revised draft ammendment to irs t29 mar13

7/28/2019 Revised Draft Ammendment to IRS T29 MAR13

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Proposed changes in IRS-T-29-2000

6.1.1 On receipt of permission for casting of prototypes, the manufacturer shall

then give 15 days notice to inspecting authority for witnessing of melting

and pouring for casting of prototypes. The witnessing of melting and

pouring shall be mandatory for casting of prototypes. However, for regularproduction, if inspecting official is not present during melting and pouring,

the manufacturer may go ahead with the casting keeping records and

samples as indicated in Clause 9.

6.2.2. Solidity Tests:

10%of the prototype castings subject to a minimum of one casting of each

type shall be selected for sectioning at seven locations preferably by

abrasive cutter as mentioned in Clause 5.2 above. Each sectioned face on

examination, shall not show a total defective area of more than 2% of the

cross-sectional area. The defect shall not be clustered at any particular

location and shall be uniformly distributed throughout. Defect within

10mm from the surface and defects connected with the outside and presence

of cracks/hot tears shall be cause for rejection. Hardness of the sectioned

faces shall be taken at the center of the thick section. Dye-penetrant test

shall be carried out on sectioned faces for detection of shrinkage and

chequered cracks.

This test shall be carried out once in two years from the clearance ofprototype or completion of 1000 CMS Crossings satisfactorily whichever is

earlier. After clearance of prototype, this test shall be carried out for each

design along with reassessment or on completion of every 1000 CMS

crossings satisfactorily whichever is earlier.

6.2.4

After solidity test and radiographic examination have been certified as

satisfactory, the firm will prepare a document mentioning parameters

(methoding size, shape and location of runners, risers and ingates, moulding

practice, source and properties of prepared sand and metal tapping and

pouring parameters) which gave satisfactory results. This document will be

countersigned by representative of RDSO. Inspectors will be free to verify

the parameters which were used during solidity test and which had been

countersigned by RDSO representative, so as to ensure the consistency of

foundry practice. The solidity test shall be carried out physically in the


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presence of RDSO representative at least once in a year as a regular

measure.

7.6.7 The CMS Crossings are prone to damage due to improper handling and

stacking prior to Heat treatment process. The crossings therefore must be

handled with due care avoiding jerks, impacts, hitting with metal surface

and improper support during lifting and placement. While placement of

crossings care must be taken to avoid metal to metal contact by using

wooden separators of adequate size.

7.7.1 All crossings along with relevant test bars carrying metal tag shall suitably

be heat-treated to render them tough. It shall be ensured that impression

insignia on the metal tag given by inspecting official is not defaced even

after heat treatment and shot blasting to facilitate inspecting officials in

identifying the test bar.

Heat treatment shall consist of uniform heating of the crossing to a suitable

temperature holding it at that temperature till uniformly heated throughout

and quenching in water, within 60 seconds from a minimum temperature of

10500C . The crossing should be kept in the quenching tank in head down

manner. The initial temperature of water in the quenching tank shall be less

than or equal to 300C and should not rise by more than 100C during and

immediately after quenching of crossing. Water in quenching tank shall be

agitated and circulated properly and a continuous temperature measuringsystem should be installed to record before and after quenching temperature

of tank for each heat treated batches of crossings. The recording of

temperature should be kept preserved for checking of inspecting officials.

7.7.2 The identification mark from the metal tag along with insignia of inspecting

official shall be transferred on the test bar in the presence of the inspecting

official.

9. INSPECTION

9.1 The CMS crossing is related to the public safety in the railway transit. The

process of manufacture is most intricate both from the foundry and

metallurgical point of view. Considering the basic characteristic of the steel

i.e. the thermal sensitivity, low diathermic character, mould metal reactivity of

the steel, the work hardening and high shrinkage characteristics of the steel,

rigorous inspection (both metallurgical and dimensional) at different stages of

manufacture shall be carried out to ensure the quality of product as detailed

herein.


