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RDSO PE SPEC AC 0138-2009 Rev 2 or Latest
RDSO PE SPEC AC 0138-2009 Rev 2 or Latest
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Government of India
Ministry of Railways
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Approved
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Page 2 of 31 EL/7.1.108/C w.e.f……. Spec no. RDSO/PE/SPEC/0138–2009 (Rev.-2)
Table of Contents
Foreword: ..........................................................................................................................3
1 Scope......................................................................................................................3
2 Scope of supply.......................................................................................................4
3 Governing Specifications ........................................................................................4
4 Operating and Service Conditions:..........................................................................4
5 Design and Technical Requirements: .....................................................................5
6 Tests: ......................................................................................................................7
7 Details of Prototype Test Procedure: ....................................................................11
8 Technical Data ......................................................................................................13
9 Manufacturer's responsibility.................................................................................13
10 Marking and packing ............................................................................................. 14
11 Warranty period and liability ..................................................................................14
12 Infringement of patent right ...................................................................................15
13 Schedule of Technical requirement:-.....................................................................15
14 Enclosures: ...........................................................................................................15
Annexure – A:..................................................................................................................21
Annexure – B:..................................................................................................................22
Annexure – C:.................................................................... Error! Bookmark not defined.
Distribution:......................................................................................................................23
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Page 3 of 31 EL/7.1.108/C Spec no. RDSO/PE/SPEC/0138–2009 (Rev.-2)
Foreword:
Presently, flexible/rigid conduits & fittings (mostly made of PVC) used in wiring/cabling in
conventional coaches are as per IS: 9537. Whereas, in LHB variant coaches, flexible
polyamide conduits of polyamide-6 (PA-6) are being used for wiring except roof wiring,
which is being done by PVC rigid conduits. Railways/Pus are also demanding for
polyamide-6 fire retardant rigid conduit for roof wiring in coaches. This specification is
prepared to standardize the use of halogen free, fire retardant, flexible and rigid
polyamide conduit & associated fitting for use in coaching stock.
1.0 Scope
1.1 This specification covers performance parameters, general & technical
requirements, method of sampling, inspection, testing and supply of polyamide
conduits system and fittings for cable management of coaching stock.
1.2 The conduit system of cable management shall comprise of polyamide-6: -
Flexible conduit and end fittings with threaded ends (both metric and Pg thread) provided
with gaskets, O-rings and metallic lock nuts ensuring minimum IP-67 protection of the
system.
Rigid conduits along with three way/ four way spouts & 90° bends (to be used for Roof
wiring).
1.3 Any deviation to this specification proposed by the manufacturer, aimed to
improve upon the performance, utility and reliability /efficiency of the equipment
will be given due consideration, provided full particulars of the deviations with
justification are furnished to RDSO. In such a case, the proposed product must
be proven in rolling stock application in tropical countries for at least five years.
The manufacturer shall submit full technical detail of the proposed product along
with the test report from reputed national/international laboratory for evaluation to
RDSO.
1.4 In case of any contradiction between the provisions of lEC/IS and this
specification, the later shall prevail.
1.5 Manufacturers of this items shall obtain RDSO approval for their product for
which the guidelines can be obtained from website
www.rdso.indianrailways.gov.in. Such manufacturers shall have infrastructure for
manufacture, testing and supply of conduits and its associated fittings as per
requirements specified in governing STR no. RDSO/PE/STR/AC/0035-2011
(Rev.1 or latest). The conduit and its accessories shall be approved as a set.
Vendor registration fee will be required on every occasion of application for any
size of conduit supply.
2 Scope of supply
Purchaser shall specify the size & type (i.e. flexible/rigid) of conduit, accessories
and type of threads in end fittings as per their requirement conforming to this
specification. However, sizes of flexible or rigid conduit and fittings normally in use
on coaching stock are as per Annexure-A and Annexure-B. Conduits and fittings
of same make will only be acceptable.
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3 Governing Specifications
Specifications/ Description
Standards
IEC- 61386-1, Conduits system for cable management- General
Requirement
IEC- 61386-21 Conduits system for cable management (Particular
requirements - Rigid conduits systems).
IEC- 61386-23 Conduits system for cable management (Particular
requirements - Flexible conduits systems).
IEC-61373 Railway applications- Rolling stock equipment -Shock and
vibration tests
IEC-60529 Classification of degrees of protection provided by
enclosures of equipment.
