ResearchDesigns&Standards Organisation
Manak Nagar,Lucknow-226011
QM-C-7.1/AB0001/M-(ERW)
Inspection Plan (Check Sheet)
Item :Pipes for Air BrakeSystemforfreight& coaching stock.
Specn.:04-ABR-02
Amd.: 08ofSept2016.
Drg. No. & Alt. No.: WD-83062-S-06,Alt.4, WD-83062-S-07 Alt. 6,WD94056-S-1,Alt.Nil
For all type of Freight & Coaching stock.
1. For Freight stock fitted with Conventional brake system:
Seamless pipe as per IS-1239(Part-I)heavy grade orASTMA-106GrAforBrake/Feedpipe32NB and for Flanges and
fittings IS 2062-2006 E250A o r IS: 6911-1992 X 04 Cr19 Ni 9304 SI or ASTM A351/A351M-03 Gr CF8 J92600
or ASTM A182/A182M/12A
F or branch pipe- 20NB,stainless steel ASTM-A312schedule 40SGr.TP(ERW) and for Flange and f ittings to
IS: 6911-1992 X 04 Cr. 19 Ni 9304 SI or ASTM A351/A351M-03 Gr CF8 J92600 or ASTM
A182/A182M/12A
2. For Freight Stock fitment with BMBS:
For Brake pipe, Feed Pipe and Branch pipe Stainless steel to ASTM-A312schedule 40SGr.T304(ERW) & for Flange
and fittings, Stainless steel toIS: 6911-1992 X 04 Cr19 Ni 9304 SI or ASTM A351/A351M-03Gr CF8 J92600 or
ASTM A182/A182M/12A
3. For Passenger stock fitment with BMBS:
For Brake pipe, Feed pipe and Branch pipe, Stainless steel to ASTM-A312 schedule 40SGr.T304 (ERW)&for flange
sand fittings, stainless steel toIS: 6911-1992 X 04 Cr19 Ni 9304 SI or ASTM A351/A351M-03 Gr CF8 J92600or
ASTM A182/A182M/12A.
1 Name ofManufacturer
2 Date ofoffer
3 Date (Period)ofInspection
4 RDSO FileNo.
5 Drawing&Alt. No.
6 P. O. No.
7 Total Quantityordered
8 Quantityearlierpassed
9 Quantitynow offered
10 Consignee
11 D.P.
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Research Designs & Standards Organization
Manak Nagar,Lucknow-226011
A) Vendor should produce Mill Test Certificate of pipe at the time of inspection, shall be consisting of
following tests as per IS 1239, Part-I Heavy Grade / ASTM A-106 Gr. A / ASTM A312 40S Gr. TP 304
(ERW)
S.No Test Details Specification Specified Parameters Value of MTC Remarks
IS 1239 Pt.I, H NA
ASTM A- OK / Not
1 Grain Size
106Gr.A NA OK
ASTM A 312 No. 7 or Coarser for TP-304
IS 1239 Pt.I, H C - 0.20 max
(In Ladle Mn - 1.30 max
Analysis) S - 0.04 max
P - 0.04 max
C - 0.25 max
Mn - 0.27 - 0.93
S - 0.035 max
P - 0.035 max
ASTM A-106 Si - 0.1 min
Gr.A Cr - 0.4 max
Chemical OK / Not
2 Cu - 0.40 max
Composition OK
Mo - 0.15 max
Ni - 0.40 max
V - 0.08 max
C - 0.08 max
Mn - 2.00 max
S - 0.030 max
ASTM A 312 P - 0.045 max
Si - 1.00 max
Cr - 18.0 - 20.0
Ni - 8.0 - 11.0
YS –NA
IS 1239 Pt.I, H UTS - 320 Mpa
% E - 12 min
ASTM A-106 YS - 205 MPa
Tensile OK / Not
3 Gr.A UTS - 330 Mpa
Requirement OK
% E - 20 min
YS - 205 MPa
ASTM A 312 UTS - 515 Mpa
% E - 35 min
Flattening IS 1239, Part-I Heavy Grade / ASTM A-106 Gr. OK / Not
4
Test A / ASTM A312 40S Gr. TP 304 (ERW) OK
Hydro static
or Non IS 1239, Part-I Heavy Grade / ASTM A-106 Gr. OK / Not
5
Destructive A / ASTM A312 40S Gr. TP 304 (ERW) OK
Electric test
Manufacturer trade mark
Marking Size of Pipe OK / Not
6
Details Heat No OK
ET or Hydro Pressure
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Research Designs&Standards Organization
Manak Nagar,Lucknow-226011
B)Raw Material Verification Sheet:
S.No Descriptions Observations/Comments
1. Verification of in voice of raw materials procured for
manufacturing of tube (in case of in houseTube Mill)
2. Thickness/diameter of raw materials for seamless
manufacturing of tube (in case of in houseTube Mill)
3. Verification of ledger of raw material for incoming pipes,
Dispatched quantity & balance both in weight & Quantity)
SIGNATURE OF FIRM REPRESENTATIVE SIGNATURE OF RDSO INSPECTOR
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Ministryof Railways
Research Designs & Standards Organisation Manak
C. LotSize: 100 sets orpart thereof
D. Visual Check:
Specified sample size -10%
Actual sample size–
Specified Observation
1. Pipe should be smooth, inside and outside must be free
OK/Not OK
From defects and must be provided with parallel threads to IS:
554 wherever called for.
