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Draft Specification for Motorrised bogie

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Draft Specification for Motorrised bogie Powered By Docstoc
					                                 SPECIFICATION
                                      FOR
           MOTORISED BOGIE COMPLETE FORWAG-9H 3-PHASE LOCOMOTIVES




                                         CLW/MS/3/SPEC/ELDO-Bogie/001
                                                  MAY 2012


           No. of pages                     8
           No. of Annexure                  1
           No of revision sheet            Nil
           Date                            ----




                                                         REVISION

             No.           Nil
           Page no.        --
            Date           --




                                                    Issued by:
                                        Dy. Chief Electrical Engineer/D-II
                                         Chittaranjan Locomotive Works
                                    Government of India – Ministry of Railways
                                              Chittaranjan – 713 331




PREPD BY         CHKD BY         REVIEWED BY      APPROVED   SPECIFICATION FOR MOTORISED   CLW/MS/3/SPEC/ELDO-
                                                     BY      BOGIE COMPLETE FORWAG-9H 3-    Bogie/001 (REV ‘Nil’)
                                                             PHASE LOCOMOTIVES                   MAY 2012
                 SPECIFICATION FOR MOTORISED BOGIE COMPLETE FOR WAG-9H
                                   3-PHASE LOCOMOTIVES

           1.0    Scope:
                  The specification covers the technical requirements for manufacturing,
                  assembling, testing and supplying of Motorised Bogie Complete for 3-Phase
                  Locomotives of WAG-9H Type. This complete Bogie shall be comprising of
                  Bogie Frame, Wheel Set, Brake Arrangement, Suspension Arrangement, Traction
                  Rod Arrangement, Traction Motor Suspension Arrangement, Pipe Arrangement,
                  Sand Box Arrangement, Step Arrangement, Bellow Arrangement, Makers Plate,
                  Traction Motor: FRA6068. Two numbers complete bogie to be required per loco
                  and to be manufactured, tested according to relevant drawing and specification.

           2.0    Technical Data:
                  Sl.    Description                                    WAG-9H
                  No.
                  1      Wheel Arrgt.                              CO-CO
                  2      Track-Gauge                               1676mm
                  3      Type of Bogie                             Fabricated
                  4      Supply of current                         25 KV.A.C.50Hz
                  5      Total weight of Loco                      133 t± 1%
                  6      Axle load (Max.)                          22 t± 2%
                  7      Bogie wheel base                          3700 mm (1850+1850)
                  8      Distance between bolsters                 12000 mm
                  9      Wheel dia (New)                           1092 mm
                  10     Max. tractive effort at start             53 t (620 kn)
                  11     Total horse power of Locomotive           4500 KW6000HP
                  12     No. of Traction Motors & Type             6 Nos. Type FRA 6068
                  13     Max. service speed                        100 Km/Hr.
                  13 (a) Max. Test Speed                           110 Km/Hr.
                  14     Traction Motor Voltage                    2180 V
                  15     T.M. Shaft out put                        850 KW
                  16     Length over buffers                       20.650 mm
                  17     Total width of Locomotive                 3130 mm
                  18     Ht. of panto in locked down position      4255 mm
                  19     Brake system                              Air,    Regenerating   &
                                                                   Parking
                  20       Traction Motor Mounting                 Axle hung nose suspended
                  21       Gear ratio                              5.1053
                  22       Min. radius curve negotiable            174 M.
                  23       Multiple operation                      2 Locos
                  24       Continuous Tractive Effort              560KN (36.7t)
                  25       Spring weight of the Loco body          88100 Kg
                  26       Possible upgrade of Loco body           90200 Kg
                  27       Sprung weight of the bogie (without 7700kg
                           motors)
                  28       Unsprung mass of one axle               3900Kg
                  29       Weight of the axle including the motors 4900Kg
                  Sl.      Description                             WAG-9H
PREPD BY         CHKD BY     REVIEWED BY   APPROVED   SPECIFICATION FOR MOTORISED   CLW/MS/3/SPEC/ELDO-
                                              BY      BOGIE COMPLETE FORWAG-9H 3-    Bogie/001 (REV ‘Nil’)
                                                      PHASE LOCOMOTIVES                   MAY 2012
                  No.
                  30         Wheel set mass (without motor)                 2750 Kg
                  31         Type of suspension                             Coil spring(Double coil)
                  32         Type of damping                                Hydraulic
                  33         Expected annual activity                       6570 hour
                  34         Total weight of motorised Bogie                22451Kg

           3.0    Operating environmental condition:
                  The environmental condition will be:
                  a) Maximum temperature }Stabled Locomotive under sun : 70ºC
                                           }On board working loco under suns: 55ºC
                  b) Minimum temperature                                     : -4 ºC

                  Humidity         : Up to 100% during rainy season.