As per NFF 16-101 Fire, smoke & toxicity requirements
& 102, UL 94,V 0
IEC-60423 Conduit system of cable management (Threads for Metric
End Fittings & lock Nuts)
DIN-40430 Threads for PG End Fittings
The conduits system and fittings shall perform satisfactorily & shall be sturdy and
suitable for the following service conditions normally to be met in service on
board/under slung on coaching stock:
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5.1 CONDUIT
The conduit system for cable management shall comprise of mainly Flexible
corrugated conduits, Rigid conduits, 2/4 way spouts, 90° bends, end fittings, lock
nuts, terminal sleeve etc.
5.1.1 The material for the conduit and its accessories shall be polyamide-6 (PA-6). It
should be free from halogen, phosphorous, sulphur and cadmium. It should be UV
resistant and resistant to abrasion and corrosive environment.
Rigid conduit will be plain conduit having even profile in the longitudinal section as
described in clause no. 3.9 of IEC-61386-1. Flexible conduit shall be internally and
externally corrugated.
5.1.2 The preferred length of a rigid conduit shall be 3 m. Other lengths are also
permitted with agreement between the manufacturer and the purchaser.
5.1.3 Material used for manufacturing of rigid, flexible conduits & fittings should
conforming to UL94 V0.
5.1.4 There shall be no sharp edges, burrs or surface projections which are likely to
damage insulated conductors or cables or inflict injury to the user or installer.
5.1.5 The dimensions of the rigid Polyamide-6 conduits shall conform to IEC 60423.
5.1.6 The conduit and conduit fittings shall withstand the stresses likely to occur during
transport, storage etc.
5.1.7 The colour of the conduits and accessories shall be black, unless otherwise
specified.
5.1.8 Flexible and rigid conduit shall be suitable for provision in the under carriage/under
roof of Railways with high impact strength. It should have following properties:-
a. Conduit should be non-flame propagating as defined in IEC-61386-1.
b. The conduit shall be suitable for A-2 application as per para 5.1 of NFF 16-101.
c. Its self-extinguishing class shall be l3 as per NFF 16-101.
d. Its smoke emission classification shall be F3 as per ISO 4589.
e. Its oxygen index shall be greater than 25%,when tested as per ISO 4589.
f. It should be suitable for continuous temperature range -10 to 105 °C.
5.1.9 Conduit shall have di-electric strength and insulation resistance as per para 11.3
of IEC 61386-1.
5.1.10 The complete cable protection system with end fittings shall be suitable for
minimum IP-67 as per IEC- 60529 for its connection.
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5.1.11 The conduit shall be circular in section with concentricity of more than 90%. The
concentricity shall be calculated as the ratio of the maximum and minimum
thickness measured on the same cross section on the opposite sides.
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Page 7 of 31 EL/7.1.108/C Spec no. RDSO/PE/SPEC/0138–2009 (Rev.-2)
temperature of (23±2)°C and a relative humidity between 40% and 60%. All
prototype tests shall be carried out immediately after general conditioning. (para
5.4 of IEC 61386-1)
6.1.3 Unless otherwise specified, each test shall be made on three new samples, and
the requirements are satisfied if the tests are met. If only one of the samples does
not satisfy a test, due to an assembly or a manufacturing defect, that test and any
preceding one which may have influenced the result of the test shall be repeated,
and also the tests which follow shall be carried out in the required sequence on
another full set of samples, all of which shall comply with the requirements. (para
5.3 & 5.7 of IEC 61386-1).
6.1.4 Unless otherwise specified, the tests shall be carried out at an ambient
temperature of (20±5)C. (para 5.2 of IEC 61386-1)
6.1.5 Only after the detail drawings and the design have been approved and the
clearance given to this effect, the manufacturer shall take up the manufacture of
the prototype. It is to be clearly understood that any changes required to be done
in the prototype or any additional tests other than specified herein are required to
be conducted on the prototype unit or its components, the same shall be done
expeditiously. During the process of manufacture of the item, if the purchaser so
desires, may conduct/repeat any of the routine or additional tests to satisfy himself
that the quality of the item being manufactured is of the required standards.
6.1.6 Subject to agreement between user and manufacturer, RDSO/ purchaser shall
repeat some or all type tests once in three years on sample basis, so as to confirm
the quality of the product to meet the specified requirements.
6.1.7 The type tests shall be carried out by RDSO representative on prototype unit
either totally or in part under the following circumstances without any additional
cost:
A manufacturer undertakes to manufacture for the first time as per this
specification.
An important change in design details of product has been introduced.
Specification is modified necessitating re-designing of product.
