall have system of recording the plant, machinery and control equipments remaining out of service, nature of repairs done etc.

d) Established system for calibrating the testing and measuring equipments through NABL accredited lab.

e) The firm shall have a system of easy traceability of the product from manufacturing stage to finished product stage.

3. QAP and Inspection Plan:

The tenderer firm should have a well-defined Quality Assurance Plan (QAP) in accordance with RDSO’s Guidelines for Vendor approval (No. MP-G-7.1-1, latest version) for products offered to be supplied by them. The QAP shall be prepared as per the guidelines contained in document no.QM-RF-7.1-3 which is given under Section-VII of online vendor registration form at RDSO website. The tenderer firm shall furnish copy of QAP alongwith offer vendor registration application. The QAP shall also include test procedure/standards and acceptance limits followed during stage manufacture of DBR fan & motor assembly. In general, the information to be furnished by the tenderer firm in the QAP is detailed at Annexure-I. The submitted QAP will require approval of RDSO.

4. Evaluation/Qualification criteria of the firm: Offers from Proven manufacturers of Dynamic Brake Hatch Assembly, who have experience in manufacture of Resistor Grids, DC Blower Motor & Fans shall be acceptable such that:

STR No. MP.STR.EM.02.02.12(Rev.-01) May‘2015

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4.1 The successful tenderer firm shall be in the field of manufacturing and supply of either Resistor Grids (for high power dissipation) or DC Blower Motor or both. The firm shall submit supply details and evidence of satisfactory performance of it‘s equipment alongwith the offer application. The manufacture of fan blades, if sub-contracted, shall be from a proven foundry conforming to ISO:9001. The firm shall submit QAP of the fan blade also. The foundry may be undertaken for inspection by RDSO, if required.

4.2 Grid and motor both should be interchangeable with existing motor/grid running on

locos. 4.3 DB hatch assembly should be compatible with all the AC-AC traction system put on

HHP locomotives. 4.4 In case the firm do not manufacture it‘s own motor, the motor shall necessarily be

sourced from the firms which are already supplying to the existing RDSO vendors of DB hatch assembly.

4.5 In case of overseas supplier firm, the firm shall submit an indigenization plan with the

offer application. Inspection of overseas premises is also mandatory and shall be got done through any agency nominated by Indian Railway.

4.6 All assemblies and sub-assemblies shall be developed and test procedure followed

as laid down in the STR. In case, firm offers proposes a superior product requiring any deviation, the same shall be evaluated by RDSO based upon merit of the design.

5. Infrastructure Eligibility Criteria: 5.1 Machinery & Plant required for manufacture of the equipment is furnished at

Annexure-II. This list is for general guidance only and tenderer firm shall submit a detailed list of in-house manufacturing equipment to IR for evaluation as a part of compliance to this STR format of which is attached at Annexure-IV. All critical final machining operations shall be carried out on CNC machine, preferably in single setting.

5.2 Final Product Testing: The tenderer firm shall offer give prototype inspection

call for Dynamic Brake Hatch Assembly for HHP locomotive conforming to following EMD documents as tabulated below:

Sub-assembly name Governing specification Resistor Grids EDPS - 498 with amendment to Para 6.1 for 4500 HP loco

as below: Max Grid Power : 413 kW Max Grid Current-HOT: 586 A

DC Blower Motor EDPS-303, MI - 4104 (page-15 & 16)

Aluminium Casted Fan Blade & Hub

EDPS-175 & EDPS-2418 EDPS-332, EMS-302, ETI-827

Other Accessories As per Drg. No.10631909

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Type Test comprising the list of tests that shall be carried out on various sub-assemblies and the relevant governing specification (EMD Document) for those tests is given in Annexure –II. The tests with "*" (asterisk mark) indicated are covered under Routine Test to be conducted on each unit during serial production. The firm must have the required test equipment/facilities to carry out these tests. An indicative list of test equipment required is given at Annexure – III.

Firm shall submit alongwith their offer application the details of such facilities available with them as a part of compliance to this STR. However, if the tenderer firm proposes an alternative test set up for conducting the type/routine tests, the complete details of such equipment shall be sumitted to RDSO for scruitiny and evaluation of the alternative test equipment used on their test bed. Special tests that are to be done only during type test can be conducted through an external NABL accredited lab with prior approval of RDSO.