                  Altitude         : Up to 1750 m above mean sea level.

                  Rainfall         : Very heavy in certain areas.

                  Atmospheric condition during hot weather: Extremely dusty and desert terrain
                  in certain areas. The dust concentration in air may reach a high value of 1.6
                  mg/m3.

                  Coastal area: The drive system shall be designed to work in coastal area in
                  humidity and salt laden and corrosive atmosphere. The maximum values of the
                  condition will be as follows:

                  a)       Maximum pH value                         : 8.5
                  b)       Sulphate                                 : 7 mg per litre
                  c)       Max. Concentration of chlorine           : 6 mg per litre
                  d)       Maximum conductivity                     : 130 micro Siemens/cm



           4.0    Motorised Bogie Complete to be manufactured as per list mentioned below:

                             LIST OF ITEMS WITH CONCERN SPECIFICATIONS

           SL. DESCRIPTION SPEC/DRG. No.                 QTY./LOCO CATEGORY                            REMARKS
           No.                                                     No.
               Motorised bogie IB011-00065               02 nos
               complete
           1   Bogie Frame     1209-01.112-001           02 nos.   R/9/0080
                               Guideline
                               No.WAG/9/Bogie/INSP/Stage
                               dtd.01.09.09

           2     Wheel Set           1209-01.111-001                    06 nos.
                 a) Wheel            1209-01.111-003                    12 nos.       U/9/0002
                 b) Axle             1209-01.111-002                    06 nos.       U/9/0001
PREPD BY         CHKD BY       REVIEWED BY   APPROVED   SPECIFICATION FOR MOTORISED       CLW/MS/3/SPEC/ELDO-
                                                BY      BOGIE COMPLETE FORWAG-9H 3-        Bogie/001 (REV ‘Nil’)
                                                        PHASE LOCOMOTIVES                       MAY 2012
               c) MSU            CLW/MS/3/201, 52, 49            06 sets         R/9/0107
                                 Drg.No: 1209-01.111-004
               d) Bearing DE     CLW/MS/3/032                    06 sets         R/9/0057
               e) Bearing NDE    -do-                            -do-            -do-
               f) Cable          CLW/ES/3/0045                   06 sets         P/2/0086
               Support Rail
               g) Axle Box       CLW/MS/3/003                    01 set          R/9/0108
               Arrgt./Comp       Drg. No: 1209-01.411-058
               with CRU
               h) Gear           MP.0.2800.19                    06 sets         0/9/0001
               i) Pinion         (REV.0.003.OCT’05
               j) Gear Case      1209-01.013-014                 06              R/9/0059
               Compt.
           3   Brake Arrgt.      CLW/MS/3/007                    06 sets         V/9/0001
               (TBU) & Safety    Drg. No: 1209-01.416-063                        T/9/0028
               Sling                                                             L/9/0032
           4   Suspension        IB011-00192
               Arrgt.
               a) Damper         CLW/MS/3/009                                    R/9/0010
                                                                                 (WAG-9)
               b) Helical        CLW/MS/3/008                                    R/9/0105
               Springs(Primary                                                   (9H)
               & Secondary)
               c) Chain          CLW/MS/3/118                                    S/9/0021
               d) Insulating     1209-01.415-15 &                                S/9/0010A
               Base              1209-01.315-16
               e) Neck Down      1209-01.315-006                                 L/9/0024
               Bolt
               f) Thread Bolt    1209-01.315-020
               g) Bolt           1209-01.315-017                                 R/9/0045
               h) Axle Holder    1209-01.315-018                                 R/9/0097
               i)Compensating    1209-01.415-011, 12, 025, 26,                   R/9/0095,
               Plate             29                                              96A
               j) Spacer         1209-01.415-007                                 R/9/0094
               k) Axle Guide     1209-01.115-004                                 R/9/009
               Comp with         1209-01.115-003                                 R/9/008
               spheribloc        RDSO/2007/EL/SPEC/0051
               l)Hardware for    BOM of drg. no:IB011-00192                      M/9/0003,7,
               suspension        CLW/MS/3/089                                    8,12,12A,13,
               Arrgt.            CLW/MS/3/090                                    28.
               m) Elastic stop   CLW/MS/3/010                  4+4 nos.          R/9/0012
           5   Traction Rod      1209-01.113-001               02 nos.           T/9/0030        .
               (Elastic Ring,    RDSO/2007/EL/SPEC/0053                          R/9/0092,05
               Housing, Push     (Rev. 0) June 2007                              S/9/0001,20,
               Pull Rod etc.)                                                    21
                                                                                 L/9/0024.
           6   Traction Motor    1209-01.118-001
               Suspension
               a) Holder for     1209-01.118-002                                 R/9/0007
PREPD BY       CHKD BY    REVIEWED BY   APPROVED   SPECIFICATION FOR MOTORISED       CLW/MS/3/SPEC/ELDO-
                                           BY      BOGIE COMPLETE FORWAG-9H 3-        Bogie/001 (REV ‘Nil’)
                                                   PHASE LOCOMOTIVES                       MAY 2012
                 Traction Motor
                 Suspension
                 b) F.S. All Steel   CLW/MS/3/089                                    M/9/0012
                 Lock Nut M24-
                 8
                 c) Hex Head         182-00018-010                                   M/9/0007
                 Bolt
                 M24x100-8.8
                 d) Hex Head         182-00019-011                                   M/9/0007
                 Bolt
                 M30x160-8.8
                 e) Torque Arm       1209-01.318-020                                 R/9/0091,08
                 Assly.              1209-01.218-003
                                     RDSO/2007/EL/SPEC/0051
                 f) Spacer           1209-01.218-003                                 T/9/0013
           7     Maker’s Plate       1209-01.410-002                                 S/9/0039
           8     Step                1209-06.242-008                                 R/9/0079
                 Arrangement
           9     Piping              CLW/MS/3/053,029,068                            S/9/0008,027
                 Arrangement         IB011-00205,247,                                T/9/0002
                                     1209-18.406-053                                 S/9/0014
           10    Traction Motor      4TMS.096.080 Or                 06 nos.         5700/004 Or
                                     4TMS.096.081                                    5700/005
           11       Bogie body       IB011-00513
                    connection
                 a) T.M. Bellow 1209-01.018-009                      06 nos.         R/9/0088
                 Assly.          CLW/MS/3/006                                        S/9/0002
                 b) Fixing cable CLW/MS/3/006                        06 nos.         S/9/0002

