SPECIFICATION NO. TI/SPC/OHE/SPRATD/0110(03/2012)
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
SPECIFICATION FOR SPRING AUTO TENSIONING DEVICE
Issued by:
T.I. DIRECTORATE
RESEARCH DESIGNS & STANDARDS ORGANISATION
MANAK NAGAR , LUCKNOW 226 011
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Specification No. TI/SPC/OHE/SPRATD/0110
INDEX
SN.
DESCRIPTION
1.
SCOPE
2.
REFERENCE SPECIFICATIONS
3.
ENVIRONMENT & WORKING CONDITIONS
4.
FUNCTION OF AUTO TENSIONING DEVICE
5.
DESCRIPTION OF SPRING ATD SYSTEM
6.
GENERAL & TECHNICAL REQUIREMENTS
7.
MATERIAL SPECIFICATION
8.
DEVIATION FORM THE SPECIFICATION
9.
FREEDOM FROM DEFECTS
10.
PACKING & MARKING
11.
INSPECTION & TESTING
12.
TESTS
13.
TEST METHODS
14.
INSTALLATION, COMMISSIONING & TRIAL
15.
TRAINING
PAGE NO.
3
3-4
4
5
5
5-6
6
7
7
7
7
8
8-13
14
14
16.
RELIABILITY
14
17.
MAINTABILITY
14
18.
WARENTEE
14
19.
TECHNICAL LITERATURE & OTHER DETAILS
14
FORMAT FOR RECORDING FIELD PERFORMANCE- Annexure-A
PURCHASER’S REQUIREMENTS- Annexure-B
15
21.
22.
SCHEDULE OF GUARANTEED PERFORMANCE- Annexure-C
17
20.
16
2
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Specification No. TI/SPC/OHE/SPRATD/0110
SPECIFICATION FOR SPRING AUTO TENSIONING DEVICE (SPRATD)
FOR
25 V a.c. TRACTION
1.0
SCOPE
1.1
Indian Railways employ 65 sq. mm Cadmium Copper catenary and 107 sq. mm. hard
drawn Copper contact wire in simple polygonal OHE for supplying power to electric
locomotives. For ensuring smooth current collection by pantographs of these
locomotives, auto tensioning devices are installed at either end of the traction
overhead line to provide a constant tension of 2000 kgf in traction overhead line
conductors, irrespective of temperature variation.
1.2
This specification covers the requirement of SPRING ATD for field trials. The
device shall be put for field trials in elevated section & tunnels where space
availability to install the counter weight is a constraint, to observe its performance.
Data shall be recorded in the format enclosed at Annexure-A to help in taking
decision regarding adoption of type and make of SPRING ATD suitable for Indian
Railways.
2.0
Reference Specifications:
In perpetration
specifications.:
of
this
specification
reference
is
made
to
the
following
i.
ii.
iii.
iv.
v.
vi.
ETI/OHE/18(4/84): Specification for “galvanised and stainless steel fasteners”.
ETI/OHE/49(9/95): Specification for “fittings used in 25 kV AC traction OHE”.
ETI/OHE/13(4/84): Specification for “galvanising of mast, tubes, fittings etc”.
BS: 970,Part4:1970 “specification for wrought steels”.
IS:549-1974: Specification for spilt pins
IS: 2266-2002 -Specification for steel wire ropes for general engineering
purposes.
vii. IS: 3973-1984 -Specification for the selection, installation and maintenance of
wire ropes
viii. IS: 6594-2001 - Specification for technical supply conditions for steel wire ropes
and strands.
ix. IS: 1608-2005 -Specification for tensile testing of metallic materials.
x. ASTM E-112 Test Methods for Determining Average Grain Size
xi. ASTM E-381 Method of Macroetch Testing of Steel Bars, Billets, Blooms and
Forgings
xii. IS: 228(Part 1 to 24) Methods of Chemical Analysis of the Steels
xiii. IS: 1500 Method for Brinell Hardness Test for Metallic Materials
xiv. IS: 2074 Ready Mixed Paint, Air Drying, Red Oxide Zinc Chrome Priming
Specification
xv. IS: 3073 Assessment of Surface Roughness
xvi. IS: 3195 Steel for the manufacture of Helical Springs (for Railway Rolling Stock)
xvii. IS: 3618 Specification for Phosphate Treatment of Iron and Steel for Protection
against Corrosion
xviii. IS: 3703 Recommended practice for Magnetic Particle Flaw Detection
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xix IS: 4163 Method for determination of Inclusion Content in Steel by
Macroscopic Method
xx IS: 6396 Methods of measuring Decarburised Depth of Steel
xxi IS: 7001 Shot Peening of Steel Parts
xxii UIC-822 Technical Specification for the Supply of Helical Compression Springs
for Tractive and Trailing Stock.
