Page 1 of 17 File no. EL/7.1.
108/SBC RDSO/PE/D/STR/0027-2009(Rev-1)
SCHEDULE OF TECHNICAL REQUIREMENTS (STR) FOR MANUFACTURE OF ALL TYPE OF SWITCH BOARD CABINET /CONTROL PANELS OF AC
AND NON AC COACHES
Clause Existing provisions in Rev-0 Proposed in Revision 1
No
The firm seeking approval for
manufacture and supply of Switch Board
Cabinet for LHB type AC coaches and
other panels of AC coaches, should
meet the technical requirements, as laid
down in this STR.
The Switch Board Cabinet contains
various electrical switch gears, controls,
protective devices, electronic
equipment’s/components for control and
regulations of the equipment’s and
electrical appliances provided in the
coach.
As the Switch Board Cabinet is a control
and regulation center of the entire
coach, firm should be able to
understand the importance of the same,
by means of
equipment/components/appliances as
per various standards. The experts with
firm should be fully conversant for
clearance & creepage distance,
Proposed changes in Revision 2
since Revision1 (Changes after
Reasoned documents.)
The firm seeking approval for manufacture and No change
supply of Switch Board Cabinet for LHB type AC
coaches and other panels of AC coaches, should
meet the technical requirements, as laid down in
this STR.
The Switch Board Cabinet/Power/Control Panel
contains various electrical switch gears, controls,
protective devices, electronic
equipment/components for control and
regulations of the equipment and electrical
appliances provided in the coach.
As the Switch Board Cabinet/Power/control Panel No change
is a control and regulation center of the entire
coach, firm should be able to understand the
importance of the same, by means of
equipment/components/appliances as per
various standards. The experts with firm should
be fully conversant for clearance & creepage
distance, electricity rules and other international
standards for safety of human as well as of
 Page 2 of 17 File no. EL/7.1.108/SBC RDSO/PE/D/STR/0027-2009(Rev-1)

electricity rules and other international equipment provided in the Switch Board
standards for safety of human as well as Cabinet/Control Panel including safety
of equipment provided in the switch precautions and cable layout.
board cabined including safety
precautions and cable layout.

Capability of personnel in design, manufacturing No change

& testing in the field of electrical panels (Switch
Board Cabinet/ Power/control Panel) is
mandatory requirement.
The firm should have manufactured and supplied No change
minimum 100 Switch Board Cabinet/Power
Panel/Control Panel of at least 25 kW load
capacity to Indian Railways/Public
sector/Electricity Authority/State
Government/Central Government body in last 3
years from the date of application for vendor
registration.
A MEASURING AND TESTING MEASURING AND TESTING INSTRUMENTS Note 3 added regarding
combined test set up
INSTRUMENTS 1. 3 Phase Power Analyzer of Fluke or equivalent Annexure1.
make for measuring required electrical

parameters simultaneously. 1no.

2. HV tester 2 Nos

3. Insulation tester 2 nos.

1. HV tester2 nos
4. Ammeter 1000 Volts, 5 Ampere. 6 nos.
2. Insulation tester2 nos.
5. Voltmeter 1000 Volts, 6 nos.
Page 3 of 17 File no. EL/7.1.108/SBC RDSO/PE/D/STR/0027-2009(Rev-1)

3. Ammeter2 nos. 6. Wattmeter 1000 Volts. 3 nos.

4. Voltmeter2 nos 7. Frequency meter. 2 nos.

5. Wattmeter2 nos.
8. Multi meter/Multifunction meter. 1 no.
6. Frequency meter2 nos. 9. Variable voltage transformer 3 Phase (0-1000

7. Multimeter1 no. Volts) AC. 1 no.

8. Variable voltage transformer 10. Measuring tape. As required

1 no. 11. Micrometer. 2 nos.

