Pincs- O8FAX DEDICATED FREIGHT CORRIDOR CORPORATION OF INDIA LIMITED. LILLE le ‘Sdikes tre wits OWNER: Dedicated Freight Corridor Corporation (I) Ltd. M PMC: SYSTRA — MOTT MacDonald (JV) SYSTIA wor M CONTRACTOR: LEr-INABENSA CONSORTIUM @naBensa PROJECT: EDFC PHASE-2 CP-204 (OHE PACKAGE) TITLE: ITP FOR IR TYPE CANTILEVER ASSEMBLY AND COMPONENTS DOC/CP-204/ QAQC/GEN/027 Date | Rev. | Modifications Prepared By Checked By ‘Approved By No. | (Purpose of issue) Name | Sign Name Sign Name | Sign T7a0.| 02 | Referpage2 | KSai Prtich cat | Deepak | 18 Prakash Mokopat | (A> | Bseeak | 2 | PMc ame Signature, chectedy TRS NAF, epee ‘Approved By Komal Shans A DFCe Name Signature Checked By pas “Approved By Date: 17.10.2018, Pages: 1of 13EDFC Phase-2 / CP-204 ITP for IR Type Cantilever Assembly and Components Revision Details Revision | gevision Date Issued by lo: Clause No. Revision o 05.06.2016 : Initial Submission 1 22.08.2018 : Revision 1 Revised as per PMC letter No. 2 17.10.2018 : PMCS/EDFC2/LTT/2018107619 dated 12.10.2018 a Document No. Rev. Date Page DOCICP-204/QAQCIGEN/O27 02 17-10-2018 | Page 2of 113EDFC Phase-2 / CP-204 ITP for IR Type Cantilever Assembly and Components Index 1. Subject. 2. Testing 24. Type Tests. 244. Coverage 2.4.2. Material verification 2.1.3. Verification of dimension and visual test... 2.1.4. Functional test. 2.1.5. Mechanical load test - Components. 2.1.6. Galvanization Test... 2.2. ‘Sample tests/Factory Acceptance Test (FAT). 2.2.1. Sampling... 2.2.2. Material verification... 2.2.3, Verification of dimensions and visual test. 2.2.4, Functional testa... 2.2.6, Mechanical load test. 2.2.6. Galvanization Test 2.3. Routine test: 2.3.1. Visual test 2.4. Site Acceptance Test 2.4.1, Visual test and Verification of dispatch documents..... 3. Inspection Test PIAN si... snne 3.1. Components not forming part of ITP 3.4.4. Insulators 3.4.2. End ftings of insulators with U-bolts. 3.2. Galvanized Stee! Tube 33.7x2.65, for Stay Arm and Register Arm Tube & Diagonal Strut 3.2.1. Material verification....... 3.2.2. Verification of dimension and visual test... 3.2.3. Galvanization test... 3.3. Galvanized Steel Tube 33.7x4, for Register Arm Tube-SPL 3.3.1. Material verification ‘| 3.3.2. Verification of dimension and visual test. 3.3.3. Galvanization test.. 3.4, Galvanized Steel Tube 70x4.3, for Bracket Arm Tube 3.4.1. Material verification. 3.4.2. Verification of dimension and visual test 3.4.3. Galvanization test... 3.5. Mast Hinge Joint: 3.5.1. Material verification e 3.5.2. Verification of dimension and visual test... 3.5.3. Functional test. ...Error! Bookmark not defined. 3.5.4. Mechanical load test. 3.5.5. Galvanization test, X36. Catenary Suspension Bracket (ROSO type! Document No. | Rev. DOCICP-204/QAQC/GENIO27 02 17-10-2018 | Page 3 of 7EDFC Phase-2 / CP-204 ITP for IR Type Cantilever Assembly and Components 3.6.1. Material verification... 3.6.2. Verification of dimension and visual test 3.6.3. Functional test, 3.6.4. Mechanical load test.. 3.7. Catenary Suspension Clamp (RDSO type)... 3.7.1. Material verification. : 3.7.2. Verification of dimension and visual test. 3.7.3. Funetional test... 3.7.4. Mechanical load test. 3.8. Double suspension clamp (RDSO type)... 3.8.1. Material verification... 3.8.2. Verification of dimension and visual test. 3.8.3. Functional test... 3.8.4. Mechanical load test 3.9. Stay Adjuster (16-hole) 3.9.1. Material vorification ....nsnnennnnne 3.9.2. Verification of dimension and visual test 3.9.3. Functional test. exmaiia Error! Bookmark not defined. 3.8.4. Mechanical load test .oonn Sees 42 3.9.5. Galvanization test.. AD 3.10. Tubular Stay Sleeve: ; 3 3.10.1. Material verification A 3.10.2. Verification of dimension and visual test 44 3.10.3. Functional test ck A 3.10.4. Mechanical load test 45 3.10.5. Galvanization test. nS 3.11. Stay Tube Sleeve 55/33.7mm: 46 3.11.1, Material verification. AT 3.11.2. Verification of dimension and visual test 47 3.11.3. Funotional test "Error! Bookmark not defined. 3.11.4. Galvanization test.. wT 3.11.5. Mechanical load test. AB 3.12. Steady Arm Assembly . 49 3.12.1. Material verification «0 i 3.12.2. Verification of dimension and visual test... 3.12.3, Functional test - 3.12.4. Mechanical load test 3.12.5. Galvanization test (For valvenizedi items only).. 3.13. Large Register Arm HOOK? wren os "Error! Bookmark not defined. 3.13.1. Material verification... 3.13.2. Verification of dimension and visual test .. 3.13.3. Functional test 3.13.4. Mechanical load test. 3.13.5. Galvanization test...... 3.14, Register Arm Eye Piece for 33.7x2.65mm registor Tube: 3.14.1. Material verification. 3.14.2. Verification of dimension and visual test. 3.14.3. Functional test. 3.14.4. Mechanical load test. Document No. Rev. Date Page DOCICP-204/QAQC/GEN/O27 02 47-40-2018 | Paged of 113”EDFC Phase-2/ CP-204 ITP for IR Type Cantilever Assembly and Components 3.14.5. Galvanization test. 3.18. Register Arm Eye Piece for 33.7x4mm register Tube: 60 61 3.15.1, Material verification... 62 3.15.2. Verification of dimension and visual test saeennnenes 3.15.3. Functional test. . Error! Bookmark not defined. 3.16.4, Mechanical load tes! 63 3.15.5. Galvanization test. 63 3.16. Drop Bracket Assembly... 64 3.16.1, Material verification 65 3.16.2. Verification of dimension and visual test... 3.16.3. Functional test 3.16.4, Mechanical load test. 3.16.5. Galvanization test.. 3.17. Strut fitting for 70 mm Tube: 3.17.1. Material verification .. 3.17.2. Verification of dimension and visual test 3.17.3. Functional test.. 3.17.4. Mechanical load test. 3.17.5. Galvanization test. 3.18. Strut Fitting for 33.7mm Tube.... 3.18.1. Material verification... 3.18.2. Verification of dimension and visual test .. 3.18.3. Functional test... 3.18.4. Mechanical load test 3.18.5. Galvanization test... ae 3.19. Strut Tube End Fitting for 33.7mm Strut Tube:.. 3.19.1. Material verification... - seeemraci 3.19.2. Verification of dimension and visual teSt 00.00 cena 3.19.3. Functional test. . Error! Bookmark not defined. 