2.1
The reference to the ASTM /BS/ IS / UIC Specifications quoted herein shall be
taken as the reference to the latest version of these Specifications, which shall be
available with the firm.
2.2
Any special requirements given in the relevant drawings submitted by manufacturer
& approved by RDSO will override the specification. Specification other than
specified, used for manufacture of auto tensioning devices, should be submitted to
RDSO along with the drawings
3.0
ENVIRONMENT & WORKING CONDITIONS
3.1
The SPRING ATD is expected to be used in varying atmospheric and climatic
conditions. The environment factors are expected to vary in the range as tabulated
below.
Ambient air temperature
00C to +500C
Maximum temperature of metallic object
700C
under sun.
iii) Minimum temperature
- 10°C
iii) Maximum relative humidity
100%
iv) Annual rainfall
Dry Arid regions and also heavy
monsoon affected regions with rainfall
ranging from 1750 to 6250mm
v) Maximum number of thunder storm days
85
per annum
vi) Maximum number of dust storm days per
35
annum
vii) Number of rainy days per annum.
120
viii) Basic wind pressure
200 kgf/m2
ix) Altitude
Altitude: 1000m above mean sea level.
Altitude: 2000 m in J & K area.
i)
ii)
3.2
The device shall be able to withstand the polluting and corrosive atmosphere, such
as in the coastal & industrial areas, in the vicinity of chemical plants and
steam/diesel loco sheds.
3.3
It shall also be subjected to vibrations due to wind and passage of trains (maximum
speed upto 200kmph) and at times to impact loading in case of breakage of OHE
conductors/Insulators.
3.4
The maximum tension length of overhead equipment which is required to be
regulated is about 750 m.
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4.0
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Specification No. TI/SPC/OHE/SPRATD/0110
FUNCTION OF SPRING AUTO TENSIONING DEVICE
SPRING ATD shall be able to maintain constant tension for temperature difference
upto ∆60oC for OHE parameters as given in the performa of Annexure-B by the
tenderer.
5.0
DESCRIPTION OF SPRING ATD SYSTEM
5.1
Auto tensioning device shall be Spring operated.
5.2
The system offered shall be of proven design and should perform satisfactorily in
the all climatic condition similar to India.
5.3
Force should be transmitted to contact wire by means of spring tensioning device to
maintain constant tension in OHE irrespective of temperature variation.
6.0
GENERAL & TECHNICAL REQUIREMENTS
6.1
Before manufacture of SPRING ATD, the manufacturer shall submit all the relevant
drawings viz. General arrangement, installation drawings and part drawings for
approval of RDSO. Approval to the drawing means the approval to the general
adaptability of the device. The manufacturer shall submit for scrutiny the drawings
in triplicate in standard size of 210mm x 297mm or multiples. Each drawing shall
carry the tabulation for item reference, item's name, drawing number, material
grade, material specification, test specification, quantity and weight. Salient
technical particulars of the assembly/components shall also be mentioned in the
respective drawings. A block as indicated below shall be provided on each drawing
for approval by Director General/Tl, ROSO, Lucknow.
APPROVED IN PRINCIPLE
FOR DIRECTOR GENERAL/ TI
ROSO, LUCKNOW, INDIA
6.2
After all the drawings are approved, the manufacturer shall submit three
Reproducible Tracing Films (RTF) for each drawing for signature of approving
authority. anly after all the design and drawings have been approved and clearance
given by purchaser/ RDSO to this effect, the manufacturer shall take up
manufacture of the prototype for ROSO's inspection. It is to be clearly understood
that any changes required to be done in the prototype as required by ROSO shall be
done expeditiously.
6.3
All fasteners and fittings shall be suitable for connection to the existing OHE, mast
and portals.
6.4
Data sheet for compensating length with respect to temperature shall be provided
by the manufacturer.
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6.5
Material used for manufacturing of SPRING ATD and its components shall be
“corrosion resistant”.
