SPECIFICATION FOR PIPES AND JOINTS FOR by pptfiles

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									                                                               SPECIFICATION
                                                              WD-20-ABR-2007




                             INDIAN RAILWAYS




              SPECIFICATION FOR COMPREG CLAMP / PACKING FOR
                   AIR BRAKE PIPES FOR FREIGHT STOCK OF
                              INDIAN RAILWAYS.




                             WD-20-ABR-2007




                               ISSUED BY:

               RESEARCH DESIGNS & STANDARDS ORGANISATION

                          MINISTRY OF RAILWAYS

                            LUCKNOW - 226011.




MARCH-2007.                                      Price Rs.



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                                                                                        SPECIFICATION
                                                                                       WD-20-ABR-2007
                            SPECIFICATION FOR COMPREG CLAMP FOR
                            AIR BRAKES PIPES FOR FREIGHT STOCK OF
                                       INDIAN RAILWAYS

 1. SCOPE

        This specification covers technical requirements of wood -based Impregnated Compressed
        Laminates –Compreg Clamps to RDSO drawing No. WD-04058-S-01and packing for use in air
        brake freight stock of Indian Railways

2. DEFINITION

2.1     'MANUFACTURERS' means firm / company from whom the offer for the supply of wood -based
         Impregnated Compressed Laminates clamps /packing is invited.

2.2     `INSPECTING AUTHORITY' means the organisation or its representative nominated by the
        Purchaser to inspect wood-based impregnated compressed laminates clamps /packing on his
        behalf.

2.3     The Research Designs and Standards organisation, Manak Nagar, Lucknow-226011 is hereafter
        referred to RDSO.

2.4     In case the manufacturers needs any clarification in respect of any clause of this specification or
         regarding the drawing, the Tenderer shall obtain the same from DG (Wagon) RDSO, for
       clarification.

3.0     PARTICULAR REQUIREMENTS

3.1     Manufacturers willing to supply wood-based Impregnated Compressed                       Laminates
        clamps/packing for the use of Indian Railways shall register themselves with RDSO.

3.2     Manufacturers who are registered with RDSO for Compreg Board to specification No. C-9407
        latest Rev. will also be permitted supply compreg clamp / packing. But such manufacturers
        should get their QAP for compreg clamp / packing approved by RDSO.

3.3     The manufacturer shall have adequate facilities for the manufacture, testing and quality control
        requirement of wood-based Impregnated Compressed Laminates clamps/packing, conforming
        to Annexure-1

3.4     The manufacturers shall have a well-documented `Internal Quality Assurance System' to ensure
        sustained quality of product being manufactured. The` Quality Assurance Sy stem' shall generally
        cover the following: -

(i)     System to ensure that correct raw material is being used.

(ii)    System to ensure that wood-based Impregnated Compressed Laminates clamps/packing having
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                                                                                        SPECIFICATION
                                                                                       WD-20-ABR-2007
        manufacturing defects are identified and destroyed so that such wood-based Impregnated
        compressed Laminates clamps / packing are not used.

(iii)   System to ensure that bought out component are strictly as per requirements laid down in the
        specification / drawing.

(iv)    System to maintain strict control of dimensions and workmanship of components.

(v)     System to test and establish that the wood-based Impregnated Compressed Laminates clamps/
        packing manufactured by the firms meets all the requirements laid down in specification /
        drawing.

(vi)    System of periodical calibration of equipment / gauges to ensure accuracy of product.

4.0     MATERIAL

4.1     Wood based Resin impregnated compressed laminates shall be used as board for
        Clamps/Packing.

 5.     DIMENSIONS

 5.1    The dimension of wood-based Impregnated compressed Laminates clamps shall be as per
        latest revision of RDSO drawing NO. WD- 04058-S-01.

 5.1      Discrepancies in dimension, if noticed, shall be brought to the notice of wagon Dte. RDSO at
         the developmental stage and sorted out.

 6.     DEVELOPMENTAL INSPECTION

 6.1     Developmental Inspection shall be carried out at the manufacturer’s premises at the time of
        registration of the firm with RDSO.

 6.2      The Inspecting authority shall make audit checks of the manufacturing procedure/`Internal Quality
         Assurance System’` to ensure that the lot offered for inspection is manufactured strictly as per
        `Internal Quality System’ and the manufacturer has carried out all test/inspection during
        manufacturing stage to ensure that Impregnated Compressed Laminates clamps / packing
        offered are strictly to the specification. During such audit checks, the Inspecting Authority shall
        also see from the records of `Internal Quality Assurance` that the Raw Material used for the
        manufacture of wood-based Impregnated compressed Laminates clamps /packing against the
        contract is as per specification laid down.