12. Vernier caliper. 2 nos.

13. MMR setting test bench 1 no.

9. Measuring tap As required
14. Test bench for Disconnecting &Earthing
10. Micrometer2 nos.
device1 no
11. Varnier caliper2 nos
15. Test bench for DC-DC converter 1 no.
12. MMR setting test bench1 no.
16. Test bench for MCB/MPCB 1 no.
13. Test bench for Disconnecting
17. Test bench for regulated battery charger
&Earthing device1 no
18. Current injection/loading facility for
14. Test bench for DC-DC
temperature rise
converter 1 no.
Page 4 of 17
15. Test bench for MCB/MPCB1
no.
16. Test bench for regulated
battery charger1 no.
17. Milli volt drop meter for
measuring volt drop across
contactor & relays. 2 nos
18. Arrangement for pick up &
dropout voltage of relay1 no.
19. Powder coating thickness
checking meter1 no
20. Thermal image camera for
checking of loose connection
during load test1 no
21. Power supply 24 V dc110 V
ac/dc
File no. EL/7.1.108/SBC RDSO/PE/D/STR/0027-2009(Rev-1)
19. Milli volt drop meter for measuring volt drop
across contactor & relays. 2 nos
20. Arrangement for pick up & dropout voltage of
relay1 no.
21. Powder coating thickness checking meter.
1 no.
22. Thermal image camera for checking of loose
connection during load test and general
wiring. 1 no.
23. Power supply 24 V dc 110 V ac/dc
230 V ac 415 V ac and 750 V ac
24. Thermometers/thermocouple. 1 no
Test room
25. Fire extinguishers.As required
26. Power factor meter. 1 no.
27. Tongue tester. 1 no.
 Page 5 of 17 File no. EL/7.1.108/SBC RDSO/PE/D/STR/0027-2009(Rev-1)

230 V ac415 V ac 28. IMR (Insulation Monitoring relay) setting test

22. Thermometers/thermocouple. bench 1 no.

1 no. 29. Standard measuring gauges/instruments-

As required
23. Test room
Other hand tools like spanner, pipe bending
24. Fire extinguishers. As
machine etc. As required.
required
NOTE:

1) Firm shall submit calibration status of each

instrument along with a copy of calibration

certificate.

2)Test room shall be equipped with all the testing

28 Other hand tools like spanner, pipe
& measuring instruments as mentioned above.
bending machine etc.As required
3) Firm shall have combined test set up
NOTE:
complying the details given in Annexure 1 to this
1) One set of each instrument shall be
document
kept as standby. Firm shall submit

calibration status of each

 Page 6 of 17 File no. EL/7.1.108/SBC RDSO/PE/D/STR/0027-2009(Rev-1)

instrument along with a copy of

calibration certificate.

2) Test room shall be equipped with

all the testing & measuring instruments

as mentioned above.

B. Plant and Machinery MACHINARIES & PLANTS CAPABLE FOR No change.

PROCESSING STEEL USED DURING
1. CNC punching machine MANUFACTURIN

2. CNC shearing machine 1. CNC Machines required for process like

3. CNC cutting machine shearing, punching, cutting and bending for

4. Bending machine fabrication of Stainless steel structure

5. Power press 2. Hydraulic/Pneumatic/Power press

6. Drill machine 3. Drill machine

4. Spot welding machine/ TIG & MIG welding

7. Spot welding machine
machine suitable SS sheet.
8. Welding machine
5. Grinding machine and portable grinder
9. Grinder/sander
 Page 7 of 17 File no. EL/7.1.108/SBC RDSO/PE/D/STR/0027-2009(Rev-1)

10. Seven tank treatment for 6. Seven tank treatment for full structure of

structure of switch board switch board cabinet/power panel/control

cabinet panel.

11. Powder coating arrangement 7. Powder coating arrangement

12. Electric Dryer/oven 8. Electric Dryer/oven

13. Cable handling fixture 9. Cable handling fixture

14. Cable cutting tools 10. Cable cutting tools

15. Crimping tools of various size 11. Hydraulic Crimping tools of various size

16. Zig and fixture for structure 12. Zig and fixture for structure

17. Trolleys for carrying material 13. Mobile trolley and hoist.

14. Jigs & Fixture suitable for welding, leveling

and mounting

15. Fork lifter of at least 3 Ton.

NOTE: 1) S.No., Rating, date of purchase along

NOTE: 1) S.N, Rating, date of purchase
with purchase bills and quantity of each items
along with purchase bills and quantity of
shall be furnished by the firm in tabulated for..
 Page 8 of 17 File no. EL/7.1.108/SBC RDSO/PE/D/STR/0027-2009(Rev-1)

each items shall be furnished by the firm

in tabulated for.. 2) The machine operators should have minimum

one-year experience of operating for each
machine mentioned in STR.