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9.1.1. For suppliers who have not completed mandatory quantity of 100 nos of

crossing of each design ( 1in 8.5 52kg & 60 kg,1 in 12 52 kg &60 kg),

subject to total of 500 Nos covering all designs, the inspection of the firm will

be considered as Developmental and shall be carried out as per offer memo

mentioned in Appendix II. The cases of special layouts will be considered

separately.9.1.2 For suppliers who have completed mandatory quantity of minimum 100 nos

of crossing of each design ( 1in 8.5 52kg & 60 kg,1 in 12 52 kg &60 kg),

subject to total of at least of 500 Nos, and have achieved annual (financial

year) rejection rate less than or equal to 5% the inspection of the inspecting

official will be considered as Normal production and shall be carried out as

per offer memo mentioned in Appendix IIA. In case cumulative rejection rate

compiled once a year i.e. in April, of a suppliers becomes more than 5% ,the

inspection will be reverted to as per offer memo given in Appendix-II. Railway

shall be free to revert the inspection of any design or all the designs of CMS

crossing to as per offer memo given in Appendix-II based on the rejection rate

and/or field performance even prior to the above scheduled compilation in

April every year.

9.2. CHEMICAL COMPOSITION

9.2.1 For Developmental Inspection:

a. The manufacturers shall intimate the inspecting authority well in advanceso as to enable him to witness sampling of molten steel at different stages

for chemical analysis and shall furnish details of charge, pouringtemperature etc. The witnessing of melting and pouring shall be mandatory

for the casting of prototypes (Para 6.1.1). For regular production (i.e.

production after clearance of prototypes) under development inspection

category (Para 9.1.1), the inspecting official will advise the firm ,if he

desires to witness pouring, if required. In case, pouring is not witnessed

then the chemical composition will be verified by testing of lug sample in

presence of by the inspecting official as provided for in offer memo at

Annexure II & IIA

b. Portions of different bath samples (BT, BP & EP) should be preserved in

two sealed envelopes. These envelopes will be jointly sealed if RDSO

official decides to witness to pouring of heat. One of the sealed envelopes

containing above samples shall be handed over to the inspecting authority

on demand during the stage inspection of casting. These samples shall be

preserved till three months after issue of IC (Inspection Certificate).

c. Integral test bars are to be cast along with the casting as per Cl.No:12.1.1.

The parting of the integral test bars should be witnessed by the inspecting

official.


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9.2.2 For Normal production Inspection

The manufacturers shall carryout sampling of molten steel at different

stages for chemical analysis and shall furnish details of charge, pouring

temperature etc. while offering for inspection at Stage I. Separation of

Integral test bar shall be done only after heat treatment in presence of

inspecting official. Chemical analysis on lug/test bar shall be done in

presence of inspecting official only. If inspecting official desires to witnessthe pouring of casting, facility as per Para 9.2.1(b) should be extended by

the manufacturer. Integral test bars are to be cast along with the casting as

per Cl.No:12.1.1.

.

9.2.3 The test results shall be presented to the Inspecting Officials for cross check

before Stage-I inspection as per Clause 9.4.2.

9.3 IDENTIFICATION OF CAST AND CORRELATION OF HEAT NUMBERS

9.3.1 The castings shall bear manufacturers identification marks, drawingnumber, serial number and month and year of cast and date of cast. A

register shall be maintained by the manufacturer correlating the casting

serial number and heat number and register shall be produced to the

Inspecting Authority for their verification on demand.

9.4 STAGES OF INSPECTION

9.4.1 Inspection plan shall be targeted to cover the following four stages. The

firm shall keep all the internal inspection records for all the stages as

mentioned below and submit it to the inspecting official. Inspection by the

inspecting official shall be planned as per corresponding offer memo ( as

mentioned in Appendix II & IIA) so that verification/inspection of quality

parameters involving all the following stages are covered completely.

Stage I: After knockout, oxy-cutting, fettling cleaning, shot blasting etc.

Stage- II: After heat-treatment and shot blasting etc.

