MODEL QUALITY ASSURANCE PLAN FOR POT-PTFE BEARINGS

1. Name of Manufacture: ………………………………………………… 2. Drg. No.: ………………………………………………………

3. Name of Project/Railway: ………………………………………………… 4. Authority (CA No./LOA No./Order No.) …………………………………
S. Component Characteristic Frequency Reference Fabriactor’s Inspection details Type of Acceptance Remarks
No. Operation Checked & Type of Document quality Inspecting Extent of Records criteria
check control Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW Physical Test As per Mill Mill TC and 1.Verification RDSO/Auth One Fabricator IS:1030 Manufacturer’s test certificate
MATERIAL: UTS, Yield TC & test Challan of reference orized integral s record Cast steel shall be furnished. UST shall
1.1 Cast Steel Stress, required by document. Inspecting Test piece Co-related shall be conducted as per provision
(CS) Elongation%, RDSO/Auth per heat with Mill generally of relevant specification before
official of
Reduction of orized TC & test comply with processing the material for
Area, inspecting 2.Complete Zonal report. Grade 280- manufacturing. UST after load
Impact test at 0 official of visual Railway 520W or 340- test shall also be carried out.
degree Zonal inspection. 570W
centigrade or -20 Railway (Grade/class
degree for sub- from Govt. as per
zero zone Lab ./ relevant
Micro Exam; NABL approved
Hardness test approved Drg.).
Chemical Test lab
C, Mn, Si, P, S,
Cr, Ni, Mo, Cu ,V

Ultrasonic
Testing 100% IS:9565
(On cast steel Level-III
100% before &
after load Test

Signature of Signature of Approval of RDSO

Fabricating Agency Railway Representative
S. Component Characteristic Frequency Reference Fabriactor’s Inspection details Type of Acceptance Remarks
No. Operation Checked & Type of Document quality Inspecting Extent of Records criteria
check control Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
1.2 Mild Steel Mechanical Test As per Mill Mill TC and 1. Verification RDSO/Auth One test Fabricato IS: 2062-11, Manufacturer’s test certificate
UTS, Yield TC & test Challan of reference orized piece per rs record E250 ,Quality shall be furnished. UST shall
Stress, required by document. Inspecting thickness Co- BO is be conducted as per provision
Elongation%, RDSO/Auth per heat. related generally of relevant specification before
official of
Bend test , orized 2.Complete with Mill used. processing the material for
Impact test at 0 inspecting visual Zonal TC & test However manufacturing. UST after load
degree official of inspection. Railway report. Quality C test shall also be carried out.
centigrade or -20 Zonal shall be used
degree for sub- Railway for sub zero
zero zone from Govt. condition.
Chemical Test Lab ./ ( As specified
C, Mn, Si, P, S, NABL in approved
CE. approved Drg.).
lab.

Physical
condition i.e.
Pitting,rusting,roll
ing defect, etc.

Ultrasonic
Testing of 100% IS:4225 or
plates (100%) ASTM A435

1.3 Stainless Physical Test As per Mill Mill TC and 1. Verification RDSO/Auth One test pc. Fabricato Stain less Manufacturer’s test certificate
Steel (S.S.) UTS, Yield TC & test Challan of reference orized Per heat r records. steel shall shall be furnished. Sample
Stress, required by document. Inspecting conform to from each lot of S.S shall be
Elongation %, RDSO/Auth AISI drawn by authorize inspecting
official of
Hardness orized 2.Complete 316L/xO2Cr1 official and tested in
inspecting visual Zonal 7Ni12Mo2 of Govt./NABL approved
official of inspection. Railway IS:6911 laboratory.
Zonal
Railway Or
Chemical Test from Govt.
C, Mn, Ni, Cr, P, Lab ./ (Grade/class
S, Si, Mo NABL As per
approved relevant
lab. approved
Drg.).

