SPECIFICATION SCHEDULE OF INFRASTRUCTURE REQUIREMENTS MDST: 108 REV: 01

FOR SINGLE BITE TYPE FITTING PAGE 1 OF 8

DATED 06.02.2023

Name Designation Signature Date Level

Tarlochan Singh SSE/Air Brake TARLOC Digitally signed

by TARLOCHAN Prepared
HAN SINGH
Date: 2023.02.07
SINGH 16:19:45 +05'30'

Jugal Kishore SME/Design Digitally signed

JUGAL byKISHOR
JUGAL Agreed
KISHOR Date: 2023.02.07
16:44:42 +05'30'

Abhey Priya Dogra Dy CME/D-II ABHEY Digitally signed

by ABHEY PRIYA
Reviewed
PRIYA DOGRA
Date: 2023.02.08
DOGRA 16:22:17 +05'30'

Akhilesh Misra CDE Digitally signed

AKHILES byMISRA
AKHILESH Approved
H MISRA Date: 2023.02.14
16:08:56 +05'30'

Issue/Rev. Details of changes Date

01 In para 1.4 material grade of carbon steel 06.02.2023
added.

Prepared By Agreed By
 SPECIFICATION SCHEDULE OF INFRASTRUCTURE REQUIREMENTS MDST: 108 REV: 01
FOR SINGLE BITE TYPE FITTING PAGE 2 OF 8
DATED 06.02.2023

1. General:

1.1. This specification covers the general design, technical and infrastructure
requirements for single bite type ferrule fitting for Mainline Coaches on Indian
Railways. The infrastructure requirements shall be complied by the tenderer at
their premises or as specified in this specification in working order.

1.2. Operating air pressure may be as high as 8.5 Kg/ cm2 Normal air pressure is 6
Kg/cm2.

1.3. Fitting shall not have sharp edge and all parts of the fittings shall be thoroughly
cleaned to get rid of burrs, dirt, grease, etc. to get a clean matt finish.

1.4. The fittings shall be of single bite type fitting, primarily consist of body, single
bite ferrule and nut. The Body, Nut and Ferrule shall be of carbon steel to
material grade SAE-1018 to ASTM-A311/A311M-04 or alternate material
grade C15 to EN10277-2-1999 with chrome free coating. The body and nut
can be manufactured either by forging or machining from forged bars.

1.5. Once ferrule bite the pipe it should not have any radial movement or longitudinal
movement and each fitting should be re-usable after dismantling & assembling
for at least 25 times excluding ferrule.

1.6. The fitting shall be able to produce a leak proof joint in either Pressure on vacuum
service.

1.7. The ferrule shall have hardness more than the stainless steel tubes. The ferule
shall be case hardened to a depth of 27 microns (Min.) through suitable case
hardening process to achieve a minimum hardness of 500 to 700 Vickers point
number HV (0.05).

1.8. Coating shall be Zinc-Nickel Cr-6 free in three layers in sequence: Zinc- Nickel
base coating (8 microns), transparent passivation (500 nano microns) and
transparent siliceous sealing coating (2 microns). The thickness of the entire
coating amounts to 10-15 microns. Corrosion resistance should be more than
720 hrs. Type of colour of coating shall be Metal Grey-Mat finish.

1.9. All tube fittings when bite with the recommended Stainless steel tubes shall be
capable of withstanding the following types of forces:

1.9.1. Internal pressure.

1.9.2. Tension or Axial pull.
Prepared By Agreed By
 SPECIFICATION SCHEDULE OF INFRASTRUCTURE REQUIREMENTS MDST: 108 REV: 01
FOR SINGLE BITE TYPE FITTING PAGE 3 OF 8
DATED 06.02.2023

1.9.3. Compression or Axial push.

1.9.4. Torque or Twist.
1.9.5. Vibration
1.9.6. Temperature variation
1.9.7. Any combination of the above

1.10. The fittings shall have the following features:

1.10.1. There shall be no axial movement of ferrules after bite.

1.10.2. There shall be no radial movement of ferrule after bite.
1.10.3. Shall not create torque or leave residua! strain on the tubes.
1.10.4. Shall not significantly reduce flow area.
1.10.5. Shall have enough tube support ahead of the seal to resist any
vibration.

2. Eligibility Criteria:

2.1. The tenderer must submit detailed clause-wise comments on the

specification specifying the availability of infrastructure with them along with
the capacity and make. In absence of above, offers shall be deemed as
incomplete and may not be considered.

