GOVERNMENTOFINDIA MINISTRYOFRAILWAYS SCHEDULEOFTECHNICALREQUIREMENTSFORMANUFACTUREANDSUPPLYOFRADIATOR ASSLYToEMD/DLWPARTNo10631855/17450408&10631856/17450410forHHP LOCOMOTIVES No.MP.STR.ES.01.09.13,(Rev.

00) August2013

Issuedby: MOTIVEPOWERDIRECTORATE RESEARCHDESIGNSANDSTANDARDSORGANISATION MANAKNAGAR,LUCKNOW226011

 SCHEDULEOFTECHNICALREQUIREMENTSFORMANUFACTURE,SUPPLYOFRADIATORASSYTO EMD/DLWPARTNo10631855/17450408&10631856/17450410forHHPLOCOMOTIVES 1.SCOPE The Locomotive radiator assembly is a very vital part of the locomotive and it needs to have very high reliability during the entire service of the locomotive. The Schedule of Technical Requirement (STR) mentioned hereunder is issued to serve as a guide to manufacturers (called the firm hereinafter) and shall be read in conjunction with the relevant drawings & specification MP.0.0500.01(Rev.03).Thefirmshallsatisfythemselvesofhavingcompliedwiththerequirements ofthelatestproductdrawingsandSTR. Thetechnicalrequirementsaremeanttoserveasguidelinesonlyandarenotexhaustive.

2.GENERALREQUIREMENTS 2.1 The firm shallhave currently validISO9001certificationissued by an approved agency with the activity desired clearly mentioned in the scope of certification. The firm shall have a Quality Manualindicatingtheextentofcontroloverproduction. 2.2 A system of regular submission of rejection details of material giving rejection rate, cause of rejection, corrective action taken etc. preferably on quarterly basis shall be followed by the firm. 2.3Thefirmshallhaveasystemofdocumentationinrespectofrejectionatcustomerend,warranty replacementandfailureofitemsuppliedbythemduringservice. 2.4 The firm shall have a system of recording the plant, machinery and control equipments remainingoutofservice,natureofrepairsdoneetc. 2.5 The testing and measuring equipment shall be duly calibrated and the validity of calibration shall be current and verified by physically checking the calibration certificate issued by the CalibrationAgencyfromwhomitwascalibrated. 2.6 The firm shall have a system of easy traceability of the product from manufacturing stage to finished product stage. Stamped identification marking with serial number of radiator shall be usedforthispurpose.

3.0ELIGIBLILITY: The firm shall have at least five year satisfactory performance experience in manufacturing & supplyingtheMBRofsamesizeorlarger/smallerinsizeofMechanicalBondedRadiatorsforusein stationary / moveable rail road equipments like Gen set application, earth movers/ excavators or Rail Engines to reputed Diesel Generator set / locomotive manufacturers viz. Cummins, San Engg., BEML,Mahendra,TELCOetc. 4.0QUALITYASSURANCEPLAN(QAP) Thefirm shall preparea Quality AssurancePlan(QAP) for all items for whichapproval is soughtand submit the same as a part of compliance with this STR & specification. The QAP shall be a comprehensivedocumentcoveringthefollowingaspects: i) Detailed Quality Control Organisation of the firm along with key personnel engaged in the QC function. ii)QualityAssuranceProcessofincomingmaterialsusedforthesubjectitems. 2

 iii) Process Flow Chart indicating process of manufacture for an individual product or for a family ofproductsiftheprocessissame. iv) Quality Assurance System Inspection process control & Testing Plan including stage inspections. v)Calibrationschemeandstatusofcalibrationofequipmentsusedinthequalityprocess. Details of the above aspects are described in the following paragraphs. The QAP shall be approved byRDSOandshallformthebasisoftheapprovalprocess. 5.0 QUALITYCONTROLORGANISATION 5.1 The complete organizational setup of the Quality control key personnel and officials along with theirqualificationandexperienceshallbefurnished. TheQualityControlorganizationshallbeheadedbyaseniorlevelofficialhavingadequatetechnical qualification,whoshalldirectlyreporttotheplantincharge. 6.0INCOMINGMATERIAL 6.1 A complete Bill of Material indicating all input material items required for manufacturing of the product, governing specification and their sources of supplies as approved by the firm in accordancewithClause7.4.1ofISO9001(2008)shallbefurnished.Testresultsofincomingraw materialwithreferencetoTestCertificateissuedbythesupplierandtheresultsofinternaltests carriedoutbythefirmforverificationshallbesubmittedasapartoftheQAP. 7.0PROCESSOFMANUFACTURE 7.1 Complete Process Flow Chart covering all steps of process of manufacture for an individual product (or fora family ofproducts if theprocess issame) shall beclearly enlisted asa part of theQAP.

7.2 The following details of machines used for all the steps for manufacturing the MBR Preparationsshallbeincluded:
o o o o Makeandmodelofthemachine Accuracy Detailsofmachiningoperations. Calibrationfrequencyfirmshallsubmitthedetailsofthecalibrationlastdoneanddue dates.

