For Official use
Government of India
Ministry of Railways
Schedule of Technical Requirements for manufacturing and supply of Ultrasonic Equipments to Indian Railways.
No.M&C/NDT/131/2009
APRIL - 2009
Research Designs & Standards Organisation
Lucknow - 226011
Page No. 01 of 10 / Effective from April -2009 / M&C/NDT/ 131/2009Schedule of Technical Requirements for Ultrasonic Testing Equipment used in Indian Railways
- FOREWORD:
Ultrasonic testing equipment viz ultrasonic single & double rail tester, ultrasonic flaw detector, ultrasonic flaw detector etc. are being used for the detection of internal defects as well as service defects in rails, welds, wheels , axles and other miscellaneous components. These ultrasonic equipment are developed by RDSO with indigenous manufacturers for its manufacturing and supply to Indian Railways. The relevant specifications for the requirement of ultrasonic equipment are prepared by RDSO as per requirement depending upon the nature of manufacturing and service defects developed in the components.
- SCOPE :
The schedule of technical requirements covers the norms for manufacturing facilities and quality control requirements of Machinery & Plant available at the firm’s premises for manufacturing & supply of ultrasonic equipment conforming relevant current specification to Indian Railways.
- GENERAL REQUIREMENTS :
Vendor seeking approval or during quality control audit by RDSO representative shall comply all the below mentioned requirements-
3.1The firm should have manufacturing, quality control, testing, storage and packing facilities in their premises. The firm should have covered area with adequate space for storage of raw materials, finished product, repair/ servicing room and packing material.
3.2The firm shall have necessary standard test pieces required during inspection and sensitivity setting blocks required for the respective equipment. The details of which should be as under-
a)IIW/ V1/A2 Block as per IS: 4904 for checking various parameters of the equipment & probes.
b)Standard Rail Test Pieces ( For Rail Tester manufacturer) Dimensions is given as Annexure ‘A’ .
c)Standard BG Track of minimum 3.0 meters length consisting Standard rail test piece ) ( For Rail Tester manufacturer)
d)Standard Weld Test Piece ( For Ultrasonic Weld Tester manufacturer) Drawing / Dimensions is given as Annexure ‘B’ .
Page No. 02 of 10 / Effective from April -2009 / M&C/NDT/131/2009e) Standard axle having artificial defect of 5 mm saw cut in a 2.5 meters approximate coach axle . The cut shall be at a distance of 60-100 mm from the far end journal end.( For Ultrasonic Axle Tester manufacturer)
3.3The firm’s premises should be neat, clean and hygienic.
3.4Applicationfor approval for ultrasonic equipment shall be restricted to the ultrasonic equipment conforming to specifications given in Clause-7.0 only.
3.5Approval of the firm will be given only when their products meets the requirement of respective relevant specification listed in Clause-7.0
3.6 The Firm shall apply for the approval/ renewal of their product on Standard MCF-2201 Form along with fee printed on the Form. Form may be down loaded from RDSO or may be requisite by this office addressing “ Executive Director/ M&C, Manak Nagar, RDSO, Lucknow-11” along with demand draft ( Fee of Form ) .
3.7The demand draft shall be in favour of “Executive Director/ Finance, RDSO, Lucknow” payable at Lucknow.
3.8Change in cost, if any, of prescribed form at the time of application shall be bearable by the firm.
3.9Ultrasonic equipment manufacturer are directly be placed in Part -I sincethese equipment are required in limited nos. and are used as an asset..
3.10 For developmental ultrasonic equipment, the cost of application form and other charges viz testing, visit charges etc. may be waved off. Executive Director/M&C is competent authority to wave off it.
3.11 Quality Assurance Plan submitted by the firm shall be approved by RDSO for approval. The time frame for various activities during approval process shall be in accordance with Dte’s process mapping No. MCP-0704 Version -0.
3.12 Firm shall have valid ISO certificate.
Page No. 03 of 10 / Effective from April -2009 / M&C/NDT/131/20094. MANUFACTURING & TESTING FACILITIES:
The firm shall have following manufacturing & testing facilities-
S.No. / Item / Qty (min.)1 / Oscilloscope: Digital Real Time, Storage, 100 MHz / 02
2 / Digital multimeters / 02
3 / DC Power Supply / 03
4 / Portable Drilling Machine / 01
5 / Hand Surface Grinding Machine / 01
6 / Dry Heat Chamber / 01
7 / Soldering Stations, Temperature controlled / 03
8 / Standard Block A2 / 02
9 / Vernier Calipers / 02
10 / Step Gauge ( 02 mm – 9 mm) / 02
11 / Sensitivity setting Blocks for rail ( For rail tester manufacturer) / 02
12 / Sensitivity setting Blocks for AT Welded rail joint ( For AT Weld tester manufacturer) / 02
13 / Calibration Blocks 50 x 50 x 50 mm or
50 x 50 x 60 mm / 02
14 / Standard axle with simulated defect ( 5 mm saw cut at journal ) ( For Axle tester manufacturer) / 01
15 / Standard Rail Track with simulated & standard defects ( For rail tester manufacturer) / 01