5.3 The complete type test of the DBR fan & motor assembly shall be conducted by

RDSO/DLW representative(s) at the premises of the firm / sub-vendors using their test facilities. The firm shall facilitate all the tests to be conducted.

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Annexure- I

1. Information to be furnished in QAP:

The firm shall prepare a Quality Assurance Plan (QAP) before approval is sought and submit the same as part of compliance to this STR. The QAP of Dynamic Brake Hatch Assembly shall include Resistor Grid, Blower Motor and Aluminium casted Hub & Blade. The QAP shall be a comprehensive document covering the following aspects:

• Complete process Flow Chart covering all steps of process of manufacture for an

individual product (or for a family of products if the process is same) shall be clearly enlisted as a part of QAP.

• The following details of machines used for all the steps of machining operations should be included:

Make and model of the machine. Accuracy. Details of machining operations.

• Details of Jigs and fixtures wherever used, during manufacture should be furnished

along with the manufacturing process.

• List of critical parts, materials and processes affecting reliability to control the effectiveness and quality of product.

• Process specification for the dip and bake or impregnation and bake process must be provided in the QAP. Details of the material utilized in the winding assembly must be provided.

• Process of brazing adopted for preparing grid terminals must be provided in the QAP.

• Details of sub vendors: The names of the items to be manufactured from sub vendors to be furnished in the QAP.

• Sources of critical parts & raw materials affecting reliability and quality of product.

• Details of inspection and testing on Incoming Material, stage inspection and inspection of final finished product shall be furnished in the QAP.

All the above information shall be given in the QAP which shall be approved by RDSO. This shall be treated as one of the basis for the approval of manufacturing of the DBR fan & motor assembly.

2. In addition, the sub-vendor shall have all the requisite infrastructure/facilities for

manufacturing and testing of the item which they manufacture under the control of tenderer firm.

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Annexure-II List of Manufacturing Facilities and Testing

The following is the indicative list of machineries and plant facilities as well as testing to be conducted on the assembly. The capacity of the machines shall be suitable for manufacturing the required job. The firm shall indicate against each operation in the QAP, the capacity of the machine needed against the available machine capacity. 1. MOTOR

1.1 List of Manufacturing Facilities

1.1.1 Machine Shop

a) CNC Rotor turning lathe b) Double headed facing and centering M/c c) Radial drilling machine d) Universal Milling M/c e) Shearing M/c

1.1.2 Press shop

a) Hydraulic press b) Fly Press c) Surface grinder machine d) Stator notching press e) Packeting press f) MIG/ TIG welding M/c g) Induction brazing machine

1.1.3 Tool Room / Machines for Miscellaneous Work Varnish Spray booth/paint booth. 1.1.4 Winding Shop:

a) Brazing unit, 75 KVA stud brazing unit b) Baking Oven (Min. Capacity of 48 KW, 3-Ph) with automatic temperature

control (Max. Temperature range 400 ºC) c) Vacuum pressure impregnation plant (with Min. Pressure Capacity of 7± 0.5

bar and Min. Vacuum capacity 0.07 bar) d) Coil winding machine e) Coil spreading M/c f) Coil Moulding Press M/c g) Automatic Coil Forming h) Looping & taping M/c for stator winding i) Induction Brazing M/c for Lead connection

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j) Stands for winding of stator k) Stand for rotor l) Facilities for annealing of Leads m) Air conditioning room for winding insulation of stator coils. n) Surge comparison tester

1.1.5 Machines for Assembly Shop

a) Universal hand press for pressing of bearings. b) Dynamic balancing machine c) Induction brazing M/c for stator Lead. d) Normal spray painting and facilities for masking and finishing.

1.2 List of tests covered under Type Test

The facilities for conducting these tests are mandatory with the firm seeking

approval for DB hatch equipment unless otherwise stated.

SN Tests on Blower motor fitted with fan

Concerning Specification

Remarks

1 Bearing

EDPS-303: Para 5.5 As per MI- 4104: • Commutator end bearing = 908198 • Fan end bearing=907831

Documentary proof

2 Direction of Rotation of motor

EDPS-303: Para 6.2 CCW from commutator end Visual check

3* Dielectric Test / HI-Pot of motor

EDPS-303: Para 7.1 (at 2400V AC for 1 min)

4* Insulation Resistance of motor

EDPS-303:Para 7.2 & 13.1 (at 1400V DC)

5* Commutation Test EDPS-303: Para 10.4 Check for sparking during over speed

6 Insulation Class EDPS-303: Para 13.1, 14.2 & 15.1: Class F or better

Supplier’s acceptance.

