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COMMENTS OF MANUFACTURERS ON RDSO‟s SPECIFICATION No. RDSO/2014/CG-02

Cl. No.

RDSO/2014/CG-02 Comments of M/s FAG

Comments of M/s TIMKEN

Comments of M/s SKF

Comments of M/s NEI

REMARKS

1.0 SCOPE

1.1 This specification covers the technical requirements of design, manufacture, supply, mounting, service performance, testing and acceptance criteria of UIC-130 Pre-sealed, Preset and Pre-lubricated Cartridge Taper Roller Bearings complete (CTRB) for use on coaches of LHB design on Indian Railways.

This specification covers the technical requirements of design, manufacture, supply, mounting, service performance, testing and acceptance criteria of UIC-130 Pre-sealed, Preset and Pre-lubricated Cartridge Taper Roller Bearings complete (CTRB) for use on coaches of LHB design on Indian Railways. (Scope of service performance to be defined clearly. Rest noted.)

Accepted OK This specification covers the technical requirements of design, manufacture, supply, mounting, service performance, testing and acceptance criteria of UIC130x230 Pre-sealed, Preset and pre lubricated cartridge tapered roller bearings complete (CTRB) for use on coaches of LHB design on Indian Railways.

M/s FAG stated that in clause scope of “Service performance” be clearly defined. However, in clause (21) of this specification, scope of “service performance” is clearly defined. M/s NEI stated that “UIC 130X230” be inserted in place of UIC 130. However, diameter of outer rings is regulated by Control Arm dimensions which are covered in clause 5.2 of this specification. Therefore, no change is required in this clause of specification.

1.2 This specification describes the requirements of CTRB for wheel-sets with pressed brake discs and mounted with control arm arrangement.

No change required (Noted)

Accepted OK No change required

1.3 This specification also covers the requirements of manufacture and supply of the following spares.

S. No.

Description Remarks

1. Cone Assembly /Set of Inner Rings

To be procured from RDSO approved bearing manufactures and as per their drawing approved by RDSO.

2. Double Cup /Outer Ring

3. Cone Spacer/ Spacer

4. Rollers

5. Polymer Cage

6. Seal Sleeve/ Spacer

7. Backing Ring

8. HDL TM

Seal/Seal

9. Grease

To be procured from RDSO

S.

No.

Description Remarks


To be procured from RDSO approved bearing manufacturers and as per their drawing approved by RDSO. HDL TM

2. Double Cup/ Outer Ring


4. Rollers

5. Polymer Cage


7. Backing Ring

8.

HDL TM

Seal/ Seal

Rollers and cages to be deleted from the list of spares as these are not offered as spares

S. No.-1 to 5: OK S. No.-6: Does not exist in SKF Design. S. No.-7: OK S. No.- 8: SKF has own Seal Design in two parts - External Part and Internal part. Suggest to keep part as only Seal. S. No.-Xx Need to add out board distance ring. S. No. - Xx Need to

S. No.-6 : Seal Sleeve/ Spacer/ Wear Ring – Inboard / Wear Ring - Outboard S. No.-8 : HDL™ Seal/ Seal Grease Seal

M/s TIMKEN stated that Rollers and cages be deleted from the list of spares which is not desirable as replacement of Cages is required in refurbishment. Based on comments of M/s FAG, M/s SKF and M/s NEI description of item at S. No. 8 is changed from “HDL TM

Seal/Seal” to “Seals”. Based on comments of M/s FAG, M/s SKF and M/s NEI description of “Remarks” is changed as below; Applicable spares to be procured from RDSO approved bearing manufactures and as per their drawings of RDSO approved design/make of CTRB. As suggested by M/s SKF the following items can be added in the Description column of list of spares and

approved bearing manufactures as per their approved make of grease.

Cartridge Type Seal

9.

Grease

To be procured from RDSO approved bearing manufactures as per their approved make of grease. (FAG L225)

add Polymer distance ring inboard side. S. No. - 9 - Grease to be as per SKF drawing approved by RDSO. SKF suggest not to keep components details since each bearing manufacturer have their own design with different components. There are several components which do not exist in all bearing manufacturers' design.

S. No. of Grease be changed to 11; (i) S. No.09 Out board distance ring. (ii) S. No.10 Polymer distance ring inboard side. However, existing item no. (9) of this clause is modified as below; Unless otherwise specified, grease, to be procured from RDSO approved bearing manufactures as per their approved make of grease.

1.4 This specifications draws reference to some of the following relevant Standards unless specified otherwise, the latest version of the relevant standards shall be taken as reference

S.No.

Spec. No. Description

1 EN 12080 Railway Applications Axleboxes –Rolling bearings

2 UIC 515-1

Passenger rolling stock –trailer bogies-Running gear-General provisions applicable to the components of trailers bogies

3 EN 12081 Railway Applications Axleboxes –Lubricating Grease

4 UIC-814

Technical Specification for official testing and supply of grease intended for the lubrication of railway vehicle roller bearing axle boxes.

5 EN 12082

Railway Applications Axleboxes –Performance testing

6 UIC 515-5

Powered and trailing stock Bogie-Running gear “Test for Axle-boxes”

7 EN ISO Heat treated steel, alloy


UIC-814 may be deleted as

EN12081covers the grease

requirements. UIC515-5 has

been replaced by EN 12082.

Relevance of UIC 515-1 is not

restricted to journal bearings

only.

OK Further include following reference documents:- 18. ISO:76 Rolling Bearings-Static Load Ratings 19. ASTM E-45 for Standard test methods for determining the inclusion content of steel

M/s Timken‟s comments are not considered as UIC standards are covered in the list of normative references of corresponding EN specifications. M/s NEI‟s comments examined and it is noted that ASTM E-45 for Standard test methods for determining the inclusion content of steel is covered in ISO 683-17-1999 (E) Annexure-B. M/s NEI‟s comments examined and it is noted that ISO: 76 Rolling Bearings-Static Load Ratings is covered in the list of normative references of ISO 281 -2007 (2). Therefore, no change is required in this clause of specification.

683-17 steels and free cutting steels – Part-17: Ball and roller bearing steels

8 EN ISO 6508-1

Metallic materials- Rockwell hardness test- Part-1:Test method (scales A,B,C,D,E,F,G,H,K T) (ISO 6508-1:2005)

9 EN ISO 6508-2

Metallic materials- Rockwell hardness test- Part-2 verification and calibration of testing machines (scales A,B,C,D,E,F,G,H,K T) (ISO 6508-2:2005)

10

EN ISO 6508-3

Metallic materials- Rockwell hardness test- Part-3 calibration of reference blocks (scales A,B,C,D,E,F,G,H,K T) (ISO 6508-3:2005)

11

ISO 281 Rolling bearings – Dynamic load rating and rating life.

12

ISO 492

Rolling bearings – Radial bearings- Tolerances.

13

EN ISO 6507-1

Metallic materials- Vickers hardness test- Part -1 test method.

14

ISO 2639

Steels -- Determination and verification of the depth of carburized and hardened cases

15

IS: 3073 Assessment of surface roughness

16

LHB document No. 17.565 Partial Document 100 ver.01

Wheel set bearing

17

LHB document No. 17.565 Partial Document 103 ver.00.

Wheel set bearing for 18t wheel set load (BG) and v=200 km/h

2.0 GENERAL

2.1 Technical details of tender offer shall be submitted in duplicate.


Accepted OK Technical details to be submitted in duplicate by the tenderer along with the offer.

M/s NEI‟s comments examined and clause modified as below; Technical details to be submitted in duplicate by the tenderer along with the

offer.

2.2 In order to facilitate examination of tender offer, the same shall be accompanied by clause by clause compliance of this specification, either confirming acceptance of the clause and elaborating wherever necessary or indicating deviations there from.


Accepted OK This sub-clause 2.2 from clause 2.0 to be removed and added in Appendix “A”

M/s NEI‟s comments examined and found not desirable as existing RDSO specifications of Bearings are inline with this clause. Therefore, no change is required in these clauses of specification. 2.3 The tenderer shall strictly adhere to this

specification. However, in the event of the tenderer being unable to conform to any clause of this specification, deviations from the same shall be clearly indicated.



2.4 In addition, the tenderer shall submit a consolidated statement of deviations.



2.5 Tender offer shall be accompanied by information listed in Appendix „A‟.


Accepted OK No comments offered

No comments offered. Therefore, no change is required in these clauses of specification.

2.6 Tenderer shall submit in duplicate, copies of English translation of standards other than those quoted in this specification except Indian Standards along with their offers.



M/s NEI‟s comments examined and found not desirable as existing RDSO specifications of Bearings are inline with this clause. Therefore, no change is required in these clauses of specification.

2.7 Tender offer not accompanied by details indicated at Clause 2.1 to 2.6 above are liable to be ignored without further reference.


Accepted OK Once requirements in Clause No. 2.2, 2.3, 2.4 and 2.6 are moved to Appendix “A” then should be rewritten as Tender offer not accompanied by details indicated at Appendix “A” are liable to be ignored without further reference.

2.8 Research Designs & Standards Organization, Lucknow-226011 is hereinafter referred to as RDSO.



No Change required in this clause.

3.0 CONTRACTER‟S RESPONSBILITY

3.1 The Contractor shall be Completely responsible for design, manufacture, supply, mounting, service performance and testing and acceptance criteria in accordance with this specification and for the satisfactory and efficient performance of the CTRB in service irrespective of-

i) Any approval which the Purchaser/ RDSO may have given for the design features; and ii) Tests/ inspection carried out by the Purchaser / RDSO or his nominee.

The Contractor shall be completely responsible for design, manufacture, supply, prototype mounting, service performance and testing and acceptance criteria in accordance with this specification and for the satisfactory and efficient performance of the CTRB in service irrespective of-

i) Any approval which the Purchaser/ RDSO may have given for the design features; and

ii) Tests/ inspection carried out by

Accepted SKF can take responsibility of Prototype mounting only. Also RDSO need to define the scope of responsibility for Service performance.

The Contractor shall be completely responsible for design, manufacture, supply, mounting, service performance and testing with this specification and for the satisfactory and efficient performance of the CTRB in service irrespective of-…………….

Comments of M/s FAG, M/s SKF and M/s NEI examined and “mounting” to be replaced with “prototype mounting” in this clause.

the Purchaser / RDSO or his nominee.

(Mounting to be referred as prototype mounting only. Scope of service performance to be defined clearly.)

3.2 The Contractor shall further, not withstanding any exercise by the Purchaser / RDSO of the power of superintendence, be responsible for sufficiency of packing, marking etc. of all the parts of the work to ensure their delivery without damage. The Contractor shall comply with the instructions of Purchaser/ RDSO or his nominee, if in his opinion, more precautions than those taken by the Contractor are necessary for the proper execution and safe delivery of all the parts of the work.



No Change required in this clause.

4.0 APPROVAL OF DESIGN

4.1 The Contractor shall have a set of their/ Collaborator‟s working drawing in metric units giving assembly and component details. The drawings shall be fully dimensioned with requisite tolerances etc. and provided with other details such as material specification, heat treatment process, and surface finish. Weight of the each bearing component shall also be indicated on the relevant drawings. These drawings shall be made available whenever required by Inspecting Authority/ Purchaser/ RDSO.


Accepted Details such as material specification, heat treatment process, and surface finish of the bearing component can be given in technical data sheet, not in the bearing drawing .

No comments offered

M/s SKF‟s comments examined and found not desirable as drawings of Bearing components without technical details like material specification, heat treatment process, surface finish are incomplete. Therefore M/s SKF‟s comments not accepted.