6.6
Procurement of spring steel rounds shall be done only from reputed spring steel
manufacturers.
6.7
Spring shall have phosphate coating to IS 3618 to prevent corrosion & greased to
reduce friction between coils which come in contact during expansion & contraction.
6.8
Bearing used shall be SKF or NBC Sealed bearings to prevent ingress of water and
dust.
6.9
Spring ATD shall be able to prevent falling of OHE on ground in case of breakage of
wirerope or fitting attached to the mast .
6.10
All components of spring ATD shall be freely inter-changeable between one
assembly and another.
6.11
Wire rope used with spring tensioning device shall have service life not less than 30
years.
6.12
Manufacturer‟s monogram and Identification No shall be provided on parts of spring
tensioning device.
6.13
Spring ATD shall be able to take up the creep of OHE conductors automatically.
Manufacturer shall submit the test report of creep test carried out on spring
tensioning device along with the offer.
7.0
MATERIAL SPECIFICATION:
7.1
The aluminium, aluminium-alloy and aluminium-bronze castings, wherever specified,
shall be conform to RDSO Specn. No. ETI/OHE/49 (9/95).
7.2
The material of wire, used for stainless steel wire ropes shall be austenitic nickel
chromium molybdenum stainless steel conforming to AISI grade 316 or its
equivalent. The wire ropes shall be manufactured in accordance with IS: 2266-2002
and IS:3973-1984.
7.3
Bolts, nuts, lock nuts, washers and screws used in the auto tensioning device shall
comply with the RDSO Specn. No. ETI/OHE/18(4/84) or its equivalent specification.
The stainless steel parts wherever specified, shall be made from stainless steel
bars conforming to grade 316S16 of BS 970:pt 4-1970 or its equivalent
specification.
7.4
All ferrous parts used in the auto tensioning device shall be hot dip galvanised to
RDSO Specification No. ETI/OHE/13 (4/84) or its equivalent specification. The
weight of zinc coating shall not be less than 610 gm./m2.
7.5
Split pins shall be of copper and shall conform to IS: 549-74 or its equivalent
specification.
7.6
The grade of material of the spring shall be 52Cr4MoV and shall comply with IS
3195-92 or its equivalent specification.
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8.0
DEVIATION FORM THE SPECIFICATION
8.1
Any deviation from this specification to improve the performance, utility and
efficiency of the auto tensioning device proposed by the tender will be given due
consideration provided full particulars with justification thereof are furnished.
9.0
FREEDOM FROM DEFECTS
9.1
All parts of auto tensioning device‟s shall be free from casting/manufacturing
defects and other irregularities. No repairs shall be done to the castings to hide
defects.
10.0
PACKING & MARKING
10.1
The auto tensioning device shall be properly packed, duly assembled, in strong
wooden boxes so as to avoid damage during transit. One box shall contain not more
than two assemblies.
10.2
Every packing shall carry, in legible and indelible lettering the following information:
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
Type of auto tensioning device.
Number of auto tensioning device‟s packed.
Production batch No.
Manufacturers name, brand or trade mark.
Net & gross weight.
Contract No. Purchase Order No. & Consignee.
Date of Inspection.
Any other particulars specified by the Purchaser.
11.0
INSPECTION & TESTING
11.1
The auto tensioning device shall be inspected and tested by the Director General/TI
[DG/TI]/RDSO] or his authorised representative at the firm‟s work. All the type
tests specified in clause 12.1 & 12.2 shall be carried out at the manufacturer‟s
works. The firm shall arrange, without making any claim or charges, all the necessary
machinery, apparatus, labour and assistance required to get the specified tests
conducted in the presence of purchaser‟s representative. If certain facilities are
not available for the tests, manufacturer may arrange these tests outside, with the
approval of RDSO. The charges for these tests shall be borne by the manufacturer.
11.2
Before giving call to RDSO for prototype testing, the manufacturer shall submit a
detailed test schedule consisting of the details of each test and nature of the test,
venue & duration of the tests and once the test schedule is approved, the test shall
invariably be done accordingly.
11.3
In case, any dispute or disagreement arises between the manufacturer and RDSO
during the process of testing, as regards to the type test and /or the interpretation
and acceptability of the type test results, it shall be brought to the notice of
DG/TI/ RDSO, whose decision shall be final and binding.