Unsatisfactory performance reported from user Railways.
Resumption of production after an interruption of more than two years.
Quality audit of firm
6.1.8 RDSO may conduct surprise check on manufacturing process and quality control
along with any of the tests to ensure quality of product and its conformance to
specification.
6.1.9 The tests shall be carried out at the works of the manufacturer or at any approved
testing laboratory in presence of Indian Railway representative on the test sample
of the conduits and its accessories as per relevant governing specifications
modified or amplified. The manufacture shall have necessary arrangement for
testing of conduits and its fittings.
6.1.10 The test protocol indicating relevant clause of the test, condition of the test,
specified value and observed value of the parameter for conduits & accessories
shall be submitted by the firm before offering the sample for testing.
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Note:
a. Test specified at S.No. 5, 6, 7, 8 & 10 in the above table shall be conducted
on conduit along with its end fitting.
b. Test at S.No. 1,3 & 11 shall also be conducted on the End Fittings.
c. Conduit shall be subjected to all tests mentioned above.
e. To check the uniformity of the conduits, three samples, each taken from
different lengths or place separated by approximately 3 metres, are cut
along a plane perpendicular to the axis. The inside and outside diameter at
each edge is measured at four places as far as possible equally spaced
around the circumference.
f. Conduit system duly assembled with its end fittings and accessories shall
be tested to IP-67 grade protection as per IEC 60529.
g. The material shall confirm to fire resistant class as per NFF 16 101 & 102.
Note: Testing/measuring instruments duly calibrated from any NABL accredited /Govt
laboratory shall be utilized during test.
6.5 Test of material composition: -
Conduit and its accessories shall be made up of virgin polyamide-6 material
having following properties.
Properties Standard Testing Value Unit
Parameter
GENERAL
Density ISO 1183-1 1.14-1.19 g/cm³
Viscosity number ISO 307 130-160 cm³ /g
MECHANICAL CONDITION Dry Conditioned
Tensile stress at yield ISO 527-2 50 mm/min >75 - Mpa
Tensile strain at yield ISO 527-2 50 mm/min >2.8 - %
Tensile strength at yield ISO 527-2 1 mm/min >3200 >1000 Mpa
Tensile Modulus
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BURNING BEHAVIOUR
UL Internal test procedure UL 94 0.75/1.5 mm V-0/V-0
Glow wire flammability lEC 695-2/12 2 mm 960 °C
index GWFI
UL 746 A
ELECTRICAL
Comparative tracking IEC 112 Solution A 600 V
index CTI
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2. 20 mm+0.0/-0.3 100
3. 25 mm+0.0/-0.4 150
4. 32 mm+0.0/-0.4 225
5. 40 mm+0.0/-0.4 310
6. 50 mm+0.0/-0.5 450
Value of the actual measured weight of conduits shall be mentioned in the
prototype test results.
7.2 Compression Test:
The sample shall be tested as per clause 10.2 of IEC 61386-1. The product shall
be of medium classification for size NW 17 and above .However size upto NW -
12 shall be of light classification for flexible conduit. Similarly, the product shall be
of “medium” classification for rigid conduit for size of 20 mm & above. However,
size upto 16 mm shall be of “light” classification.
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The sample shall be tested as per clause 10.8 of IEC 61386-1. The product shall
be of medium classification for size NW 17 and above .However size upto NW -12
shall be of light classification for flexible conduit. Similarly, the product shall be of
“medium” classification for rigid conduit for size of 20 mm & above. However, size
upto 16 mm shall be of “light” classification.
7.9 Dielectric strength and insulation resistance :
The sample shall be tested as per clause 11.3.1 & 11.3.2 of IEC 61386-1. The
product shall be of medium classification for size NW 17 and above .However size
upto NW -12 shall be of light classification for flexible conduit. Similarly, the
product shall be of “medium” classification for rigid conduit for size of 20 mm &
above. However, size upto 16 mm shall be of “light” classification.
8 Technical Data
8.0 The manufacturer shall submit their compliance or comments against each
clause and sub-clause of the technical specification with the offer. The
manufacturer shall for this purpose enclose a separate statement, if necessary,
indicating the Annexure and clause reference and compliance/comments. The
manufacturer shall also furnish the full technical data and dimensions for each
size of Flexible/rigid Polyamide conduits as per the format given as Annexure “C”
of the specification.
9 Manufacturer's responsibility
9.1 The supplier shall supply detailed instructions for proper installation of the
equipment on Rolling stock. For this purpose, the supplier shall depute his
engineers/supervisors to sites during installation of the conduit system.