16 / Center lathe machine with accessories / 01
17 / Weighing machine capacity 100Kg. / 01
18 / Bench grinder / 01
19 / Pressing machine / 01
20 / Shaping machine / 01
21 / Painting spray machine (For Rail testing trolley) / 01
22 / Electronic digital weighing machine capacity 5 Kg. / 01
5.QUALITY CONTROL REQUIREMENTS
5.1 There shall be a system to ensure the traceability of products from raw material to finished product stage.
Page No. 04 of 10 / Effective from April -2009 / M&C/NDT/ 131/20095.2 There should be qualified technical personnel having adequate experience in the relevant field to look after the production, quality check and testing activities of equipment. He should be able to take corrective step in case of any difficulties. He should also be able to take step to comply with QAP. The R&D / Quality Control staff shall be able to provide technical services to the railways as and when required.
5.3The firm shall have records of inspection of raw materials and brought out component in proper registers/files for conformance to specifications of raw material. The firm shall produce these registers/files to RDSO officials during quality audit of firm or as and when demanded. The quality audit shall be carried out by RDSO Gazetted Officer twice a year to verify the quality assurance plan and R&D / Quality Control plan of the firm.
5.4The firm shall also have records of internal inspection of finished equipment in proper registers/files for conformance to relevant RDSO specifications. The firm shall produce these registers/files to RDSO officials during quality audit of firm or as and when demanded.
5.5Thefirm shallprovide to RDSO the list of sub contracts along with QAP of sub-contractor from where any part/parts of the system is manufactured. The firm shall also maintain the quality check parameters of brought out part/parts in proper register/file.
5.6 The firm shall keep records of rejected, reworked, revalued components information.
5.7 Thefirm shall ensure that all the relevant latest RDSO specification, IS specification required for testing/inspection are available in original.
5.8 Firm should give an undertaking that annual maintenance service to the equipment supplied to railways will be provided.
5.9 Firm should give an undertaking that in case there are more than two valid complaints from railways about quality of equipment the firm’s name will be deleted from the list of approved suppliers.
(i)If valid complaint were found , Quality assessment should be carried out at the earliest. Firm shall be given warning for Ist valid complaints if established. On second established valid complaints vendor may be delisted. Complaints may be received directly from Railway or through Railway Boards.
Page No. 05 of 10 / Effective from April -2009 / M&C/NDT/ 131/2009(ii) Firm may also be delisted for the reasons mentioned below-
(a)Complaints regarding poor performance reported by Rlys directly of through Rly Board.
(b)The product/material not conforming to the specification as established through joint inspection/testing of samples drawn from consignees.
(c)The product/material not found conforming to the specification during quality audit check at the firm’s premises/ Railway Workshop/Production units.
(d)A major deviation in approved quality assurance plan and deficient infrastructure facilities or furnishing incorrect information in the original application.
(e)Withdrawal /discontinuation of ISO certification.
(f)During the course of approval period if the specification is amended but the vendor has not upgraded the additional infrastructural requirements within a specified time frame.
(g)Banning of business by competent authority.
(h)Non-replacement of defective product to the end user.
(iii) In the even when the vendor is approved for more than one product the case of delisting will be considered on product basis only. The delisting shall be for a minimum period of one year for a specific product/products of the vendor.
(iv) After expiry of this period the application of vendor shall be treated as that of a new entrants.
(v) Vendor who quote in cartel are warned and their names are likely to be delisted from the list of approved venders. On receipt of information from the Rly regarding cartel formation, action will be initiated for down gradation/delisting.
Page No. 06 of 10 / Effective from April -2009 / M&C/NDT/ 131/2009(vi) In case of banning of business dealing by competent authority , the vendor as a whole irrespective of the product shall be delisted for the period imposed by the competent authority. Such vendors shall be treated as new entrants if and when they become eligible.
(vii) In case of deletion, the company will be issued a show cause notice whenever required and if no satisfactory reply is received within the time limit of 30 days, the name of the company shall be deleted from the approved list. This condition is not applicable in case of banning of business dealing by competent authority.
(viii) In the event of non-co-operation during joint testing/inspection either during quality audit or supply it shall lead to deletion of the firm.
6.0 CHANGE IN THE NAME OF THE VENDOR:
(a)On receipt of request from the vendor for change of name, which is already on the approved vendor list, the same shall be effected after verification of the firm’s premises by the nominated RDSO officials.