4.2 Detailed material specification for each component shall be indicated on the relevant drawings.


Accepted Material specification detail requirement already covered in above para.

M/s SKF‟s comments examined and this clause can be deleted.

4.3 Tests according to the standards/ specifications covered in this specification or as agreed to by the Contractor and Purchaser to which the components and the assembly shall be subjected to by the Contractor at his works to establish the quality of the product and its satisfactory working shall be indicated in the drawings.


Accepted RDSO need to clarify on this para, which tests? Tests required in manufacturing process are defined in QAP/Control Plan by SKF.

Tests according to the standards/ specifications covered in this specification or as agreed to by the Contractor and Purchaser to which the components and the assembly shall be subjected to by the Contractor at his works to establish the quality of the product and its satisfactory working shall be indicated in the drawings QAP.

Comments of M/s SKF and M/s NEI examined and last word of this clause “drawings” to be replaced with “drawings/QAP”.

4.4 CTRB shall pass an approval procedure as agreed and documented in accordance with Clause (4.0) of DIN EN 12080-2011-01 by the Purchaser and the Contractor.


Accepted OK CTRB shall pass an approval procedure as agreed and documented as per

Comments of M/s NEI examined and clause modified as below;

below information. 1. Purchaser to provide following information:- 1.1 Interface drawing showing mounting conditions; all dimensions of the space available for the rolling bearings; dimensions, tolerances and materials of shaft and box housing. 1.2 Load spectra. 1.3 Ambient temperature conditions. 1.4 Steel composition, cleanliness if required. 1.5 Conditions for quality records and traceability. 2. Following requirements to be agreed between the contractor and purchaser:- 2.1 Boundary dimensions and interface tolerances of the rolling bearing. 2.2 Internal clearance values before and after mounting. 2.3 Steel chemical composition and inclusion rating. 2.4 Type of heat treatment and methods of testing. 2.5 Marking details. 2.6 Inspection plan. 2.7 Grease designation, quantity and distribution.

Unless otherwise specified in this specification CTRB shall pass an approval procedure as agreed and documented in accordance with Clause (4.0) of DIN EN 12080-2011-01 by the Purchaser and the Contractor.

4.5 A valid copy of UIC/AAR approval certificate (of the collaborator in the case of an indigenous manufacturer for the size/ design and brand of CTRB offered). For programmed indigenization under collaboration of an AAR/UIC manufacturer please refer Clause (22) of this specification.


Accepted and AAR certification is applicable only for freight cars.

Approval by AAR is given only for Freight car bearings. Also there is no approval granted by UIC for the bearings.

A valid copy of UIC/AAR approval certificate (of the collaborator in the case of an indigenous manufacturer for the size/ design and brand similar type of CTRB offered). For programmed indigenization under

M/s SKF M/s FAF and M/s NEI provided documentary proof in support of their comments. Considering that AAR does not carry out product and facility certification of Metric bearings and also of the suppliers which are not supplying to North American Rail roads, therefore the provisions related to AAR

collaboration of an AAR/UIC manufacturer please refer Clause (22) of this specification. ** This Clause does not talk about Indian Indigenous manufacturer and for manufacturers which are having only AAR approval for similar products

can‟t be included in this clause. Further, as per comments of M/s SKF and M/s FAG UIC does not carry out product and facility certification of the suppliers. A valid copy of AAR approval certificate (of the collaborator in the case of an indigenous manufacturer for the similar type of CTRB offered). For programmed indigenization under collaboration of an manufacturer please refer Clause (22) of this specification.

4.6 After approval, the customer shall be notified of any change of design and specification which may influence the function, as well as transfer of work to a different manufacturing plant. The Contractor may require a new approval procedure as covered in annexures E & F of DIN EN 12080-2011-01.


Accepted

OK After approval, the customer RDSO shall

be notified of any

change of design and specification which

may influence the function, as well as

transfer of work to a

different manufacturing plant.

The Contractor may

require a new approval procedure as covered

in Annexures E & F of

DIN EN 12080-2011-

01.

M/s NEI‟s comments examined and RDSO comments are as below; (i) As per requirements covered in this specification CTRB shall be conforming to EN12080. In order to ensure compliance of CTRB to EN 12080 subsequent modifications in CTRB shall also pass testing as stipulated in EN 12080 and to remain conforming to EN 12080. In the first line of this clause “the customer” shall be replaced with “RDSO” and in the 5

th line of this clause

“may” is replaced with “shall”.

4.7 Before regular manufacturing, the plan, the service life computation as per ISO 281, latest revision in proof of the statistical load-carrying capacity and endurance test report are to be submitted to the Purchaser/RDSO. A set of comprehensive technical instructions for mounting /removal and manufacturer of CTRB offered are to be submitted to the Purchaser/RDSO.

Before regular manufacturing, the plan, the service life computation as per ISO 281(L10), proof of the statistical load-carrying capacity and endurance performance test report are to be submitted to the Purchaser/RDSO. (L10 already covers statistical load carrying capacity. No endurance test specified in the specification, hence performance test report to be submitted to RDSO.)

Accepted

OK This sub-clause 4.7 should be removed. The requirement is already covered in Appendix “A”.

M/s FAG‟s comments examined and RDSO comments are as below; In order to ensure compliance of CTRB to EN 12080 CTRB shall also pass endurance testing as stipulated in EN 12080. M/s NEI‟s comments examined and found not desirable as existing specification of Bearings are inline with this clause. Therefore, no change is required in these clauses of specification.

5.0 DESIGN INPUTS OF CTRB Drawings mentioned

5.1 Axle Journal


Accepted

OK M/s NEI‟s comments examined and RDSO

The CTRB covered in this specification shall be suitable for axle journal to RCF Drg. No. LW 02100 latest revision.

in Clause 5.1, 5.2, 5.3 and 5.4 should be attached and made part of this specification.

comments are as below; Drawings of interfacing components are of RCF, Kapurthala and not required to form part of this specification. However, alteration status of these drawings will be incorporated in this specification at a later date and any change in drawing will be notified to RDSO approved vendors of CTRB. M/s FAG‟s comments will be examined at the time registration as existing vendors and Railways have not reported problems in current design of security disc.

5.2 Control Arm The CTRB covered in this specification shall be suitable for control arm to RCF Drg. Nos. 1267716, 1267717, 1277122 & 1268845 latest revisions.


Accepted

OK

5.3 Security Disc The CTRB covered in this specification shall be suitable for security disc to RCF Drg. No. 1902094 latest revision.

Minor modification in End cap seating tolerance required for better guidance. (We recommend from our experience to modify End-cap seating diameter from 130 D7 (+0.145 /+0.185) to 130 E7 (+0.085 / +0.125) in order to have a better guidance for both phonic-wheel and earth return- parts mounted on the end-cap.)

Accepted

OK

5.4 The CTRB covered in this specification shall be suitable for axle end cover to RCF Drg. No. 1268835, 1902713 & 1902714 latest revision.


Accepted

OK

5.5 The CTRB covered in this specification are intended to be installed on bogies, which are in use on Broad Gauge of Indian Railways. The main details are as below;

a) Axle load 18t b) Max. speed in running order:160 kmph c) Height of center of gravity of coach 2000 mm 2000 mm d) The running technique service trials of the vehicles take place at 160 kmph +10%


Accepted

OK No comments Considering development of LHB design coaches for 200 kmph the option (A) and option (B) to be added in revised clause; Option (A) a) Axle load: 18t b) Max. speed in running order:160 kmph c) Height of center of gravity of coach: 2000 mm d) The running technique service trials of the vehicles take place at 160 kmph +10% Option (B)

a) Axle load: 18t b) Max. speed in running order:200 kmph c) Height of center of gravity of coach: 2000 mm d) The running technique service trials of the vehicles take place at 200 kmph +10%

6.0 CTRB DESIGN

6.1 Bearings shall be a Double Row Pre-sealed Preset and Pre-lubricated Cartridge Taper Roller Bearing equipped with seals and shall be with cylindrical bore. The bearing shall be of a design which is proven in service on


Accepted

OK This sub-clause 6.1 should be removed. The requirement is already covered in clause 4.5

M/s NEI‟s comments examined and it is noted that clause 4.5 is related to UIC/AAR approval.

Rolling Stock in other Railway system in the world in a similar application.

However, the last sentence of this clause shall be revised as below; The bearing shall be of a similar design which is proven in service on Rolling Stock either on IR or in any other Railway system in the world in a similar application.

6.2 Boundary dimensions (in mm) of bearings for axle load applications shall be as under:

Description 18.0 t Axle Load CTRB

Bearing Outside dia.

229.87 +0.051/-0.000

Bearing Bore dia.

129.967 +0.013/-0.000

Bearing Cup(width)

160.00 +0.051/-0.051

Boundary dimensions (in mm) of bearings for axle load applications shall be as under:

FAG Design

Descrip -tion

18.0 t Axle Load CTRB

Bearing Outside dia.

229.87 +0.051/

-0.000

230.00 0.000/

-0.100

Bearing Bore dia.

129.96 7

+0.013/

-0.000

130.00 -0.025/

+0.000

Bearing Cup(width

)

160.00 +0.051/

-0.051

160.00 -0.250/

+0.000

(FAG's Bearing dimension to be added. OR As per RDSO approved drawing.)

Boundary dimensions (in mm) of bearings for axle load applications shall be as under:

Descripti

on

18.0 t Axle Load

CTRB

Bearing

Outside

dia.

229.87 +0.051/-0.000

To be Changed to

229.873(+0.127/-0.000)

Bearing

Bore dia.

129.967 +0.013/-0.000

To be changed to

129.967 (+0.025/-

0.000)

Bearing

Cup(widt

h) 160.00 +0.051/-0.051

This is because Timken is

currently supplying with these

dimensions

Description 18.0 t Axle Load CTRB Bearing Outside dia. 230

-0.130/+0

Bearing Bore dia. 130

-0.025/+0

Bearing Cup(width) 160.00

+0.051/-0.051

SKF strongly recommend to avoid Dimensional tolerances in the Specification, which is anyway has to eb as per RDSO approved Drawing.

Boundary dimensions (in mm) of bearings for axle load applications shall be as under: Brg Outside Dia. 229.87 +0.13/-0 Brg Bore Dia. 129.967 +0.025/-0 Brg Cup Width 160 +/-0.051

Boundary dimensions and interface tolerances of control arm and axle Journal are mentioned in clause 6.4 of this specification. This specification provides for manufacturer/make specific tolerances on dimension of CTRB. Therefore this clause is to be deleted.

6.3 CTRB‟s internal clearance, axial and/or radial, depending on the type of design of CTRB, shall conform to the values documented in Clause (4.0) of DIN EN 12080-2011-01.The methods for radial and/or axial clearance inspection can be agreed and documented inline with Clause (4.3) of DIN EN 12080-2011-01.

CTRB's “Bench Lateral' shall confirm to respective RDSO approved drawings. The method for measuring 'Bench Lateral' shall be mutually agreed. (No value for radial / axial clearance mentioned in Clause 4.0 of DIN EN 12080-2011-01.)

Accepted

OK, however there is no radial clearance in this bearing design.

Lateral clearance should be same for all manufacturers. RDSO to provide lateral clearance before and after mounting for UIC130x230.

Comments of M/s FAG, M/s SKF and M/s NEI have been examined and are found to be inline with clause of this specification. M/s NEI‟s comments regarding standardization of lateral clearance is acceptable and clause modified as below; CTRB‟s internal clearance, axial and/or radial, depending on the type of design of CTRB, shall conform to the values documented as per Clause (4.0) of DIN EN 12080-2011-01 and mentioned in the drawing approved by

the firm. The methods for radial and/or axial clearance inspection can be agreed and documented inline with Clause (4.3) of DIN EN 12080-2011-01.