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12.0
TESTS
12.1
Tests on auto tensioning device Components –
12.1.1 Visual examination (13.1)
12.1.2 Verification of dimensions (13.2)
12.1.3 Chemical composition (on test bars and components including wire rope & spring)
(13.3)
12.1.4 Dye penetration/Radiographic examination of castings.(13.4)
12.1.5 Mechanical tests (on test bars)-(13.5)
12.1.6 Breaking load test on wirerope & fittings (13.6)
12.1.7 Galvanizing test (13.7)
12.1.8 Tests on fasteners (13.8)
12.1.9 Tests on wirerope ( 13.9)
12.1.10 Tests on spring (13.10)
12.2
Tests on auto tensioning device
12.2.1 Performance Test (13.11)
12.2.2 Endurance Test(13.12.1)
12.2.3 Proof load test(13.12.2)
12.2.4 Releasing test(13.12.3)
12.3
Type tests: Three units shall be produced by the manufacturer, on which test as
per clause 12.1 followed by clause 12.2 shall be carried out.
12.4
Bulk Manufacture : Only after clear written approval of the results of tests on the
prototype is communicated by the DG(TI), RDSO to the manufacturer, he shall take
up bulk manufacture of ATDs which shall be strictly with the same material and
process as adopted for the prototype .
12.5
Acceptance & Routine Tests: The tests specified in clauses 12.1 & 12.2.1 constitute
acceptance tests & tests specified in clause 12.1.1, 12.1.2 & 12.1.3 constitutes routine
tests.
12.6
Criteria for acceptance
12.6.1 The auto tensioning device shall be offered for inspection in lots of not more than
100 numbers. Lot shall be made from the same production batch. The two units from
each batch shall be selected at random from the offered lot for tests given in
clause 12.1 and test as per clause 12.2.1.
12.6.2 If any sample fails to comply with any test(s) specified in this specification, test(s)
shall be repeated on three samples, taken from the same batch but limited to the
test(s) in which failure occurred. If in the retest(s) any sample fails, the batch
represented by the sample shall be deemed not to comply with specification and the
batch shall not be cleared for supply.
13.0
TEST METHODS
13.1
Visual examination: All the components of the SPRING ATD shall be visually
examined. Part identification no., manufacturers monogram and month/year of
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manufacture shall be checked. The casting, if used, shall be clean, sound, free from
harmful inclusions, blow holes, cracks etc. The zinc coating on the galvanized
components shall be uniform, reasonably smooth and free from imperfections such
as flux, ash, bare patches, black spots, pimples, lumpiness and runs, rust stains, bulky
white deposits and blisters. The forged heads of bolts and holes of nuts & washers
shall be concentric. The bearings and axles of the pulleys shall be examined for the
free running.
13.2
Verification of dimensions
13.2.1
Verification of groove profile:
The pulley shall be checked by means of a „template reference‟ (model) in order to
check the complete development of the radius as well as the holes concentricity.
Pulley groove radius shall be as mentioned in the drawing. if pulley groove radius is
found less than the specified , pulley groove should be remachined to specified
groove radius. Pulley shall be rejected, if groove radius is found more than the
specified value. Pulley groove profile shall be checked with Go, No gauge, which shall
be produced by the manufacturer at the time of inspection.
13.2.2 Verification of other critical dimensions
The dimensions of the castings, and other components of the auto tensioning device
shall conform to the drawings approved by RDSO.
13.3
Chemical composition
Test certificate for Chemical composition of the different components shall be
obtained from the supplier and submitted at the time of testing. The purchaser
shall be at liberty to analyse chemical composition of any component in addition to
test bars. Test result shall meet the requirement of clause 7.0
13.4
Radiographic Examination:
Radiographic examination shall be carried out on castings for inclusion, blow holes,
cavities, cracks, porosity. Radiographic Test Results shall meet the requirement of
RDSO‟s specification no. ETI/OHE/49(9/95) or its equivalent specification.
13.5
Mechanical Tests on Test Bars :
Test reports of mechanical tests on test bars from the suppliers shall be
submitted at the time of testing. Test results shall meet the requirement of
specification mentioned in the drawing approved by RDSO.
13.6
Tensile load test on wirerope & fittings:
The fitting shall be assembled with the wire rope in a manner {as approximately as
possible} in which it is intended to be used in service. The assembly shall be held in
a tensile testing machine. A tensile load equal to 90% of the breaking load of the
rope shall be applied and the rope marked so as to detect any movement relative to
the fittings. The load shall be maintained for one minute. There shall be no
relative movement of the fitting during this period of one minute. Then the load
shall be gradually increased. The fittings shall not deform, break or slip at loads
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less than the minimum specified breaking load of the rope. Wire rope shall
withstand the specified breaking load.