Signature of Signature of Approval of RDSO

Fabricating Agency Railway Representative
1.4 PTFE a) Tensile As per Manufacturer 1. Verification RDSO/Auth One test pc Fabricato Grade A of Manufacturer’s test certificate
(confined & strength manufactur test certificate of reference orized for Full Lot rs record. BS:3784 shall be furnished. Sample
dimpled ) b) % of er &Challan document. Inspecting of supply or from each lot of PTFE shall be
certificate & equivalent drawn by authorize inspector
Elongation At official of
test 2.Complete and tested in Govt./NABL
break. required by visual Zonal (Grade/class approved laboratory.
c) Dimensional RDSO/Auth inspection. Railway as per
Stability orized . relevant
d) Resistance to inspecting specification /
heat official approved
e) Durometer from Govt. Drg.).
lab./ NABL
Hardness
approved
f) Specific lab
Gravity.
g) Density
h) Electric
strength (
Proof test)
i) Appearance
and finish
1.5 Elastomer Physical As per Mill Manufacturer Verification RDSO/Auth From each Fabricato IRC:83 Test certificate shall be
( Neoprene properties TC & tests test certificate of reference orized batch at rs record. (Part-III) & furnished by manufacturer.
WRT/ required by &Challan document. Inspecting Random (Part-II) and Sample from each lot of
RDSO/Auth Elastomer as prescribed in
Bayprene a) Hardness official of IS:3400 (as
orized specification shall be drawn by
110 or (IRHD) Zonal Zonal per relevant authorize inspecting official of
equivalent/D b) Minimum Railway Railway test RDSO /Zonal Railway and
enka Tensile inspecting procedure) tested in Govt./NABL approved
strength official from laboratory.
(MPa) Govt.lab/
c) MinimumElo NABL
approved
ngation at -
lab
break (%)
d) Max.
Compression
set (%)
e) Accelerated
ageing
f) Max. change
in hardness.

Signature of Signature of Approval of RDSO

Fabricating Agency Railway Representative
S. Component Characteristic Frequency Reference Fabriactor’s Inspection details Type of Acceptance Remarks
No. Operation Checked & Type of Document quality Inspecting Extent of Records criteria
check control Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
g) Max. change
in tensile
strength.
h) Max. change
in elongation

Chemical Test As per Mill Manufacturer Verification RDSO/Auth From each Fabricato IRC:83 Test certificate shall be
i) Ash content TC & tests test certificate of reference orized batch at rs record. (Part-II) & furnished by manufacturer.
shall not required by &Challan document. Inspecting Random IS:3400 (as Sample from each lot of
exceed 5% RDSO/Auth official of per relevant Elastomeric as prescribed in
orized specification shall be drawn by
ii) The raw Zonal test
Zonal authorize inspecting official of
elastomeric Railway Railway procedure) RDSO /Zonal Railway and
( polychlo- inspecting tested in Govt./NABL approved
roprene) official from laboratory.
content of the Govt.lab/
compound NABL
shall not be approved
lab
lower than
60%.
iii) Sp. Gravity
1.6 Brass Physical As per Mill Manufacturer Verification RDSO/Auth One test pc Fabricato IS:410, Test certificate shall be
sealing Ring properties TC & tests test certificate of reference orized for full lot of rs record. CuZn37 (HB) furnished by manufacturer.
required by &Challan document. Inspector supply One sample for full lot of
(20mm wide (i) Tensile RDSO/Auth appointed Or sealing ring supply shall be
x 2mm strength orized by Zonal drawn by RDSO/Authorized
Thick) (N/mm2), Zonal Railway (Grade/class Zonal Railway inspecting
(ii) Elongation % Railway As per official and tested in
(iii) Bend test inspecting relevant Govt./NABL approved
(iv) Vickers official from approved laboratory.
Hardness Govt.lab / Drg.).
NABL
approved
lab