6.4 Diameter (in mm) of axle-box housing/control arm bore and journal dia. on which these bearings are to be housed shall be as under:

Description 18.00t Axle Load CTRB

Dia of Axle Box Housing bore/Control Arm

230+0.122/

+0.050 (F8)

Dia of journal

130+0.068/

+0.043 (p6)

Diameter (in mm) of axle-box housing/control arm bore and journal dia. on which these bearings are to be housed shall be as under:


Dia of Axle Box Housing Bore (Lower Con- trol Arm)

230+0.122/

+0.050 (F8)

Dia of Axle Box Housing Bore (Upper Con- trol Arm)

230.05+0.1

Dia of journal

130+0.068/

+0.043 (p6)

(Diameter of Upper Control Arm & Lower Control Arm should be added acc. to ref. drg. no. 127712 Ver. 01 & 1267716 ver.00)

Accepted

Dia of Upper and Lower part of Control Arm need to be added

Comments of M/s FAG, M/s SKF accepted and clause modified as below;


Dia of Axle Box Housing Bore (Lower Con- trol Arm)

230

+0.122/

+0.050 (F8)

Dia of Axle Box Housing Bore (Upper Control Arm)

230.05

+0.1

Dia of journal

130 +0.068/+0.043

(p6)

6.5 The variation in diameter of rollers on one bearing shall not exceed 0.003 mm i.e. largest roller diameter as 21.732 mm & smallest roller diameter as 19.868 mm. (To be specified by the respective manufacturer of the CTRB)

Dimensions of individual component like Inner ring, Outer ring, Roller, Cage, Spacer, Seal, etc.. Should be according to respective manufacturer's drawings approved by RDSO. (Each CTRB manufacturer will have different component dimensions suitable to boundary condition & hence should be acc. to respective CTRB manufacturer's RDSO approved drawing.)

To be changed –The variation in diameter of rollers on one bearing shall not exceed 0.0025mm with 99% confidence interval

OK The variation in diameter of rollers on one cone assembly set shall not exceed 0.005 mm.

As per requirements covered in this specification CTRB shall be conforming to EN12080. In order to ensure compliance of CTRB to EN 12080, variation in diameter of rollers on one bearing shall not exceed 0.003 mm. Therefore, this clause modified as below; The variation in diameter of rollers on one bearing shall not exceed 0.003 mm

6.6 Tolerance on the length of rollers shall be +0.015/-0.0 mm for CTRB covered in this specification. (To be specified by the respective manufacturer of the CTRB)

Dimensions of individual component like Inner ring, Outer ring, Roller, Cage, Spacer, Seal, etc.. Should be according to respective manufacturer's drawings approved by RDSO. (Each CTRB manufacturer will have different component

Tolerance on the length of rollers shall be +0.102/-0.254 mm for CTRB covered in this specification.

Length of the tapered roller can not be maintained to 0.015 mm tolerance; the design of tapered roller does not allow such narrow tolerance on

The variation in length of rollers on one cone assembly set shall not exceed 0.508 mm.

As per requirements covered in this specification CTRB shall be conforming to EN12080. In order to ensure compliance of CTRB to EN 12080, tolerance on the length of rollers shall be +0.015/-0.0 mm.

dimensions suitable to boundary condition & hence should be acc. to respective CTRB manufacturer's RDSO approved drawing.)

width/length. Therefore, no change in this clause is required.

6.7 Variation in width of individual inner ring/cone shall be as per the drawings submitted by the supplier.

Dimensions of individual component like Inner ring, Outer ring, Roller, Cage, Spacer, Seal, etc.. should be according to respective manufacturer's drawings approved by RDSO. (Each CTRB manufacturer will have different component dimensions suitable to boundary condition & hence should be acc. to respective CTRB manufacturer's RDSO approved drawing.)

Accepted

OK No change required

6.8 Surface finish shall be checked in accordance with IS: 3073. In case manufacturer adopt to any other standard, English translation of standard as per which surface finish is measured shall be supplied by the Contractor whenever required by Purchaser/RDSO /Inspecting Authority.


Accepted

ok as per tech data sheet.

No change required

6.9 Cone, double cup, cone spacer and rolling elements shall have Rockwell hardness (HRC) between 57 to 66 HRC. There shall not be more than 4 HRC difference between the values measured. (i) On all the rings of one roller bearing. (ii) On all the rolling elements in one roller bearing.

Cone, double cup, cone spacer and rolling elements shall have Rockwell hardness (HRC) between 57 to 66 HRC. There shall not be more than 4 HRC difference between the values measured. i) On all the rings of one roller bearing. ii) On all the rolling elements in one roller bearing. (Spacer are not heat treated & hence to be deleted.)

Accepted

OK Cone, double cup, cone spacer and rolling elements shall have Rockwell hardness (HRC) between 57 to 66 HRC. There shall not be more than 5 HRC difference between the values measured. ……………

Comments of M/s NEI regarding variation in Rockwell hardness (HRC) examined and it is noted that variation of 5 HRC is in excess of 4 HRC stipulated in clause 10.4 of EN12080. As per requirements covered in this specification CTRB shall be conforming to EN12080. In order to ensure compliance of CTRB to EN 12080 all components shall also be conforming to requirements detailed in EN12080. Therefore, comments of M/s NEI in this regard are not acceptable. M/s FAG‟s and M/s NEI‟s comments regarding hardness of cone spacer are incomprehensible considering acceptance of 4 HRC variation in hardness on all the rolling elements in one bearing.

6.10 Surface hardness shall be inspected according to the Rockwell method, referred in EN ISO 6508-1 to 3. For case hardened steel roller bearing, surface hardness may be measured by the Vicker HV 30 method referred to EN ISO 6507-1, or by another equivalent method agreed and documented in accordance with Clause (4.4) of DIN EN 12080.

Surface hardness shall be inspected according to the Rockwell method, referred in EN ISO 6508-1 to 3 or by another equivalent method agreed and documented in accordance with Clause (4.4) of DIN EN 12080. For case hardened steel roller bearing, surface hardness may be measured by the Vicker HV 30 method referred

Accepted

RDSO need to specify the method in the spec itself.

This sub-clause 6.10 should be removed. The requirement is already covered in clause 1.4

Comments of M/s NEI examined and it is noted that clause 1.4 provides consolidated list of reference standards not the requirements covered in this specification. M/s FAG‟s and M/s SKF

to EN ISO 6507-1, or by another equivalent method agreed and documented in accordance with Clause (4.4) of DIN EN 12080. (Noted)

comments examined and it is noted that as per requirements covered in this specification CTRB shall be conforming to EN12080. In order to ensure compliance of CTRB to EN 12080 hardness testing of the components shall also be conforming to requirements detailed in clause 10.4 of EN12080. Therefore, comments of M/s FAG in this regard are not acceptable.

7.0 Material

7.1 Material Grades

S.No.

Description Material Grades


Cone grade 8219 (for TIMKEN make)

2. Double Cup/Outer Ring

Material grade 4319 (for TIMKEN make)


Material 1020 (for TIMKEN make)

4. Rollers Material grade 8219(for TIMKEN make)

5. Polymer Cage

Polyimide


SAE 1060 (for TIMKEN make)

7. Backing spacer

EN 8 (S 462E) (for TIMKEN make)

8. Backing Ring

EN 8 (BS 970, S 462) (for TIMKEN make)

9. HDL TM Seal/Seal

-

Steel should be selected from the grades specified in EN ISO 683-17. Alternative steel grades selected by bearing manufacturers may be used by agreement between Purchaser and Contractor. However, the Contractor shall provide complete details of alternative materials to the Purchaser/RDSO.


Accepted

S.No. 1. one Assembly /Set of Inner Rings - as per ISO 683-17 2. Double Cup/Outer Ring - as per ISO 683-17 3. Rollers - as per ISO 683-17 4. Polymer Cage : Polymer SKF recommends not to put material in specification and approve these deatils separately during approval process. Also, design of individual manufacturer do not have same parts in the bearings. HDL™ is property of specific manufacturer, SKF has it's own design.

Alternate material to be added as approved by RDSO S. No.: 1: Alternatively SAE8720 MOD./ SAE8620/ 20MnCr5 (20MC5) to be added. 2: Alternatively SAE8720 MOD./ SAE8620/ 20MnCr5 (20MC5) to be added. 3: Alternatively IS: 2062 Gr 1 or IS:3601 Gr-HFS 240 to be added. 4: Alternatively SAE8720 MOD. to be added. 5: Polyamide 6: Alternatively SAE52100/ AISI1050 to be added. 7: Alternatively SAE52100/ AISI1050 to be added. 8: Alternatively Class-2 to IS:1875 & IS:2004 to be added. 9: HDL™ Seal/ Seal Grease Seal

M/s SKF and M/s NEI comments are inline with the provisions in this clause and are acceptable and clause is changed as below; Steel Grades Steel should be selected from the grades specified in EN ISO 683-17. Alternative steel grades selected by bearing manufacturers may be used by agreement between Purchaser and Contractor. However, the Contractor shall provide complete details of alternative materials to the Purchaser/RDSO

7.1.2 Inclusion Rating

7.1. 2.1

The inclusion rating shall meet the requirements of EN ISO 683-17. For steel with special composition, metallurgical quality or manufacturing processes the inclusion content shall be documented in accordance with Clause (4) of DIN EN 12080.


Accepted

OK

The inclusion rating shall meet the requirements of EN ISO 683-17 or ASTM E-45. For steel with special composition………..

M/s NEI‟s comments examined and it is noted that ASTM E-45 for Standard test methods for determining the inclusion content of steel is covered in ISO 683-17-1999 (E) Annexure-B. Therefore, no change is required in this specification.

7.1. 2.2

The method of determining the inclusion content shall be agreed between Purchaser and Contractor.


To be changed : The contractor must produce a certificate from the steel source on inclusion rating for the batch of steel used to manufacture bearing components viz Outer rings (double Cup) and inner rings (Cones)

OK M/s TIMKEN‟s comments examined and it is noted comments are inline with the provision of clause. Therefore no changes are required in this clause of specification.

7.1. 3

The steel used for manufacture of bearings shall be free from defects such as pipes, seams, laminations, excessive inclusion of non-metallic impurities and such other internal defects as would render the material unsuitable for the purpose for which it is intended. On microscopic examination it shall show fine grain size and shall be free from signs of overheating.


To be changed: The contractor must submit a certificate from the steel source or a third party approved source for steel cleanliness and metallurgical composition to ensure that the steel used for manufacture of bearings shall be free from defects such as pipes, seams, laminations, excessive inclusion of non-metallic impurities and such other internal defects as would render the material unsuitable for the purpose for which it is intended.

OK M/s TIMKEN‟s comments examined and it is noted comments are inline with the provision of clause. Therefore no changes are required in this clause of specification

7.1. 4

In case the CTRB offered by the tenderer have been manufactured using materials other than to standards given above, the tenderer shall indicate details of the following:


Accepted

OK

This sub-clause 7.1.4 should be removed. The requirement is already covered in clause 2.5 Appendix “A”

M/s NEI‟s comments examined and found not desirable. Therefore no change required in this clause of specification

7.1. 4.1 7.1. 4.2 7.1. 4.3 7.1. 4.4 7.1. 4.5

Specification of materials (English translation of standards shall be submitted along with the offer). Hardness of the component for which the steel to grade indicated at Sub-Clause 7.1.4.1 above is proposed to be used. Inclusion rating and microstructure of steel proposed to be used for manufacture of rings and rollers shall be indicated by Contractor. Drawing showing the constructional arrangement of the bearing. Details of successful application of such bearings on Rolling Stock in the following format:

i) Name of Railway System ii) Year of supply. iii) Number of CTRB supplied. iv) Designation of CTRB supplied. v) Axle load. vi) Operating Speed. vii) Report from the Railway System regarding the performance of the bearing.