Stage III: After removal / rectification of defects and straightening

Stage IV: After final finishing prior to final acceptance

9.4.2.: For developmental Inspection:

Inspection of Prototypes and inspection of further quantity manufactured

against furtherpurchase orders is to be carried out as per the Format of

seven offer memos (Offer Memo No: 1 to 7) given in Appendix-II.

However, on achieving the desired level of consistency in quality

measured in terms of rejection rate after manufacturing of minimum

mandatory quantity as mentioned in para 9.1.2 i.e. less than 5% of

cumulative rejection rate during manufacture and supply of at least 500

CMS including minimum 100 CMS Crossing of each design, the reduction

in stages of inspection can be permitted as mentioned for normal inspection

in Para 9.4.3


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Sr.no Stage of

Inspectio

n

Offer memo no

of Annexure II

to be presented

by firms

Quality In

charge to RDSOinspecting

official by the

firm

Condition for signing the offer memo

by RDSO inspecting official.

1 Stage-I Offer Memo 1 After witnessing pouring and

confirming satisfactory chemistry by

witnessing molten steel sample testing

and observation of temperature during

various stage of casting

Offer Memo 2 After demoulding, and stamping of

integral test bars and verification of

chemical composition of integral test

bar, in case witnessing of pouring not

done earlier

Offer Memo 3 After fettling, shot blasting and

cleaning and observing satisfactory

dimension and surface quality.

2 Stage-II Offer Memo 4 After satisfactory heat treatment and

shot blasting, satisfactory surface and

gross dimension checking .3 Stage-III Offer Memo 5 Identifying surface defects and

permitting them for repairs, if

admissible, Testing of integral test bars

for impact bend test, Hardness test,

Grain size microstructure test.

Permitting for machining.

Offer Memo 6 After satisfactory removal of defects

after welding on permitted location,

No unauthorized welding, satisfactorymachining, Straightening, Dye

penetration test. Magnetic test,

Satisfactory Radiography test results

and Gross dimensional check.

4 Stage

-IV

Offer Memo 7 1. Checking satisfactory

Straightening including DPT.

2. Detailed Dimension checking

using approved gauges.

3. Satisfactory Quality (dimension,


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metallurgical)of

components/fittings being

supplied with CMS Crossing.

4. Satisfactory checking of all

records pertaining to previous

inspections.

9.4.3 For Normal Production Inspection:

Inspection of above stages are to be carried out as per the Format of three

offer memos (Offer Memo No: I, IA & II, 1, 2, 2A & 3) given in Appendix-

II A. The consistency of the Quality of product of a firm shall be reviewed

over a period of calendar year and if cumulative rejection rate is found

beyond 5 % then the firm may be considered for resorting to inspection as

per seven offer memos as mentioned in 9.4.2.

Sr.no

Stage ofInspectio

n

Offer memo noof Annexure

IIA to be

presented by

firms Quality In

charge to RDSO

inspecting

official by the

firm

Condition for signing the offer memoby RDSO inspecting official.

1 Stage-I Offer Memo 1 1. After verifying chemistry bywitnessing testing of lug sample.

2. After demoulding and stamping

of integral test bars.

3. After fettling, shot blasting and

cleaning and observing

satisfactory dimension and surface

Quality.

2 Stage-II Offer memo 2 1. After satisfactory heat treatment

and shot blasting, satisfactory

surface and gross dimensionchecking . After satisfactory heat

treatment and stamping of integral

test bars.

2. Testing of integral test bars for

impact bend test, Hardness test,

Grain size microstructure test.

Permitting for machining

Checking satisfactory


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Straightening including DPT.

3. Satisfactory

Quality(dimension,

metallurgical)of

components/fittings being supplied

with CMS Crossing.

4. Observing satisfactorydimension and surface Quality and

gross dimension checking .

5. Identifying surface defects and

permitting them for repairs if

admissible.

6. Identifying surface defects and

permitting them for repairs if

admissible, Testing of integral test

bars for impact bend test, Hardness

test, Grain size microstructure test.

Permitting for machining.

3 Stage-III Offer memo 2A After satisfactory removal of defects

after welding on permitted location,

No unauthorized welding, satisfactory

machining, Straightening, Dye

penetration test. Magnetic test,

Satisfactory Radiography test results

and Gross dimensional check.

