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Government of India - Welcome to Research Design and Standards

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A graduate Engineer or a Diploma holder with minimum 5 years experience must head the inspection/final quality control section for inspection of SAW Wire

    Government of India

    Ministry of Railways

    QMS -102: 2009

    (Revision 0)

    Schedule of Technical Requirements

    for Infrastructural, Manufacturing & Testing Facilities

     and Quality Control

    For

Wire and Flux for Submerged Arc Welding as per

    IRS: M 39 2001(With Amendment No. 1&2)

    Quality Assurance (Mechanical) Directorate

    Research Designs & Standards Organisation

    Manak Nagar, Lucknow 226011

     March 2009 (Price Rs. 900/-)

1.0 SCOPE

     This schedule covers the technical requirements for manufacture of Wire and Flux

    for Submerged Arc Welding (SAW) as per IRSM39-01.

1.1 The welding consumables for submerged arc welding have been grouped as below

    on the basis of infrastructure facilities, manufacturing process, quality control and

    application at users end. , W, W, W W 12 3 4 ,5 SAW Flux, Class FGroup VIII B , F, FF F12 3 , 4 ,5 SAW Wire, Class WGroup VIII A

2.0 REQUIREMENTS FOR SAW WIRE ( Class W, W, W, W W) 12 3 4 ,5

2.1 GENERAL

2.1.1 The firm should have well illuminated and ventilated covered shed with sufficient

    height and space for performing various manufacturing activities like Decoiling,

    Wire drawing, Wet wire drawing, Pickling, Washing, Copper Coating, Finished

    drawing, Spooling, Packing etc.

2.1.2 Separate identified area for storage of raw materials and finished product and

    scraps.

2.1.3 Separate quality control laboratory for physical and chemical testing

2.2 MINIMUM PRODUCTION FACILITIES

    The firm should have the following facilities:

2.2.1 Wire drawing and Copper coating facilities consisting of Decoiler, Wire drawing

    set, Pickling bath, Washing bath , Coppering bath, Rinsing bath, Finish drawing

    and Coiling arrangement

2.2.2 Butt welding machine of suitable capacity for joining wires.

2.2.3 Automatic Spooling machine for winding of wire.

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    QMS 102 :2009 (Rev. 0) Page 2 of 7

2.2.4 Weighing facilities.

    2.2.5 Packing facilities as per clause 4.4 of IRS M-39-01.

2.3 TESTING FACILITIES

2.3.1 GENERAL

2.3.1.1 The firm should have duly calibrated micrometer with least count 0.01mm. for

    measurement of diameter of wire.

    2.3.1.2 The firm should have arrangement for measurement of copper coating thickness

    of wire by colorimeter/wet analysis method.

    2.3.1.3 The firm should have SAW (Submerged Arc Welding) machine of capacity

    minimum 500 Ampere and nozzle of various sizes for carrying out performance

    test of wire.

2.3.2 MECHANICAL TESTING OF WIRE

    2.3.2.1 The firm should have one duly calibrated universal testing machine of capacity

    5 MT min. for carrying out UTS of finished wire.

2.3.3 CHEMICAL TESTING

    2.3.3.1 The firm should have chemical testing laboratory consisting of Carbon-Sulphur

    determination apparatus, Chemical balance, Hot plate, Muffle furnace (800ºC),

    Electric oven, Barometer, Hygrometer, Platinum crucible, Glass-wares and

    Chemicals.

3.0 REQUIREMENTS FOR SUBMERGED ARC WELDING FLUX

3.1 GENERAL

3.1.2 The firm manufacturing agglomerated flux should have well illuminated and

    ventilated covered shed with sufficient height and space for various manufacturing

    activities consisting of Weighing of flux ingredients, Dry mixing, Wet mixing,

    Agglomerating, Sieving of final product, Weighing of final flux product and Packing.

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    QMS 102 :2009 (Rev. 0) Page 3 of 7

     The firm manufacturing fused flux should have well illuminated and ventilated

    covered shed with sufficient height and space for various manufacturing activities

    consisting of melting in a furnace, quenching, drying, crushing of lump flux,

    sieving of final product, weighing and packing.

    3.1.2 The firm should have separate identified area for storage of raw material, finished

    product and scrap.

    3.1.3 The firm should have separate welding room for performance test and test weld

    preparations.

    3.1.4 The firm should have separate laboratory for physical and chemical testing of raw

    material and weld metal.

    3.1.5 The firm should have mechanical testing laboratory for carrying out mechanical

    test of weld metal.

    3.2 MINIMUM MANUFACTURING FACILITIES

    3.2.1 Requirement for Agglomerated Flux

     The firm should have following machines/equipment

    3.2.1.1 Sieve (B.S. Mesh size 10 or equivalent) for coarse screening of raw material.

    3.2.1.2 Dry mixer, capacity 100 Kg. minimum, (generally electrically operated).

    3.2.1.3 Wet mixer, capacity 100 Kg. minimum, (generally electrically operated).

    3.2.1.4 Drying Oven, 2000C, electrically operated of suitable capacity.

     03.2.1.5 Agglomerating Furnace, 600C of suitable capacity with automatic temperature

    control.

3.2.1.6 Sieving set of B.S. mesh size 10, 40, 100 mesh or equivalent for sieving of

    finished product.