2) The work related to S.N. B 1) to 12)

may be outsourced, provided that the

firm (sub-vendor) should have plant and

machineries mentioned against S.No. B

1) to 12). The sub-vendor shall also

have ISO 9001-2008. Quality

Management System confirming the

requirements mentioned in clause No.

D) of STR.

6.4 POWDER COATING FACILTY

A. The firm should have powder coating
testing facilities for which ISO 9001-2008
certification is mandatory.
B. Phosphate coating Tank used for
treatment of SBC/panel shall be of adequate size
to accommodate the entire SBC in one go.
Activity of powder coating and
seven tank treatment process
may be outsourced with ISO
certified sub vendor under
Notarized MOU.
Sub vendor shall have all
stipulated facilities /M&P /
 Page 9 of 17 File no. EL/7.1.108/SBC RDSO/PE/D/STR/0027-2009(Rev-1)

C. Firm should have the pollution control Certification i.e. Red or applicable
board certificate for Red category. category.

D. The machine operators should have Sub vendor shall be visited by

minimum one-year experience of operating for
each machine mentioned in STR.
E. Powder coating process with necessary
gauges & control for accurate coating thickness
shall be available with the firm.
Firm should have the facility of checking of quality
of powder coating in terms of abrasion, corrosion,
hardness, inflammability, finishing etc. to ensure
the quality of powder coating.
RDSO official during assessment
visit to ensure the quality of work
and verification of MOU, ISO
certificate, QAP and M& P of sub
vendor. Firm shall have to take
prior approval in case of change
of sub vendor for this purpose.

