109 317359/2020/O/o PED/TMM/RDSO ISO: 9001-2015 Document No.: TM-52 Revision 01 Date Effective From:--/--/---- Document Title: Specification of Spirit Level (For use in Box type cum level)

SPECIFICATION OF SPIRIT LEVEL (For use in Box type gauge cum level)

(No.TM-52 Dt.24.05.2000)

First Revision, October-2020

Track Machines & Monitoring Directorate

RESEARCH DESIGNS AND STANDARDS ORGANISATION Manak Nagar, Lucknow-226011

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1.0 SCOPE: This specification covers the essential dimensional, functional and material characteristics with method of testing and accuracy of the spirit level. The spirit level is used to define a reference horizontal to compare the horizontality of the base of the spirit level with the plane containing the touching surfaces of the rail seatings of the gauge-cum-level.

1.1 Preference to make in India: compliance of the instruction contained in public procurement (preference to make in India) order -2017 “Make in India” shall be ensured or latest instructions issued on subject shall be ensured.

1.2 All the provisions contained in RDSO’s ISO procedures laid down in Document No. QO- D-8.1-11 dated 12.09.2018 (titled Vendor – Changes in approved status”), subsequent versions / amendments thereof shall be binding, and applicable on the successful manufacturers/suppliers in the contracts floated by Railways to maintain quality of products supplied to Railways.

20 REFERENCE DOCUMENTS: Following BIS/IS codes and references have been referred to in this specification. Updated copies of the same should be available in the works of the manufacturer/Suppliers.

i. IS: 292-1983 Leaded Brass Ingots and Castings. ii. IS: 733-1983 Wrought aluminium and aluminium alloy bars, rods and sections for general engineering purpose. iii. IS: 737- 1986 Wrought aluminium and aluminium alloy shuts & springs for general engineering purpose. iv. IS: 1632- 1993 Optical instruments bubbles ( Ist revision) v. RDSO Drg. No. Spirit Level TM/2004

3.0 TERMINOLOGY: For the purpose of this specification following shall apply:

3.1 Bubble : The bubble is a device, which when fitted to an instrument can be used to define a reference horizontal plane as in leveling. It consists of a glass tube containing a filling liquid having low viscosity and which maintains its fluidity over a fairly wide range of temperature, thereby making its use possible at low temperature as well.

3.2 Bubble vial : A sealed glass tube suitably processed, partially filled with a liquid of low freezing point and low viscosity leaving an air-bell inside.

3.3 Air-bell : The small space, created inside the sealed tube due to its partial filling, which forms a bubble of mixed air and liquid vapour.

3.4 Bubble-Run : The travel of the `air-bell’ inside the tube corresponding to any angular tilt given to the bubble.

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3.5 Sensitivity : The sensitivity of a bubble is the angle of tilt which would cause its air-bell to move through one scale division.

3.6 Roll : The rotation of the bubble round an axis which is parallel to the axis of the bubble.

3.7 Effective Range : The internally processed surface of the bubble which responds correctly to the various functional requirements and is usually confined to the limits of the etched lines.

3.8 Consistency : The characteristics of the air- bell of the bubble each time to set itself to its original position throughout its effective range when such a setting is disturbed & restored.

3.9 Sluggishness : The incapability of the air-bell to exhibit corresponding deviations in its position as warranted by small changes in it.

4.0 SIZE & TYPE: The bubbles shall be of cylindrical type having outside diameter of 9.0 + 1 mm and length 70 + 1.0 mm .

5.0 Accuracy : The accuracy of the spirit level shall be from 0.05 mm/M to 0.1 mm/M at 270 C.

6.0 GENERAL REQUIREMENTS:

6.1 The glass vial shall be suitably housed in aluminium - alloy ( IS: 737-1986,Design HE 9 or HE 30) tubing in such a way that the housing shall protect primarily the vial from damage i.e there shall not be any physical contact of vial with the housing. The mounting of the vial with the housing shall be such as to permit slight longitudinal expansion ( Thermal ).

6.2 The metallic housing shall have a bubble opening of 50 mm x 8 mm. The metallic housing including the vial shall be encased in a tubing having a transparent Perspex covering on the top.

6.3 All machined surfaces on the level shall be painted to have suitable protective finish.

6.4 The weight of the spirit level shall be within 150 gms (unpacked).

7.0 MATERIALS:

7.1 Housings of the vial : The main housing of the bubble shall be made from square tubing of Aluminium extrusion as per IS: 733 -83, Design-HE 9 or HE 30. The initial circular housing (Mounts ) of the vial shall be made of Aluminium alloy as per IS: 737-86 (Grade-1C).