Chemical Test
Cu ,Pb, Fe and
total Cu+Pb+Fe&
Remainder Zn

Signature of Signature of Approval of RDSO

Fabricating Agency Railway Representative
S. Component Characteristic Frequency Reference Fabriactor’s Inspection details Type of Acceptance Remarks
No. Operation Checked & Type of Document quality Inspecting Extent of Records criteria
check control Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
1.7 Bolts & Nuts Physical As per Mill Manufacturer Verification Authorized As per Fabricato IS:1364 & Test certificate shall be
properties TC & test test certificate of reference Inspector relevant rs record. IS: 1367 furnished by manufacturer.
required by &Challan document. appointed by specificatio (property One sample for each lot of
(i) Tensile RDSO/Auth Zonal n class 8.8) Bolts & Nuts supply shall be
strength (MPa) orized Railway drawn by authorize inspecting
(ii) Hardness inspecting Or official of Zonal Railway and
(BHN) official tested in Govt./NABL approved
(iii) Head sound - from (Grade/class laboratory.
ness test Govt.lab/ as per
(iv) Depth of NABL relevant
decarburization. approved approved
& lab Drg.).
Chemical Test

C,P & S

Dimensional
check as per Visual &
specification Measureme
nt
1.8 Adhesive for Peel of strength As per Mill Manufacturer Verification Zonal One Fabricato Adhesive for Test report shall be furnished
bonding TC & test test certificate of reference Railway. sample per rs record. bonding to inspecting official.
PTFE required by &Challan document. lot. PTFE to
Zonal backing
Railway plates shall
inspection produce a
official from bond with a
Govt./ minimum peel
NABL strength of
approved 4N/mm width
lab. when tested
in accordance
with BS:5350
( Part C9)
1.9 Paint Verification of Visual Manufacturer Verification Zonal Each Batch Fabricato As per Paint should be as per IRS: B1
Manufacture’s test certificate of reference Railway. rs record. relevant
Test Certificate, &Challan document. Specification
Inspection
Certificate,
Chalan

Signature of Signature of Approval of RDSO

Fabricating Agency Railway Representative
S. Component Characteristic Frequency Reference Fabriactor’s Inspection details Type of Acceptance Remarks
No. Operation Checked & Type of Document quality Inspecting Extent of Records criteria
check control Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
2.0 Manufacturi
ng Process

2.1 a) plan Dimensional Visual & As per Measureme Manufactur 100 % Fabricato IRC 83 Part- Internal report shall be
dimension inspection Measureme approved nt of er’sinspecti rs record. III & as per furnished, However random
b) individual nt drawing dimension ng official drawing check may be done in
height of presence of Zonal Railway
the inspecting official.
componen
t
c) Thickness
of
elastomeri
c pad
2.2 Check after Dimensional Visual & As per Measureme Manufactur 100% Fabricato IRC 83 Part- Internal report shall be
attachment inspection Measureme approved nt of er’s rs record. III, IS: 822 & furnished, However, random
of stainless nt drawing dimension inspecting IS:3658 check may be done in
steel plate official presence of Zonal Railway
a) Flatness inspecting official.
b) Surface
Finish
2.3 NDT test DP Test, weld DP Test of As per Visual Manufactur Fabricato IS:3658 -1981 Internal report will be furnished
Size , visual weld, visual approved inspection & er’sinspecti rs record. by the manufacture and final
DP test on & gauge WPSS &Drg. verification ng official/ 100% clearance will be given by
welding of of dimension Zonal RDSO.
the top plate by gauge. Railway/RD
and bearings SO
after load
test
2.4 Hardness Hardness tester measureme
a) On nt As per drg. Fabricators Manufactur 100% Fabricato IRC 83 Part- Internal report will be
major and relevant record & er rs record. III furnished, however, random
steel specification check. inspecting check will be done in presence
compon official/ of Railway representative
ents Zonal inspecting authority.
b) On the Railway Firm should keep the records
hard of hard facing and submit the
facing same to inspection official at
zone the time of inspection