Note 2: Item no. 6,7 & 8 are only required for

7.0 PERSONNEL & EXPERIENCE
7.1 Firm should have at least one graduate
engineers in electrical discipline having
not less two-year experience in the field
of panel designing, cable layout and full-
fledged knowledge of protection
devices. They shall be able to
understand the requirement and
importance of the product with relevant
standards including electricity rules. The
experience details in similar field shall
be submitted by the firm.
SBC/Power panel/control panel required to be
powder coated.
Firm should have at least one Graduate No change.
Engineers in Electrical Engineering discipline
having not less two-year experience in the field of
panel designing, cable layout and full-fledged
knowledge of protection devices. They shall be
able to understand the requirement and
importance of the product with relevant standards
including electricity rules. The experience details
in similar field shall be submitted by the firm.
 Page 10 of 17
7.2 There should be quality control set up
headed by minimum graduate engineer
having 5 years’ experience in similar
field. The experience details in similar
field shall be submitted by the firm.
7.3 There should be a testing department
headed by at least diploma engineer in
electrical engineering with at least two
years’ experience in testing of electrical
control panel.
7.4 One mechanical engineer is also
required, working with firm having
experience in fabrication of different
structure. The engineer shall have full
fledge knowledge of welding, brazing
and riveting works along with relevant
Indian/International standards, required
in making structure.
7.5
7.6
File no. EL/7.1.108/SBC RDSO/PE/D/STR/0027-2009(Rev-1)
There should be Quality Control set up headed by No change.
minimum Graduate Engineer of
Mechanical/Electrical/Electronics/instrumentation
having 5 years’ experience in similar field. The
experience details in similar field shall be
submitted by the firm.
7.1 There should be a testing department No change.
headed by at least Diploma Engineer in Electrical
Engineering in firm with at least 02 year
experience in Testing of Electrical Control Panel
Wiring .
One Graduate Mechanical Engineer in firm shall No change.
also be required, working with firm having
experience of minimum 02 years in fabrication of
different structure. The mechanical engineer shall
have full fledge knowledge of welding, brazing
and finishing works along with relevant
Indian/International standards, required in
making structure.
Firm should also have well trained manpower No change.
conversant with switch gear and protection
system. In this regard, firm shall submit details of
manpower along with their qualification and
experience of personnel.
Firm should also have website for logging No change.
complaints of their product as after sales service.
It shall include details of complaints number, date
& time of complaints login and man deputed to
attend complaints along with their mobile number
etc. Firm should have their maintenance service
engineers at major cities of India and they should
 Page 11 of 17 File no. EL/7.1.108/SBC
7.7 D. ISO AND QUALITY ASSURANCE
PLAN FOR SWITCH BOARD
CABINET
1. Firm intended to manufacture &
supply of switch board panel for
Indian Railways should have ISO
9001-2008. The certifying agency
of ISO shall be accredited with
NABCB.
2. ISO certificate shall contain
design, manufacturing,
fabrication, testing & supply of The Quality Assurance Plan shall cover the
switch board cabinet as scope of following:
work.
3. Firm should produce their
proposed quality assurance plan
(QAP) in respect of procurement
of raw material, manufacturing
and in-house inspection and
testing on Switch Board Cabinet.
4. The Quality Assurance Plan shall
cover the following:
RDSO/PE/D/STR/0027-2009(Rev-1)
attend the failure within 24 hours at city like
Mumbai, New Delhi, Kolkata, Hyderabad,
Chennai, Bangalore, Patna, Bhopal.
7.1 No change.
The firm should have ISO 9001-2008 certification
or better for manufacture & design of Power
panel/Control panel/Switch board cabinet or
similar item in quality management
Firm should produce their proposed quality
assurance plan (QAP) in respect of procurement
of raw material, manufacturing and in-house
inspection and testing of switch board cabinet.
a) Organizational chart clearly bringing out
the quality control set up.
b) Qualification log sheets of the personnel
meaning the quality control set up.
c) Process flow chart indicating the process
of manufacture of an item or a family of items for
which the process is same.
d) Details of sub-vendors:
• Name of the item for which sub-vendor is
approved.
• Inspection criteria of the sub-vendor.
 Page 12 of 17
a) Organizational chart clearly
bringing out the quality control
set up.
b) Qualification log sheets of the
personnel meaning the quality
control set up.
c) Process flow chart indicating the
process of manufacture of an
item or a family of items for which
the process is same.
d) Details of sub-vendors
 Name of the item for which sub-
vendor is approved.
 The name of the approving
agency.
 Inspection criteria of the sub-
vendor
 The sub-vendor has ISO:9000
certification.
 QAP of the sub-vendor is
approved by the primary vendor.
 Sub-vendor has submitted the
quality manual to the primary
vendor.
 Sub-vendor has all the requisite
infrastructure of manufacturing
File no. EL/7.1.108/SBC RDSO/PE/D/STR/0027-2009(Rev-1)
• The sub-vendor has ISO:9001 certifications.
• QAP of the sub-vendor is approved by the
primary vendor.
• Sub-vendor has submitted the quality
manual to the primary vendor.
• Sub-vendor has all the requisite
infrastructure of manufacturing and testing
facilities, preferably under one roof.
• Periodical inspection schedule for sub-
vendor is being followed strictly by the
primary vendor.
e) Quality Assurance System - Inspection &
Testing Plan. This shall cover the following:
• Incoming material
• In Process control
• Final inspection.
f) Calibration plan for measuring instruments
g) Customer complaint system as per ISO
norms.
h) Any additional information
 Page 13 of 17 File no. EL/7.1.108/SBC RDSO/PE/D/STR/0027-2009(Rev-1)

and testing facilities preferably

under one roof.
 Periodical inspection schedule
for sub-vendor is being followed
strictly by the primary vendor.
e) Quality Assurance System-
Inspection & Testing Plan this
shall cover the following
 Incoming
material
 Process control
 System control
 Gauging scheme-in the format
of each operation gauges
should be maintained.
7.8 NOTE: 1. Firm shall keep all the Firm shall keep all the records related to internal No change.
records related to internal quality quality control, stage/process inspection and
control, stage/process inspection, final testing of the product/individual
routine and final testing of the equipment/component for easy traceability of a
particular job.
product/individual
equipment/component for easy
traceability of a particular job, in
addition to the inspection of brought The firm shall furnish documentary evidence for
out material. In addition, firm should information already submitted to RDSO in online
maintain all the records of test done application form.
on various part/components on
respective test bench as per QAP.

