Para No.

Requirement as per Para Machinery Capacity Cost

GENERAL REQUIREMENTS
2.1 Class “A” Foundry as per IS: 12117 (1996) or latest
2.2 ISO 9001 : 2015
GENERAL INFRASTRUCTURAL AND MANUFACTURING FACILITIES
One EOT Crane for Melting, Moulding , Fettling EOT Crane 5/15 Tons 40 lk ( 02 nos.)
One EOT Crane for Heat Treatment EOT Crane 5/15 Tons 40 lk
3.1
One EOT Crane for Gauging & Assembly EOT Crane 5/15 Tons 40 lk
One EOT Crane for Load Testing Area EOT Crane 5/15 Tons 40 lk

Covered area with sufficient space for handling raw material like Sand, EOT Crane 5/15 Tons 40 lk
3.2
Scrap etc provided with EOT crane and conveyor, magnetic chuck Conveyor
Magnetic Chuck 3 lk ( 02 nos)
tilting type electric arc furnace having laddle refining facility with
3.3 Arc Furnace 5 Tons (Min.) 3.5 Cr. (5 ton). 6.0 Cr.( 10 ton)
minimum 5t capacity
Minimum three numbers of Charging buckets of suitable capacity for
3.4 charging bucket 3 No. s (Min.) 5 lk (4 nos)
scrap and foundry returns should be available
Facilities for pre-heating of laddle should be available Insulating Laddle
Laddle Pre-heater 1 No. (Min.)
3.5 Insulating Laddle Lining Board or High Alumina bricks should be used for Lining Board/High
1 No. (Min.) 5 lk + 7 lk
Laddle lining Alumina bricks Laddle
Separate identified area for different grade of scrap and foundry lining
3.6
returns should be available for avoiding wrong charging
Facilities should be available for oxygen lancing and Argon purging for Oxygen Lancing 25 lk
3.7
removal of entrapped gases Argon purging
Mobile Crane
Adequate material handling Equipments viz. Mobile crane/EOT EOT Crane
crane/Fork lifter/ Payloader/Magnetic crane/Tractor Trolley/Loading Fork Lifter 20 lk ( 4 nos)
3.8
Tempo/Tram beam/Piller crane should be available for handling of Pay Loader
material at all stages of production Magnetic Crane
Hydra 30 lk ( 02 nos)
Weighing machine of minimum 500 Kg capacity for Ferro alloys charge Electronic Weighing
3.9 1 Ton (1 No.) 7 lk ( 04 nos.)
and minimum 1 ton capacity for finished casting weighment machine
3.10 Ensure that refractory pouring cups & down spruce are used
SAND PREPARATION Adequate as per
Sand drier and cooling arrangement of adequate capacity for drying
4.1 Automatic Sand Drier production 10 lk
incoming sand
sand continuous mixer
with suitable machine
automatic for making Mould
transportation and Core
arrangement. Automatic sand
4.2 should be available. The mixer should be intensive type with calibrated continuous mixer requirement 10 Cr.
dozing of important ingredients. machine
 Ensure that the system exist for testing of prepared sand as per the
following frequency: i)
4.3
Moulding sand 1 in every 5 batch. ii) Core
sand 1 in every 20 batch. Rapid Moisture Teller Qty.: 01 No. 20 k