13.7
Galvanizing test:
Ferrous parts if used shall be hot dip galvanised to RDSO's specification No.ETI/
OHE/13(4/84) with A&C slip No.1 to 3 or its equivalent specification & shall meet
the requirement of clause no. 7.3 .
13.8
Tests on fasteners:
The fasteners used in auto tensioning device shall be tested for their conformity
to RDSO's specification No. ETI/OHE/18(4/84) with A & C slip no. 1 to 4 or its
equivalent specification.
The specification No. ETI/OHE/13(4/84) with A & C Slip No.1 to 3 and
specification No. ETI/OHE/18(4/84) with A & C slip no. 1 to 4 and specification No.
ETI/OHE/49(9/95) may be obtained by the successful tenderer from Director
General (Tl)/Research Designs & Standards Organisation, Manak Nagar, Lucknow226011(India).
13.9
Tests on wirerope: All the tests specified below shall normally be carried out at
the manufacturer‟s works. In case the facilities do not exist with the manufacturer,
tests can be conducted with reputed and recognised testing agencies after specific
approval of DG(TI), RDSO. The charges for these tests shall be borne by the
supplier. Test certificate of chemical composition shall be obtained from the
suppliers of the raw material procured/processed. The manufacturer shall also
check the chemical composition of every lot of raw material purchased. The
certificates of these shall be produced at the time of inspection.
13.9.1 Visual Examination:
The wire rope shall be free from defects, like loose wires, broken wires, open
strands or other irregularities. The wires shall be free from injurious defects i.e.
cracks, pit marks, flattened surfaces, rusting, slivers and peeling etc. The surface
shall be perfectly smooth. The wire ropes shall be manufactured in accordance with
IS:2266-2002 and IS:3973-1984. Microscopic examination of the surface shall be
carried out on the wires taken from finished rope. The wire shall be examined at
magnification of 100X or more. The defects such as pits and slivers shall be within
1% of the wire diameter.
13.9.2 Measurement of diameter & lay length:
Wires rope construction, diameter, lay length & lay direction shall be recorded.
Construction, diameter of wires & wirerope shall as specified by the manufacturer.
Lay length of wirerope shall not be more than eight times the diameter of wirerope.
13.9.3 Ovality:
The ovality (out of roundness) shall be taken in accordance with annexure A of IS
6594:2001. The maximum variation between any four measurements of dia of the
rope shall not be more than 0.51 mm
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13.9.4 Chemical Analysis:
Material of wire used for manufacture of wire rope shall confirm to clause no. 7.2
of specification.
13.9.5 Tensile test on wires:
Test samples tested in accordance with IS: 1608-2005 shall conform to the tensile
strength. Tensile Strength shall not be less than 145kgm/sq. mm..
13.9.6 Breaking load test on wirerope:
Breaking load test shall be conducted in accordance with Appendix-B of IS: 65942001. The breaking load of wirerope shall not be less than 4200kgf.
13.9.7 Intercrystalline corrosion bend test:
The Intercrystalline corrosion bend test shall be carried out, in accordance with
Clause 1.13.4 of BS:970 Pt: 4-1970, on the wires taken from the finished ropes and
the wires shall satisfy the requirements mentioned therein.
13.9.8 Measurement of residual stress:
The residual stress shall be measured either by X-Ray diffraction method or layer
removal method. The residual stresses shall not exceed 20kgf/mm2. on the wires
taken from the completed rope.
13.9.9 Measurement of - martensite content:
- Martensite Content shall be measured by magnetic hysteresis saturation loop
method. The - martensite content shall not exceed 10% on the wires taken from
the completed rope.
13.9.10 Measurement of relative magnetic permeability:
The relative magnetic permeability of the wires taken from finished rope shall be
measured accordingly to any of the test methods given in specification BS: 58841999. The relative magnetic permeability of the wires taken from completed ropes
shall not exceed 2.5.
13.9.11 Performing Test:
A test of the performing of the ropes shall be carried out by unlaying at one end of
the rope, two strands opposite to each other for approximately two rope lay
lengths. When these two strands are relaid into the rope, the wires shall maintain
their position in the strands and strands shall resume their position in rope.