 6.3    During developmental Inspection, test for which facilities are available at RDSO will be conducted
        at RDSO. Remaining tests for which facilities are not availab le but available with the firm, such
        tests shall be carried out in the firm’s premises /sub vendor in the presence of inspecting
        authority.
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                                                                                         SPECIFICATION
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6.4     Two percent of each lot of 100 numbers wood-based Impregnated              compressed Laminates
        clamps /packing shall be tested as per procedure given in para-8

6.5     Ten percent of each lot of 100 numbers wood-based Impregnated compressed Laminates
        clamps/packing picked up at random shall be checked for dimensions with respect to RDSO
        drawing.

6.6     The manner of collection and distribution of the test samples for different tests prescribed shall
        be at the discretion of the inspecting officer.

7.      PURCHASE INSPECTION

7.1     Purchase inspection shall be carried out at the premises of manufacturer who are cleared for the
        regular manufacture of wood-based Impregnated compressed Laminates clamps /packing and
        registered with RDSO. The following procedure shall be followed for the purchase inspection: -

7.2     The Inspecting authority shall make audit checks of the manufacturing procedure/`Internal Quality
        Assurance System’ to ensure that the lot offered for inspection is manufactured strictly as per
        `Internal Quality System’ and the manufacturer has carried out all test/inspection during
        manufacturing stage to ensure that Impregnated Compressed Laminates clamps/ packing offered
        are strictly to the specification. During such audit checks, the Inspecting Authority shall also see
        from the records of `Internal Quality Assurance` that the Raw Material used for the manufacture of
        wood-based Impregnated compressed Laminates clamps/ packing against the contract is as per
        specification laid down.

7.3     After having satisfied about the quality standards. The Inspecting Authority shall conduct the
        following checks from a lot of not more than 100 numbers of wood-based Impregnated
        compressed Laminates clamps/packing.

7.3.1   One percent of each lot of 100 numbers wood-based impregnated compressed Laminates
        clamps/packing shall be tested as per procedure given in para-8

7.3.2    Five percent of each lot of 100 numbers wood-based Impregnated compressed Laminates
        clamps/packing picked up at random shall be checked for dimensions with respect to RDSO
        drawing.

7.4     The manner of collection and distribution of the test samples for different tests prescribed shall
        be at the discretion of the inspecting officer / purchaser.




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                                                                                            SPECIFICATION
                                                                                           WD-20-ABR-2007
8.        TESTS

8.1       The samples shall comply with the requirements given in Table -I.

                                                   TABLE-I

S. No.                                  Characteristics       Requirements                 Method of test
   1        Sp. Gravity                                          1.1 - 1.25                Appendix - A
   2        Water Absorption, Maximum                         5.0% for type-II             Appendix - B
   3        Resistance to boiling water                      To pass the test              Appendix - C
   4        Bending strength        Along the grain                1200
                                                                                              IS: 1658
            (kg/cm 2 ) Minimum
                                    Across the grain                600
      5     Resistance to impact                             To pass the test              Appendix - D
      6     Resistance to chemicals                          To pass the test              Appendix - E
      7     Resistance to ageing                             To pass the test              Appendix - F
      8     Resistance to spread of flame                    Minimum Class B            Appendix – 4 of UIC-
                                                                                             564-2 OR
      9     Deterioration of visibility due to smoke         Minimum Class B            Appendix – 15 of UIC-
                                                                                             564-2 OR
     10     Limiting Oxygen Index                               Minimum 28                   IS: 13501
     11     Toxicity                                            Less Than 1                 NCD – 1409

8.2       No. of Test: -
                   All the test given in Table –1 except the test of Limiting Oxygen Index and Toxicity shall
          be carried out of each lot. The Limiting Oxygen Index and Toxicity are type tests. The test of
          Limiting Oxygen Index shall be done in six months and the test for Toxicity shall be done once in
          a year. For this purpose of these tests an authorized representative of inspecting authority shall
          draw a sample at the time interval mentioned above the firm shall arrange testing at reputed
          laboratory as decided between RDSO/ Inspecting authority and manufacturer. The cost of testing
          will be borne by manufacturer. The above tests may also be carried out in presence of RDSO/
          Inspecting authority at firm’s premises, in case the testing facilities are available with them.