                 C)Hardware for      BOM of IB011-00513                              M/9/0010,12,
                 damper fixing                                                       07.
                 body-side
           12    Sand Box            1209-01.138-031                 01 set (08      R/9/0049
                 Arrangement                                         nos.)
           13    Set of cable        CLW/ES/3/0045                                   P/2/0086
                 cleat with DIN
                 rail for TM
           14    Al Cable cleat      CLW/ES/3/0039                                   P/1/0086
                 for TM
           15    Cable (Single &     CLW/ES/3/0458 &                                 N/0/0029
                 Double core)        CLW/ES/3/0459
           16    Cable Lug           CLW/ES/3/0130                                   P/0/0036



           5.0    QAP/Approvals/Experience of the products/manufacture
                  a)   The manufacturer must be certified with ISO 9001:2008 (the scope of the
                       ISO Certificate has to specifically refer to the manufacturing of the full
                       range of products).

PREPD BY         CHKD BY      REVIEWED BY   APPROVED   SPECIFICATION FOR MOTORISED       CLW/MS/3/SPEC/ELDO-
                                               BY      BOGIE COMPLETE FORWAG-9H 3-        Bogie/001 (REV ‘Nil’)
                                                       PHASE LOCOMOTIVES                       MAY 2012
                  b)       Test Reports/certificates from accredited laboratory/institute for the similar
                           or identical design system shall be submitted.
                  c)       Credentials/Experience of the manufacturer: The supplier shall provide
                           reference of all those projects executed by them for various applications of
                           the same or similar systems during the last 5 years.
                  d)       The firm shall submit two copies of Quality Assurance Plan (QAP)
                           outlining all aspects of quality control required to obtain a quality product
                           for approval of CEE/CLW.
                  e)       The manufacturer shall proceed for manufacturing of motorised bogie
                           complete only after approval of QAP. The firm shall follow the
                           stipulations of QAP strictly.

           6.0    Source of components / hardware / lubricating oil / adhesive etc.
                  a)     All components to be procured from CLW approved sources. If not
                         available, RDSO approved source may be considered.
                  b)     All standard hardware items to be procured from CLW approved source.
                  c)     Records of purchase documents and test certificate of components to be
                         maintained and to be produced during inspection.

           7.0    Manufacturing process:
                  a)   Motorised bogie frame complete to be manufactured according to related
                       drawings/specifications and instruction manual ( Anexure-1). During
                       manufacture of prototype motorised bogie complete, the vendor is required
                       to co-ordinate and maintain liaison with CLW/CRJ or purchaser for any
                       clarification required with regard to drawing/specification, manufacturing
                       and testing etc.
                  b)   During manufacture any assembly of prototype motorised bogie complete
                       and changes in the design considered necessary shall be identified by the
                       Purchaser/CLW and these changes shall be incorporated on all the
                       motorised bogie complete manufactured by the firm.

           8.0    Deviation (s):
                  If deviations from original design, material specifications, dimensions etc. are
                  desired by the tenderer, specific proposals with reasons shall be submitted to
                  CLW or purchaser for approval. Commencement of manufacture shall not be done
                  till clear authorisation for acceptance of the deviation is given.