7.3 Machiningprocessshallbesuchthatallcriticaldimensions(i.e.headerplates&tanks)arefinal machined on CNC machining centres, preferably in a single setting or may be procured from anotherservicehavingsimilarfacilities. 7.4 DetailsofJigsandfixturesusedduringmanufactureshallbefurnishedmentioningthestepsof theprocess. 7.5 List of typical M & P required for manufacture is furnished in AnnexureI. The list is for general guidance only and actual manufacturing operations shall be submitted and got approved by thefirmasapartoftheQAP. 8.0QUALITYASSURANCEPROCESSINSPECTIONANDTESTINGPLAN 8.1 Complete Inspection and testing Chart covering all steps of process of manufacture for an individualproductincludingfinalinspectionshallbeclearlyenlistedasapartofQAP. 3

 8.2Thefollowingdetailsofmeasuringinstruments/equipments/jigs/fixturesusedformanufacturing thesubjectitematallthestepsofmeasurementoperationsshallbeincluded:
oMakeandmodelofthemeasuringequipment.
oAccuracy
oQuantitytobemeasuredandacceptablevaluerange. 8.3 Stage inspection detailing inspection procedure, inspection parameters, destructive / non destructivetesting.Recordoftestresultsofstageinspectionshallbeavailableandfurnished. 8.4 The listof Testing andMeasuring instruments areshown in AnnexureIIrespectivelyfor general guidance only. However the specific Testing & measuring instruments, gauges used by the firm willalsoformapartoftheQAP,whichshallbesubmittedandgotapprovedbythefirm. 8.3Dimensionalmeasurementsshallbemadebyaccuratemeasuringinstrumentspreferably3DCo ordinate Measurement Machines onprototype and on sample lots. The firm shall have the said facility with requisite accuracy in accordance with the dimensions of the jobs to be measured. MeasurementsshallbeincludedasapartoftheQAP.

 ANNEXURE1 A.MACHINERY&PLANT(M&P)FORMANUFACTURING Thefollowingistheindicativelistofmachiningfacilitiestobeavailablewiththefirm: E=EssentialV=VitalD=Desirable SN 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. Description Finmakingmachine Precisetubecuttingmachine Corebuilder Headerfixingmachine Bakingoven Tubeflaringmachine Uniformtubeexpandermachine Tubeannealingmachine CNCdrillingmachinesforheaders Toptankfixtures/Jigs CNCTurretmachineforsideframe CNCbendingmachineforsideframe TemplateGauges Torquewrench EOTcrane Paintbooth Weighingmachine Weldingmachines SpotWeldingmachines AirCompressor PedestalGrinder SurfaceGrinder PowerPress VMC HMC HydraulicPress FluxingBath ShearingMachines BendingMachines E/V/D E E E E E E E V V E V E D D E E D D D V V D D D D D E D D

B.LISTOFTESTINGFACILITIES 1 2 3 Calibration of the Testing / Measuring Equipments shall be done at least once in a year or prior,accordingtothecriticalityoftheequipment. InspectionStaffconductingnondestructivetestingshallbeadequatelytrainedandqualified byarecognizedagencyandshallhaveadequateexperience. StaffconductingtestslikeChemicalAnalysisandMechanicalPropertiesshallhaveadequate skill & competence and shall have under gone sufficient training. Skill of such staff shall periodicallybequalifiedbymakingthemcarryouttestsonblindsamples. 5

 Followingtestingfacilitiesshallbeavailablewiththefirmoralternativelymaybeoutsourced: ANNEXUREII A. SN 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. B.METALLURGICALANDCHEMICALLABORATORY: Manufacturer shall have facility to conduct metallurgical testing of the product in their premises or shallhavearrangementtogetitdonefromNABLlab. o Magnaflux/DyePenetrateTest(DPT)facilitiesforcheckingofsurfacecracks. o MagneticParticleInspection(MPI)facilitiesforcheckingsubsurfaceflaws. o C.PHYSICALLABORATORY: Manufacturershallhavefacilitytoconductphysicaltestingoftheproductintheirpremisesorshall havearrangementtogetitdonefromNABLlab. Metallurgical Microscope with magnification power up to 500x & metallographic sample preparationfacilitieswithappropriateaccessoriestotakephotographsofslides. Description Vibrationtestrigforthreeaxisupto15g WindtunneltestrigforheatdissipationasperISstandard Pressureimpulsetestingmachine Hotair&ColdWatercyclictemperaturetestingmachine Hotwater&ColdAircyclictemperaturetestingmachine InternalCorrosionTesting SaltSpraytestStand PressureTesting ChemicalTestingofnonFerrouselements SquarenessTesting SurfacePlate Airleakandwaterleaktestingfacilities PaintTestingFacilities VernierCallipergauge Heightgauges Go,Nogogauge Measuringtape TubesolderthicknessmeasurementM/c E/V/D D E E E E D V E D E E D V E E E E D