8.3       RDSO may draw the sample for quality check at its discretion and firm shall arrange testing of
          these samples in a reputed outside laboratory as decided between RDSO and manufacturer.
          Testing charges shall be borne by the manufacturer.

8.4       The samples shall be collected from wood based Impregnated compressed boards for testing
      the         Bending strength , Resistance to ageing ,Resistance to boiling water and Resistance to
      impact test    as given in Table-1.




8.5       The sample shall be collected for remaining tests as per given in Table -1.
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                                                                                     SPECIFICATION
                                                                                    WD-20-ABR-2007

8.6    If the wood-based Impregnated compressed laminates board is procured from RDSO approved
       source, the testing clause will not applicable.

9.     MARKING

       Each wood-based Impregnated Compressed Laminates clamps/packing should be legibly
       marked with the following particulars: -

           1) Name of manufacture / Initials
           2) Month and year of manufacture. ( in the format mm/yy)

10.    PACKING

10.1   The wood-based Impregnated compressed Laminates clamps /packing shall be securely
       packed in cardboard boxes so that there is no damage during transit. Packing drawing to be
       approved by RDSO.

10.2   Contractor shall also ensure wood-based Impregnated Compressed Laminates clamps/packing
       are adequately packed before dispatch to prevent damage in handling and storage.

11.    WARRANTY/GUARANTEE

11.1   The warranty /guarantee period will be 30 months from the date of delivery or 24 months from the
       date of commissioning whichever is earlier.




                                            APPENDICES

A.     Determination of specific gravity:
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                                                                                   SPECIFICATION
                                                                                  WD-20-ABR-2007

            Specimen of size 40mm X 40mm X t*, free from major defects shall be taken and
    specific gravity determined using standard method by taking weight in air and in water at the
    temperature of 271 C.

B   Determination of water absorption:

            Specimen of size 40mm X 40mm X t* with cut edges, shall be weighed and kept
    suspended in distilled water at the temperature of 271 C for 24 hrs. It shall then be removed,
    surface and edges dried in folds of blotting paper and weighed. Increase in weight expressed,
    as percentage of original weight shall give water absorption. Water absorption shall not be more
    than 7.5% for type-I and 5% for type-II.

C   Resistance to boiling water:

            Specimen of 100mm X 100mm X t* with cut edges, smoothened with fine emery shall be
    taken for test. Measure the thicknesses of specimen at the centres of its four edges and with the
    external edge of the micrometer anvil approximately 5mm from each edge (Fig.1). Mark the
    measuring points so that the subsequent measurement can be made in the same places. It shall
    then be kept suspended in boiling distilled water at 1001 C for 8 hrs. Then the specimen shall
    be transferred from boiling water and kept submerged in water at the temperature of 271 C for
    one hour. Specimen shall be removed and dried in folds of blotting paper. Measure the
    thickness at measuring points already marked. Calculate the percentage increase in thickness at
    measuring points and their average shall be taken as percentage increase in thickness. It shall
    also be examined for any delamination, deterioration of surface appearance, appreciable
    softening, etc. The specimen have passed the test if:

    i)    It does not show any of the defects mentioned above.
    ii)   The increase in thickness is within the 10% of original thickness.




D   Resistance to impact

    Specimen of size 300mm x 300mm x t* is supported in a suitable square as per Fig.-2 given
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                                                                                       SPECIFICATION
                                                                                      WD-20-ABR-2007
     below. The steel ball of 1 kg. is dropped from a height of 2 metres by a suitable device to strike
     the board within 25mm from its centre. Test shall be repeated on 2 more specimens. After the
     test, the specimen shall not develop any cracks in or around the area of impact or on the under
     surface or show any defects such as delamination, split etc. This test is applicable only for
     thicker section of 10 mm and above.

                        Min
                              .




                                                   Fig.
                                                   2
E.   Resistance to chemicals

     Specimens each size of 40mm X 40mm X t* shall be kept immersed separately in following
     solutions, in clean glass beakers for 24 hours,

     (i)        In dilute hydrochloric acid (5 vol. Of conc. HCL to IS: 265-1962 in 100 vol. of distilled
                water),
     (ii)       Sodium carbonate solution (1% by weight),
     (iii)      Soap solution (1% by weight of soap to IS: 285-1964 in distilled water) and
     (iv)       Detergent solution (1% by weight distilled water at 27 1 C)

     The specimens when withdrawn and examined shall not show any surface defects like checks,
     splits, blisters, warps discolouration, overlap, gap, open joints etc.