2. The firm shall furnish

documentary evidence for
 Page 14 of 17 File no. EL/7.1.108/SBC RDSO/PE/D/STR/0027-2009(Rev-1)

information already submitted to

RDSO have been filled in proforma
‘A’.
7.9 R & D FACILITIES R & D FACILITIES No change.

The firm should have R & D facilities to The firm should have set up to investigate the
various types of line failures of Switch Board
investigate into the various types of Cabinet/Power/Control Panel and evolve
failures and evolve necessary remedial necessary remedial measures to avoid failures in
measures to avoid failures in future. future.
8.0 1. DG set of adequate capacity Diesel Generator set of adequate capacity as It is further clarified that incoming
as stand/by power supply. standby power supply shall be available with firm power supply connection and DG
set capacity shall be adequate to
2. Firm should have valid digital conduct temperature rise at 125
signature certificate for e- Amp at 415 V 3 phase AC 50 Hz
procurement/tendering
3. Following power supply
arrangement for testing Switch
Board Cabinet
1. 24 V dc
2. 110 V ac/dc
3. 230 V ac
4. 415 V ac
4. The firm should have the
capacity for manufacturing at
least 200 Switch Board
Cabinet in one year.
1. Firm should also furnish the
qualification and experience of
the operator of various
machines.
 Page 15 of 17 File no. EL/7.1.108/SBC RDSO/PE/D/STR/0027-2009(Rev-1)

Annexure -1
Details of the testing set up ( for guidance only) for SBC for EOG/HOG AC and Non AC coaches

 Output A: Contact resistance of each contact/pole of Disconnecting & Earthing Device 8 pole, 2 Way, 125 A/ 750 V AC (1000 V insulation) 2 NO+2 NC of M/s.
Salzer/L&T to be checked and displayed on milliohm meter (1 pole at a time)
 Output B: 750 V Voltage phase control Net 1 &Net 2 (MMR-Measuring & Monitoring Relay K03-K04), 3 phase 750 V AC, Aux. voltage 24-60 V AC/DC Part No BD
9080, CM-MPN.72 S of M/s. ABB or DOLD/CARLO GAVAZZI make with equivalent part no. shall be tested for Single phasing, Phase unbalance by Varaic in at least
2 phases , over voltage, under voltage with tripping time to be displayed on meter and indication on test bench panel.
 Output C: Operation of K01&K02 feeder contactor (for Net 1& Net2, 750 V AC, 200 A , Main pole 4 NO, aux contact 2 NO+2NC Control voltage 380-415 V AC with
surge suppressor), pickup& drop out voltage and milli volt drop on full load to be displayed on meter.
 Output D: Operation of K41 &K42 ( contactor for Local main Supply 1, 95 A , AC-3,415 V, 3 NO main pole, Aux contact 2 NO+1 NC ),K43 (Main contractor for Local
Main Supply 415 V AC , 110 A, Main Pole 4 NO, Aux Contact 2 NC , control voltage 380-415 V AC with surge suppressor) and K44 (Contactor for 60 kVA transformer
200 A,415 V AC , 4 NO main pole, Aux contact 1 NO+1 NC control voltage 180-300 V AC with surge suppressor) - pickup& drop out voltage and milli volt drop on full
load to be displayed on meter.
 Output E:415 V K45 (Voltage phase control MMR 400/480 V AC +/- 15 %, 50-60 Hz with IP-20) of part No CM-MPS.41 of M/s. ABB, DPS01DM48,400/480 of M/s.
Carlos Gavazzi or equivalent part no of Croutez/Fanox shall be tested for Single phasing, Phase unbalance, over voltage, under voltage with tripping time to be
displayed on meter and indication on test bench panel.
 Output F Use commercially available MCB/MPCB test Kit and output with tripping time to be displayed on meter and indication on test bench panel. 415 AC
MCB/MPCB set up for 415 V AC, 110 V AC MCB/MPCB from 0.63 amp to 16 Amp current rating shall be tested. Voltage, current and tripping time to be noted.
 Output G : Use commercially available DC MCB test Kit and output with tripping time to be displayed on meter and indication on test bench panel. 110 V DC/AC
MCB set up (up to 16 Amp current rating) shall be tested. Voltage current and tripping time to be noted. DC-DC Converter 110 V DC/24 DC shall be checked for Input
Output Voltage.
 Page 16 of 17 File no. EL/7.1.108/SBC RDSO/PE/D/STR/0027-2009(Rev-1)

