Government of India
Ministry of Railways
QMS -102: 2009
Schedule of Technical Requirements
for Infrastructural, Manufacturing & Testing Facilities
and Quality Control
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/-)
This schedule covers the technical requirements for manufacture of Wire and Flux
for Submerged Arc Welding (SAW) as per IRS–M–39-01.
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
2.1.1 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
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.
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
126.96.36.199 The firm should have duly calibrated micrometer with least count 0.01mm. for
measurement of diameter of wire.
188.8.131.52 The firm should have arrangement for measurement of copper coating thickness
of wire by colorimeter/wet analysis method.
184.108.40.206 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
220.127.116.11 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
18.104.22.168 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
3.0 REQUIREMENTS FOR SUBMERGED ARC WELDING FLUX
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.
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
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
22.214.171.124 Sieve (B.S. Mesh size 10 or equivalent) for coarse screening of raw material.
126.96.36.199 Dry mixer, capacity 100 Kg. minimum, (generally electrically operated).
188.8.131.52 Wet mixer, capacity 100 Kg. minimum, (generally electrically operated).
184.108.40.206 Drying Oven, 2000C, electrically operated of suitable capacity.
03.2.1.5 Agglomerating Furnace, 600C of suitable capacity with automatic temperature
220.127.116.11 Sieving set of B.S. mesh size 10, 40, 100 mesh or equivalent for sieving of
18.104.22.168 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
22.214.171.124 Sieve (B.S. Mesh size 10) for coarse screening of raw material
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0 126.96.36.199 Oil fired/Gas fired/Electric melting furnace, 1500C min. of adequate capacity, 188.8.131.52 Dry mixer, capacity 100 Kg. minimum, (generally electrically operated). for melting of charged dry mix.
184.108.40.206 Quenching System consisting of Quenching Tanks with arrangement of
continuous flow of water for effective quenching of melted flux.
220.127.116.11 Crushing Arrangement, Gyratory/Jaw crusher to crush the lumps to the required
03.2.2.6 Drying oven, 200C, of suitable capacity for drying of crushed flux.
18.104.22.168 Sieving set of B.S. mesh size 10, 40, 100 mesh or equivalent for sieving of
22.214.171.124 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
126.96.36.199 The firm should have facilities for determination of grain size distribution of flux,
measurement of tap density and moisture content of flux.
188.8.131.52 The firm should have facilities for determination of Basicity Index of flux by XRF
method or by Chemical Analysis method.
184.108.40.206 The firm should have SAW machine of capacity 1000 Amp. for performance test
and welding of test weld samples.
3.3.2 MECHANICAL TESTING
220.127.116.11 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.
18.104.22.168 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.
QMS– 102 :2009 (Rev. 0) Page 5 of 7
3.3.3 CHEMICAL TESTING
22.214.171.124 The firm should have chemical testing laboratory for chemical analysis of raw
materials and weld metal.
126.96.36.199 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
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
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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