3.19.4. Mechanical load test.. <1 3.19.5, Galvanization test... 7 3.20. Bracket Tube Cap-Spl, 70mm... TB 3.20.1. Material verification ae 3.20.2. Verification of dimension and visual test .. 3.21. Register Arm Tube Cap, 3.7mm: 3.21.1. Material verification ...n.snne 3.21.2, Verification of dimension and visual test .. 3.22. Register Arm Tube Cap (SPL), 33.7mm, 4mm th 3.22.1. Material verification... se 3.22.2. Verification of dimension and visual test 3.23, Register Arm Dropper Assembly: 79 oT) 80 81 Bi 82 3.23.1. Material verification... ea 3.23.2. Verification of dimension and visual test 3.23.3, Functional test... 3.23.4. Mechanical load test... 3.23.5. Galvanization test. si 3.24, Raised Register Arm Adjuster (25mm): 3.24.1. Material verification... Document No. |__ Rev. Date Pave i _| DOCICP-204/QAQC/GENIOZ7 I 02 17-10-2018 | Page 5 ofti3_|EDFC Phase-2/ CP-204 ITP for IR Type Cantilever Assembly and Components 3.24.2. Verification of dimension and visual test 3.24.3, Functional test... 3.24.4. Mechanical load test... 3.24.5. Galvanization test... 3.25, Raised Register Arm Clamp: 3.25.1. Material verification... o 3.25.2. Verification of dimension and visual test 3.25.3. Functional test. o 3.25.4. Mechanical load test 3.25.5. Galvanization test... 3.26. Wind stay:.... 3.26.1. Material verification... ss 3.26.2. Verification of dimension end visual tast 3.27. Eye clip for wind stay, 3.7mm: 3.27.1. Material verification 3.27.2. Verification of dimension and visual test 3.27.3. Functional test 7 3.27.4. Mechanical loa 3.27.5. Galvanization test. 3.28. U-bolts: rt 3.28.1. Verification of dimension and visual test 4, Inspection test plan for cantilever assembly 44. General 42. Loading... o 43, Testset-up.... 4.3.1. Mast... 4.3.2. Load component. 4.3.3. Load component. 4.3.4. Load component 4.3.5. Measurement equipment. 4.4, Test procedure... . 4.4.1. Loading sequence. 4.4.2, Requirements. 44.3, Test sequence... 5. Full scale test cases... 5.4. General... 5.2, Test case criteria... Document No. Rev. Date Page DOCICP-204/QAQCIGENI027 02 | 17-10-2018 | Page 6 of 113EDFC Phase-2/ CP-204 __ ITP for IR Type Cantilever Assembly and Components 4. Subject Technical specification for EDFC Project requires testing of components of IR modified type - Cantilever System. Component testing shall follow requirements of EN 50119. Component tests comprise type tests and random sample tests. Type tests are intended to establish design characteristics. They are normally only made once and repeated only when the design or the material of the component is changed. The results Of type tests are recorded as evidence of compliance with design requirements. Random sample tests are intended to verify the quality of materials and workmanships. They are carried out as factory acceptance tests (FAT) on delivery batches. This report documents type tests as per following test table: ‘Sectio | smousm | Dimensio] Material | Mechanie Designation as per RDSO | RDSO Drawing | Sect | SuOLISM | TAC | "Check. | al Po Ne report | performed | Petforme | performe | Strength Galvanized Stel Tube 33.712.65, REQIP2401 55 . a e 7 Stay Arm and Register Arm | RE/S3/P/2421 Tube, Diagonal strut Galvanized Stee! Tube 33.7x4, Register Arm Tube BERS /2Ez1 (3) aa ic a v tl Gavarzoy Stel Toba : 70x4.3, Bracket Arm Tube _| R€/33/P12081 (S) oa a it = Mast Hrge dont EWOHERIT Tag |v 7 | : ‘aienry Sspesion ——} EMORETPETST ; : Bracket (S), 2132 (S) ae a o Cattery Sespasion | REET) : er aaline 7 7 Cater Dab RETA 4g erate - ‘Suspension Clamp ETV/OHEIPRAOZA Stay Adstr teneworeea | 39 |v ’ v : canise 106 OFEFTS ‘Tubular Stay Sleeve E/RDSON00004/03/ | 3.10 v v “ - § Say Take Same 55357 | ORGTOREIOS 5 mi an | 7 7 : steady Am Assontiy | EWOHEPAI [aig |v Zo - ETVOHEIPDT6T-2 Large Restoran Hook | RUOHEPRIST? | ag |v 7 ¥ : RegstorAmEyePiece | EMOHERZ«22 |S, |v 7 v : RogisterArm Eye Piece | Fay onelPl2az22 | 3 15 v “ v - Drop Bracket Assony | ETVOREPAGO—|a1e—| 7 z : Stat Fine fr 70mm —| ETTORE RABI 5. | > a : Tube Si) 262-282) Stul Fiing OST ma | ETOHEPITGTZ Tube ($2), 2162-2 (S3) he s cf = - 38 7m Shut Tbe End] ETVOMEIPIOGZ2T : Fitting (3), oe a “ a erate Tobe SSH ervonemntost | a2 | PaeeEoe d RegsiorAm Tube CaP, Tervoneimaaza+ | azt | _- “ 7 . Register i Tube Cap, | ETVOREIP24257 | 555] . savmm (SPL) 8 Document No. Rev. Date | DOCICP-204/QAQC/GEN/027 02 17-10-2018EDFC Phase-2 / CP-204 ITP for IR Type Cantilever Assembly and Components ETWOHE/P/2460, 5 RegairAmOopee — [Earrigi acer | aaa |v 7 . ; ere 4,2471-1 Raed RegterArm raga : Teer neasprae | 324 | : Rated Regatoram Cano | eTvoHemra7o2 | 328 |__~ 7 z Wind Sey eworernsoasy| 326 | - 7 7 = GyeciptorWrdSay | EWOHERPasoue)| 327 | 7 z 7 = ETVOHEIP/50, is Ube ETOH a2 | 7 7 2. Testing 24. Type Tests 24.4. Coverage The following tests shall be performed: - Material test, - Dimension and visual test; - Functional test; = Test of mechanical load capacity. As per EN 0119, 4 test specimens shall be selected, but as in FAT the same components shall be retested where nos. of sample shall be more than 4 nos., hence for acceptance, testing of single component is done. 2.4.2, Material verification ‘Type tests shall include verification of materials to ensure that they are in accordance with the documents. This verification shall be carried out by inspecting documentation relating to material purchasing specifications, certificates of conformity or other quality documentation. For chemical compositions of material, the certificates received from the sub-supplier shall be furnished. Should such documentation not be available, verification of metallic materials shall be conducted by spectrometer and values of chemical composition shall be noted down. Fittings, if cast out of the same melt, shall be considered as one lot. Material verification shall be conducted on sample fitting drawn from each lot. 2.1.3. Verification of dimension and visual test Key dimensions as encircled in the given drawings which affect the functionality and the strength of the fitting shall be measured on the samples. A visual examination shall include a check for the general condition and the surface of the sample for cracks, sink marks, inadmissible burrs or flashes, etc. Visual examination shall also include verification of marking (identification of fitting, manufacturer's identification, marking allowing traceability of component, e.g. date of manufacture). 