No change required (Noted) No change required (Noted) No change required (Noted) No change required (Noted) Details of successful application of such bearings on Rolling Stock in the following format: i) Name of Railway System ii) Year of supply. iii) Number of CTRB supplied. iv) Designation of CTRB supplied. v) Axle load. vi) Operating Speed. vii) Report from the Railway System regarding the performance of the bearing. (Supply details consisting of details from point i) to vi) is possible. Obtaining performance report other than Indian Railway operators worldwide is not possible.)

Accepted Accepted Accepted Accepted Accepted and

Sub clause (vii) to be deleted as

Railway companies in Europe

rarely issue such a report.

Spec of material should be submitted to RDSO during approal process instead of submitting with tender. OK OK OK OK

No comments offered No comments offered No comments offered No comments offered Details of successful application of same or similar product CTRB‟s on Rolling Stock in the following format: No comments offered

M/s SKF‟s comments examined and it is noted comments are inline with the provision of clause. Therefore no change required in this clause of specification No change required No change required No change required M/s FAG‟s and M/s TIMKEN‟s comments are examined and found not desirable. Therefore no changes are required in this clause of specification.

7.2 CTRB shall be fitted with a polymer cage. The material for polymeric cage shall be as per Annexure-D of DIN EN 12080-2011-01.


Accepted

OK, As per approved design of SKF TBU , already in the proven in the field.

CTRB shall be fitted with a polymer cage. The material for polymeric cage shall be as per Annexure-D of DIN EN 12080-2011-01. Alternative material selected by bearing manufacturers may be used by agreement between Purchaser and Contractor. However, the contractor shall provide complete details of alternative materials to the Purchaser/RDSO.

M/s SKF‟s and M/s NEI‟s comments examined and it is noted comments are inline with the provision of this clause. Therefore no changes are required in this clause of specification.

8.0 MANUFACTURE

8. 3.1

Steel Manufacturing The process of steel manufacture in mass production shall be such that the metallurgical characteristics are the same as those of the rolling bearings submitted for the approval procedure.


Accepted

OK To be removed.

No change required.

8.3.2 Heat Treatment

8.3. 2.1

The heat treatment processes for the CTRB components shall be such that the hardness values specified in DIN EN 12080-2011-01 are achieved. The heat treatment shall be such that all the CTRB produced in a production batch are treated uniformly.


Accepted

Hardness values will remain as per defined by bearing manufacturer.

The heat treatment processes for the CTRB components shall be such that the hardness values specified in DIN EN 12080-2011-01 Clause 6.9 are achieved. The heat treatment shall be such that all the CTRB produced in a production batch are treated uniformly.

M/s SKF‟s comments are examined and found acceptable. M/s NEI‟s comments examined and it is noted comments are inline with the provision of this clause. Therefore this clause of specification is revised as below; The heat treatment processes for the CTRB components shall be such that the hardness values as specified in clause (6.9) and physical properties as specified in clause (9.0) of this specification are achieved. The heat treatment shall be such that all the CTRB produced in a production batch are treated uniformly.

8.3. 2.2

The heat treatment cycle shall be such that dimensional stability of CTRB components under operating conditions covered in this specification is maintained over service life of CTRB.


Accepted

OK

RDSO to clarify??

M/s NEI‟s comments examined and modified clause of this specification is as below; The heat treatment cycle shall be such that dimensional stability of CTRB components is ensured for operating temperatures up to +150

0C under operating

conditions covered in this specification over service life of CTRB. Therefore no changes are required in this clause of specification.

8.3.3 Traceability The supplier shall set up and maintain a system of identification and traceability of finished products, which allows the detection, based on an identification mark, of the following elements: (i) Material origin including the chemical


Accepted

OK

M/s NEI‟s comments examined and not accepted as boundary dimensions are desirable for quality assurance.

analysis of every heat and steel manufacturing batch. (ii) Heat treatments. (iii) Inspection of boundary dimensions as well as inspection of soundness. (iv) Batch number.

8.3.3 iii: Should be removed. Not Required.

9.0 PHYSICAL PROPERTIES

9.1 Rings and rolling elements shall be free of any defects especially on working surface, which can be harmful to their function (such as burrs, scratches, rust stains, nicks and dents). There shall be no grinding burns during the different grinding operations.


Accepted

OK No comments offered

No change required

9.2 CTRB‟s cage shall exhibit no defects that might affect its function (such as burrs, scratches, rust).To avoid crack initiation, the connection between the cage bars and the annular body shall be smooth and conform to rounding-off shown on the detail drawing. If not otherwise documented in Clause (4.4) of DIN EN 12080-2011-01, the requirements of cages of polymeric material shall be as per Annexure-D of DIN EN 12080-2011-01.

CTRB‟s cage shall exhibit no defects that might affect its function (such as burrs, scratches, rust).To avoid crack initiation, the connection between the cage bars and the annular body shall be smooth and conform to rounding-off shown on the detail drawing. If not otherwise documented in Clause (4.4) of DIN EN 12080-2011-01, the requirements of cages of polymeric material shall be as per Annexure-D of DIN EN 12080-2011-01. (CTRB for LHB Coach are equipped with Polyamide cage, Which does not prone to rust.)

Accepted

The cage material as per SKF design, which is proven and running in Indian conditions for more then 15 years.

CTRB‟s cage shall exhibit no defects that might affect its function (such as burrs, scratches, rust).To avoid crack initiation, the connection between the cage bars and the annular body shall be smooth. and conform to rounding-off shown on the detail drawing. If not otherwise documented in clause (4.4) of DIN EN 12080-2011-01, the requirements of cages of polymeric material shall be as per Annexure-D of Din EN 12080-2011-01.

M/s FAG‟s comments are examined and accepted. M/s SKF‟s comments examined and it is noted comments are inline with the provision of this clause. M/s NEI‟s comments are examined and it is noted that as per requirements covered in this specification CTRB shall be conforming to EN12080. In order to ensure compliance of the CTRB component (cage) shall also be conforming to requirements detailed in clause 4.4 of EN12080. Therefore, the rust defect is removed from this clause and rest is same of this clause.

9.3 Soundness of rings and rolling elements Should be removed since no such requirement is there in existing passenger coach Spherical roller bearings.

9.3. 1 9.3. 2

The soundness shall be inspected by the manufacturer. The method is described in Annexures A, B and C of DIN EN 12080-2011-01. Any alternative methods to be used, which give equivalent results, shall be agreed and documented in accordance with Clause (4) of DIN EN 12080-2011-01. Soundness of rings and rolling elements shall conform to Class 1 as defined in Annexure-A of DIN EN 12080-2011-01.) Internal soundness of rings The reference method for the inspection of internal soundness of rings is described in Annexure-A of DIN EN 12080-2011-01. When tested, no ring shall exhibit defect indication on the raceway, or in a section of 4mm depth below the raceway, with the amplitude greater or equal to observed with

No change required (Noted) Internal soundness of rings The reference method for the inspection of internal soundness of rings is described in Annexure-A of DIN EN 12080-2011-01. When tested, no ring shall exhibit defect indication on 0,5 mm in diameter and 0,5 mm deep for Class 1 rolling bearings, in accordance with

Accepted Accepted

OK OK

M/s NEI‟s comments are not accepted as design requirements of CTRB are different. M/s FAG‟s comments are examined and found in line with this clause of specification. Therefore, no changes are required in this clause.

9.3. 3 9.3. 4 9.3. 5

the master defect corresponding to the soundness class in question in accordance with Annexure-A of DIN EN 12080-2011-01. Larger defects are tolerated at deeper than this section, though the defect indications shall not be more than twice the amplitude of that observed with the master defect. Soundness of ring surfaces The reference method for the inspection of surface soundness of rings is described in Annexure-B of DIN EN 12080-2011-01.when tested, no evidence of defects shall be observed on any of the ring surfaces. Surface soundness inspection of rings can also be carried out with an approved equivalent standardized inspection method, e.g. calibration and test procedure analogous to the eddy current testing of rollers as covered in Annexure-C of DIN EN 12080-2011-01.

Soundness of roller raceway surfaces The reference method for the inspection of the raceway surface soundness of rollers is described in Annexure-C of DIN EN 12080-2011-01. When tested, no roller shall exhibit defect indications on its raceway with amplitude greater than or equal to observed with the master defect as defined in Annexure-C of DIN EN 12080-2011-01. For rolling bearings manufactured of case–hardened steel, the effective depth of the hardened case shall be documented in accordance with Clause (4) of DIN EN 12080-2011-01. The depth of the hardened case is determined as a function of the change on hardness of the transversal cross section of a test piece or a prepared sample. The hardness shall be measured in accordance with EN ISO 6507-1 and EN ISO 2639 or another process agreed and documented in accordance with Clause (4) of DIN EN 12080-2011-01. At this depth, the

Annexure-A of DIN EN 12080-2011-01. Larger defects are tolerated at deeper than this section, though the defect indications shall not be more than twice the amplitude of that observed with the master defect. (According to Annexure - A of DIN EN 12080-2011-01 clause 4.4.2 sensitivity is defined as 0,5 mm in diameter and 0,5 mm deep for Class 1 rolling bearings, which are followed world wide.) No change required (Noted) No change required (Noted) No change required (Noted)

Accepted Accepted Accepted

OK Eddy current is done During manufacturing of rollers. No comments

No change required M/s SKF‟s comments examined and it is noted comments are inline with the provision of this clause. Therefore no changes are required in this clause of specification. No change required

Vikers hardness shall be at least 550 HV1.

10.0 PERFORMANCE

10.1

Environmental Conditions The CTRBs together with the running gear are subject to the following environmental conditions:

Temperature variations: -400 C to +70

0 C

Relative humidity: 30% to 100%

Exposure to:

Rain, snow, ice, ozone, salty air (coastal areas) and smog.

Sand, sandstorms, brake dust, and industrial environments.

Damage from flying stones raised from the ballast track bed.

Oil and grease residue, feces, kitchen waste

Both acidic and basic cleaning products to RDSO spec.: M&C/PCN/101

Frequency of cleaning: every 2-5 days The mounted CTRBs are to be cleaned together with the running gear before inspection with water under 40 bar pressure and temperature up to 50

0C.

Environmental Conditions The CTRBs together with the running gear are subject to the following environmental conditions: • Temperature variations: -40

0 C to

+700 C

• Relative humidity: 30% to 100% • Exposure to: • Rain, snow, ice, ozone, salty air (coastal areas) and smog. • Sand, sandstorms, brake dust, and industrial environments. • Damage from flying stones raised from the ballast track bed. • Oil and grease residue, feces, kitchen waste • Both acidic and basic cleaning products to RDSO spec.: M&C/PCN/101 • Frequency of cleaning: every 2-5 days The mounted CTRBs are to be cleaned together with the running gear before inspection with water under 40 bar pressure and temperature up to 50°C. (Roller bearings should never be cleaned with water. It should be clean with proper cleaning method with MTO. Request to provide RDSO spec no..: M&C/PCN/101 for study purpose.)