2.2. Since, Railways are facing problems of leakages and corrosion on bite type

•
fittings, leading to train detention and punctuality lose, bulk or regular
procurement orders shall only be given to the firms who have infrastructure
as mentioned In Para #3, 4 and 5 of this specification. Firm will be assessed
by CDE/RCF wherever required for ascertaining the infrastructure.

3. Infrastructure Requirements:

3.1. Separate covered area for storage of raw material. e.g. billets, bars, forgings
etc. The covered area should have display board showing different colour
shades nominated to different grades of steel to avoid mix up of materials.
Arrangement of painting the billets, bars etc. with particular paint shade
previously nominated according to the grade of steel should be available.

3.2. Firm should have forging facilities in-house or have tie-up with reputed
forging unit. Forging unit should be ISO certified and firm shall have
documented vendor approval process and control on quality of the forged
Prepared By Agreed By
 SPECIFICATION SCHEDULE OF INFRASTRUCTURE REQUIREMENTS MDST: 108 REV: 01
FOR SINGLE BITE TYPE FITTING PAGE 4 OF 8
DATED 06.02.2023

components. Firm has to submit the details of forging unit Including its
machinery and plant. Firm has to get the approval of out-sourced forging unit
from CDE/RCF.

3.3. Firm should have facility for PMI testing (Positive material testing) and UT

•
testing (Ultrasonic testing) for on line checking of raw material.

3.4. Firm should have at least two high precision CNC machines for manufacture
of fitting components i.e. Body, Nut and Ferrule.

3.5. Firm should have laser printing or dot matrix printing or roller printing
machine for marking particulars on finished components to have proper
identification and traceability.
3.6. Well-equipped design center for designing the fittings. Design team should
be aware of current National and International Standards along with their
requirements. Firm should have 2-D/3-D Modeling and analysis softwares
along with technically trained, experienced designers capable of performing
such analysis. Firm should have wide range of standards/references at
design center. Design validation of fittings should be done by theoretical
calculation, 3-D Modeling and experimental analysis in testing laboratory.
3.7. Firm should have well equipped Heat Treatment facilities for ferrule
hardening of bite type fittings in-house or the same shall be outsourced from
a .firm having expertise for the same. Firm has to get the approval of
facilities of outsource firm from CDE/RCF. The process adopted for case
hardening (Heat Treatment) shall not cause any depletion affecting the
corrosive properties of parent material. Internal test certificate along with the
Export/Import documents if any, issued by the firm conducting the case
hardening shall also be submitted.

3.8. Firm should have well equipped facilities for chrome free surface treatment
in-house or the same shall be outsourced from a firm having expertise for
the same. Firm has to get the approval of facilities of out-sourced firm from
COE/RCF.

3.9. Firm should be ISO: 9001certified.

4. Performance Test Facilities for tube fittings: Following type test facilities
should be available at firm premises and shall be conducted by manufacturer
and shall be witness by CDE/RCF or by inspecting agency prior to approval:

Prepared By Agreed By
 SPECIFICATION SCHEDULE OF INFRASTRUCTURE REQUIREMENTS MDST: 108 REV: 01
FOR SINGLE BITE TYPE FITTING PAGE 5 OF 8
DATED 06.02.2023

4.1. Hydraulic test: The test assembly loop shall be ma.de as per Clause-7.7
of BS: 4368 (Part-4)- 1984. The loop shall consist of 3 fittings and 2 tubes
of different sizes and tightened 1 ¼ turn past snug. The hydraulic media
shall be water. The loop is pressurized up to 100 kg/cm2 and to be held at
pressure for 5 minutes. If no leak is found the fittings are to be dismantled
and to be inspected for formation of fatigue cracks at thread roots, damage
to ferrules, damage to sealing faces, damage or cracking of tubes.

4.2. Pneumatic Pressure Test: After the completion of hydraulic test,

assemble the test assemblies tightened 1 ¼ turn past snug and pressurize

• each test assembly to 40 kg/ cm2 {Pneumatic {air/02) pressure) and to be

held at the pressure for 5 minutes. If no leak is found the fittings are to be
dismantled and to be inspected for formation of fatigue cracks at thread
roots, damage to ferrules, damage to sealing faces, damage or cracking of
tubes.

4.3. Pressure Impulse cum Vibration Test: After the completion of Pneumatic
Test, assemble the test assemblies tightened 1 ¼ turn past snug. Each test
assembly shall be subjected to vibration frequency of 23-47 Hz with
amplitude of 5 mm, simultaneously pressure cycling from 0 to 100 Kg/cm2,
at 30-40 Impulse/minute for a minimum of 5 x 105 impulses/ 20 x 106
Vibration cycles. The equipment shall have a suitable counter for counting
the impulses and the vibrations. The impulse and vibration frequencies may
be so chosen that they conclude simultaneously. On completion of tests the
assemblies must successfully pass the Hydraulic test as mentioned in
Para-4.1 and pneumatic test as mentioned In Para-4.2. If no leak is found
the fittings are to be dismantled and to be Inspected for formation of fatigue
cracks at thread roots, damage to ferrules, damage to sealing faces,
damage or cracking of tubes.