13.10
Tests on Springs:
13.10.1 Inspection of Raw Material:
Test certificates:
The manufacturer shall obtain the test certificate for the following tests carried
out on steel rounds used for manufacture of springs from the steel manufacturer.
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(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
Effective from
Specification No. TI/SPC/OHE/SPRATD/0110
Visual examination & dimensional checks as per IS3195.
Chemical composition determined as per IS228
Inclusion contents of rounds as per IS 4163
Macro examination as per IS4163
Depth of decarburisation as per IS6396
Hardness as per IS1500
Grain size as per ASTM E-112
Quality of the raw material:
The rolled bars shall be free from harmful defects namely seams, folds, laps,
cracks, holes, deep pits, grooves, excessive scaling and non metallic inclusions
which may lead to cracking during hardening or impair the serviceability of
material. The material shall also be free from harmful internal defects such as
piping and segregation.
Hardness of spring round material when tested to IS 1500 shall be 310BHN
maximum for untreated surface and 255max. for annealed surfaces.
Macro etching shall be used to evaluate the heterogeneity of steel and to ensure
freedom from harmful defects. The macro etching test samples shall be prepared
in accordance with IS 7739. Macro etch level shall not be worse than C2, R2, S2
of ASTM E-381 plate 1 for billets & blooms.
Macroscopic examination shall be conducted on a longitudinal section for
evaluation of non metallic inclusion content. Inclusion rating shall be 2.0 ABCD for
thin series and 1.0ABCD for thick series when compared to the chart for
determining the inclusion content of secondary refined steel of IS 4163-1982.
Average grain size of the bar shall be to ASTM no. 6 or finer when checked as per
ASTM E-112.
The permissible depth of seam and lap in the rolled bar shall be d/100 or 0.4mm
whichever is less. The test procedure for detecting surface seams shall be as per
IS 3703.
Tolerance on diameters of hot rolled steel bars shall be +1.0% & -0.8%. All other
conditions shall be as per IS 3195.
13.10.2 Inspection during manufacture: The records of inspection during manufacturing
process of spring shall be presented to inspecting official. The records shall be as
per QAP.
13.10.3 Inspection of finished springs:
Following checks shall be carried out by the inspecting official on randomly
selected springs.
(i)
Visual examination of springs: The shape & dimension of the spring shall
be as per the drawing submitted by the manufacture of spring ATD and
approved by RDSO.
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(ii)
Hardness testing: Hardness of the spring shall be tested as per IS 1500
and hardness of the spring shall be in the range of 415-460BHN.
(iii)
Crack detection: springs shall be tested for crack detection in accordance
with Appendix „B‟ of Specification UIC-822 or equivalent specification, for
both longitudinal and transverse cracks. A suitable device to rotate the
springs in position is also essential to facilitate testing of entire surface of
the spring in one setting. After crack detection, the spring shall suitably be
demagnetized.
(iv)
Shot Peening: springs shall be shot peened in a continuous type shot
peening machine, in accordance with IS:7001 to improve fatigue life of the
spring. During shot peening, it should be ensured that the springs are shot
peened uniformly over the entire area of the springs. The intensity shall be
checked by almen strip and shall not be less than 0.40mm.
13.11 Performance Test: Pull and position value with respect to temperature shall be
checked as per data sheet supplied by the manufacturer. The specified tension in
the line shall be within +5% as per customer‟s requirement throughout the
temperature range.
13.12 Mechanical endurance and proof load test: These tests shall be conducted to judge
the ability of the equipment to withstand shocks/jerks encountered in service.
13.12.1 Mechanical endurance test:
The test shall be conducted on testrig simulating actual working condition for
10,000 operations. Movement of + 300mm of spring should constitute one operation.
After completion of 10000 operations, the components offspring tensioning device,
shall not show any deformation or any irregularities. During Endurance test complete
set of pull and position values with respect to temperature must be recorded and
the variation of pull around at the nominal value should be + 5%.
13.12.2 Proof load test:
Spring tensioning device shall be subjected to 4000 kgf load for five minutes in
endurance test rig. The tensioning equipment shall be able to withstand this test
successfully without any breakage or deformation of the components.
After this, complete set of pull and position values with respect to
temperature must be recorded and the variation of pull around at the nominal value
should be + 5%.