Accepted

Ø Temperature variations: -40

0C to

+700C

(Not required for -40 degree C, upper limit OK, material for -40 degree C steel will be different and costly). • Damage from flying stones raised from the ballast track bed. (Not applicable , bearing fitted in housing) The mounted CTRBs are to be cleaned together with the running gear before inspection with water under 40 bar pressure and temperature up to 50

0C. - OK ,

however this test can be done during testing of prototype bearing on test rig.

1. RDSO to put realistic environment temperature range suiting Indian weather conditions.

2. Pressure limit is too high. RDSO to clarify??

Comments of M/s FAG, M/s SKF and M/s NEI have been examined and found acceptable and minimum environmental temperature changes as: --10

0C in line with the

Electrical Directorate/RDSO spec. No./RDSO/2006/EL/Spec/0044 (Rev. 13). and last para of this clause is modified as below; The axle box with mounted CTRBs is cleaned together with the running gear before inspection with pressurized water jet water and temperature up to 50

0C.

10.2 Computation of Loads Until the existence of binding UIC or EN norms, the following assumptions are valid for proof of statistical load-carrying capacity: Single wheel force horizontal/lateral = 80 kN Vertical force per wheel = 110 kN However, dynamic load on account of wheel shelling etc. have not been considered in above loads.


Accepted

No comments offered

No comments offered

No change required

10.3 Performance Requirements The CTRBs must provide the following performance: Interval for additional lubrication, inspection, and operating safety not less than 1.2x10

6km

Service life not less than 3.0x10

6km

Performance Requirement The CTRBs must provide the following performance: Interval for additional lubrication , inspection, and operating safety not less than 1.2x10

6km

Service life L10 not less than 3.0x10

6km

Performance Requirements The CTRBs must provide the following performance: Interval for additional lubrication, inspection, and operating safety not less than 1.2x10

6km

The republication interval for Indian weather and track conditions , SKF has given as 0.8 x106km Service life (L10 life) OK

1. RDSO to provide operational parameter and method to calculate service life similar to given in C-8527 Clause 5.

Considering RDSO requirements detailed against clause (5.5) in this column, the last para of this clause needs to be deleted.

The CTRBs shall meet requirements detailed in para 10.1 such as penetration by foreign particles, dampness, and cleaning products. A possible penetration must not hinder the operating safety within an inspection interval of 1.2x10

6 km or 60 months whichever is

earlier.

Service life is determined using the following data: a) wheel set load 18t b) ) wheel set weight including brake

discs1320 kg c) Max. Speed: 160 kmph d) Mean wheel diameter 880 mm


6 km or

60 months whichever is earlier. Service life L10 is determined using the following data:

a) wheel set load 18t b) wheel set weight including brake

discs 1320 kg c) Max. Speed: 160 kmph d) Mean wheel diameter 880 mm

(Instead of service life it should be read as L10)

Service life not less than 3.0x10

6km


6 km

or 60 months whichever is earlier.

SKF has recommended Inspection interval of 0.8 x106 km or 60 months whichever is Earlier.

2. Interval of additional lubrication, inspection and operating safety is mentioned in mileage 1.2 million Kms. It should be mentioned in terms of time duration (Months/years) and should be linked with POH interval, wheel disc change interval etc 3. Service life requirement is mentioned in 3.0 million Kms, does it mean that after this bearing will be discarded? RDSO to clarify??

10.4 The occurrence of fretting corrosion on contact surfaces within the CTRBs and in between CTRBs and axle is to be protected using the latest appropriate technical measures in such a way that operating safety of the CTRB in a given interval according to paragraph 10.3 is ensured.

The occurrence of fretting corrosion on contact surfaces within the CTRBs and in between CTRBs and axle is to be protected using the latest appropriate technical measures in such a way that operating safety of the CTRB in a given interval according to paragraph 10.3 is ensured. Recommend to use FAG ARCA.MOUNTINGPASTE during mounting of CTRBs. (We recommend to use FAG ARCA.MOUNTINGPASTE during mounting of CTRBs to avoid fretting corrosion & to improve sliding behaviour of bearing on the shaft.)

Accepted

OK, SKF has unique and patented designed Polymer Distance Ring to prevent fretting corrosion within bearing.

No comments offered

M/s NEI‟s and M/s SKF‟s comments examined and it is noted that comments are inline with the provision of this clause. Therefore no changes are required in this clause of specification.

11.0 MOUNTING/DISMOUNTING

11.1 The assembly, locking and initial lubrication of the CTRB shall be done in India by the supplier. The suppliers shall also arrange to supply necessary equipments and tools for mounting/dismounting the CTRB against Railways requirement, if any.

The assembly, locking and initial lubrication of the CTRB shall be done in India by the supplier. The suppliers shall also arrange to supply necessary equipments and tools for mounting/dismounting the CTRB on chargeable bases against Railways requirement, if any. (Tools requried for assembly, locking and initial lubrication can only be supplied on chargable bases, being very high value items.)

Accepted

OK, however mounting / dismounting tools will be chargeable.

The assembly, locking and initial lubrication of the CTRB shall be done in India by the supplier for prototypes only. The suppliers shall also arrange to supply necessary equipments and tools for mounting/dismounting the CTRB against Railways requirement, if any on cost basis.

Clause title changed to Prototype Mounting/ Dismounting in place of Mounting/Dismounting against the comment received by M/s NEI. M/s FAG‟s, M/s SKF‟s and M/s NEI‟s comments are not accepted against the comments given in this clause that “The assembly, locking and initial lubrication of the prototype CTRB. The suppliers shall also arrange to supply necessary equipments and tools for prototype mounting/dismounting the

CTRB on chargeable bases against Railways requirement, if any.

11.2 It would be the responsibility for the CTRB supplier to check and certify the fitness of the axle journal before undertaking the prototype mounting of the CTRB and that the tolerances on the journals are adequate for a correct fit.


To be deleted: reason: Currently

there is no contract with Railways

to perform this activity at their

premises.

This can be recorded by bearing manufacturer for prototype fitment however measurement facility and manpower required by user Railway.

No comments offered

M/s TIMKEN‟s and M/s SKF‟s comments are not accepted. Therefore, no changes are required in this clause of specification.

11.3 The supplier should keep proper records for prototype mounting indicating the details of the following: a) D

Date of mounting. b) M

Manufacturers Code of axle. c) M

Month and year of manufacture of axle d) C

Consecutive No. of axle e) J

Journal Inspection: Visual f) J

Journal diameter: By gauge g) S

Shoulder diameter of axle: By gauge h) C

Cartridge Bearing Serial No. and manufacturers code

i) FForce during mounting of CTRB

j) FFinal seating force of CTRB.

k) LLateral/end play

l) CCap Screw torque.


To be deleted : reason: Currently

there is no contract with Railways

to perform this activity at their

premises.

a) OK b) OK c) OK d) OK e) OK f) OK g) OK h) OK i) Force during mounting not recommended by SKF j) OK k) OK l) OK

No comments offered

M/s TIMKEN‟s and M/s SKF‟s comments are not accepted. Therefore no changes are required in this clause of specification.

12.0 WORKMANSHIP Should be merged with clause 9.0

12.1 The rolling elements shall be free from defects of workmanship and material which may affect their serviceability.


Accepted

OK M/s NEI‟s comments are not accepted because this clause is required for clarity in this specification. Therefore, no changes are required in this clause of specification.

12.2 The surfaces of the bore, outside diameter, sides and load carrying areas shall be smooth and shall not show any damaged/corroded areas.


Accepted

OK

13.0 RETOUCHING

13.1 Retouching of the bearing or its components with or without the intention of concealing a defect is prohibited.


Accepted


No change required

14.0 LUBRICATION

14.1 The grease used in CTRB shall meet the requirements detailed in EN 12081.


To be changed: The grease used

in the CTRB shall be proposed by

the contractor and from a RDSO

approved source

Grease will be as per SKF, already being used in the field and approved.

Should be removed.

M/s TIMKEN‟s, M/s SKF‟s and M/s NEI‟s comments are not acceptable. Therefore, no changes are required in this clause of specification.

14.2 When it is specified that the rolling bearings shall be delivered pre-lubricated with grease, this shall be with grease approved by the Purchaser in accordance with EN 12081. The grease type, the quantity and its distribution shall be documented in accordance with Clause (4) of DIN EN 12080-2011-01.


To be changed : The grease type, the quantity and its distribution shall be documented in accordance with Clause (4) of DIN EN 12080-2011-01.

Grease type and distribution is part of bearing design and already defined by SKF.

Grease selected by bearing manufacturers may be used by agreement between Purchaser and Contractor. However, the contractor shall provide complete details of grease to the Purchaser/RDSO.

Current FIAT specification prescribes requirement of grease to UIC-814. As per requirements covered in this specification CTRB shall be conforming to EN12080. In order to ensure compliance of the of CTRB to 12080 grease used in CTRB shall also be conforming to requirements detailed in clause 15.1 of EN12080 which states that in pre lubricated CTRB grease shall be as per EN12081. Therefore, in this clause of specification “the purchaser” shall be replaced with “RDSO”.

14.3 The supplier shall furnish the test results of grease to be used for initial lubrication of CTRB.


Accepted

Already proven grease in the field for many years.

The supplier shall furnish the test results of grease (supplier‟s TC) to be used for initial lubrication of CTRB.

M/s SKF‟s and M/s FAG‟s comments examined and it is noted comments are inline with the provision of this clause. Therefore no changes are required in this clause of specification.

14.4 The supplier shall guarantee satisfactory performance of their bearings with the brands of grease used by them.

The supplier shall guarantee / warranty satisfactory performance of their bearings with the brands of grease used by them. (Warranty term to be added.)

Accepted


M/s FAG‟s Comment accepted and guarantee is changed with guarantee/warranty.

14.5 The tenderer should give specific recommendations for the roller bearing offered regarding: i) Period for change of grease and quantity of grease required for each replenishment/change. ii) Period of grease seal change. iii) Period for dismantling and complete bearing examination.


Accepted


No change required

14.6 Rust Protection All rolling bearings shall be delivered protected against corrosion with a product free from toxic or harmful substance. The compatibility of the preservative with the


Accepted

Bearing is protected from rust by phosphate coating.

No comments offered

M/s SKF‟s comments examined and it is noted comments are inline with the provision of this clause.

lubricating grease shall be guaranteed and documented in accordance with Clause (4) of DIN EN 12080-2011-01.

Therefore, in 1st line of this

clause of specification “All rolling bearings” is replaced with “all bearing elements”.

15.0 QUALITY ASSURANCE PROGRAMME

15.1 Contractor shall submit his internal Quality Assurance Programme (QAP) in triplicate to the Purchaser/RDSO. In this, the frequency of various checks, details of nature of work involved in the checks and records maintained regarding these checks shall be indicated. The details of tools and gauges to be used during inspection of bearing /bearing components shall be also indicated in the QAP.


Accepted


No change required

15.2 Contractor shall, on demand by the Purchaser/ RDSO or Inspecting Authority nominated by Purchaser, make the records of checks carried out during internal quality assurance available for scrutiny.


Accepted

Record of the checks are made as per QAP.

No comments offered

M/s SKF‟s comments examined and it is noted comments are inline with the provision of this clause. Therefore no changes are required in this clause of specification.

15.3 Contractor should have the ISO 9001 certification for manufacture of CTRB.


Accepted

OK

Contractor should have the ISO 9001/UIC/AAR certification for manufacture of CTRB.

M/s NEI‟s comments examined and it is noted that regarding certification of CTRB to UIC/AAR is covered in clause no. 4.5 of this specification. And following is added to: The personnel responsible for non destructive testing shall be qualified and certified to the system used should offer equivalence with EN 473.