Whenever the sand is tested the following properties of prepared sands Permeability Tester Qty.: 01 No. 35 k
shall be checked. Green Compressive Strength, Green Shear Strength, Sand Shatter Index Qty.: 01 No. 28 k
Moisture, Permeability, Shatter Index flowability, hardness etc. The Universal Sand
4.4 Qty.: 01 No. 1.20 lk
acceptance value for each test must be clearly specified and any sand Testing Machine
Sand Flowability
not meeting the above parameters must not be used for mould/core Qty.: 01 No. 10 k
testing Equipment
making Sand Muller Qty.: 01 No. 2.5 lk
Mould Hardness
Qty.: 01 No. 20 k
Tester
Core Hardness
Jolting M/c OR Tester Qty.: 01 No. 20 k
Jolt and Squeeze machine or mechanised moulding line should be
4.5 Mechanised Moulding Qty.: 01 No. 25 Cr.
Mould cavity & core must available for moulding
be painted with mould wash Alkalic base / PaintingLineFacility by
4.6 Qty.: 01 No. 5 lk
Zircon base in nature to reduce mould metal reaction
Ensure that the facilities are existing for preparation of cores by No ContiniousWash
Zircon Mixture
4.7 Qty.: 01 No. 50 lk
bake method Machine
Heat treatment facilities capable of handling the entire production HEAT
mustTREATMENT
Multi point Automatic
Gas-fired Heat-
5.1 be available in house. Heat treatment furnace should be either
Heat treatment furnace should be provided with multi point automatic treatment oil fired continuous Qty.:01
Qty.: 02No.
No.at
s 2.5 Cr (05 nos )
Furnace
5.2 continuous temperature or Gas fired orarrangement
recording electric typewith digital indicators Calibration Temperature of heat every five feet do
The heat treatment furnace must be calibrated using sufficient no. of Thermocouples/
for each treatment furnace is Calibration
lengthOnce
5.3 thermocouple for point (onetemperature
assessing point at every at five feet length).
different zones at various recording
temperature 35 k
Thermocouples, temperature indicators should be to be done
arrangement at least in a yearOnce
5.4 temperature
Serial nos. ofranges. Theunder
castings calibration
heat is to be
treatment done at calibrated
should least once at
be recorded in least
ainyear
a indicators
Calibration
once in 6 month once inshould
Register ato be be
year in 6 month
do
register for traceability with temperature time curve
Arrangement of proper sealing of doors of HT furnace should be and date. Display calibrated at least
5.5 maintained for do
of available
temperature curveoxidation
to avoid near the /furnace for the guidance
scale formation of the operator
on the surface of the once
Sealing inof6 doors
monthof
5.6 Traceability
Heat Treatment do
casting. should be ensuredinside to avoid entry of air
The HeatThere should
Treatment be positive
recorder/Graph pressure
should have sealing arrangement HT furnace
recorder/Graph
5.7 from outside do
Positioning of the nozzlesto of avoid tampering
oil fired/Gas fired furnace should be such should have sealing
5.8 Burnersarrangement
of HT furnace do
that the flame does not come in direct contact with the castings. Calibration Once
5.9 The burners of HT furnace should be calibrated at every
Induction hardening Machine or alternative equipment to achieve three months should be calibrated do
in 3 month
5.10 specified hardness in terms of Drg. No. WD-97049-S/3 should be atInduction
every three hardening
months Qty.: 01 No. 45 lk
Machine
Shot Blasting
available SHOT BLASTING MACHINE
Machine (Conveyor
Suitable shot blasting machine conveyor monorail type/ Twin table
6.1 Monorail type / Twin Qty.: 01 No. 1.4 Cr
Casting to be given type/Hanger
shot blastedtype should
before beafter
and available.
heat treatment using Steel
6.2 TableShot
typeof/ size
Hanger SS
20 lk
steel shot of size SS 1000, IS 4606 1000, IS 4606
type)
SAND TESTING
All incoming sand must be tested before acceptance as per frequency
set by QC Department. The following must be checked
AFS grain size Sieve Shaker M/c Qty.: 01 No. 45 lk
7.1
Clay content Qty.: 01 No. do
Moisture content Qty.: 01 No. do
7.1