Signature of Signature of Approval of RDSO

Fabricating Agency Railway Representative
S. Component Characteristic Frequency Reference Fabricator’s Inspection details Type of Acceptance Remarks
No. Operation Checked & Type of Document quality Inspecting Extent of Records criteria
check control Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
2.5 Corrosion
Protection
a) Grit Visual and As per drg. Fabricators Manufactur 100% Fabricato IRC 83 Part- Internal report shall be
Blasting measureme and relevant record & er rs record. III furnished. However,total DFT
b) Zn nt specification check. inspecting shall be checked randomly
metalizin official/ from the finished store in
g Zonal presence of inspecting
c) Painting Railway authority of Zonal Railway.
2.6 Assembly
a) Paralleli Dimensional Visual and As per drg. Measureme Manufactur 100% Fabricato IRC 83 Part- During assembly all the
sim Inspection measureme and relevant nt of er rs record. III bearing components should be
b) Overall nt specification dimensions . inspecting checked for proper cleanliness
Height official/ and greasing of PTFE &
Zonal Stainless steel surfaces.
Railway Random check shall be done
in presence of Zonal
Railway’sinspecting authority.
2.7 Marking IRC 83 Part- Fabricators Manufactur 100% Fabricato IRC 83 Part- During internal final inspection
III record. er’s rs record. III the same component shall
inspecting have to be fixed on each
official/ bearing.
Zonal
Railway
2.8 Tolerance of
fit between
different
component
of bearing
a) Piston
Cylinder Dimensional Visual and As per Measureme Manufactur 100% Fabricato IRC 83 Part- Inspection records to be
b)Elastomeri Inspection measureme relevant Drg. nt of er’s rs record. III furnished. However random
c pad & nt dimensions . inspecting checking may be done in-
Cylinder official/ presence of inspecting
c) Guide & Zonal authority of Zonal Railway.
Adjacent Railway
compone
nt
d) Pin &
Cylinder

Signature of Signature of Approval of RDSO

Fabricating Agency Railway Representative
S. Component Characteristic Frequency Reference Fabriactor’s Inspection details Type of Acceptance Remarks
No. Operation Checked & Type of Document quality Inspecting Extent of Records criteria
check control Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
2.9 Overall Dimensional Visual and As per Measureme Manufactur 100% Fabricato As per Checking records to be
dimension Inspection measureme relevant Drg. nt of er rs record. relevant furnished. However random
of any un- nt dimensions . inspecting specification checking may be done by
machined agency inspecting authority of Zonal
cast steel Railway.
component
2.10 Load Test
a) Deflectio Load Testing One As per Fabricators RDSO Random Fabricato IRC-83 Part- Deflection test will be done for
n Test parameters as bearing will relevant Drg. record. (One rs record. III all bearings by manufacturer
b) Co- per IRC-83 Part- be tested bearing will and checking record to be
efficient III per lot of 25 be tested furnished by the manufacturer.
of friction nos. or part per lot of 25 However test shall be carried
test nos or part) out on the bearings randomly
c) Combine selected by the RDSO official.
d Load For other
test cases as
d) Rotation per code.
test
3.0 Final Part dimension Visual and As per Measureme RDSO Fabricato IRC 83 Part- After load testing, DP Test
Inspection checking, overall measureme relevant Drg. nt of 100% rs record. III &ultrasonic testing of bearings
Over all height inspection nt & dimension to be done by RDSO to check
dimensional and after load specification for damage during testing.
check of test condition of Final clearance given by
finished components RDSO.
bearing inspection Firm should keep the records
of hard facing and submit the
same to inspection official at
the time of inspection and
inspection official of RDSO
should also check hardness of
hard facing randomly.

Note: 1. Firm should maintain traceability of raw material used for fabrication of every POT-PTFE bearings and the record should be made available
to the inspecting authority on demand.
2. Certificate of elastomeric should not be older than 6 months.
3. Certificate of PTFE should not be older than 1 year.

Signature of Signature of Approval of RDSO

Fabricating Agency Railway Representative