2.1.4, Functional test Samples shall be assembled according to the supplier's instructions, using all | connecting parts. Bolts shall be tightened to 1.1 times the tightening torque sta OXON Sune (or \ {= fel Document No. Rev. | Date \SPage- _| ||5]—DOcTeP.204/QAQciGENI027 02 | 47-10-2018 | Page 8of 113 |EDFC Phase-2 / CP-204 ITP for IR Type Cantilever Assembly and Components supplier. No failure or unacceptable deformation is permitted unless itis intended to do so by design 2.1.5. Mechanical load test - Components Mechanical Load Tests = | as = feet aeStaaEeauEne re el ‘SMOL ete i terkaps | Beepon | Accessory parts for insulators and supporting assemblies are tensioned in the tensile testing machine using corresponding tensioning parts so that loading as close as possible to operation is achieved. These tensioning parts shall not influence the test result. The test specimens shall be loaded with a constantly and smoothly increasing load up to the maximum force Fax. For components, the following characteristics shall be determined: ~ the test specimen shall be able to withstand 1.33 times the operational force without a permanent deformation occurring; ~ the failure load Fnx of the test specimen shall be equal or greater than the nominal force Fron. The test data shall be used for determining the nominal force Fram or permissible operating force Foemop. The maximum force Fnax of the test specimen shall be equal to or greater than the required nominal force Fron, Nomenclature: Fnac actual force at which failure occurs in test (failure load) Frem nominal force, the minimum load declared by the supplier at which mechanical failure will not take place (specified minimum failure load SMFL) Fop operating force, corresponding to characteristic load Fremep permissible operating force, corresponding to specified minimum deformation load (SMDL), the minimum load declared by the supplier at which unacceptable permanent deformation will not take place. FA Document No. Rev. Date 1 || DOCICP-204/QAQC/GENIOZ7 02 | 47-10-2018EDFC Phase-2 / CP-204 ITP for IR Type Cantilever Assembly and Components 2.1.6. Galvanization Test The galvanised component of the fittings shall be tested for mass of zinc coating (Clause 5.0 of Specification No.ETVOHE/13 (4/84) with A & C slip 1 to 3), uniformity of coating, adherence and other defects (Clause 3.2 of Specification No. ETV/OHE/13(4/84) with A & C slip 1 to 3). The minimum zinc coating shall be 610 gms/sq. m for fittings and 425 gmsisq. m for Tubes as per RDSO specification for Tubes no. ETV/OHE/11 (5/89), 2.2. Sample tests/Factory Acceptance Test (FAT) 2.2.1. Sampling 2.2.11. Number of test specimens Random sample tests shall be performed only if a sufficient quantity of components is made, typically more than 100 of the same components. The number of the test specimens for the random sample test, p, shall be in accordance with the following formulae. p=3(min) for n< 100 p=3 for 100 20000 Where n is the batch size. 2.2.1.2. Selecting the test specimens and repeat tests The test specimens are selected arbitrarily from the batch. If the specimens pass the random sample test, then the batch shall be accepted. If one test specimen does not pass the random sample test, the test shall be repeated but with twice the number of samples selected from the same batch. If all the new test specimens pass the tests, then the batch shall be accepted. If any test specimen falls the random sample test then the batch shall be rejected. Test specimens subjected to the random sample test shall not be used for further testing or in service. 2.2.2, Material verification ‘Sample tests shall include verification of materials to ensure that they are in accordance with the documents. This verification shall be carried out by inspecting documentation relating to material purchasing specifications, certificates of conformity or other quality documentation. For chemical compositions of material, the certificates received from the sub-supplier shall be furnished, Should such documentation not be available, verification of metallic materials shall be conducted by spectrometer and values of chemical composition shall be noted down. Fittings, if cast out of the same melt, shall be considered as one lot. Material verification shall be conducted on sample fitting drawn from each lot. 2.2.3. Verification of dimensions and visual test Key dimensions given in the drawings which affect the functionality and the strength of the fitting shall be measured on the samples. A visual examination shall include a check fo general condition and the surface of the sample for cracks, sink marks, inadmissible flashes, etc. The critical dimensions important for correct function shall agree with EC ~_Document No. Rev. Date pate] it DOCICP-204/QAQCIGENI027 02 17-10-2018 | Page 10 or 713 |EDFC Phase-2 / CP-204 ITP for IR Type Cantilever Assembly and Components determined in the appropriate standards and supplier's drawings. Sample tests shall include visual examination to ascertain conformity of the components, in all essential respects, with the design drawings. Visual examination shall also include verification of marking (identification of fitting, manufacturer's identification, marking allowing traceability of component, e.g. date of manufacture). 2.2.4. Functional test Samples shall be assembled according to the supplier's instructions, using all necessary connecting parts. Bolts shall be tightened to 1.1 times the tightening torque stated by the supplier. No failure or unacceptable deformation is permitted unless itis intended to do so by design. 