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7.2 Mountings : Fixing of the vial with mount shall preferably be done by providing Teflon /adhesive tape at the ends of the vial. Both the ends of the mount shall be plugged with brass/ gunmetal plugs, suitably designed.

7.3 Vial : The glass tube used shall be well annealed, transparent, free from scratches, flaws and other defect and of 1.25 mm to 2.5 mm wall thickness. The composition of the glass shall be such that it is not reacted upon by the filling liquid. Borosilicate or soft soda glass tubes are suitable.

7.4 Filling liquid : Ethyl ether, industrial methylated spirit ( Grade -1), methyl alcohol, acetone, absolute alcohol or any other suitable liquid shall be used. The liquid shall be clear, shall not be discoloured and shall not cloud or noticeably change in fluidity with, age or at temperature as low as - 40 0 C. The liquid shall be chemically inert to the glass tube and the colouring material, if used. The liquid shall be free of water and impurities and shall not decompose under light and temperature.

7.5 Base Plate: The spirit level shall have two base plates as per drawing no. TM/2004 made of brass of grade LCB2 conforming to IS: 292-1983. The bottom of the base plate shall be machined so as to move smoothly over the ramps of gauge cum level.

8.0 FUNCTIONAL REQUIREMENTS: The spirit level shall have the following technical features:

(i) Base length : 200 mm + 1 mm (ii) Base width : 20 mm + 0 - 1 (iii) Height : 25 + 1 mm (iv) Bubble opening : 50 mm x 8 mm (length x width) (v) Sensitivity : 2 Min. 30 Sec per 2 mm arc division of the vial (vi) Least count of graduation : 2 mm (vii) Weight (Without packing box) :150 gms. (approx). (viii) Effective length of bubble : 20 + 1 mm

8.1 The Perspex on the top of the spirit level shall be as transparent as glass and shall have enough mechanical strength to withstand breakage. Transparency shall be retained and shall not be frosted or hazy due to aging.

8.2 The dimension of the glass tube shall be so proportioned and the filling liquid inside the glass tube shall be so adjusted that both ends of the bubble may always be read against scale over a temperature range of 5 to 45 0 C and the air-bell shall retain an effective length for accurate measurements up to 70 0 C.

8.3 The bubble shall show displacement for at least a cross level difference of 1.0 mm. The design of the spirit level shall be such that necessary adjustment of the vial can subsequently be made in a simple way.

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8.4 The spirit level shall be durable and its functioning shall not be affected by aging up to its life span.

8.5 The spirit level shall have a suitable arrangement within the housing for adjusting the bubble vial portion. The arrangement mechanism shall be able to shift one end of the vial in vertical plan.

9.0 TESTING & CALIBRATION:

9.1 Requirements for Calibration : Calibration shall be made as per following requirements :

(i) Adjustable Calibration test bench : The test bench shall have the facility for tilting the spirit level, being calibrated, from one end with an accuracy to match the bubble’s sensitivity. For an angular displacement (in vertical plane) of the spirit level of 2 Min 30 Sec, the air bell shall run a linear division i.e. 2 mm in the bubble tube.

(ii) The test bench shall have a suitable dial to indicate the tilting angle of the horizontal plane on which the spirit level is placed during calibration . The dial shall have circular graduated scales along its periphery divided in four quadrants each of which have least count of one second.

(iii) The sensitivity of the test bench shall be tested and calibrated from time to time for which the manufacture shall have the facility.

9.2 TYPE TESTS: Following type test are to be conducted on Prototypes at the time of initial approval. The manufacturer/supplier shall produce three prototype samples before inspecting officials for type tests. The cost of type tests shall be borne by the manufacturer/supplier. All arrangement to conducts type tests shall be made by manufacturer/supplier.

(i) Visual & dimensional check. (ii) Tests of mechanical properties of main housing. (iii) Tests for bubble sensitivity. (iv) Test for accurate functioning of spirit level when used in gauge-cum-level. (v) Test of bubble sensitivity and effective length of air bell in higher temperature.

9.2.1 Details of type tests:

(i) Visual & Dimensional check : All the major dimensions of the spirit level should be checked to conform the requirements as mentioned in the drawing of spirit level (Drg No. TM/2004).