7* Dynamic Balancing Armature Assembly Fan Assembly

EDPS-303: Para 15.3 MI-4104: max. unbalance = 360 mg-m max. unbalance = 2160 mg-m

Documentary proof

8* Over Speed Test EDPS-332: Para 3.5.3 1.15*1650 = 1897.5 RPM for 2 minutes

9

Cold resistance measurement & Temperature Rise Test of motor

MI-4104: @ 75°C • Armature : • Series field: • Interpole field:

EDPS-303: Para 19 • Armature • MP Field Coil + IP • Commutator

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10 Fan Performance & Air Flow Measurement

EDPS-332: Para 3.8 EDPS-498: Para 8.0 (As per EMD Curve)

Test shall bedone on windtunnel basedsetup per IS3588 / BS 848(latest version)

11* Noise measurement EDPS-332: Para 3.9.2

12 Unit Weight of Fan & Hub, Motor, and Bracket

13*

• Visual Inspection & Dimensional Check,

• Blade tip clearance from frame

• Maximum fan height of roof-mounted fans from the mounting surface

As per Drawing no. 2801444 E for motor, 8324008 H for bracket, MI- 4104: min. = 1.6mm EDPS-332: 260.35 mm

14*

Commutator eccentricity (measured over C-Brush)

MI- 4104: TIR-Cold: 0.03mm TIR-Hot: 0.05mm

15

Shock Loads & Vibrations test for fan assembly

EDPS-332: Para 3.4

Either shock Loads & Vibrations test OR FEM analysis shall be done from Govt. approved lab. and submit report

16

Fan Guards Loading & its Shock Loads & Vibrations test EDPS-332: Para 3. 6.2.2

To be substantiated through design strength calculation

2. RESISTOR GRIDS:

2.1 List of Manufacturing Facilities

a) Resistance strip corrugation (Element forming) machine. b) Hydraulic Press & Die for Embossing of resistor material. c) Spring clip / Holding clamps forming machine. d) Induction brazing using electric induction heater for Ag brazing of terminals. e) Insulator (DMC material) development.

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2.2 List of tests covered under Type Test

The facilities for conducting these tests are mandatory with the firm seeking approval for DB hatch assembly unless otherwise stated.

S.

No. Tests on Resistor Box : Concerning Spec. EDPS 498 Remarks

A. Environmental Test 1 VIBRATION TEST Para 5.3

Report may be submitted from Govt. approved lab

2 MECHANICAL SHOCK TEST Para 5.4 3 DUST TEST Para 5.5 4 MOISTURE RESISTNCE Para 5.6

B. Electrical Test

1* IR Para 5.5: min 1MΏwith 500V Megger

2

ELECTRICAL REQUIREMENTS • Max. Grid power • Max. Grid current-HOT • Max. DC volts across

resistance

• Max/Min Grid Resistance – Cold

• Assumed R Hot/R Cold

Para 6.1: 413 kW (4500HP) 586 A 2700 V As per Drg. Nos. -10634215B(non fan tap) and 10634216 B (fan tap) 1.10 max.

Excluding cold resistance value check, for evaluation of other parameters one complete set of DB Hatch assembly shall undergo temperature rise test and performance evaluation for 30 days at nearby shed after mounting on loco subject to dispatch clearance from RDSO. See note below for acceptance criteria.

3* HIGH POT TEST Para 6.3:

4000V AC for 1 minute.

4 WARPAGE TEST Para 10.9.1

To be conducted on ribbon, when resistance material used is from different supplier other than proven one (VDM/Kanthal).

C. Mechanical Test 1*

VISUAL INSPECTION

• Rating plate • Insulator type • Ribbon layout • Supplier of

ribbon • Terminal

Brazing technique

Resistance material for ribbon to be sourced from VDM/Kanthal.

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2 MECHANICAL SUPPORT provided by insulator to the terminals & the ribbon

Para 7.1 Supplier’s acceptance

3 LIFTING Para 7.2 4* DIMENSIONS Para 7.3 Non fan tap: 10634215 B,

Fan tap: 10634216 B, 10631909.