2.2.5. Mechanica! load test Marks will be applied at the tube next to the component for observing possible slippage. The test specimen shall be then loaded with the same load speed up to the maximum force Fae or up to failure of the component. Mechanical Load Tests [eeeraeee] 2.2.5.1. Components All test values shall be recorded in the test report and statistically evaluated. In the case of accessory parts for insulators and support assemblies the following characteristics shall be determined: - the component shall not have a permanent deformation which affects its functionality after applying a load of 1.33 times the operating load; = the maximum force Fina: The force at which a deformation impairs the function shall be greater than the permissible operating force Fyemop required for the component. The maximum force Fmax of the test specimen shall be equal to or greater than the required nominal force Fron or that specified in the test plan/ procedures. ument No. Rev. Date 04/QAQCIGENIO2Z7 | 02 | 17-10-2018 | Page 11 of 113 |EDFC Phase-2/ CP-204 ITP for IR Type Cantilever Assembly and Components 2.2.8.2. Clamps The force at which a permanent deformation occurs, which affects the correct function of the test specimen, shall be greater than 1.33 times the permissible operating force Foemop fequired for the corresponding component. The maximum force Finsx of the test specimen shall be equal to or greater than the required nominal force Foam. 2.2.6. Galvanization Test The galvanised component of the fittings shall be tested for mass of zinc coating (Clause §.0 of Specification No.ETIOHE/13 (4/84) with A & C slip 1 to 3), uniformity of coating, adherence and other defects (Clause 3.2 of Specification No. ETVOHE/13(4/84) with A & C slip 1 to 3). The minimum zine coating shall be 610 gms/sq. m for fittings and 425 gms/sq. m for Tubes es per RDSO specification for Tubes no. ETVOHE/11 (5/89). 2.3. Routine test: 2.3.1. Visual test A visual examination shall include a check for the general condition and the surface of the sample for cracks, sink marks, inadmissible burrs or flashes, etc. The critical dimensions important for correct function shall agree with the values determined in the appropriate standards and supplier's drawings. Routine tests shall include visual examination to ascertain conformity of the components, in all essential respects, with the design drawings. Visual examination shall also include verification of marking (identification of fitting, manufacturer's identification, marking allowing traceability of component, e.g. date of manufacture). Routine test is performed for all components and tubes. NOTE: Routine test shall include visual examination and verification of dimensions compatibility. 2.4. Site Acceptance Test: 2.4.1, Visual test and Verification of dispatch documents ‘A visual examination shall include a check for the general condition and the surface of the sample for cracks, sink marks, inadmissible burrs or flashes, etc. Site Acceptance tests shall also include verification of marking (identification of fitting manufacturer's identification, marking allowing traceability of component, €.g. date of manufacture). The verification of documents related to the dispatch of the product shall also be a part of the test. Site acceptance test is applicable for all tubes and components. Document No. Rev. |. Date T Page DOCICP-204/QAQCIGEN/027 02 17-40-2018 | Page 12 of 113 |EDFC Phase-2/ CP-204 3. Inspection Test Plan ITP for IR Type Cantilever Assembly and Components atari | V*rieato | eunctional Test | Mechanical Load Drawing No. Description | Vereat| pig Lg —" fon Test jompane | Clam | Compone a ne : mpene | Clamp Galvanized Steer Tube 33.72.65, RE/S3/PI2401 Stay Arm and i 1s 7 : RE/2Q/P/2421 Register Arm _ a Tube, Diagonal strut Galvanized Steel Tube 33.74, ReraayPr2aat (S) | Pubes 4, T Ts - - 7 7 Tube. Gavanized Steel RE/33/P/2081 (S) ‘Tube 70x4.3, T TS - - - - Bracket Arm Tube TROPPO [wantingedont | 7 | 78 | vs | - | 7s | - Gatenary ETVOHEIPI2131 | Suspension i (8), 2132(8) Bracket Top & 7 1 ue a cd Bottom ; Catenary REIS/P/1161 (S) ‘Suspension T TS TS T TS et Ciamp Double RERSP171(8) ‘Suspension T TS TS T TS T Clamp ETVOHEPIRA02-1 (SI)ETVOHEPI24 | Stay Adjuster r Ts 1s : Ts E 02-1 ($2) TIDRGIOHERTGF ErDsoreoncaioa | Tuber Stay + | ts Jos | - |] - : a feove TUDRG/OHED08S | Stay Tubs Sioove {S) 55/33.7 mm_ a a3) Ts bs 7 cf ETVOFEIPI2RE0, | Sieady Arm 2392 (S) Assembly a Ts Ts = is ic ETVOHEDIZGT2 | Large Register ($1), 2162-2 (S1) Arm Hook i 1 Ts : Te f ETVOHE/P/2422-2 | Ragister Am Eye (St) Piece y Ts Ta 7 1s EIVOHEPTERE2 | ReaisterAmeve | = Ts 7 Ge z ‘Diop Bracket ETUOHEIP 2380 | BrP BS T TS TS Ts - ETVOHEIP2161-2 | Strut Fiting for (St), 2162-2 (S2) 970 mm Tube a 1s Ts Ee ae) or ETVOHEIP2161-2 | Strut Fiting for (82), 2162-2 ($3) 933.7 mm Tube Ti 1s 1s oe ie) - ETVOHEIPI2422°2 | Strut Tube End (83), Fitting a i) 78 ct ™s = Bracket Tube emvonermaios-s [ Bracket Tube |r Ts E - - : Register Arm ETVOHE/PI2423-1 | Tube Cap, T Ts - 3 4 337mm Rogister Arm ewvonsraiet | Te Sen z 1s z i z 33,7mm (SPL) ETVOHEIPI2460, | Register Arm 22778), 2461- t Ts T : T : Bre Dropper Assembly Document No. Rev. Date Page, DOCICP-204/QAQCIGENIO27 02 47-40-2018 Page 13 of 143EDFC Phase-2 / CP-204 ITP for IR Type Cantilever Assembly and Components mamma [ERE | a [as [ts |) | Enionemravoa [RasesReose [7 [| rs | ts | - | ts | - ETVOHEIP 290218) | Wind Sty 7 | ia a ee ee : ervorepasas) [Eearerwr | | ts | ts | - | - : EVOREDPTS, ae : aoe Ubot 7 | 39 ; T=Type Tent Sz Sergi Tet Notes: 1. In dimensional verification of the components, the key dimensions only have to be verified which affects the overall functionality and interchangeabilty of the fitings. 