4.4. Vacuum Test: After the completion of pressure impulse cum vibration Test,
assemble the test assemblies tightened 1 ¼ turn past snug. Vacuum test
shall be conducted at 750 milli bars with a test volume of l litre of water
capacity. The deterioration of vacuum shall not exceed 20 milli bars over a
period of 20 minutes. If no leak is found the fittings are to be dismantled and
be inspected for formation of fatigue cracks at thread roots, damage to
ferrules, damage to sealing faces, damage or cracking of tubes.

4.5. Make And Break Hydrostatic Test: After the completion of pressure
impulse cum vibration test and Vacuum test, assemble the test assemblies,
tightened 1 ¼ turn past snug and then: Assembled torque to be recorded.
Dismantle and re-assemble the fitting to the original torque. Repeat make
Prepared By Agreed By
 SPECIFICATION SCHEDULE OF INFRASTRUCTURE REQUIREMENTS MDST: 108 REV: 01
FOR SINGLE BITE TYPE FITTING PAGE 6 OF 8
DATED 06.02.2023

and break for 6 times. After sixth assembly pressurize the assembly with
suitable hydraulic media to 100 Kg/cm2 and hold the pressure for 5 minutes
and observe leak. If no leak is found, release the pressure and continue the
make and break test for 25 cycles. After the end of 25 cycles, pressurize the
test assembly to 100 kg/cm2 and hold the pressure for 5 minutes. If no leak
is found the fittings are to be dismantled and to be inspected for formation of
fatigue cracks at thread roots, damage to ferrules, damage to sealing faces,
damage or cracking of tubes. Any specimen exhibiting damage or leakage
shall be considered as failure.

4.6. Temperature Cycling Test: After completion of test above (4.1 to 4.5),
temperature cycling test is to be conducted. Assemble one test assembly for
each size of tube tightened 1 ¼ turns past snug and then subject the
assemblies to temperatures from ambient to 200 degree centigrade in
approximately 90 minute cycles, i.e. raise gradually to 200 degree
centigrade over 30 minutes, hold for 30 minutes and cool over the next 30
minutes to ambient/minimum possible temperature gradually. Repeat this
cycle for total three cycles. On completion of three cycles, repeat hydraulic
test as per Para-4.1 and Pneumatic test as per Para-4.2 above respectively.
If no leak is found the fittings are to be dismantled and to be inspected for
formation of fatigue cracks at thread roots, damage to ferrules, damage to
sealing faces, damage or cracking of tubes. Any specimen exhibiting
damage or leak shall be considered as failure.

•
4.7. Measurement of surface Hardness and case depth of ferrule or can be out-
sourced to an agency or which approval is obtained from CDE/RCF.

4.8. Burst Test: as per IS: 10103-1982.

4.9. Salt spray test for surface treatment.

5. Measuring Instruments: Firm should have following measuring instruments,

duly calibrated, at firm's premises traceable to National, International standard:

5.1. Profile projector

5.2. Rockwell hardness testing machine
5.3. Plating thickness gauge
5.4. Digital Vernier Calipers (O mm to 50 mm minimum).
5.5. S.S. Inside & outside Micrometers (0 to 50 mm minimum).
5.6. Bore dial gauge (150mm max.).
5.7. GO and NO-Go plain plug gauges
5.8. Profile gauges or profile projector
5.9. Filler gauges
5.10. Thread ring and plug gauges
Prepared By Agreed By
 SPECIFICATION SCHEDULE OF INFRASTRUCTURE REQUIREMENTS MDST: 108 REV: 01
FOR SINGLE BITE TYPE FITTING PAGE 7 OF 8
DATED 06.02.2023

6. Testing and Approval Of Prototype:

6.1. Tenderer must submit and get approval of Quality Assurance Plan from
CDE/RCF before taking up prototype manufacture.