15.4 Break-up of indigenous and imported components to be used in the CTRB shall be clearly spelt out.


Accepted

OK

No comments offered

No change required

16.0 MARKING

16.1 The marking area shall be agreed and documented in accordance with Clause (11) of DIN EN 12080-2011-01. Each bearing shall carry on the side face of its inner ring visibly and indelibly the following markings: i) Contractor's Name/Code/Trade mark/Country of origin.

ii) Production plant code, if there is more than one plant.

iii) Complete designation of the bearing.

iv) Consecutive number of the bearing. v) Month and year of manufacture.


Accepted

OK OK Component marking is done on each component. Unique serial

The marking area shall be agreed and documented in accordance with Clause (11) of DIN EN 12080-2011-01. Each bearing shall carry on the side face of its inner ring outer diameter of outer ring/double cup visibly and indelibly the following markings:

M/s SKF‟s comments examined and it is noted comments are inline with the provisions of this clause. However, M/s SKF‟s suggestion for marking on the Outer ring of CTRB is acceptable. M/s NEI‟s comments examined and not acceptable. As per requirements covered in this specification the marking on CTRB shall be conforming to EN12080.

number is marked on Outer ring. OK

16.2 Drawing showing the marking arrangement, proposed to be followed by the tenderer shall be submitted along with the offer.


Accepted


No change required

16.3 Laser marking shall be used for marking on the CTRB.


Accepted

Laser marking can not be done on Outer ring OD and not suitable also for the application.

The supplier is responsible for selecting the suitable marking process.

M/s SKF‟s and M/s NEI‟s comments examined and changes in this clause of specification is as below; The supplier is responsible for the selecting marking process for marking as per clause 16.1 above on the CTRB. However, Marking by Laser is desirable and by electric pencil is prohibited.

17.0 PACKING

17.1

The bearing shall be packed as under:

17. 1.1

Only one bearing shall be packed in a wooden/Carton box


To be changed : Bearings shall

be packed in a wooden/ carton

box

Bearings are supplied in a pallet not in individual packing.

No comments offered

M/s TIMKEN‟s and M/s SKF‟s comments are not accepted.

17. 1.2

Plastic wedges and plastic straps shall be used to prevent damage during transit.


Accepted

OK

17.1.2: Not applicable for CTRB & should be removed (applicable for spherical roller bearings only)

M/s NEI‟s comments are not acceptable. Therefore no changes are required in this clause of specification against comments of NEI.

17. 1.3

Rust preventive oil shall be used to cover all the surfaces.


Accepted

OK

No comments offered

No change required

17. 1.4

Bearing shall be suitably wrapped/packed in oil/grease resistant paper /polyethene before being packed in the box.


Accepted

OK

No comments offered

No change required

17. 1.5

Bearing shall be finally packed in pallets or wooden cases depending upon mode of transport. These pallets or wooden boxes will be strapped with steel/nylon band and lead seal on wire, by Inspecting Authority before shipment.


Accepted

OK

No comments offered

No change required

17. 1.6

The supplier will be responsible for proper packing and shall ensure that these packing methods are adequate for handling at Indian Ports and Inland Rail/Road Transport and in Railway workshops.


Accepted OK

No comments offered

No change required

18.0 ACCEPTANCE CRITERIA

18.1 General

18. 1.1 18. 1.2 18. 1.3

Inspection shall be carried out by Purchaser or Inspection Authority nominated by Purchaser. Inspection of the bearings shall be carried out at the Contractor‟s premises. For this purpose, the Contractor shall provide, free of charge, labour and appliances required by Inspecting Officer for inspecting whole of the work under contract, whether inspected at his own or his Sub-Contractor‟s Works.

No change required (Noted) No change required (Noted) No change required (Noted)

Accepted Accepted Accepted

OK OK No comments offered

No comments offered No comments offered No comments offered

No change required No change required No change required

18.2 Presentation of Delivery

18. 2.1

On completion of manufacture including marking as per Clause 16.0, fully assembled bearings shall be presented for inspection in lots.


Accepted

OK

No comments offered

No change required

18. 2.2

Bearings with the same designation, belonging to the same manufacturing batch and presented at the same time shall constitute a lot.


Accepted

OK

No comments offered

No change required

18. 2.3

The bearings shall be in un-lubricated and unpacked condition, if not specified otherwise.


The bearings shall be in un-lubricated and unpacked condition, if not specified otherwise. To be changed: The bearings shall be in unpacked condition. This is because , once bearings are assembled, they cannot be stored in unlubricated condition. This is also contradictory to 18.2.1

The assembled bearing cannot be un-lubricated.

18.2.3: Not relevant for CTRB. Should be removed.

Comments of M/s TIMKEN, SKF and NEI examined and clause changed as below; The bearings shall be in unpacked condition, if not specified otherwise.

18.3 Temperature

18. 3.1

All measurements shall be carried out at ambient temperature. The gauges and measuring instruments and the parts to be inspected shall be stabilised at this temperature before any test is carried out.


Accepted

OK

No comments offered

No change required

18. 4

The side face opposite to the bearing designation marking shall be considered as the reference side.


Accepted

This depends on bearing manufacturing process, also Outer ring does not have marking on Face.

Not relevant for CTRB. Should be removed.

M/s SKF‟s and M/s NEI‟s comments are examined and found acceptable. Therefore, this clause changes is required to be deleted in this specification.

18.5 General Inspection

18. 5.1

Inspection as per Clauses 18.5.2 to 18.5.6 shall be carried out on each of the bearing in the lot offered.

No change required (-----)

Accepted

OK

No comments offered

No change required

18. 5.2

The diameter of bore of inner ring/cone and outside diameter of outer ring/double cup shall be measured as per procedure agreed to between the manufacturer and Inspecting Authority/RDSO.

The diameter of bore of finished inner ring/cone and outside diameter of outer ring/double cup shall be measured as per procedure agreed to between the manufacturer and Inspecting Authority/RDSO. (Finished bearing components to be checked.)

Accepted

OK

The diameter of bore of inner ring/ cone and outside diameter of outer ring/ double cup shall be measured as per procedure agreed to between the manufacturer and inspecting authority/ RDSO.

M/s FAG‟s comments is acceptable and diameter of bore of inner ring/cone to be changed as diameter of bore of finished inner ring/cone. M/s NEI‟s comment examined and not found acceptable.

18. 5.3

Width of inner ring/cone and of outer ring/double cup shall be measured as per procedure agreed to between the manufacturer and Inspecting Authority/RDSO.

Width of finished inner ring/cone and of outer ring/double cup shall be measured as per procedure agreed to between the manufacturer and Inspecting Authority/RDSO. (Finished bearing components to be checked.)

Accepted

OK

Width of inner ring/ cone and of outer ring/ double cup shall be measured as per procedure agreed to between the manufacturer and inspecting authority/ RDSO.

M/s FAG‟s comments is acceptable and width of inner ring/cone to be changed as width of finished inner ring/cone. M/s NEI‟s comment examined and not found acceptable.

18. 5.4

Radial internal clearance of the bearing shall be measured as per procedure agreed to between the manufacturer and Inspecting Authority/RDSO.

Radial Axial internal clearance of the bearing shall be measured as per procedure agreed to between the manufacturer and Inspecting Authority/RDSO. (CTRB are having axial clearance only.)

To be deleted : reason ; Axial

clearance are maintained in the

bearing when they are mounted

on the journal as required

There is not radial clearance , it‟s axial clearance or lateral play to be checked in TBU.

Radial internal Lateral clearance of the bearing shall be measured as per procedure agreed to between the manufacturer and inspecting authority/ RDSO.

The comments of M/s FAG, TIMKEN, and NEI examined and clause changed as below; Internal clearance of the bearing shall be measured as per procedure agreed to between the manufacturer and Inspecting Authority/RDSO.

18. 5.5

Appearance of bearings shall be visually examined (without magnification). All essential portions of the roller bearings shall be clean and free from defects such as porosity, burrs, hardening cracks, grinding marks, indentations, rust marks etc.,

No change required (Noted) No change required (Noted)

Accepted

OK

No comments offered

No change required

18. 5.6

Functioning of all bearings shall be checked, as per the method agreed between Contractor and Supplier.

To be Clarified: Functioning

before mounting?

OK

Not relevant for CTRB. Should be removed.

This clause prescribes general functionality check of CTRB as per visual norms.

18. 5.7

Only those bearings of a lot which meet requirements in respect of Clauses 18.5.2 to 18.5.6 stipulated on approved drawings above shall form the lot for the purpose of Sampling Inspection as per Clause 18.8.

To be deleted (Statement not clear.) No change required (Noted)

Accepted

OK

No comments offered

No change required

18.8 Sampling inspection

18. 8.1

Inspecting Authority shall select bearings at random from each lot presented for carrying out Sampling Inspection as per Clauses 18.8.3 to 18.8.10. The size of sample to be selected for these tests shall be as indicated below:

No. of bearings in the lot

No. of sample bearings to be selected

Up to 100 2

101-250 3

Over 250 4


Accepted

OK

No comments offered

No change required

18. 8.2

Sample bearings selected as per Clause 18.8.1 shall be indelibly marked.


Accepted

OK

No comments offered

No change required

18. 8.3

Inner ring width variation on each of the sample bearing shall be checked


Accepted

OK

No comments offered

No change required

18. 8.4

Radial run-out of inner and outer rings in the assembled bearing.

Radial run-out of inner and outer rings in the assembled bearing component stage to be measured. (Run out of individual components is being checked 100 % during

To be deleted : It is not possible

to check radial runout of an

assembled CTRB precisely.

OK

18.8.4: Not relevant for CTRB. Should be removed.

Radial run out of assembled CTRB is required to be measured to ensure proper mounting on journal and also for proper clamping of

manufacturing. Moreover, this calls for size specific tapered mandrels which now days are not required due to manufacturing technology advancement at each stage of manufacturing. If run outs of individual components are controlled within the limits, the run out outcome in assembled bearing is bound to come within limit by virtue of manufacturing.)

outer ring of CTRB with control arm. Therefore no change is required.

18. 8.5

The length and diameter of all rollers on each of sample bearings shall be measured and variation therein determined.


To be deleted:

Reason: It is not possible to measure roller dimensions in assembled bearing. Secondly, it is a logistic nightmare to track rollers from individual bearings after the bearings are disassembled.

OK

No comments offered

M/s TIMKEN‟s comment examined and not found acceptable as during inspection CTRB will be dis-assembled. Therefore no changes are required in this clause of specification.

18. 8.6

Magnetic Particle Test shall be carried out on rings of each sample bearing. It shall be carried out as per Annexure-B of DIN EN 12080-2011-01. The rings should not show any signs of cracks or harmful defects. After this test, bearing components shall be de-magnetized.


To be deleted: reason : EN 12080 calls for MPI testing for each component. So not required for acceptance audit.

OK

18.8.6: Magnetic particle test shall be carried out on rings of each sample bearing. It shall be carried out as per Annexure-B of DIN EN 12080-2011-01. The ring should not show any signs of cracks or harmful defects. After this test, bearing components shall be demagnetized.

M/s NEI‟s comments are not acceptable as Annexure-B of this specification prescribes process details of MPT. M/s TIMKEN‟s comment are not acceptable. Therefore, no change required in this clause.

18. 8.7

Before and after the tests as per Clause 18.8.6 sample bearings shall be checked as per method, agreed between Purchaser and Contractor for residual magnetism. The residual magnetism shall not exceed 0.5mT.