2. The tolerance for erection of Cantilever Assemblies shall be considered as +/- 1 om, 3. Itis endeavored to test both the alternatives for the Catenary Suspension Bracket, Clamps and associated Adjuster Assembly simultaneously in the proposed Type test, hence both types are the part of the submitted ITP. The Cantilever Assembly drawing for one In-run and OOR cases have been added below for with component serial numbers for identification of the components in this report. The Serial numbers in the Cantilever Assembly drawings resembles with the section numbers for various components in the ITP, e.g. Component having sr. no. 4 in the Assembly drawing has been included in section 3.4 in this report. The serial numbers of same components used in In-run and OOR cantilever have been kept same in order to avoid confusion. Document No. Page DOCICP-204/QAQCIGENIO27 02 | 47-40-2018 | Page 14 of 113 |ITP for IR Type Cantilever Assembly and Components EDFC Phase-2 / CP-204 ang tp ‘ano wad 10) 944 yorsna “Aiquossy sonoINUED UMas A on ‘35eS peo] ayo. uado 40} wi ¢g'p OF dN UOREWeFdL) 10} aiqeoidde sing yes adh yo-ysN ‘UNy-Uy JEULON 10, A\quiassy JaABIIUED SUL“ SaI0N Page 190 15} MZ Spec Date 47-10-2018 De ws ae ‘SINNOAPIOO TONULLS sea) fanemar eu ky ‘oe ene 8 w@ 6h, ase yo 39va Rev. 02 Document No. DOCICP-204/QAQC/GEN/027 zyITP for IR Type Cantilever Assembly and Components EDFC Phase-2 / CP-204 ans yer ainoy ado 10} Aiquiassy s0AajUeD UNYCANO oni. seo Guypeo) ayno1 ww gap orn uowewerdiu! io) 3/99 SHIMS Pm BIA) YOO 40 AiNassy LOOMED SKILL ‘Se, Page Page 16 of 113 | I T Date ‘47-10-2018 The pancanos [owe ‘SLNANOANOD / ONLI asviv 90 20¥a Document No. DOCICP-204/QAQC/GEN/O27 ee ‘Ss aEDFC Phase-2/ CP-204 ITP for IR Type Cantilever Assembly and Components 3.4. Components not forming part of ITP 3.1.4. Insulators Insulators shall be tested by the supplier. ITP will be provided separately. However, the insulators will be part of full scale tests. 3.1.2. End fittings of insulators with U-bolts End fittings of insulators shall be tested by the supplier. ITP will be provided separately. However, the end fittings of insulators will be part of full scale tests. SPN Document No. Rev. | Date [Page| |_| SbocicP-204/QaQc/GENI027 02 17-10-2018 | Page 17 of 113 | v7ITP for IR Type Cantilever Assembly and Components EDFC Phase-2 / CP-204 Galvanized Stee! Tube 33.7x2.65, for Stay Arm and Register Arm Tube & Diagonal Strut: 3.2. LE iets anwas I] tore//ec/au | NOMW31SIY19 313 AVIV Pees eerie Phe een ae ae bno/aay of ax¢| cS ae (wu sz) aand? Avis ae Page Page 18 of 113 Date 47-10-2018 Rev. 02 Document No. DOCICP-204/QAQCIGENIO27 EITP for IR Type Cantilever Assembly and Components EDFC Phase-2/ CP-204 Registration Tube: Pages Page 19 of 113, Date 17-40-2018 Rev. 02 Document No. DOCICP-204/QAQCIGENIOZ7EDFC Phase-2 / CP-204 ITP for IR Type Cantilever Assembly and Components 3.2.1, Material verification Type tests shall include verification of materials to ensure that they are in accordance with the contract documents. This verification shall be carried out by inspecting documentation relating to material purchasing specifications, certificates of conformity or other quality documentation. For chemical compositions of material, the certificates received from the sub-supplier shall be furnished. Should such documentation not be available, verification of metallic materials shall be conducted by spectrometer and values of chemical composition shall be noted down. Requirements: = Chemical composition (Inspection certificate provided by sub-supplier shall be furnished) = Tensile strength (Inspection certificate provided by sub-supplier shall be furnished) Denomination Material Specification Tube 33.7 x 2.65 Galvanized Stee! ETVOHE11 (For fabrication) ETVOHE/13 (for galvanization) Note: The chemical composition and mechanical strength of the specified grade of material in the RDSO specification ETI(OHE!11 shall be checked as per the standards specified in the RDSO specification ETHOHE/11. 3.2.2, Verification of dimension and visual test Functional dimensions as encircled in the given drawings shall be measured on the samples. A visual examination shall include a check for the general condition and the surface of the sample for cracks, sink marks, inadmissible burrs or flashes, etc. Requirement - Outer tube diameter - Wall thickness Note: The tolerances for the dimensions shall be followed as per the mentioned specifications and drawings. 3.2.3. Galvanization test For Tubes, galvanization of 425 gms/sq. m shall be followed as per RDSO specification for Tubes no. ETHOHE/11 (5/89). ~ Document No. [Rev —}-~ _Date Page DOCICP-204/QAQCIGENIO27 |= 17-10-2018 | Page 20 of 113ITP for IR Type Cantilever Assembly and Components EDFC Phase-2/ OP-204 | coxsenet w rhs SI 2) wy sore ee . cxrmve| io use| Pa | Nomen | 2 RIS J eteve | S|" als | NSLS 2 waits 3 say [eomeees | meen | ces | rsown | fad 2 3\8 3 d\e 2 Es < 3 2 p > ales é ls % tr 88/018) ass 3 ni Wi aawaa x Ir 8 5 3 3 2 & 5 se 3 25) ao 3 Ss F 3 3 = g\8 £ ele g 8 8 | — iM NN \EDFC Phase-2 / CP-204 ITP for IR Type Cantilever Assembly and Components. 3.3.1. Material verification Type tests shall include verification of materials to ensure that they are in accordance with the contract documents. This verification shall be carried out by inspecting documentation relating to material purchasing specifications, certificates of conformity or other quality documentation. For chemical compositions of material, the certificates received from the sub-supplier shall be furnished. Should such documentation not be available, verification of metallic materials shall be conducted by spectrometer and values of chemical composition shall be noted down, Requirements: - Chemical composition (Inspection certificate provided by sub-supplier shall be furnished) = Tensile strength (Inspection certificate provided by sub-supplier shall be furiished) Denomination Material Specification Tube 33.7 x4 Galvanized Steel | 15 10748 (For fabrication) ETVIOHE/13 (for galvanization) Note: The chemical composition and mechanical strength shall be checked as per the mentioned specifications for the Grade-5 of steel, as used in the design. 3.3.2, Verification of dimension and visual test Functional dimensions as encircled in the given drawings shall be measured on the samples. A visual examination shall include @ check for the general condition and the surface of the sample for cracks, sink marks, inadmissible burrs or flashes, etc. Requirements: - Outer tube diameter - Wall thickness Note: The tolerances for the dimensions shall be followed as per the mentioned specifications. 