F.   Resistance to ageing

     (i)     Dry Heat Test: -
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                                                                                        SPECIFICATION
                                                                                       WD-20-ABR-2007

               3 specimens of size 200mm x 100mm x t* shall be kept in an air oven at 70 + 1deg.C for
               168 hours followed by cooling at 27 +1 deg. C for 3 hours. They shall be examined after the
               above test. The specimens are considered to have passed the test if no surface defects
               likely to mar the aesthetic value or protective coating or no warping could be seen.

        (ii)      Ageing test: -

               3 specimens of size 200mm x 100mm x t* with all four edges smoothly trimmed shall be
               subjected to seven cycles successively, each cycle consisting of the following operations:

                  a)    Age at 70 +1deg. C for 8 hours in an air oven
                  b)    Immerse in cold water 27+1 deg C for 16 hours.

        After completion of 7 cycles the specimen shall be dried in folds of blotting paper and
        examined.

        The aged specimen shall not show any surface defects likely to mar the aesthetic value or
        protective coating or warping.

t* = refers to thickness of the actual component in mm.


                                               ----------------




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                                                                                         SPECIFICATION
                                                                                        WD-20-ABR-2007

                                                                                                  Annexure-1
1.      Requirements

        The vendor seeking approval of impregnated compressed laminates shall comply all the
        requirements mentioned below.

1.1     General and Manufacturing facilities

1.1.1   There should be a provision of covered area, with adequate space underneath for storage of raw
        material.

1.1.2   The firm should have resin manufacturing plant with at least one number of resin kettle of
        adequate capacity.

1.1.3   The firm should have resin impregnation plant of adequate capacity .

1.1.4   The firm should have at least one boiler of adequate capacity with all its accessories.

1.1.5   The firm should have at least one number four daylight heavy duty hydraulic hot press to
        manufacture floor boards of final size 800 mm x 500 mm x 55 mm with adequate margin of
        trimming. The press should have heating and cooling facilities with temperature, pressure and
        time control.

1.1.6   The firm should have indirectly heated drying chamber for drying the veneer.

1.1.7   The firm should have at least one number of heavy duty double dimension saw.

1.1.8   The firm should have a small machine shop consisting of thickness planer, drilling machine etc.

1.1.9   The firm should have weighing machine, platform type, for measuring up to 200 kg. of weight.

1.2     Testing Facilities: - The firm should have the following testing facilities.

1.2.1   The testing lab should be air conditioned to control the temperature and humidity.

1.2.2   The firm should have an electronic balance.

1.2.3   The firm should have hot water bath complete with thermostatic controller and thermometer. The
        controller should be calibrated once in three month.

1.2.4   The firm should have one universal testing machine of 5 t capacity.

1.2.5   The firms should have facility for impact testing as per Appendix ‘D’.
1.2.6   The firm should have a chemical laboratory for conducting test to resistance to chemicals as per
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                                                                                           SPECIFICATION
                                                                                          WD-20-ABR-2007
            Appendix ‘E’ of this STR.

1.2.7   The firm should have at least one hot air oven for checking resistance to ageing with thermostatic
        controller and thermometer. The controller should be calibrated once in three months.

1.2.8   The firm should have facility for conducting test for resistance to spread of flame as per
        Appendix – 4 of UIC – 564-2 OR.

1.2.9   The firm should have the following instruments:

        a)         Vernier caliper with digital display
        a)         Micro meter with digital display
        b)         Moisture meter with digital display
        c)         Thermometer with digital display
        d)         Hydrometer
        e)         Measuring scale
        f)         Measuring tape

1.2.10 The firm should have arrangement for periodical calibration of all the gauges & instruments.

1.3     Quality Control Requirements

1.3.1    There should be a system to ensure the traceability of the product from raw material stage to
         finished product stage. The system should also facilitate to identify the raw material composition
         from the finish product stage.

1.3.2 The firm must ensure that there is a QAP for the product detailing various aspects: -

        •          Organisation chart
        •          Process flow chart
        •          Stage inspection details from raw materials stage to finish product stage
        •          Various parameters to be checked and level of acceptance of such parameters
                   indicated and method to ensure control over them.
        •          Disposal system of rejected raw material and components.


1.3.3   The firm should have acquired ISO: 9001-2000 certification and the product for which the approval
        is sought should be broadly covered in the scope of the certification for manufacture and supply.

1.3.4   The firm must ensure that proper analysis is being done on monthly basis to study the rejecti ons
        at various internal stages and it is documented.

1.3.5   The firm should ensure that all the relevant specifications, IS standards are available with the firm.



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