6.2. Type test/routine test shall be carried out by CDE/RCF or inspecting agency
as under:
6.2.1. Type Tests: The Type Test shall be conducted for approval of the firm
and as a part of audit check/modified specification when required by
the purchaser at any point of time. Report of 'TYPE TEST' results

•
witnessed by CDE-RCF/RITES, shall be submitted by the firm before
executing first supply. One assembly as per Cluase-4.1, drawn at
random shall be subjected to the test as specified In the Clause-4.1 to
4.6 In case any assembly fails, one more assembly shall be drawn at
random and subjected to the tests as mentioned in the Clause-4.1 to
4.6. The assembly shall pass the test specified or else the entire lot
shall be rejected. The lot shall be accepted if the sample passes the
tests. In the event of rejection fresh lot shall be offered for type tests.
One test piece from each item viz. body, nut & ferrules shall be tested
as per relevant specification, including microstructure of forged steel at
NABL accredited lab. Hardness and case depth for ferrule shall be
done at NABL accredited lab/designated Govt. lab such as
NML./Jamshedpur Or, the same shall be outsourced to a firm having
expertise for the case hardening. The process adopted for case
hardening shall not cause any chromium depletion affecting the
corrosive properties of parent material. The hardness and case depth
shall be measured by using Knoop micro hardness tester. Internal test
certificate along with the Export/Import documents if any, issued by the
firm conducting the case hardening shall also be submitted.

6.2.2. Routine Tests: Five percent test pieces of a lot for each fitting, selected

•
at random shall be subjected to the tests as specified above (4.1 to
4.7) In case the item/assembly falls, one more assembly shall be
drawn at random and subjected to the tests mentioned above. The
assemblies shall pass the tests specified or else the entire lot shall be
rejected. The lot shall be accepted if the sample passes the tests. In
the event of rejection fresh lot shall be offered for tests.

Prepared By Agreed By
 SPECIFICATION SCHEDULE OF INFRASTRUCTURE REQUIREMENTS MDST: 108 REV: 01
FOR SINGLE BITE TYPE FITTING PAGE 8 OF 8
DATED 06.02.2023

7. Code of Practice for Quality Control and Inspection:

7.1. Regular inspection shall be done by inspecting agency as per approved

Quality Assurance Plan.
7.2. The raw materials should be procured from the authorized distributor of
original manufacturer along with their test certificates. These test certificates
shall be co-related with the stamping on the raw material taken up for
manufacture, prior to commencement or with any other adequate alternate
system to ensure proper traceability with the raw material.
7.3. Wherever test certificates are not available, sample shall be drawn and
tested both for chemical composition and physical properties in the presence
of Inspecting Agency. All records of physical and chemical tests shall be
made available to Inspecting Agency.
7.4. The manufacturers shall furnish to the purchasing/ inspecting authorities
information in respect of quality control systems in force at their works on
various materials used In the manufacture of components.
7.5. The manufacturers shall furnish to the Purchasing/ Inspecting authorities the
details of tests and inspection records and other relevant records as required
under the quality control systems in force.
7.6. These records and reports shall be maintained by the Competent Technical
Authority of the manufacturer and shall be open to examination by the
Purchasing/ Inspecting Authorities at all reasonable time.
7.7. Purchasing/ Inspecting Authorities at their discretion may select samples of
products at any stage of production for conformity tests of raw material at the
works of the manufacturer or in an approved laboratory. In case the samples
do not conform to the requirements of the specification, double the number
of samples from the same lot/batch shall be drawn for re-tests. If any of the
re-test samples do not conform to the requirements, the entire lot/batch shall
be rejected.

8. Identification Marking:

Each fitting shall have the following marking clearly on the body for the ease of
identification and trace-ability:
1. Manufacture's Name/logo
2. Size
3. Material
4. Part/Drawing No.
5. Year of Manufacture.

Prepared By Agreed By
 SPECIFICATION SCHEDULE OF INFRASTRUCTURE REQUIREMENTS MDST: 108 REV: 01
FOR SINGLE BITE TYPE FITTING PAGE 9 OF 8
DATED 06.02.2023

9. Packing:

The packing shall be such that all the machined surfaces shall be properly
protected against rubbing/ impact/scratches during transportation. The
contractor, before actual supply, shall ensure that exposed threaded portions of
fittings are suitably covered with air tight protection caps to prevent ingress of
foreign matter, formation of moisture and damage to threads during handling,
transportation and storage. The protection caps shall be fitted in such a manner
that they should not fall off on their own during transit, storing and handling.
Contractor shall also ensure that fittings are properly packed with necessary
anti-rust/anti-galling treatment in sealed carton boxes. Each package shall be of
convenient mass for easy handling.

10. Warranty:

The manufacturer shall warrant the fitting for conformance to quality for a period
of 30 months from date of supply or 24 months from date of Installation which
ever shall be sooner, as per IRS conditions.

-----------------X-----------------

Prepared By Agreed By