3.3.3. Galvanization test For Tubes, galvanization of 425 gms/sq. m shall be followed as per RDSO specification for Tubes no. ETIOHE/11 (5/89). Document No. Page DOCICP-204/QAQCIGENI027 I 47-10-2018 | Page 22 of 113ITP for IR Type Cantilever Assembly and Components EDFC Phase-2 / CP-204 alvanized Steel Tube 70x4.3, for Bracket Arm Tube: 3.4. oss a POURS Sa YE “Tone a Met eee Page 23 Ottis} ‘ Date 47-10-2018 Rev. 02 Document No. DOCICP-204/QAQC/GENIO27EDFC Phase-2 / CP-204 ITP for IR Type Cantilever Assembly and Components 3.4.1. Material verification Type tests shall include verification of materials to ensure that they are in accordance with the contract documents. This verification shall be carried out by inspecting documentation relating to material purchasing specifications, certificates of conformity or other quality documentation. For chemical compositions of material, the certificates received from the sub-supplier shall be furnished, Should such documentation not be available, verification of metallic materials shall be conducted by spectrometer and values of chemical composition shall be noted down. Requirements: - Chemical composition (Inspection certificate provided by sub-supplier shall be furnished) - Tensile strength (Inspection certificate provided by sub-supplier shall be furnished) Denomination Material Specification Tube 70x4.3mm | Galvanized Stee! 1S 2062: 2011 (for fabrication) ETVOHE/13 (for galvanization) Note: The chemical composition and mechanical strength shall be checked for the grade E- 850 A (as used in Design) of steel as per the mentioned specifications. 3.4.2. Verification of dimension and visual test Functional dimensions as encircled in the given drawings shall be measured on the samples. A visual examination shall include a check for the general condition and the surface of the sample for cracks, sink marks, inadmissible burrs or flashes, etc. Requirements. = Outer tube diameter = Wall thickness Note: The tolerances for the dimensions shall be followed as per the mentioned specifications. 3.4.3. Galvanization test For Tubes, galvanization of 425 gms/sq. m shall be followed as per RDSO specification for Tubes no. ETVOHE/11 (5/89). Document No, Re [27 Date Page \) /|=)__ DOCICP-204/QAQCIGEN/O27 02 17-10-2018 | Page 24 of 113 |_EDFC Phase-2/ CP-204 ITP for IR Type Cantilever Assembly and Components 3.5, Mast Hinge Joint: : k mali j HL iti j e | i A ae a id | 4 aL EI A p z i S]ilels ala a(t : io iii = tlie a [8 I an eh/ es i 1 ie : oss ria ss & , : ; ; ae pee ek 7 ] iy Document No. Rev. Date Page it 2 ]DOGICP-204/QAQCIGENIO27 02 17-10-2018 | Page 25 e613 |CS EDFC Phase-2 / CP-204 ITP for IR Type Cantilever Assembly and Components 3.5.1. Material verification Type tests shall include verification of materials to ensure that they are in accordance with the documents. This verification shall be carried out by inspecting documentation relating to material purchasing specifications, certificates of conformity or other quality documentation. For chemical compositions of material, the cerlificates received from the sub-supplier shall be fumished. Should such documentation not be available, verification of metallic materials shall be conducted by spectrometer and values of chemical composition shall be noted down Requirements: Chemical composition (Inspection certificate provided by sub-supplier shall be furnished for verification) Denomination Material Specification Mast Hinge Joint Forged Steel Class-2 | IS: 2004 Note: The chemical composition shall be checked as per the mentioned specifications. 3.5.2, Verification of dimension and visual test Functional dimensions as encircled in the given drawings shall be measured on the samples. A visual examination shall include a check for the general condition and the surface of the sample for cracks, sink marks, inadmissible burrs or flashes, etc. Requirements: - Measured values shall be documented on the drawings ‘aN aN Document No. Rev. Date | _—~ Page. x =) DOGICP-204/QAQC/GENIO27 02 77-10-2018 | Page 26 of 113EDFC Phase-2 / CP-204 ITP for IR Type Cantilever Assembly and Components 3.5.3. Mechanical load test ‘Mechanical Load Tests ‘mein toe sical | 3.5.3.1. Components Accessory parts for insulators and supporting assemblies are tensioned in the tensile testing machine using corresponding tensioning parts so that loading as close as possible to operation is achieved. These tensioning parts shall not influence the test result. The test specimens shall be loaded with a constantly and smoothly increasing load up to the maximum force Fmnsx. For components, the following characteristics shall be determined: the test specimen shall be able to withstand 1.33 times the operational force without a permanent deformation occurring; the failure load Fm: of the test specimen shall be equal or greater than the nominal force From. The test data shall be used for determining the nominal force Fren or permissible operating force Fpermop. The maximum force Fnax of the test specimen shall be equal to or greater than the required nominal force From Requirements: SMDL = Fpermop = 19.54 KN (direction of force as given in drawing) SMFL = From = 35.44 kN (direction of force as given in drawing) 3.5.4. Galvanization test The galvanised component of the fittings shall be tested for mass of zinc coating (Clause .0 of Specification No.ETVOHE/13 (4/84) with A & C slip 1 to 3), uniformity of coating, adherence and other defects (Clause 3.2 of Specification No. ETIOHE/13(4/84) with A & C slip 1 to 3). The minimum zinc coating shall be 610 gms/sq. m for fittings. Document No. Rev. | Date ‘Page | DOCICP-204/QAQCIGENI027 02 | 47-10-2018 | Page 27 of 113| J ITP for IR Type Cantilever Assembly and Components EDFC Phase-2 / CP-204 Catenary Suspension Bracket : TOP FITTING: 3.6. Se Tae = = veo | Eye eee |. 3l = —— ah a = s Be = wns | ER, rue | Ppaans | 3) — & * = é =| ats | arty een ° . 