           9.0    Inspection and Testing:
                  a)     Internal inspection: Firm to inspect all incoming/own make component
                         material as per approved QAP and internal inspection plan complying
                         related drawing and specification. Purchase documents and testing
                         certificate of outsourcing agencies and firm’s own internal reports to be
                         maintained properly and to be produced to the purchaser during final
                         inspection. Stage-wise internal inspection and testing to be done and
                         record to be maintained properly.
                  b)     Prototype inspection: Firm should submit a suitable prototype inspection
                         plan stage-wise (i) availability of raw materials and components with their
                         test certificate and calibrated jigs & fixture, (ii) sub-assembly condition,
                         (iii) final stage list of test documents mentioned in annexure 1

PREPD BY         CHKD BY      REVIEWED BY   APPROVED   SPECIFICATION FOR MOTORISED       CLW/MS/3/SPEC/ELDO-
                                               BY      BOGIE COMPLETE FORWAG-9H 3-        Bogie/001 (REV ‘Nil’)
                                                       PHASE LOCOMOTIVES                       MAY 2012
                   c)       Bulk/routine inspection: Firm should submit a suitable routine inspection
                            plan stage-wise (i) sub-assembly, (ii) final inspection.
                   d)       Purchaser has every right to visit any time during manufacturing at the
                            firm’s premises for the inspection and testing without prior information.

           10.0    Painting/marking/delivery:
                   a)     All components to be paint as per RDSO specification
                          No.M&C/PCN/100/2009 green grey RAL7009.
                   b)    (i) All components to be marked prominently name of manufacturer, month
                               and year.
                           (ii) Complete bogie frame shall be provided with an identification plate at
                                 an easily visible location. The identification plate shall contain,
                                 manufacturer’s monogram, contract number/P.O. No., Serial No.,
                                 Month & Year of Manufacture.
                   c)     Motorised bogie complete to be delivered with proper protection using
                          suitable arrangement avoiding damage etc. after passed by Inspecting
                          Authority. All records to be furnished during inspection also to be supplied
                          along with bogie.

           11.0    Field Trial:
                   Prototype 02 nos. bogies after successfully passing the prototype test shall be put
                   under field trial for at least one year. Field performance shall be monitored and
                   observations report to be obtained then firm may be allowed to further production.

           12.0 Guarantee/Warranty:
               A) The supplier shall undertaken Guarantee/Warranty for any damage during
                 transition for delivery. Any rectification/replacement required to be carried out by
                 the supplier at his own cost.

              B) The manufacturer shall undertake warranty for trouble – free and satisfactory
                 service performance on motorist bogie complete supplied by them for a period to
                 be fixed by the purchaser from the date of commissioning into service. The
                 recommended period as mentioned in respective specifications from the date of
                 commissioning into service. Any repairs/rectification required due to defects
                 observed during service on these motorised bogies complete on account of
                 metallurgical and / or manufacturing deficiency of raw material, manufacture and
                 workmanship shall be carried out by the supplier at his own cost. The firm shall
                 arrange replacement of motorised bogie complete if the motorised bogie complete
                 is considered unserviceable due to defects observed during warrantee period on
                 account of metallurgical and / or manufacturing deficiency of raw material,
                 manufacturer and workmanship. The decision of purchaser in this regard shall be
                 final.




PREPD BY          CHKD BY      REVIEWED BY   APPROVED   SPECIFICATION FOR MOTORISED    CLW/MS/3/SPEC/ELDO-
                                                BY      BOGIE COMPLETE FORWAG-9H 3-     Bogie/001 (REV ‘Nil’)
                                                        PHASE LOCOMOTIVES                    MAY 2012
                                                  Annexure – I


           A.    LIST OF DOCUMENTS FOR TESTING OF COMPLITE BOGIE



                 1.       T.M. and Gear Case Running Test No.96121508        -      02 Pages

                 2.       Gear Box Type Test Procedure IB012-00787           -      16 Pages




           B.    LIST OF ASSEMBLY INSTRUCTION


                 1.       Wheel and Axle load adjustment procedure ABB Report No.IB18-10.0

                 2.       Assembly Instruction for T.M. and Gear Case Installation 96121502 (06

                          Pages)

                 3.       Instruction for assembly and disassembly IB012-00785 (16 Pages)

                 4.       Pinion Assembly and Removal Instruction IB012-00784 (03 Pages)

                 5.       Traction Rod Assembly Fixture V01875-118




PREPD BY        CHKD BY      REVIEWED BY   APPROVED   SPECIFICATION FOR MOTORISED   CLW/MS/3/SPEC/ELDO-
                                              BY      BOGIE COMPLETE FORWAG-9H 3-    Bogie/001 (REV ‘Nil’)
                                                      PHASE LOCOMOTIVES                   MAY 2012

				
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