 Output H: Use commercially available MCB/MPCB test Kit and output with tripping time to be displayed on meter and indication on test bench panel. 230 AC MCB
set up (up to 16 Amp current rating) shall be tested. Voltage current and tripping time to be noted. DC-DC Converter 110 V DC/24 DC shall be checked for Input Output
Voltage.
 Output I 240 V AC V Insulation control (Insulation Monitoring Relay-IMR A7) with part no IR 470LY-21 A, RI-R138 of M/s. Contrel , CM.IWS.2 S of M/s. ABB, 3
UG4581-1AW30 of M/s. Siemens or equivalent part no. of M/s. Bender/WOKA shall be tested on meter with indication.
 Output J 110 V AC Insulation control (Insulation Monitoring Relay-IMR A6) with part no IR 140 Y-4 , RI-R22 of M/s. Contrel , CM.IWS.1 S of M/s. ABB, 3 UG4581-
1AW30 of M/s. Siemens or equivalent part no. of M/s. Bender/WOKA shall be tested on meter with indication.
 Output K: Use Earth leakage test on positive and negative side by resistance method (10 mA to 60 mA) to be checked and output to be displayed on meter and
indication on test bench panel.
 Output L 190 V AC 3 Phase for checking of 16 A Low Voltage Fuse in Non AC Switch Board cabinet.
NOTE
1. Standard test bench for measuring Parameters of component of Switch board cabinet for LHB EOG type AC coaches can be used for temperature rise of
component of SBC except the temperature rise of disconnecting & Earthing Device, 125 A fuses, K01 & K02 feeder contactors.
2. Temperature rise of Contactors K41, K42, K43 & K44, 100 A fuse,80 Amp fuse, MCB/MPCB can be carried out with test bench in connection with appropriate
load as per rating of component.

3. Control connections from panel to test setup to be with clip on (on panel side) & Jack in Connector (test set up side) type shall be used.
 Page 17 of 17 File no. EL/7.1.108/SBC RDSO/PE/D/STR/0027-2009(Rev-1)
Variac in
at least 2 Step down
Step Up Phases for transformer 750 V
415 V 3 phase Supply variable
transformer AC /415 V AC
3 phase power
415 V AC/ 415/750 V Supply
190 V AC AC 750+/-10
3 Phase % AC 3
415 V AC 415 V AC 415 V AC 415 V AC
for Phase 4 insulation
Wire Supply to Supply to Supply to
Checking Contactors Phase standard
control
fuse 16 A 750 V AC Supply to D&E D Relay A7
K44, K41, Monitoring MCB/MP (IMR)
in Non AC under Test Output A
K42 and K43 Relay K45 CB test Output I
SBC under Test (MMR)under Kit
Output D Test
750 V AC Supply to Phase Output E Output F
1 Phase
Monitoring Relay K03 , K04
240 V AC
(MMR)under Test Output B
Supply out
of 3 Phase
4 Wire 415 750 V AC Supply to Feeder to
V AC Feeder contactor K01&K02
Mains under Test Output C

110 V AC Insulation Control Relay A6

(IMR) Output J
110 V DC Supply to MCB
test Kit and DC- DC
Electrical power 240 240 V AC Converter check Output G 110 V DC to24 V DC
connection
V AC to 110 V converter to check Earth
240 V AC
1 DC Leakage Relay Output K
Phase converter

240 V AC Supply to
Pantry MCB under
test Output H