5 7, WAISAS ao ey a\s & Col fz sae warp] arr Gi cnr etd essa i 5 ze A £/8 alg ag ale S 3 8 8ITP for IR Type Cantilever Assembly and Components EDFC Phase-2/ CP-204 BOTTOM FITTING: wenn formgye| = | aii | Sale fas % voce | ath [imac] oaite | sR | en 3 3 8 |e é le | moe ae) ee t] 3/8 ae z = : aly als ‘Document No. DOCICP-204/QAQC/IGENIO27 Eee SEEEDFC Phase-2/ CP-204 ITP for IR Type Cantilever Assembly and Components 3.6.1, Material verification Type tests shall include verification of materials to ensure that they are in accordance with the contract documents. This verification shall be carried out by inspecting documentation relating to material purchasing specifications, certificates of conformity or other quality documentation. For chemical compositions of material, the certificates received from the sub-supplier shall be furnished. Should such documentation not be available, verification of metallic materials shall be conducted by spectrometer and values of chemical composition shall be noted down, Requirements: = Chemical composition (Inspection certificate provided by sub-supplier shall be furnished) Part | Denomination Material ‘Specification No. | 7 Catenary Suapension ‘Aluminium 1S:3091 Bracket Bottom Bronze 2 Catenary Suapension ‘Aluminium 1$:3097 Bracket Top Bronze Ubolt Dia 14mm Galvanized Steel a Nut Galvanized Steel 5 ‘Spring Washer B 14 Galvanized Steel Note: The chemical composition and mechanical strength shall be checked as per the mentioned specifications. 3.6.2, Verification of dimension and visual test Functional dimensions as encircled in the given drawings shall be measured on the samples. A visual examination shall include a check for the general condition and the surface of the sample for cracks, sink marks, inadmissible burrs or flashes, etc. Requirements; - measured values shall be documented on the drawings 3.6.3. Functional test Samples shall be assembled according to the supplier's instructions, using all necessary connecting parts. Bolts shall be tightened to 1.1 times the tightening torque stated by the supplier. No failure or unacceptable deformation is permitted unless itis intended to do so by design, Requirements - Nuts of U-bolt Ma= 56 Nm Rev Date Page 02 77-10-2018 | Page 30 of 113EDFC Phase-2/ CP-204 ITP for IR Type Cantilever Assembly and Components 3.6.4. Mechanical load test | Mechanical Load Tests Le | | | 3.6.4.1. Components Accessory parts for insulators and supporting assemblies are tensioned in the tensile testing machine using corresponding tensioning parts so that loading as close as possible to Operation is achieved. These tensioning parts shall not influence the test result. The test specimens shall be loaded with a constantly and smoothly increasing load up to the maximum force Fnax. For components, the following characteristics shall be determined: - _ the test specimen shall be able to withstand 1.33 times the operational force without a permanent deformation occurring; ~ the failure load Fax of the test specimen shall be equal or greater than the nominal force Fron, ‘The test data shall be used for determining the nominal force From or permissible operating force Fpem,cp. The maximum force Fria of the test specimen shall be equal to or greater than the required nominal force From Reauirements: ‘Suspension bracket top = SMDL = Fpemap = 16.41 KN (direction of force as given in drawing) = SMFL = From 33.01 KN (direction of force as given in drawing) ‘Suspension bracket bottom = SMDL = Fpsinep = 8.99 KN (direction of force as given in drawing) - SMFL = From = 17.50 KN (direction of force as given in drawing) Note: The suspension bracket fitting shall not slip on the Tube, during the test up to SMDL value of load. Document No. z Rev. Date. I Page-\ =} QOCICP-204/QAQCIGENIO27 02 17-10-2018 | Page 31 ot413_| StEDFC Phase-2 / CP-204 ITP for IR Type Cantilever Assembly and Components 3.7. Catenary Suspension Clamp: Ee : : SyStrA Document No. Rev\o- ft )/Date Page _DOGICP-204/QAQC/GEN/O27 02 ~}17-40.2018 | Page 32 of 143,EDFC Phase-2/ CP-204 ITP for IR Type Cantilever Assembly and Components 3.7.1. Material verification Type tests shall include verification of materials to ensure that they are in accordance with the contract documents. This verification shalll be carried out by inspecting documentation relating to material purchasing specifications, certificates of conformity or other quality documentation. For chemical compositions of material, the certificates received from the sub-supplier shall be furnished. Should such documentation not be available, verification of metallic materials shall be conducted by spectrometer and values of chemical composition shall be noted down. Requirements: - Chemical composition (Inspection certificate provided by sub-supplier shall be furnished) Part | Denomination Material ‘Specification 1 | Suspension Clamp Body ‘Aluminium Bronze 15:3091 2 | Ubot Stainless Steel 3 | Pindia Tomm/asmm Stainless Steel 4 | Suspension Clamp Lock Plate | Annealed Copper 5 [Nut Stainless Steel 6 | Spiitpin ‘Annealed Copper 7 Punched Washer A12 Phosphor Bronze Note: The chemical composition and mechanical strength shall be checked as per the mentioned specifications. 