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9.2 The supplier shall be responsible for commissioning, testing and field trials of the
conduit system in service and depute team of engineers/supervisors for this
purpose during developmental stage.
9.3 The supplier shall be responsible for carrying out improvements and
modifications at his own expense on all the conduit systems supplied, provided
such modifications/improvements are decided to be necessary for meeting the
requirements of reliability, performance etc, jointly between manufacturer and
purchaser.
9.4 For the purpose of technical decisions on improvements/ modifications etc. on
conduit system the final authority from the purchaser's side will be RDSO.
10 Marking and packing
10.0 The following information shall be marked with laser printing at every one meter
length of conduits :
a. Size of conduit.
b. Name or trade mark or identification mark of the manufacturer.
c. Year and batch of the manufacture.
10.1 Accessories are also required to be marked with the vendor name or trademark
or identification mark. The product identification mark, which may be, for
example, a catalogue number, a symbol or the like, in such way that it can be
identified in the manufacturer’s literature however for the items where it is
impractical, then the mark may be on the label attached to the product or on the
smallest supplied package.
10.2 The marking shall be durable and clearly legible. Compliance is checked by
inspection, using normal or corrected vision, without additional magnification and
by rubbing the marking by hand for 15 s with a piece of cotton cloth soaked with
water and again for 15 s with a piece of cotton cloth soaked with petroleum spirit
n-hexane 95 % along its entire length at intervals of preferably 1 m but not longer
than 3 m with each length being marked at least once.
10.3 It is mandatory to mention the classification code for conduit system on the
supplied packet as per Annexure A of IEC61386-1. Classification code shall
include at least the first four digits as per Annexure with detail of coding. Detail of
first four digit is given below:
First digit – Resistance to compression
Second digit – Resistance to impact
Third digit – Lower temperature range
Fourth digit-Upper temperature range.
Indian Railways shall not be responsible for infringement of patent rights arising
due to similarity in design, manufacturing process, use of similar components in
the design & development of the system and any other factor not mentioned
herein which may cause such a dispute. The entire responsibility to settle any
such disputes/matters lies with the manufacturer/ supplier.
Details / design/documents given by firm are not infringing any IPR and they are
responsible in absolute and full measure instead of railways for any such
violations. Data, specifications and other IP as generated out of interaction with
railways shall not be unilaterally used without the consent of RDSO and right of
Railways / RDSO on such IP is acceptable to them.
13 Schedule of Technical requirement:-
Firm desiring to get RDSO’s approval for this product shall comply to schedule of
technical requirement no. RDSO/PE/STR/AC/0035-2011(Rev-1 or latest).
14 Enclosures:
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Annexure - A:
A-1: Sizes of Flexible Polyamide Corrugated Conduits
S.No. Nominal Size Outer Diameter (mm)
1. NW10 13.0±0.2
2. NW12 15.8±0.2
3. NW17 21.2±0.2
4. NW23 28.5±0.2
5. NW29 34.4±0.2
6. NW36 42.4±0.2
7. NW48 54.4±0.2
8. NW56 67.2±0.2
9. NW70 80.0±0.2
10. NW95 106.0±0.2
The minimum inside diameter of the conduit system shall be as declared by the
manufacturer as specified in clause 8.2 of IEC 61386-23. The compliance is checked by
measurement.
A-2: Sizes of Straight PG Metal Thread End Fittings
S.No. Thread Size Fits to Conduit Size
1. Pg9 NW10
2. Pg11 NW12
3. Pg16 NW17
4. Pg13.5 NW17
5. Pg21 NW23
6. Pg29 NW29
7. Pg36 NW36
8. Pg48 NW48
A-3 Sizes of 45° PG Metal Thread End Fittings
S.No. Thread Size Fits to Conduit Size
1. Pg9 NW10
2. Pg11 NW12
3. Pg16 NW17
4. Pg13.5 NW17
5. Pg21 NW23
6. Pg29 NW29
7. Pg36 NW36
8. Pg48 NW48
A-4 Sizes of 90° Elbow PG Metal Thread End Fittings
S.No. Thread Size Fits to Conduit Size
1. Pg9 NW10
2. Pg11 NW12
3. Pg16 NW17
4. Pg13.5 NW17
5. Pg21 NW23
6. Pg29 NW29
7. Pg36 NW36
8. Pg48 NW48
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Annexure – B:
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Annexure – C:
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Distribution:
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