5 WEIGHT Para 7.5 Max. 300 Lbs

6 DRAWING REQUIREMENTS Para 9.0 Note: In general, at full load condition during self load box test of loco, grid temperature

after stabilization usually remains in the range of 280-300°C with an average air flow through grids 10.6m/s under atmospheric ambient of 33°C. However, for safe operation, the maximum allowable element temperature at any section of grid shall not exceed 330°C.

3. FAN BLADE & HUB

3.1 The facilities for Aluminium casting of fan & hub shall be ISO-9000 certified.

3.2 Firm/Sub-vendor shall have facility to carry out validation testing of the design and

FEA analysis of the blades, hub, frame and structure. The firm or his sub-vendor shall have strain gauge testing machine and Universal testing machine.

3.3 The firm/sub vendor shall have following testing facilities:

• Universal Testing Machining of 40 Ton capacity with graphical recording facilities

for conducting tensile tests. • Direct reading Hardness Testing of capacity 95-500BHN. • Impact Testing machinery (Charpy V-notch) of 0-300 joules capacity for

conducting impact test with facilities for notch cutting & undertaking this test at subzero temperature as per the specified standard.

• Shadowgraph facilities for assuring correct notch profile and dimension for impact test specimen.

3.4 The Qualification of the blade manufacturing procedure is to be established and

maintained by periodic evaluation of individual fan blade structure through test stipulated below. Facilities to conduct those tests should be available with the vendor, sub-vendor or else may got done through NABL accredited laboratory.

3.5 The fan blade and hub shall be manufactured as per EMD part no. 9525578 and

9518871 respectively.

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List of tests covered under Type Test

Facilities to conduct these tests shall be available with the blade/hub manufacturer or can be got done through an NABL accredited laboratory.

SN Tests on Fan Blade (EMD part no.: 9525578)

Concerning Specification (Acceptance Criteria)

Remarks

1* AERODYNAMIC REQUIREMENTS: Blade dimension & profile check

EDPS 175: Para 2.1 EMD part no.: 9525578

Blade profile to be submitted

2*

X-RAY EXAMINATION / RADIOGRAPHIC TESTING Radiography is to be evaluated according to ASTM-E155. Acceptance Limit is of level-I:

• Gas holes • Gas Porosity • Shrinkage

EDPS 175: Para 2.2.1 Test no.1 Para 5.5 of ETI 827, Acceptance limit level – III (of Aluminium association standards AA-CS-M5-&71)

Radiography report may be submitted from Govt. approved lab. 100% testing to be done as a part of routine test.

3

SECTIONING & EXAMINATION OF BLADE ROOT AREA.

• Chemical analysis • Mechanical Properties

• Tensile Strength • Yield Strength • Elongation • Hardness

• Micro Structure:

EDPS 175: Para 2.2.1 Test no.3 Clause 2 of EMS 302: 356-T6 Clause 4 of EMS 302: 356-T6 ” ” ” ” Para 5.4 of ETI 827

Report from Govt. approved lab. may be submitted

4* DYE PENETRATION TEST EDPS 175: Para 2.2.1 Test no.4

Visually check on unfinished cast blade

5 BLADE SURFACE QUALITY EDPS 175: Para 2.2.3 Visual check of unfinished cast blade

6* MOUNTING BASE SURFACE OF FAN BLADE

EDPS 175: Para 2.2.4 (Inspection gauge for 48” blade)

Visual check of finished blade on jig/fixture.

7* BLADE LOT IDENTIFICATION EDPS 175: Para 3 Visual check SN Tests on HUB

(Part No 9518871) Concerning Specification EAI 2418 (Acceptance Criteria)

Remarks

1*

X-RAY EXAMINATION / RADIOGRAPHIC TESTING Radiography is to be evaluated `according to ASTM- E155. Acceptance Limit is of level-I:

• Gas holes • Gas Porosity • Shrinkage

Cl. 2 at page 1 of EAI 2418 At area 1 & 2 : Level-A At other areas : Level-C Para 5.5 of ETI 827, Acceptance limit level –III (of Aluminium association standards AA-CS-M5-&71)

Radiography report may be submitted from Govt. approved lab.

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2 CHEMICAL ANALYSIS

Cl. 3 at page 2 of EAI 2418 Clause 2 of EMS 302: 356-T6 Para 5.4 of ETI 827

Report from Govt. approved lab. may be submitted.

3

MECHANICAL PROPERTIES

• Tensile Strength • Yield Strength • Elongation • Hardness

Cl. 4 at page 2 of EAI 2418 Clause 4 of EMS 302: 356-T6 ” ” ” ”

Report from Govt. approved lab. may be submitted.