3.2.1.7 Packing arrangement as per clause 5.6 of IRS- M- 39 -01.

3.2.2 Requirement for fused Flux

     The firm should have following machines/equipment

3.2.2.1 Sieve (B.S. Mesh size 10) for coarse screening of raw material

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    QMS 102 :2009 (Rev. 0) Page 4 of 7

     0 3.2.2.3 Oil fired/Gas fired/Electric melting furnace, 1500C min. of adequate capacity, 3.2.2.2 Dry mixer, capacity 100 Kg. minimum, (generally electrically operated). for melting of charged dry mix.

3.2.2.4 Quenching System consisting of Quenching Tanks with arrangement of

    continuous flow of water for effective quenching of melted flux.

3.2.2.5 Crushing Arrangement, Gyratory/Jaw crusher to crush the lumps to the required

    grain size.

     03.2.2.6 Drying oven, 200C, of suitable capacity for drying of crushed flux.

3.2.2.7 Sieving set of B.S. mesh size 10, 40, 100 mesh or equivalent for sieving of

    finished product.

3.2.2.8 Packing arrangement as per clause 5.6.2 or alternatively as per Clause 5.6.3 of

     Amendment 2 of 2005 to IRS- M- 39 01 as stated below :

    “Alternatively flux shall be packed in a polythene inner bag sealed & kept it

    inside the polythene lined paper bag or polythene lined plastic bag. After

    filling the flux, these bags shall be sealed so that flux is protected through two

    polythene coverings. The thickness & strength of inner polythene & outer

    polythene lined bag shall be adequate resistance against transportation

    damage. The net weight of flux in this type of packaging shall be kept as

    20?1Kg or 25?1 Kg. The outer bag shall contain the information as given in

    clause 5.6.2 for plastic container.”

3.3 TESTING FACILITIES

3.3.1 GENERAL

3.3.1.1 The firm should have facilities for determination of grain size distribution of flux,

    measurement of tap density and moisture content of flux.

3.3.1.2 The firm should have facilities for determination of Basicity Index of flux by XRF

    method or by Chemical Analysis method.

3.3.1.3 The firm should have SAW machine of capacity 1000 Amp. for performance test

    and welding of test weld samples.

3.3.2 MECHANICAL TESTING

3.3.2.1 The firm should have Universal Testing Machine of capacity 20MT min. with

    necessary attachment for measuring Yield Load and Breaking Load and carrying

    out Bend Test. The machine should be calibrated by a recognized agency and the

    firm should have valid calibration certificate.

3.3.2.2 The firm should have duly calibrated Impact Testing Machine capacity 30 kgfm

    (Charpy ‘V’ notch type test piece) with testing facilities at room temperature, 0ºC,

    -20ºC and -46ºC depending upon the requirement of the product offered.

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    QMS 102 :2009 (Rev. 0) Page 5 of 7

3.3.3 CHEMICAL TESTING

3.3.3.1 The firm should have chemical testing laboratory for chemical analysis of raw

    materials and weld metal.

    3.3.5.2 The chemical laboratory should consist of Carbon-Sulphur determination

    apparatus, chemical balance, hot plate, muffle furnace (800ºC), electric oven,

    barometer, hygrometer, platinum crucible, glass wares and chemicals.

Note: Use of Spectrometer or any other modern facilities for determination of element

    present is permissible.

4.0 QUALITY CONTROL REQUIREMENTS

    4.1 There should exist a system to ensure trace ability of the product from raw

    material stage to finished product stage.

4.2 Quality Assurance Plan (QAP) for the product detailing various aspects like

     Organizational chart

     Brief description of the process & Process flow chart

    Stage inspection details and acceptance criteria at each stage of manufacture

    starting from raw material to finished product.

     Policy of disposal of rejected product

    Various parameters to ensure control over them by statistical analysis of data and

    process capability calculations.

    The QAP shall be available and submitted (in triplicate) alongwith vendor

    approval application form for approval by RDSO.

    4.3 A graduate Engineer or a Diploma holder with minimum 5 years experience must

    head the inspection/final quality control section for inspection of SAW Wire and

    Flux.

     The Chemist must be a Science Graduate with Chemistry as one of the subject.

     _______________________________

    QMS 102 :2009 (Rev. 0) Page 6 of 7

    4.4 The vendor shall have acquired ISO Certification (ISO: 9000 : 1994 and ISO:

    9001 : 2000 are acceptable upto 14.12.2003 and only ISO : 9001 : 2000 version is

    acceptable thereafter) in respect of all the products applied for and the same shall

    be covered in the certification.

    4.5 There should exist a quality manual of the firm indicating the extent of control

    over production and testing.

4.6 The firm should ensure that proper analysis is being done on monthly basis to

    study the rejection at various internal stages and it is documented.

    4.7 The firm should ensure that all the relevant specifications and IS standards are

    available with them.

    4.8 The firm should ensure that proper record of complaints received from users

    (Railways) is being maintained and corrective action is taken.

    4.9 Calibrated quality control measuring equipment/instrument like UTM, Impact

    testing machine, Vernier callipers/Screw guage, Tong tester, Weight boxes etc.

    shall be used.

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    QMS 102 :2009 (Rev. 0) Page 7 of 7

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