Accepted

RDSO need to clarify on unit of measurement i.e. mT. The magnetism is measured either in A/cm or Gauss

18.8.7: Before and after the test as per clause 18.8.6 sample bearings shall be checked as per method, agreed between purchaser and contractor for residual magnetism. The residual magnetism shall not exceed 0.5mT 5

M/s NEI‟s comments are not acceptable as 1 mT is equal 10 mG. Therefore, no change required in this clause.

Gauss

18. 8.8

Eddy current inspection of rollers shall be carried out on rollers of each sample bearing. It shall be carried out as per Annexure-C of DIN EN 12080-2011-01. The raceway surface of rollers should not show any signs of grinding cracks, heat treatment or hardening cracks lines and scores due to drawing, marks etc.


To be deleted: reason: EN 12080

calls for eddy current testing for

each roller. Eddy current testing

for rollers cannot be done in

assembled bearing. So not

required for acceptance audit.

Eddy current check of the rollers is done during manufacturing - in case of imported / outsourced rollers it can not be done.

Inspection of rollers shall be carried out on rollers of each sample bearing by suitable method. The raceway surface of roller should not show any sign of grinding cracks, heat treatment or hardening cracks lines and scores due to drawing, marks etc.

M/s TIMKEN, M/s SKF‟s and M/s NEI‟s comment examined and not found acceptable. Therefore, no change required in this clause.

18. 8.9 18.8. 9.1

Hardness Testing Hardness of both rings and three rollers of each sample bearing shall be checked as per Clause (12).

Hardness of both rings and three rollers of each sample Bearing shall be checked as per Clause (12). or by another equivalent method agreed and documented in accordance with Clause (4.4) of DIN EN 12080. (Noted)

Accepted

OK

No comments offered

M/s FAG‟s comment examined and found accepted and clause modified as: Hardness of both rings and three rollers of each sample Bearing shall be checked as per Clause 12 of DIN EN 12080-2011-01.

` 18.8. 10

Expansion testing of inner ring of each of the sample bearing shall be carried out as per Clause (9) of DIN EN 12080-2011-01.


To be amended : Expansion testing of inner ring of each sample bearing produced from Through hardening heat treatment process shall be carried out as per Clause (9) of DIN EN 12080-2011-01. This is because, Case Carburised bearings are exempted from Expansion testing as per Clause (9) of DIN EN 12080-2011-01.

Expansion testing not required for bearing heat treated in Bainite Heat Treatment.

Clause 9 of DIN EN 12080-2011-01 can be written as it is.

M/s TIMKEN‟s comment examined and are not understood. M/s SKF‟s comment examined and found acceptable and are in line with this clause of specification. M/s NEI‟s comment not accepted because this clause is required for clarity in this specification. Therefore no changes are required in this clause of specification.

18.8. 11

Surface finish of both rings and three rollers of sample bearing shall be checked in accordance with IS: 3073. However at the time of prototype bearing testing, surface finish of all rollers of sample bearings shall be checked.


Accepted

SKF suggest to check roughness of sample rings and rollers only.

Surface finish of both rings and three rollers of sample bearing shall be checked in accordance with IS: 3073. However at the time of prototype bearing testing, surface finish of all rollers of sample bearings shall be checked.

M/s SKF‟s and M/S NEI‟s comments are examined and not found acceptable. Therefore no changes are required in this clause of specification.

18.8.12

In case any of the sample bearings when tested as per Clauses 18.8.2 to 18.8.11 does not meet the requirements of this specification, the whole lot shall be rejected.


Accepted

OK

No comments offered

No change required

18.9 Chemical Composition Analysis

18. 9.1

Manufacturer shall furnish ladle analysis, microstructure and inclusion rating of steel for each heat. This shall correspond to the stipulations in the approved drawings.

Manufacturer shall furnish test report / certificate of ladle analysis, microstructure and inclusion rating of steel for each heat from raw material supplier. This shall correspond to the stipulations in the approved drawings. (It can only be checked in raw material stage.)

Accepted

OK, however this should be applicable only for Prototype lots.

Manufacturer shall furnish ladle analysis chemical composition analysis, microstructure and inclusion rating of steel for each heat. This shall correspond to the stipulations in the approved drawings.

M/s FAG‟s, M/s SKF‟s and M/s NEI‟s comments are examined and not found acceptable. Therefore no changes are required in this clause of specification.

18. 9.2

Manufacturer shall furnish actual chemical composition of cage material of which cages on bearings in lot offered have been manufactured. This shall correspond to the stipulations in the approved drawings.

Manufacturer shall furnish actual chemical composition of Cage material shall be acc. to DIN EN 12080:2011-01, Clause D.3 of Annex D of which cages on bearings in lot offered have been manufactured. This shall correspond to the stipulations in the approved drawings. (Cage material should be in accordance with DIN EN 12080:2011-01, Clause D.3 of Annux D.)

To be amended : Manufacturer shall furnish the cage material which cages on bearings in lot offered have been manufactured. Cage material composition is a proprietary information so we request that confidentiality is respected by the purchaser.

OK

Manufacturer shall furnish actual chemical composition supplier Test certificate of cage material of which cages on bearings in lot offered have been manufactured. This shall correspond to the stipulations in the approved drawings.

M/s FAG‟s, M/s TIMKEN‟s and M/s NEI‟s comments are examined and are acceptable. So the following to be added in this clause: Cage material should be in accordance with Clause D.3 of Annex D of DIN EN 12080:2011-01.

18. 9.3

Inspector may order retest on rings, rollers and cage of one bearing out of every 1000 bearings inspected.


To be amended : Inspector may order retest of dimensions , special geometries on rings and rollers as agreed between the purchaser and the contractor. Cutting of finish sample bearings for case depth checks is requested to be avoided . Testing on Cage in the bearing manufacturing premises is not possible.

Rings Chemical test should be valid for prototype testing only Polyamide Cage material composition cannot be checked.

Inspector may order retest on rings, rollers and cage of one bearing out of every 1000 bearings inspected.

M/s TIMKEN‟s, M/s SKF‟s and M/s NEI‟s comments are examined and not found acceptable. Therefore no changes are required in this clause of specification.

18. 9.4

In case the results of tests at Clause 18.9.3 or the analysis in Clauses 18.9.1 and 18.9.2 do not conform to stipulations on approved drawings, the whole lot of bearings shall be rejected.


Accepted

OK however with above considerations.

No comments offered

No change required

19.0 INSPECTION BY MANUFACTURER

Should be removed already covered in Clause 15.0

19.1 Inspection Plan If not otherwise documented in accordance with Clause (4.4) of DIN EN 12080-2011-01, the sampling plan and the number of inspections to be undertaken by the supplier shall be accordance with table -1 of Clause (12) of DIN EN 12080-2011-01.


Accepted

OK M/s NEI‟s comment not accepted because this clause is required for clarity in this specification. Therefore no changes are required in this clause of specification.

20.0 SERVICE PERFORMANCE TESTING

20.1

The performance testing of axle box for all type of rolling stock is to be done as per EN 12082 to ensure suitability for the required service, i.e. assembly of box housing, bearing, sealing and grease is well suited for the service requirements. This testing is made up of two stages, a “Rig performance test”, and other “Field test”. Test parameters and minimum performance requirements for vehicles in operation on main lines are as specified in Clause (6) and Annexure-A of EN 12082.


Accepted


Considering changes in clause (10.1) of this specification, the clause is revised as below; The performance testing of axle box for all type of rolling stock is to be done as per EN 12082 to ensure suitability for the required service, i.e. assembly of box housing, bearing, sealing and grease is well suited for the service

requirements. This testing is made up of two stages, a “Rig performance test”, and other “Field test”. Test parameters and minimum performance requirements for Rig performance test for vehicles in operation on main lines are as specified in Clause (5) and Clause (6) and Annexure-A of EN 12082-2007.

21.0 FIELD PERFOPRMANCE MONITORING

The supplier shall regularly collect data and samples of previous supply from field to assess actual life obtained nature of defects occurring in the service and should take necessary action to improve quality. Half yearly report should be submitted to Director General (Carriage), Lucknow on data, samples collected and corrective action taken. This shall also be part of QAP of the supplier.

The supplier shall regularly collect data and samples of previous supply from field to assess actual life obtained nature of defects occurring in the service and should take necessary action to improve quality. Half yearly report should be submitted to Director General (Carriage), Lucknow on data, samples collected and corrective action taken. This shall also be part of QAP of the supplier.

The supplier shall regularly provide bearings supplied to various sheds & production units of Indian Railways, half yearly report should be submitted to Director General (Carriage), Lucknow on data of the same. (With various past experience Indian Railway Sheds / Production units will not provide such data to bearing manufacturers. However, RDSO shall collect performance feed-back from respective railway sheds or production units with reference to supplies detail provided, and further improvement quality improvement can be mutually agreed.)

Accepted

Supplier can only collect the data and samples of bearings for Prototype bearings only. For regular supplies Railway Units need to perform this exercise.

M/s FAG‟s, M/s SKF‟s and M/s NEI‟s comments are examined and not found acceptable. Therefore no changes are required in this clause of specification.

22.0 INDIGENISATION OF BEARING COMPONENTS

Not applicable for already RDSO approved indigenous supplier.

22.1 The following procedure would be followed for clearing indigenization of bearing components (cup, cone, roller, cage, seal wear rings, grease seal, spacer etc.).


Accepted

OK M/s NEI‟s comment not accepted. Therefore no changes are required in this clause of specification.

22.2 The component manufacturer will obtain drawings/specifications, know-how of manufacturing processes/manufacturing tolerances from bearing manufacturer and set up necessary machinery and plant to undertake manufacture of the component proposed for indigenization and submit a certificate from bearing manufacturer that the facilities set up are adequate for manufacture of the component to bearing manufacturer standard.


Accepted


22.3 The component manufacturer will then manufacture a batch size prescribed by the bearing manufacturer, which shall be sent to the collaborator for testing and approval. Should sampling be necessary from this batch, it shall be done by the RDSO using


Accepted


random sampling procedures.

22.4 The bearing manufacturer will arrange to get the component and assembly fitted with such components tested as prescribed in EN 12080-2011-01. This may be done by the bearing manufacturer on their own machines and in their own laboratories or in any other laboratories equipped to undertake such tests ensuring that the tests are similar to those done by UIC/AAR with prior approval of purchaser.


Accepted

OK M/s NEI‟s comment not accepted. Therefore, “UIC/AAR” in this clause of specification be replaced with “UIC/AAR/EN”

22.5 On successful development of the component the component manufacturer will develop full testing and inspection facilities as prescribed by bearing manufacturer for mass production of the component and furnish details thereof to the Railways. Mass production of the component should normally be started after these facilities have been developed. If however, full testing and inspection facilities are not yet developed the manufactures will advise the Railways the places where testing/inspection will be done.


Accepted


22.6 On being satisfied about adequacy of the testing/inspection procedures as prescribed by the bearing manufacturer, the component manufacturer will be permitted by RDSO to manufacture the component for use on Indian Railways subject to continued certification by the bearing manufacturer as per Clause 21.9 below.

On being satisfied about adequacy of the testing/inspection procedures as prescribed by the bearing manufacturer, the component manufacturer will be permitted by RDSO to manufacture the component for use on Indian Railways subject to continued certification by the bearing manufacturer as per Clause 21.9 22.9 below. (To be corrected)

Accepted

OK M/s FAG‟s comment is accepted because of this is the typographical mistake. M/s NEI‟s comment not accepted. Therefore, the change is required in this clause of specification to be corrected as clause 22.9 below in place of clause 21.9 below.