4

VISUAL POROSITY: (Porosity uncovered by Machining) Visual inspection of machined surface on 100% area.

Cl. 5 at page 2 of EAI 2418

Visual check

5 Die Penetration Tests 100% quantity 6 Dimensional Check 100% quantity

4. Calibration of the Testing/ measuring equipments should be done at least once in a

year unless stated otherwise. 4.1 Inspection staff conducting non-destructive testing shall be adequately trained and

qualified by recognized agency and shall have adequate experience.

4.2 Staff conducting tests like chemical analysis and mechanical properties shall have adequate skill of components and shall have under gone sufficient training. Skill of such staff shall periodically be qualified by making them carry out tests in blind samples.

4.3 In addition to motors (2 nos.), Resistor Grids (6 nos. Non fan tap & 2 nos. Fan tap),

supplier has to provide a list of accessories (such as sheets, pipes, cables, box, etc.) as per drawing no. 10631909 (latest revision) which shall also be checked.

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Annexure-III 1. Test bed equipment for Type / Routine test of Dynamic Brake Hatch Assembly: 1.1 A test setup shall generally be based on state of the art technology. Details of

facilities and major equipment needed for conducting Type/Routine test as per Annexure-II above are furnished below. All items are mandatory and shall be available with the firm at the time of application.

1. Variable voltage DC drive panel as a power supply source of appropriate range

with display arrangement showing Voltage, Current, RPM. 2. Wind tunnel based test setup as per IS 3588 or BS848. 3. Anemometer 4. Manometer 5. Digital Multimeter(s), (clamp type) of adequate measurement facility & suitable

range. 6. Digital Micro Ohm meter 7. Speed (RPM) sensor (contact less type) 8. Contact less type digital thermometer or min. 8-channel Temperature Scanner 9. Hg bulb thermometer 10. Insulation Tester (Megger) of suitable capacity. 11. Hi-pot tester 12. Noise Level Meter 13. Vibration meter 14. Vernier caliper, screw gauge, filler gauge, dial indicator, micrometer, micrometer

outside, bore micrometer, Bore dial gauge, Vernier height gauge, Ultrasonic thickness gauge of suitable range for dimensional check.

15. Sprit level with angle setter 16. Jigs/fixtures for blade profile and mounting base measurement.

Calibration of the testing / measuring equipments should be done atleast once in a year unless stated otherwise. Supplier Firm shall demonstrate that qualifying fixtures, test equipments, gauges etc. are calibrated and certified to international standards.

ANNEXURE- IV (Format QM-RF-7.1-1)

ANNEXURE TO STR (Details of M&P/T&P available with the firm)

Name of Firm: ………………… ………… Factory address: ………………………………………………. Item: ……………………………………….. STR No.: ………………………………………………….

S. No.

STR para

no. Requirement of M&P/T&P as

per STR Details of the M&P/T&P available with the firm

Name of M&P/T&P

Range /Capacity

of M&P/T&P Name of M&P/T&P Model Make Machine

No. Year of

built Range/

Capacity Proof of

ownership

1. 2.

UNDERTAKING OF THE FIRM “I hereby give an undertaking that if at any time after approval is accorded, some machinery and plant (M&P/T&P) is found deficient and my firm had failed to inform the RDSO, with reasons for the same, then it may be presumed that proof of ownership was incorrect. Suitable action against the firm may be initiated by RDSO immediately including delisting of the firm. Firm’s registration/approval for the item(s) given by RDSO may be withdrawn with immediate effect. Date: Signature Place: Name in capitals & Designation

Stamp of the firm Remarks: i) Annexure to STR (Details of M&P/T&P available with the firm) for the item applied for / approved by RDSO should be furnished by

vendor completely as per the above format QM-RF-7.1-1 alongwith proof of ownership in the form of affidavit on 100/- Non-judicial stamp paper duly notarized (Original copy may be submitted during field assessment).

ii) In addition to affidavit, for proof of ownership of M&P/T&P available with the firm, firm may also furnish the documents available

with the firm, if any. Further, firm may also be asked to submit the documents as deemed necessary. It is mandatory to inform the RDSO through FAX (followed by confirmation copy through courier/speed post as soon as any machinery is removed from the firm’s premises (even for repair etc.) or upgraded. RDSO should be informed again, when is brought back and made operational.

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