2. Pipe should be cleaned, free from dust/rust &moisture. OK/Not OK
3. Painting (if included in Purchase Order):Exterior to be
painted
(a) Mid Brunswick green paint to ISCno.226 of IS: 5- 2007
ready mixed paint to IS: 119 for Brake pipe.
OK/Not OK
(b) Ready mixed white finish paint toIS: 127 for feed pipe.
4. Welding Joints to pipe shall be in accordance with
Procedure given in annexure A and for stainless steel pipe to
Annexure B of the specification no. 04-ABR-02 OK/Not OK
5. Marking.
1. Stencil of mfg initial, month and year to be stamped
OK/Not OK
on pipe after paint.
2. Punchin4 mm size mfg. initial, month and year on
flange
SIGNATURE OF FIRM REPRESENTATIVE SIGNATURE OF RDSO INSPECTOR
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Ministryof Railways
Research Designs & Standards Organisation Manak
E. Dimensional Check: Specified sample size-10%.
Actual sample size-
1. Check the pipes with piping layout as per RDSO Drg. For OK/Not OK
Relevant type of Wagon/Coach.
2. Measure pipe OD& wall thickness for Seamless pipe as per
Observed dimensions
IS-1239 ,Part-I heavy grade/ASTM A-106Gr.A and
Stainless Steel pipe to ASTM A312 40S Gr.TP 304 (ERW
& Seamless)
Nominal OuterDiameter Wall Thickness OuterDiameter Wall Thickness
Bore (Taking variation of Observed Observed
+12.5% / - 0%onstd.value)
Value Value
32mm 42.0 to42.9(IS-1239) 4.0 to 4.5 Ok/ Ok/
41.4 to43.0(ASTM A-106) 3.55 to 4.0 NotOk NotOk
41.36 to 42.96(ASTMA312) 3.56 to 4.0
25mm 33.3 to34.2(IS-1239) 4.0 to 4.5 Ok/ Ok/
33.00 to 33.8(ASTM A-106) 3.38 to 3.8 NotOk NotOk
32.60 to 33.80(ASTM A312) 3.38 to 3.8
20mm 26.5 to27.3(IS-1239) 3.2 to 3.6 Ok/ Ok/
26.3 to27.1(ASTM A-106) 2.87 to 3.22 NotOk NotOk
25.87 to 27.07(ASTM A312) 2.87 to 3.22
15mm 21.0 to21.8(IS-1239) 3.2 to 3.6 Ok/ Ok/
20.9 to21.7(ASTM A-106) 2.77 to 3.11 NotOk NotOk
20.54 to 21.74(ASTM A312) 2.77 to 3.11
10mm 16.7 to17.5(IS-1239) 2.9 to 3.26 Ok/ Ok/
16.7 to17.5(ASTM 106) 2.3 to 2.59 NotOk NotOk
16.35 to 17.55(ASTM 312) 2.31 to 2.59
3. Ball Test: Pipes must be tested after bending for free
Passage with a ball of following dia: OK/Not OK
32mm nominal dia pipe 28mm ball
25mm nominal dia pipe 22mm ball
20mm nominal dia pipe 16mm ball
15mm nominal dia pipe 11mm ball
10mm nominal dia pipe 8.5mm ball
4. Threads checking with gauge. OK/Not OK
5. Thickness of Pipe material after threading
32 NB – 1.60 minimum
25 NB – 1.60 minimum
20 NB – 1.30 minimum
15 NB – 1.30 minimum
10 NB – 1.10 minimum
6. Flange, Socket &‘O’ Ring to be measured as per Drg. OK/Not OK
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Ministryof Railways
Research Designs & Standards Organisation Manak
F. Chemical, Tensile&bend test as per related specification: (One sample perlot perHeat Number of
Rawmaterial to be tested fromNABL accredited Laboratory).