13.12.3 Releasing load test
A releasing device between load cell and the auto tensioning device should be placed
as described in standard IEC 61109. The auto tensioning device is pulled to the end
of working range. Tensioning equipment shall be subjected to Releasing. The
tensioning equipment shall be able to withstand this test successfully without any
breakage or deformation of the components.
At the end of test, complete set of pull and position values with respect to
temperature must be recorded and the variation of pull around at the nominal value
should be + 5%.
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14.0
Effective from
Specification No. TI/SPC/OHE/SPRATD/0110
INSTALLATION, COMMISSIONING & TRIAL
The manufacturer shall be responsible to install commission and carry out trials of
the SPRING ATD on the line to the satisfaction of DG/TI/RDSO. Necessary
assistance in this regard shall be provided by the purchaser.
15.0
TRAINING
Manufacturer should provide adequate training free of cost to Indian Railways
officials for two days in calibration, installation, operation, troubleshooting and
maintenance of the system in India.
16.0
RELIABILITY
16.1
SPRING ATD as a unit is expected to provide reliable services for at least 30 years.
16.2
The manufacture shall, therefore, ensure that the system supplied including all parts
and components etc. used are free from manufacturing defect. SPRING ATD shall
be of highest quality and in conformity with the specification.
16.3
The manufacturer shall submit the schedule of guaranteed particulars for SPRING
ATD as per Annexure-C.
17.0
MAINTAINABILITY
17.1
If the SPRING ATD is manufactured by the firm outside India, a service center
shall be located in India.
17.2
The manufacturer should provide at his own expense the services of competent
engineers during the warranty period for any manufacturing and design defects and
also to impart instructions for regular service and maintenance.
17.3
The manufacturer shall furnish list of recommended spares, tool & plants for proper
upkeep and trouble free service of SPRING ATDs. Price of all these shall also be
quoted separately. These details, and an undertaking that spares shall be made
available during the service life (30 years) of SPRING ATDs shall be furnished
alongwith the offer.
18.0 WARRANTEE
The SPRING ATD shall be guaranteed for satisfactory performance for a period of
24 months from the date of commissioning.
19.0 TECHNICAL LITERATURE & OTHER DETAILS
The manufacturers shall furnish the technical details regarding the precautions to
be taken while handling, periodicity & the details of maintenance activity, storage
instruction, instruction for replacement & maintenance of bearings, springs wirerope
& pulley during overhauling, installation of SPRING ATD and also submit in triplicate,
the installation manual, maintenance manual and troubleshooting manual.
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14
Annexure-A
Performance Report of SPRING ATD
(To be filled up every month)
Railway:-______________________
Division:_______________________
Section:_________________________
ATD make & model No.
Location
Date of Installation
Date of
Inspection
Performance of SPRING ATD : Satisfactory/ Not satisfactory
Temperature
indicator
reading
Correspondi
ng
compensatio
n length
Whether
compensation
length is as per
the chart
supplied by the
manufacturer
Any other
remark
Annexure-B
OHE parameters (to be given by tenderer)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Catenary material
:
Catenary cross sectional area
:
Coefficient of thermal expansion of catenary
:
Catenary tension
:
Contact wire material
:
Contact wire cross sectional area
:
Coefficient of thermal expansion of contact wire:
Contact wire tension
:
Tension Lengths
:
Proposed catenary arrangement
:
Total OHE tension
:
Minimum Temperature
:
Maximum Temperature
:
Any other requirement
:
Annexure-C
SCHEDULE OF GUARANTEED PARTICULARS FOR SPRING ATD
S.No.
1.
2.
3.
4.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
14.
15.
16.
17.
18.
19.
20.
Item
Name of manufacturer
Country of origin
Specification & drawings of spring ATD
Material specifications
Max. Line Tension (kgf)
Max. Tension Length(meter) of OHE
Maximum & Minimum ambient working
temperature range (Degree centigrade)
Max. compensating length(mm)
Dimensions (Max. Length & Width)-(mm)
Weight of unit (kg)
Safety measures
Max. Endurance test cycles
Over load capacity of spring ATD(kgf)
Data sheet
Wire rope construction
Min. Breaking load of wire rope
Specified breaking load of fittings
Bearing designation
Static & dynamic load rating of bearing
Maintenance manual
Service life of spring ATD, wirerope ,
spring & bearing
Any other particulars of the system
Description
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