3.7.2. Verification of dimension and visual test Functional dimensions as encircled in the given drawings shall be measured on the samples. A visual examination shall include a check for the general condition and the surface of the sample for cracks, sink marks, inadmissible burrs or flashes, etc. Requirements: = measured values shall be documented on the drawings 3.7.3. Functional test ‘Samples shall be assembled according to the supplier's instructions, using all necessary connecting parts. Bolts shall be tightened to 1.1 times the tightening torque stated by the supplier. No failure or unacceptable deformation is permitted unless it is intended to do so by design. Requirements: - Nuts of U-bolt - Ma=32Nm Date 47-10-2018 | Page 33 of 113 DocumentNo, DOC/CP-204/QAQC/GEN/027EDFC Phase-2 / CP-204 ITP for IR Type Cantilever Assembly and Components Mechanical load test Mechanical Load Tests i ee | | = eer . | 3.7.4.4. Components ‘Accessory parts for insulators and supporting assemblies are tensioned in the tensile testing machine using corresponding tensioning parts so that loading as close as possible to operation is achieved. These tensioning parts shall not influence the test result. The test specimens shall be loaded with @ constantly and smoothly increasing load up to the maximum force Fnax. For components, the following characteristics shall be determined: - the test specimen shall be able to withstand 1.33 times the operational force without a permanent deformation occurring; - the failure load Fras of the test specimen shall be equal or greater than the nominal force From The test data shall be used for determining the nominal force Fron or permissible operating force Fpamap. The maximum force Fras of the test specimen shall be equal to or greater than the required nominal force Fram. Requirements - SMDL = Fremop = 14.94 KN (direction of force as given in drawing) - SMFL = From = 18.48 KN (direction of force as given in drawing) AL Document No, | Rev: _ Date Page [.<) DOCICP-204/QAQC/GENI027_ 17-10-2018 _| Page 34 of 113EDFC Phase-2/ CP-204 ITP for IR Type Cantilever Assembly and Components 3.7.4.2. Clamps Accessory parts for conductors, anchor cables and wires are assembled with the intended conductors corresponding to the assembly instructions and inserted in the testing machine using suitable clamping parts. For bolted clamps the bolts are tightened with a tightening torque provided by the supplier. The tensile force will be increased to 1.33 times the permissible operating force Foemap and held for the duration of one minute. Marks will be applied at the exit of the conductor from the test specimen for observing possible slippage. For suspension clamps the maximum force Fax in the direction of the force effective in operation (weight force of the conductor and additional loads) shall be determined. For accessory parts to conductors, the following results shall be determined: ~ force when the conductor starts to slip in the clamp; - maximum force Frae of slipping through or breaking of the conductor in the area of influence of the clamp; For stranded conductors the first wire break shall be considered as a breakage of the conductor, Requirement - Condustor Slipping force, Fsip = 25% of Breaking Load of Catenary wire ie. 18.87 KN $0\__ Document No. Rev. Date Page {ICP-204/QAQC/GENIO27 [oz | 47-10-2018 | Page 35 0f 113 | IS b aEDFC Phase-2/ CP-204 ITP for IR Type Cantilever Assembly and Components 3.8. Double suspension clamp: ; 3 is = i Pladi gle ELE a | 983 |. Lee a1 | Document No. Page | DOCICP-204/QAQC/GEN/027 Page 36 of 113EDFC Phase-2/ CP-204_ ITP for IR Type Cantilever Assembly and Components 3.8.1. Material verification Type tests shall include verification of materials to ensure that they are in accordance with the contract documents. This verification shall be carried out by inspecting documentation relating to material purchasing specifications, certificates of conformity or other quality documentation. For chemical compositions of material, the certificates received from the sub-supplier shall be furnished. Should such documentation not be available, verification of metallic materials shall be conducted by spectrometer and values of chemical composition shall be noted down. Requirements; - Chemical composition (Inspection certificate provided by sub-supplier shall be furnished) Part | Denomination Material ] Specification] 1 Double Suspension Clamp Body | Aluminium Bronze 1S: 3091 2 Double Suspension Lock plate Aluminium Bronze 1S: 3091 3 U bolt Stainless Steel 4 Packing Saddle Copper 5 Nut Stainless Steel 6 ‘Suspension Bracket Lock Plate Annealed Copper a Pin dia 10mm/35mm Stainless Steel 8 Split pi Annealed Copper 9 Punched Washer A12 Phosphor Bronze Note: The chemical composition and mechanical strength shall be checked as per the mentioned specifications. 3.8.2. Verification of dimension and visual test Functional dimensions as encircled in the given drawings shall be measured on the samples. A visual examination shall include a check for the general condition and the surface of the ‘sample for cracks, sink marks, inadmissible burrs or flashes, etc. Requirements - measured values shall be documented on the drawings 3.8.3. Functional test Samples shall be assembled according to the supplier's instructions, using all necessary ‘connecting parts. Bolts shall be tightened to 1.1 times the tightening torque stated by the supplier. No failure or unacceptable deformation is permitted unless itis intended to do so by design. Requirements = Nuts of U-bolt My = 32.Nm Document No Rev. Date Page DOCICP-204/QAQC/GENIO2T 02 47-10-2018 | Page 37 of 113,EDFC Phase-2 / CP-204 ITP for IR Type Cantilever Assembly and Components 3.8.4. Mechanical load test Mechanical led Tet i jee — Se eee i r fee Tene | t. stella 4 detalles i | | | | | | | 3.8.4.1. Components ‘Accessory parts for insulators and supporting assemblies are tensioned in the tensile testing machine using corresponding tensioning parts so that loading @s close as possible to operation is achieved. These tensioning parts shall not influence the test result. The test specimens shall be loaded with a constantly and smoothly increasing load up to the maximum force Fmex. For components, the following characteristics shall be determined: = the test specimen shall be able to withstand 1.33 times the operational force without a permanent deformation occurring; = the failure load Finax of the test specimen shall be equal or greater than the nominal force Foam. The test data shall be used for determining the nominal force From or permissible operating force Fpamop. The maximum force Fmax of the test specimen shall be equal to or greater than the required nominal force Fron Requirements: ‘semop = 8.68 KN (direction of force as given in drawing) From = 16.35 KN (direction of force as given in drawing) Document No Rev. Date. Page i DOCICP-204/QAQC/GEN/O27 02 47-10-2018 | Page 38 of 113