4 Stage -IV Offer memo 3 1. No unauthorized welding hasbeen done.

2. After satisfactory Straightening,

maching Dye penetration test.

Magnetic test, Satisfactory

Radiography test results.



4. Satisfactory Quality (dimension &

,metallurgical) of


supplied with CMS Crossing



inspections.



7. Satisfactory Quality (dimension,

metallurgical) of


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supplied with CMS Crossing.



inspections.

9.5 Initial Surface as well as Dimensional Inspection (Stage-I)

9.5.1 For developmental inspection, the inspection will be carried out as per Para

9.4.2 whereas for Normal production, inspection procedure as laid down in

Para 9.4.3 will be followed.

9.5.2 After fettling and shot blasting as per clause 7.6 ,the defective areas of the

surface of crossing if any shall be marked with the dimension of defects

(i.e. length, width and depth) and shown in isometric view as shown inAppendix-V and their locations indicated from a datum line. The details

are also to be tabulated and certified by the manufacturer in a proforma

prescribed by the inspecting official and shall be submitted to the inspecting

official for the verification / inspection. The inspection should be aimed at

detecting foundry defects like cracks, sand holes, cold shuts, pin holes,

porosity, extra metal, sand fusion etc. Crossing having cracks, unauthorized

welding, grinding, buffing markshall be straight away rejected.

9.5.3 The crossing shall be checked for gross dimensions and discrepancies shallbe tabulated with the remark in a sketch with isometric view classifying the

castings.

9.5.4 At this stage, gross dimensions such as overall length, distance between

actual nose and heel, actual nose and toe end, height at different locations

flange thickness at different locations, web thickness, roof thickness, flange

way clearance, throat clearance, flange well depth wheel tread at toe end

and opposite to actual nose, nose thickness, nose depression and offsets

bottom, bottom width, tie thickness, extent of vertical bend etc, shall be

checked and recorded.

9.5.5 After satisfactory inspection if crossing is considered fit for further

processing, Offer Memo No. 1, 2 & 3 as per Appendix-II for

Developmental Inspection and Offer Memo No. 1 as per Appendix-II A for

Normal Production Inspection shall be signed as mentioned in Clause 9.4.2

& 9.4.3 above.

9.6 Metallurgical & Dimensional Inspection (Stage-II)


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9.6.1 Metallurgical inspection shall be carried out as after heat treatment as per

clause 7.7 & shot blasting for both Developmental as well as Normal

Production inspection.

9.6.2 The heat treatment of castings in a batch shall cover all castings of one heat.

The castings belonging to one melting heat and heat treatment batch shall

be referred as casting of one heat. Micro structure shall be checked by

inspecting official per heat as per clause No; 7.7.7 as amended as percorrigendum no 2 of August 2001. Two micro test pieces are to be cut each

from first and last casting, poured from same melting heat and both the

pieces are required to be passed in micro-structure test. Solidity test shall be

conducted as per clause 6.2.2.

9.6.3 At this stage, gross dimensions as mentioned in clause 9.5.4.3 shall be

checked.

9.6.4 Crossings having cracks as well as unauthorized welding/repairs shall be

rejected.

9.6.5 Integral Test bars shall be detached from the casting in presence of

inspection authority at the time of inspection. At least two test bars per

casting should be made available to the inspecting officer. The test bars are

to be stamped by inspecting official with proper identification. The firm

shall also keep their internal metallurgical test results readily available and

those shall be presented to the Inspecting Officials for cross check during

inspection

9.6.6 Impact Bend test on stamped test bars shall be conducted in presence of the

inspecting official as per Clause 12.1 and record of test shall be maintained.

Suitable hardness test shall be conducted at this stage both on thick and thin

section of each casting as per Clause 12.2 and also on test bars representing

a patch in presence of inspecting official and record shall be maintained.