(b)If the RDSO official is satisfied on scrutiny of documents like memorandum of article of association, list of tools, plans and machineries, undertaking by the new firm for liability of old firm, resolution by board of directors ,partnership deed etc., he will recommend for change of the name of the firm and put up to Dte. head for approval.
(c)If change of name is done as a result of bifurcation of existing works premises, in addition to checking of documents are above, reassessment will also be carried out by RDSO officials before effecting the change of the name of firm.
(d) The vendor shall be informed in writing that the change of name has been noted by RDSO and the changed name shall be advised to all copy holders of the vendor list.
6.1 CHANGE IN WORKS ADDRESS OF THE VENDOR:
On receipt of request from the vendor for change of address, the nominated RDSO officials shall verify that,
(a)The office established has been shifted totally.
(b)The machinery and plants have been shifted totally.
(c)The testing and laboratory facilities have been shifted totally.
Page No. 07 of 10 / Effective from April -2009 / M&C/NDT/ 131/2009(d) The approved QAP can be implemented as it is or more effectively in new premises.
(e) Factory license, ISO 9001 certificate and SSI/NSIC CERTIFICATE (if applicable) are available for new address.
(f) The name of the firm is same.
(g) The samples manufactured by the firm at new premises have been tested by RDSO, as in re-assessment cases, for items where purchase inspection is not being done by RDSO.
6.1.1 After scrutiny of the report, the acceptance in change of address shall be communicated to the vendor, with the approval of the Directorate Head. The validity of the registration in such case shall not get affected. The status of approval (Part-I/Part-II) shall remain the same.
6.1.2The procedures laid down above shall also be applicable in case of partial shifting of works, i.e. in case apart of the operation are shifted from the old location to a new location.
6.2 ADDITIONAL WORKS SETUP BY APPROVED VENDOR:
6.2.1 Vendor shall inform RDSO in writing regarding setting up additional works for manufacturing the approved item(s) ,(in the same or other location) without affecting the works, which was already approved. In such cases, the nominated RDSO official shall verify that:
(a)The Machinery & Plants are similar to the works already approved.
However, the vendor may use some of the facilities of the original
works, as required. It should be brought in the QAP which operations
are being performed in the new works.
(b) The testing and laboratory facilities are similar to the works
already approved .
(c)The approved QAP can be implemented it is or more effectively
in new premises.
(d)Factory license, ISO 9001 certificate and SSI/NSIC certificate (if
applicable) are available for new address.
(e)The name of the firm is same.
(f)The sample manufactured by the firm at the new premises have
been tested by RDSO, as in re-assessment cases, for items where
inspection is not being done by RDSO.
Page No. 08 of 10 / Effective from April-2009 / M&C/NDT/ 131/20096.2.2 After scrutiny of the report, the acceptance for the inclusion of the address of new unit shall be communicated to the vendor, with the approved of the Directorate Head. The validity of the registration in such case shall not get affected. The status of approved new works shall be same as that of the original works and subsequently, the same status of both works shall be one and the same.
6.3 PROCEDURE TO DEAL WITH THE CASES DURING CHANGE OF SPECIFICATINS ETC.
6.3.1 Whenever there is change in procedure/specification/STR/Drawing or any other aspects having relevance in manufacturing and quality of the product, the changes shall be informed to vendor by Directorate controlling these documents. These revisions shall be given to the approved vendors free of cost.
6.3.2 The already approved vendor shall required to comply with above mentioned charges on a written time bound basis. However , the applicant seeking fresh approval shall be required to comply with all the charges before the approval is granted.
7.0LIST OF ULTRASONIC EQUIPMENT WITH RESPECTIVE SPECIFICATION
7.1Technical Specification of digital ultrasonic testing equipment for welded rail joint with LCD screen, trignometrical function and a-scan storage along-with data setup. SpecificationNo.M&C/NDT/129/2005 ( Oct 2005)
7.2Technical specification for digital Ultrasonic Single Rail Tester with coloured signals and A-scan logging along with data setup Specification No.RDSO/M&C/NDT/128/2007 ( October-2007 )
7.3Technical Specification for Digital Ultrasonic Double Rail Tester with coloured signals and A-scan logging along-with data setup. (Spec.No.M&C/NDT/130/2007 )
7.4 Specification for portable Digital Ultrasonic Flaw detector with A- Scan storage
( Specification No.M&C/NDT/125/2004 )
7.5 Technical Specification for hand operated Double Rail Tester (Pulse Echo Type )
for testing of rails in track for flaws. ( Specification No.M&C/NDT/102/2000 )
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Page No. 09 of 10 / Effective from April 2009 / M&C/NDT/131/2009Annexure ‘A’
Page No. 10 of 10 / Effective from April 2009 / M&C/NDT/131/2009Annexure ‘B’