Loss of Ignition Qty.: 01 No. do

For testing incoming virgin sand, moulding sand, core sand the
following equipment atleast one number each should be available
Permeability tester Permeability tester Qty.: 01 No. do
Sand Rammer Sand Rammer Qty.: 01 No. do
Quick moisture teller Quick moisture teller Qty.: 01 No. do
Chemical balance Chemical balance Qty.: 01 No. 40 k + 20 k ( 02 nos)
Sand sieve shaker Sand sieve shaker Qty.: 01 No. do
Sand Muller of 2.0 to
7.2 Sand Muller of 2.0 to 5.0 Kg. capacity Qty.: 01 No. do
5.0 Kg. capacity
Shatter Index tester Shatter Index tester Qty.: 01 No. do
Dry compression
Dry compression strength tester Qty.: 01 No. 35 k
Sandstrength tester /
mouldability
Sand mouldability / Compatibility tester Qty.: 01 No. 30 k
Compatibility tester
Sand flowability
Sand flowability tester Qty.: 01 No. do
Mould/Core testerhardness
Mould/Core hardness tester Qty.: 01 No. do
Methylene tester
blue test
Methylene blue test equipment for clay Qty.: 01 No. 20 k
Ensure that the calibration of the above equipment is done once in a Calibration equipmentOnce for clay
in a Calibration Once
7.3
year year in a year
Computerised
Computerised emission spectrometer with automatic printer CHEMICAL should be LABORATORY
emission
8.1 available
Wet forfacilities
analysis analysisincluding
and recording of steel
Strohlein composition
apparatus at different
for carbon analysis, spectrometer with Qty.: 01 No. 40 lk
8.2 stages of manufacturing
conducting chemical test of incoming raw materials, refectories, ferro Metalographic 6 lk
automatic printer
Metalographic polishing
alloys should equipment
be available viz. Cut off
in addition machine, Belt
to spectro polishing machine,
8.3 Qty.: 01 No. 1.3 lk
polishing/Rotary polishing Machine etc. should be available Belt polishing/Rotary
PHYSICAL LABORATORY
polishing Machine
Universal testing machine of 40T capacity with graphical recording/
Universal testing
Computer recording & printing facility for conducting tensile test of 40 Tons Min. 8 lk
9.1 machine
sample from each heat should be available.
calibrated once in a Calibration Once
The machine is to be calibrated once in a year
Direct reading year in a year
9.2 Impact testinghardness
machinetesting
0-300Jmachine
capacity capacity 95-500Impact
for conducting BHN should
Test atbe Brinell Testing M/c 95-500 BHN 3 lk
available
room temperature and Sub-zero temperature with cold chamber with Impact testing
9.3 0-300J 4 lk
digital temperature indicator for sub-zero test arrangement
Shadowgraph facilities for assuring correct notch profile and dimensionshould be machine
9.4 available Profile Projector Qty.: 01 No. 1.5 lk
for impact test specimen
9.5 Liquid penetrant test facilities for checking surface welding cracks Die Penetration Test 30 k
Magnetic particle Inspection facilities for crack detection should be Magnetic particle Test
9.6 1.5 lk
available facility
Radiographic
examination facilities
Radiographic examination facilities with well equipped standard room
9.7 withASTM E-446
well equipped 2 lk
should beradiograph
Relevant ASTM E-446 reference Available for comparing level of referenceroom radiograph
9.8 standard should 5 lk
radiographic quality should be available Metallurgical
for comparing
be Availablelevel of
9.9 Metallurgical microscope with 1000 x magnification microscope
radiographic with 1000
quality Qty.: 01 No. 2.5 lk
9.10 SCRATA comparator for assessing surface quality x magnification
SCRATA comparator Qty.: 01 No. 3.5 lk
 Person in charge of the metallurgical area is at least Graduate in
9.11 Staff conducting test likewith
chemical analysis,
metallurgical not less than 5 Sand
years testing of mechanical
experience
9.12 properties have adequate skill and competence and have under gone
Skill of such staff is periodically
training qualified
to give the by making
reasonable them carry out test
reliability
9.13 Muffle furnace 0-1200 degree C with temperature recorder should be
on blind samples.
9.14 available for chemical analysis and Jominy test with calibration on Muffle furnace 0-1200 degree C 2.7 lk
yearly basi Hot air oven Qty.: 01 No. 1 lk
Hot plate Qty.: 01 No. 40 k
Hot air oven, Hot plate, Electrical oven and other accessories and Electrical oven Qty.: 01 No. 30 k
9.15 chemical agents necessary for wet analysis should be available including
platinum crucibles (atleast 2nos.) Chemical agents do
Apparatusfor
Chemical Testing
Platinum Crucibles Qty.: 02 No. s 2.5 lk
STATIC LOADHydraulic
TESTING
Hydraulic Press for
Press for
Load testing arrangement for Bogie with 100t hydraulic power pack Loadload
Proof testing
and
10.1 Proof load and destructiveshould
load testing arrangement for side frame and 100 Tons Min. 10 lk
be available arrangement for
destructive load
10.2 bolster with Hydraulic power pack of 300 tonnes capacity should be Bogie 300 Tons Min.
testing arrangement
available MACHINING forFACILITIES
side frame and
The firm should have a machine shop equipped with the following bolster
Plane miller machine of suitablemachines
capacity for machining bolster surface.
Plano miller machine
Lathe machine.
Air Compressor Air Compressor 60 lk (02 nos)
Drilling machine Drilling machine 1.5 lk
11.1
Swing grinder Swing grinder 10.5 lk
Welding transformer
Welding transformer DC 12 lk (08 nos)
DC
Welding rectifier DC Welding
Powerrectifier
saw forDC
Power saw for sectioning sides frame/Bolster sectioning sides 8 lk (02 +01)
Firm should have gauges as detailed in RDSO’s specification number
11.2 3frame/Bolster
sets of Gauges 30 lk
WD-31-Misc-99 & use these during & after machining operations
including Aluminium pattern and core box 30 lk

Total 50 Cr
 Remarks

.0 Cr.( 10 ton)