9.6.5 After satisfactory inspection as per provisions of Clause 9.6 above, if

crossing is considered fit for further processing, Offer Memo No. 4 as per

Appendix -II for Developmental Inspection and Offer Memo No. 2 as per

Appendix-IIA for Normal Production Inspection shall be signed as

mentioned in Clause 9.4.2 & 9.4.3 respectively.

9.7 Surface & Dimensional Inspection (Stage III) (After Removal /

Rectification of casting defects only)

9.7.1. Before putting up to the inspecting official, the castings shall be suitably

prepared for the removal/rectification of defects as per Clause 7.8 and


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straightened as per Clause 7.9. No crack shall develop on locations repaired

by welding, due to straightening operation.

9.7.2 Repair welding shall be done strictly as per the procedure for

repair/rectification of CMS Crossings at Appendix-III. The manufacturer

will produce a certificate to this effect.

9.7.3 The castings shall be offered to the inspecting official in the manner as in

Stage-I and Stage II for metallurgical and dimensional inspection, if

necessary.

9.7.4 The machining operation as per the product drawing shall be carried out at

this stage. No gross dimension except flange thickness,tie thickness,height

at different locations shall be checked.

9.7.5 The crossings which are considered process able shall be permitted for final

finishing and Offer Memo No. 5&6 shall be signed as per Appendix -II for

Developmental Inspection and Offer Memo No. 2A as per Appendix -IIA

for Normal Production Inspection.

9.8 Final Dimensional check up & Magnetic Test (Stage-IV /Final Stage)

9.8.1 After final internal inspection and certification by the Works Inspector of

the firm as per clause 15.3 the crossing shall be offered for dimensional

check up (as per sequence shown in Appendix-IV) on the inspection

table/marking table with the approved gauges/templates/equipment as

mentioned in clause 8.2.

9.8.2 Theeach casting shall be visually inspected for surface defects employing

dye-penetrant tests. Each casting shall also be tested for its non-magnetic

characteristics either by portable permanent magnet or by suitable electro-

magnet. The check will be done on head surface preferably after heat

treatment.

9.8.3 Dimensions of crossings shall be checked with the help of approved

gauges/templates, fishing cord, straight edge, filler gauge etc.

9.8.4 Crossing should be checked for alignment after straightening operation (if

straightened). Dye Penetration Test shall be carried out after straightening

operation to detect development of any crack.

9.8.5 Radiography shall be conducted as per Para 6.2.3

9.8.6 After the inspecting officials are satisfied that the crossing conforms to

relevant drawing and specifications, the crossing shall be accepted finally


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and offer Memo No. 7 as per Appendix II for Developmental Inspection

and Offer Memo No 3 as per Appendix-IIA for Normal Production

Inspection shall be signed.

9.8.7 The inspected crossings should be handled properly avoiding impact and

stacked properly to avoid metal to metal contact among CMS Crossings by

keeping wooden spacer below the crossings.

14.1 Rejection;

Any batch of crossings produced from the same melt and heat treated

together under the same conditions which fails to comply with the

requirements of the specifications shall be rejected. Rejected crossings shall

be made unusable by gas cutting or by any other means in to at least two

pieces preferably near middle of crossing in order to avoid mixing up with

the crossings under processing/finishing/inspection and kept stacked

separately till verified by inspecting official. A certificate to this effect shall

be enclosed with next inspection call.

14.2 Any crossing which fails to comply with the requirements of the

specifications shall be rejected. Rejected crossings shall be made unusable

by gas cutting or by any other means in to at least two pieces preferably

near middle of crossing in order to avoid mixing up with the crossings

under processing/finishing/inspection and kept stacked separately till

verified by inspecting official. A certificate to this effect shall be enclosed

with next inspection call.

15.1 All the inspections offer memos shown in Appendix-II and IIA shall be gotprinted by the manufacturer in sufficient numbers. They will be bound in

separate booklet with all pages duly machine numbered in duplicate for

Appendix II and Appendix IIA respectively. One set of offer memo of

Appendix II (in duplicate) or Appendix IIA in respective

developmental/regular production shall be used for recording details of

only one crossing during its different stages of manufacture/inspection.

revised draft ammendment to irs t29 mar13

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