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(ii) Test of Mechanical properties of Main Housing:

The tests shall be carried out in the premises of the manufacturer under witnessing of the inspecting official. If the manufacturer doesn’t have the facilities for testing of Mechanical properties, a certificate from a reputed test house for tests of mechanical properties as listed below shall be produced by the manufacturer to the inspecting officials. The inspecting official, if desires may get upto three additional samples tested under his witnessing at the premises of the reputed test agency who has issued the certificate. All the arrangements for such testing as well as witness shall be arranged by the manufacturer including cost of testing.

(a) Minimum Tensile Strength in N/ sq mm. (b) Minimum Elongation in percentage ( on 50 mm gauge length )

The results should conform to table 2 of IS:733:1983.

(iii) Tests for bubble Sensitivity : The sensitivity is to be tested on the calibration bench. The sensitivity shall be 2 Min 30 secs. For an angular movement ( in the vertical plane ) of the spirit level for an angle of 2 Min 30 secs of the spirit level, the bubble shall run one smallest divisions ( 2mm ) in the linear scale. The sensitivity to be tested twice by reversing the spirit level to 180 0 on the calibration bench.

(iv) The functioning of the spirit level shall also be tested on calibration bench keeping the spirit level on the gauge-cum-level.

(v) Test of bubble sensitivity and effective length in higher temperature:

The bubble shall be placed in an electric oven and the temperature raised gradually at the rate of 10C per minute ( average 50C over a period of not more than five minutes) to a temperature of 65 0 C and shall be retained for three hours at that temperature. The air-bell shall not entirely disappear and retain the effective length for accurate measurements up to this temperature (Ref :Clause No. 6.6 of IS: 1632- 1993). After heating is completed, sensitivity is to be checked.

(Note : This test should be carried out in such a way that the bubbles do not come in contact with a hot metallic surface resulting in cracks due to localized heating)

9.3 Acceptance Tests:

This includes the following tests in sequence. Every instrument in the consignment shall be subjected to the acceptance tests : (a) Visual & Dimensional check - as per clause no. 9.2.1(i). (b) Test for sensitivity of the bubble - as per clause no. 9.2.1(iii). (c) Test for functioning of spirit level while used in gauge- cum- level as per clause No. 9.2.1(iv).

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Note: (i) Manufacturer shall have facilities for conducting of these tests at his premises. The manufacturer shall produce internal test certificate for every sample. Samples shall be numbered suitably.

(ii) Above mentioned acceptance tests are applicable for every sample. Any deviation from the test results from the requirements in the specification shall be the cause of rejection of the sample instrument.

iii) The acceptance tests shall be carried out under the witnessing of the consignee/inspecting official. The manufacturer shall produce all relevant documents as a proof for conformity of the quality of all the raw materials used in the instrument. The certificate shall include procurement source also.

10.0 Inspection: The inspection the instrument shall be carried out as per following Para:

10.1 As this is a precision instrument, every instrument in the consignment shall be subjected to acceptance tests as per clause 9.3 in case of regular procurement.

10.2 The inspection of the sprit level shall be carried out by the purchaser Zonal Railway or any representative/other agency authorized by purchaser/ Zonal Railway. The inspection procedure and the test scheme should be submitted to the purchaser for approval. The cost of inspection and testing shall be borne by the manufacturer/supplier.

10.3 Minimum level of inspecting official shall be SSE.

11.0 WARRANTY & AMC: (i) Any part of the instrument failing or proving unsatisfactory in service due to defective design, material or workmanship within 24 months from the date of supply shall be replaced by the manufacturer at his own expenses. The manufacturer /supplier shall provide prompt after sale service for the satisfaction of the customer. Further should any design modification be made in any part of the instrument offered, the period of twenty four months would commence from the date, the modified part is put in service.

(ii) Copies of Maker’s certificate guaranteeing the performance of the instrument shall be supplied in duplicate along with the delivery of each instrument. The manufacturer shall also submit a certificate that the materials used in different parts of the instrument are strictly as per the specifications mentioned in this standard.

11.1 During procurement of the Spirit Level, railways should go post-warranty AMC with the supplier for a pre-determined period as decided by the purchaser Railway as per Comprehensive Guidelines on Procurement, Operation, Maintenance and Repair of Small Track Machine Repot no TM 227. This may be incorporated in the tender document as a condition of contract/Tender/Supply.

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12.0 MARKING AND PACKING: 12.1 The machine shall be legibly and indelibly marked with: i) Name, initials and trade-marks of manufacturer. ii) Contact No. iii) Serial number of Spirit Level. iv) Month & year of supply.

12.2 Packaging: The instrument shall be supplied in due packing as per best trade practice, preferably in a good quality polished wooden box.

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