Specifiedsamplesize:
a. Chemical Test (including Pipe, Socket and Flange)-1 No each.
b. Tensile and Bend Test (Pipe only)-1 No each.
c. Actual samplesize:
1. Chemical Test:
OK/Not OK
Freight stock fitted withBMBS
a. Feed /Brake pipe & Branch pipe as per stainless steel to ASTM A 312 schedule
40S GrTP-304(ERW).
b. Flanges and fittings for Stainless steel (ERW) pipes to
IS: 6911-1992 X 04 Cr. 19 Ni 9304 SI or
ASTM A351/A351M-03 Gr CF8 J92600 or
ASTM A182/A182M/12A
Freight stock fitted withConventional Brake system
c. Brakepipe / Feedpipe as per seamless toIS: 1239 (Part – 1)heavy grade/ ASTM
A-106 GrA.
Flanges/fittingsforseamless pipes of Freight stockas per
IS: 2062- 2006 E 250 Aor
IS: 6911-1992 X 04 Cr. 19 Ni 9304 SI or
ASTM A351/A351M-03 Gr CF8 J92600 or
ASTM A182/A182M/12A
Passenger stock fitted withBMBS
d. Feed /Brakepipe&Branch pipe as per stainless steel to ASTM A 312 schedule 40S
GrTP-304(Seamless).
e. Flanges and fittings for Stainless steel (ERW) pipes to
IS: 6911-1992 X 04 Cr. 19 Ni 9304 SI or
ASTM A351/A351M-03 Gr CF8 J92600 or
ASTM A182/A 182M/12A
f.
2. Tensile&Bend Test: Observed Values OK /
a. Freight stock Brake pipe/ Feed pipe / Branch pipe as per seamless to IS: 1239 (Part – NOT OK
1)heavy grade/ ASTM A-106 GrA/ ASTM-A-312 schedule 40S GrTP-304(ERW).
YS UTS %E
IS 1239 Pt.I, H
NA 320 Mpa 20 min
ASTM A-106 Gr.A 205 MPa 330 Mpa 35 min
ASTM A 312 schedule 40S GrTP-304(ERW) 205 MPa 515 Mpa 35 min
Bend test at 180ºangle.
b.Passenger stock Brake pipe / Feed pipe / Branch pipes
Specification YS (Min) UTS (Min) %E
ASTM-A-312 schedule 40S Gr TP- 205 Mpa 515 Mpa 35 (Min)
304(Seamless).
Bend test at 180º angle.
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Ministryof Railways
Research Designs & Standards Organisation Manak
G. Metal structure& Macro Etching: OK/Not OK
Metal structure &Macro Etching test (for Seamless pipe)– Pipe should sound and
reasonably uniform material free from injurious laminations, cracks, seams, scabs, tears etc
H. Leakage Test: Specified sample size -5% of offered lot and in caseof failure, 20%of reoffered lot.
Actual samplesize-
Leak Test at 10kg/cm2compressed dryair pressure, dippingin OK/Not OK
watertank
I.Packing:
i. Outer ports & exposed threaded portion of pipes and joints Available/NotAvailable
are suitably covered with airtight protection caps.
ii. Pipes and Joints should be adequately packed to prevent Adequate /Inadequate
damage in handling and storage.
J. Calibrationstatus checked. OK/Not OK
K. Dimension check for flange/ fittingfor pipes are asper RDSO DRG WD83062 S-06 Alt. 4
&WD83062 S-07 Alt. 6
Material for flange and fittings for BP/FP/Branch pipes are as per
i) IS 6911-1992 X 04 Cr. 19 Ni 9304 SI
ii) ASTM A351/A351M-03 Gr CF8 J92600
iii) ASTM A182/A 182M/12A
iv) IS : 2062– 2006 E250 A)
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