22.7 The field experience gained with such bearings will be reviewed by RDSO at the end of every six months of service for two year to assess the actual performance of the bearings and the desirability of continuing indigenous manufacture. Should this review involve opening of the bearings the bearing manufacturers will be associated.


Accepted


22.8 To facilitate this review, every time a fresh component is indigenized the bearing lot/lots fitted with such component will be given a distinctive identification marking by the component manufacturer. Details of the marking system would be worked out by the bearing manufacturer in consultation with RDSO and circulated to user Railways.


Accepted


22.9 The bearing manufacturers will also No change required Accepted OK M/s NEI‟s comment not

periodically furnish to the Railway a certificate from their collaborator that they have the necessary facilities (including subcontractors for component manufacturers) to consistently manufacture bearings of desired quality and accuracy under mass production conditions. The collaborators, consistent with their quality standards shall specify the periodicity of this certificate. This should be done before commencement of the indigenization program.

(Noted)

accepted. Therefore no changes are required in this clause of specification.

22. 10

All intended indigenization must be completed two years before the expiry of the collaboration agreement so that within the pendency of the collaboration unconditional license to manufacturers can be granted. Should the indigenization not be completed in this manner, the manufacturer will seek extension of collaboration.


Accepted


22. 11

All bearings with indigenously manufactured components will carry either the collaborator‟s name or the legend „Manufactured under license by ….‟ This legend may be abbreviated to „LIC …‟.


Accepted

There is no license provide within SKF being one organization, therefore bearings sold as "SKF".

M/s SKF‟s comments examined and it is noted comments are inline with the provision of this clause. M/s NEI‟s comment not accepted. Therefore no changes are required in this clause of specification.

23.0 MAINTENANCE INSTRUCTIONS

23.1 With the delivery of the first lot of CTRB, the supplier shall provide all the necessary maintenance, inspection, and service instructions, including replacement parts list, in written form. In particular, construction and operating limits as well as required measuring points must be provided.


Accepted

Need for clarification on construction and operating limits as well as required measuring points must be provided.

No comments offered

M/s SKF‟s Comment not acceptable. Therefore no changes are required in this clause of specification.

23.2 The supplier shall assist and advise Indian Railways regarding the process, machinery and plant required and train adequate staff for the purpose of setting up inspection, testing and servicing facilities in three Nominated Workshops at no extra cost. The setting up of maintenance facility will be at the discretion of the Purchaser.

Reconditioning of Cartridge Tapered Roller Bearings (CTRB) shall be done by bearing manufacturers at their premises on chargable basis. (It is strongly recommended to do reconditioning / overhalul of CTRB by bearings manufacturer being safety item.)

Accepted


M/s FAG‟s comments not acceptable. Therefore no changes are required in this clause of specification.

23.3 The supplier shall agree to train officers and staff in disassembly, cleaning, inspection of bearing components, greasing and assembly of the CTRB at their works. Officers and Staff to be trained of each nominated Workshop shall be as below: - O

fficers/Supervisors - 5 nos.

No change required (To be deleted in case clause no. 23.2 is incorporated)

Accepted



- Artisans -10 nos.

23.4 The successful bidder shall agree to supply, free of cost, one „cut-model‟ of Cartridge bearings arrangement per contract for educational purpose.

The successful bidder shall agree to supply, free of cost, one „cut model‟ or 3D model images in soft copy of Cartridge bearings arrangement per contract for educational purpose. (3D model images can be easily circulated to various sheds & production units for educational purpose compare to 'cut model'.)

Accepted


M/s FAG‟s comments not acceptable. Therefore, the following changes are required in this clause of specification. The successful bidder shall agree to supply, free of cost, one „cut-model‟ of Cartridge bearings arrangement per contract, if ordered by Railways for educational purpose.

23.5 For every 500 bearings ordered, the Contractor shall supply one Maintenance Manual for guidance of Indian Railway Workshops/Maintenance Staff in maintenance of the bearings. However, the Contractors who are supplying CTRB to Indian Railways for first time shall supply 100 Maintenance Manual with first purchase order. The Manual shall be complete in all respect of – 1. Description of the CTRB. 2. Procedure for initial mounting and

lubrication of the bearing, indicating quantity of lubricant per box.

3. Maintenance checks in service such as frequency of bearing examination, seal change, grease change etc. between major examinations.

4. Procedure for bearing extraction, examination and assembly, along with details of special tools required, if any, for this purpose.

5. Initial and condemning limits of clearances.

6. Details of other criteria for withdrawal of CTRB from service.


Accepted

OK Not applicable to Bearing for passenger coaches. OK OK Condemning limits not applicable for passenger coach TBU (Tapered Bearing Unit / CTRB) OK

No comments offered

M/s SKF‟s comments not acceptable. Therefore no changes are required in this clause of specification.

23.6 New Contractor shall submit the draft of Maintenance Manual to Purchaser/RDSO before its finalization.

To be deleted (Bearings shall be maintained as directed by bearing manufacturer in order to give satisfactory performance.)

Accepted



24.0 WARRANTY

24.1 The contractor shall ensure that design of CTRB is such that it performs satisfactory for a minimum period of 48 months after supply or 36 months after putting into service whichever is later. The warranty shall cover design, material, and workmanship.

The Contractor also warranty that the said goods/stores/articles would continue to conform to the description and quality as aforesaid, for a period of 30

Accepted

Warranty has to be as per Contract.

The contractor shall ensure that design of CTRB is such that it performs satisfactory for a minimum period of 48 36 months

M/s FAG‟s and M/s NEI‟s comments not acceptable. Therefore no changes are required in this clause of specification.

months after their delivery or 24 months from the date of placement in service whichever shall be sooner, and this warranty shall survive notwithstanding the fact that the goods/stores/articles may have been inspected, accepted and payment thereof made by the Purchaser. (IRS terms to be followed.)

after supply or 36 24 months after putting into service whichever is later. The warranty shall cover design, material, and workmanship.

24.2 The period of warranty shall stand extended by the duration for which the CTRB remain inoperative under exercise of this Clause. In such cases, the period of 48 months after supply or 36 months after putting into service whichever is later would commence when the replaced bearing are commissioned in service. The sole judge in this case would be the Purchaser. Further, should any design modification be made any part of the device as a result of any defects/fault /lacunae/shortcoming in the original design feature, the period of 48 months after supply or 36 months after putting into service whichever is later for the purpose of deciding warranty of CTRB would commence from the date of modified part is commissioned into service.

To be deleted (IRS terms to be followed.)

Accepted

Warranty has to be as per Contract.

The period of warranty shall stand extended by the duration for which the CTRB remain inoperative under exercise of this Clause. In such cases, the period of 48 36 months after supply or 36 24 months after putting into service whichever is later would commence when the replaced bearing are commissioned in service. The sole Purchaser. Further, should any design modification be made any part of the device as a result of any defects/fault /lacunae/shortcoming in the original design feature, the period of 48 36 months after supply or 36 24 months after putting into service whichever is later for the purpose of deciding warranty of CTRB would commence from the date of modified part is commissioned into service.


25.0 RECONDITIONING

25.1 The bidder shall also undertake reconditioning of CTRB as a complete unit, in case it is desired by the purchaser. The reconditioned bearing shall perform satisfactory in service and shall meet the requirements laid down in Clause (10) of this specification.

To be deleted (Reconditioned bearing had undergone substantial service life before being reconditioned & hence can not be guarranty performance requirement laid down in Clause (10) of this specification 100%.)

Accepted

Refurbished bearing can not have same properites like new bearing eg. L10 life.

No comments offered


26.0 DISPOSAL OF REJECTED BEARINGS

26.1 Bearings which are finally rejected shall be marked in distinguishable manner and shall be disposed off in such a manner as the Purchaser/RDSO /Inspecting Authority may direct.


Accepted

Has to be done as per RDSO approved QAP.

No comments offered

No change required.

27.0 RIGHTS OF PURCHASER/INSPECTING AUTHORITY/RDSO


No change required.

27.1 Purchaser/RDSO/Inspecting Authority shall adopt any means he may consider necessary to satisfy himself that all materials or components specified are actually used throughout the construction.


Accepted

No comments offered

No change required.

27.2 Purchaser/RDSO/Inspecting Authority shall have right to visit at any reasonable time and without previous notice, either Contractor's Works or his Sub-Contractor's Works to inspect the manufacture and quality of work at any stage.


Accepted

No comments offered

No change required.

27.3 Purchaser/RDSO/Inspecting Authority shall have free and ready access to Contractor's Quality Assurance Records, Procedures etc.

Purchaser/RDSO/Inspecting Authority shall have free and ready access to Contractor's Quality Assurance Records, Procedures etc, if felt necessary. (Noted)

Accepted

No comments offered

No change required.

27.4 Purchaser/RDSO/Inspecting Authority shall have to reject any material that do not conform to the relevant standard specifications or have not been manufactured in accordance with approved practices. The rejected materials shall be marked in a distinguishable manner and shall be disposed off in such a manner as specified in QAP.


Accepted

No comments offered

No change required.

Appendix „A‟ INFORMATION TO BE SUBMITTED BY TENDERER ALONG WITH OFFER

1.

Drawing of the bearing showing: i) Boundary dimensions (width, outside

diameter and bore diameter) along with tolerances.

ii) Material of Cone, Double Cup, Cone Spacer, seal, Backing Spacer, Sealing Ring & Backing Ring (for Timken) / Distance Ring, Z Labyrinth (Internal Parts), Z Labyrinth (External Parts),Distance Rings (For SKF).

iii) Values of parameters necessary for calculation of life rating of the bearing as per ISO 281 i.e. number of rows of rollers per bearing, number of rollers per row, mean roller diameter, effective length of rollers, angle of contact and pitch circle diameter of rollers as defined in the ISO Standard).

Drawign of the bearing showing: i) Boundary dimensions (width, outside diameter and bore diameter) along with tolerances. ii) Material of Cone, Double Cup, Cone Spacer, seal, Backing Spacer, Sealing Ring & Backing Ring (for Timken) / Distance Ring, Z Labyrinth (Internal Parts), Z Labyrinth (External Parts),Distance Rings (For SKF). iii) Values of parameters necessary for calculation of life rating of the bearing as per ISO 281 i.e. number of rows of rollers per bearing, number of rollers per row, mean roller diameter, effective length of rollers, angle of contact and pitch circle dia¬meter of rollers as defined in the ISO Standard). (To be deleted as point iii) already covered in Clause 2 below as L10 calculation.)

Accepted

No comments offered ii) Material of cone, double cup, cone spacer, seal, backing spacer, sealing ring & backing ring (for Timken)/ Distance Ring, Z Labyrinth (Internal Parts), Z Labyrinth (external Parts), distance ring (for SKF) / Wear Ring – Inboard , Wear Ring- Outboard, Backing Ring (for NEI)

No change required.

2. Life rating calculations as per ISO 281 latest revision.


Accepted

No comments offered

No change required.

3. Confirmation that bearings are strictly in accordance with the specification. If there are deviations from any Clause, they must be clearly listed Clause wise.


Accepted

No comments offered

No change required.

4. Country of origin. No change required (Noted)

Accepted

Country of origin & plant

No change required.

5. Details of extent to which bearings proposed to be offered. are in use on Rolling Stock on other Railways, This information should include details of year wise supply to the Railway Systems and the numbers supplied in each year.


Accepted

To be added further:- 6. Quality Assurance programme 7. Clause by clause compliance 8. Statement of deviation 9. English translation of standards

No change required.

comments of manufacturers on rdso‟s specification no… docume… · en iso 6507-1 metallic...

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