GOVERNMENT OF INDIA
Ministry of Railways
Research Designs and Standards Organization
Manak Nagar, Lucknow-226011
Notice for Expression of Interest
Notice No. CT/PTX/EOI
Applications are invited for development of vendor for Micro Flow Metal Spray
Powder for minimum life of 25GMT for reconditioning/reclamation of wheel burns/scabs,
AT weld cupped joints from the firms capable of manufacturing the powder as per
RDSO’s guidelines.
Application form alongwith guidelines for registration can be obtained from the
Office of Executive Director/Track-II, RDSO, Main Building, Manak Nagar, Lucknow –
226011 during office hours on any working day upto 18.01.2010 (12.00 hrs.) on payment
of Rs.5300/- and Rs. 100/- extra if required by post, through demand draft in favour of
Executive Director (Finance), RDSO, payable at Lucknow. Application form can also be
downloaded from website on www.rdso.gov.in. and submitted as above along with
charges of Rs.5300/-
Intending manufacturers satisfying the conditions stipulated in the Application
Form should apply to express their interest with requisite information in duplicate to the
Executive Director /Track-II, Research Designs and Standards Organisation, Ministry of
Railways, Manak Nagar, Lucknow – 226011 latest by 18.01.2010 (15.00 hrs.) RDSO will
not be responsible for any delay in postal transit.
Note : Firms who are applying for vendor development for the above product should
have at least an average turnover of Rs.50 lacs per annum during the last 3 years and
should possess ISO 9001 certificate.
Director/Track-3
For Director General (Track)
RDSO, Lucknow
(for & behalf of President of India)
D:\for_web\Expression of Interest for Powder.doc
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D:\for_web\Expression of Interest for Powder.doc
Government of India
Ministry of Railways
DOCUMENT NO. M&C/W/103-2003
Guidelines for Infrastructural, manufacturing, work execution, testing
& quality control requirements for
Micro flow Spray Powder for reconditioning of scabs, wheel burns of Rails
and Cupped A.T. weld Joints (R&D Project)
Price: Rs. 1700/-
M&C Directorate
RESEARCH DESIGNS & STANDARDS ORGANISATION
MANAK NAGAR, LUCKNOW – 226011
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INFRASTRUCTURAL, MANUFACTURING, WORK EXECUTION, TESTING &
QUALITY CONTROL REQUIREMENTS FOR MICRO FLOW SPRAY POWDER
1.0
SCOPE
1.1
This schedule covers the technical requirements for manufacturing, testing and quality
control of Micro flow Spray Powder for reconditioning of scabs / wheel burns and any
other shallow surface defects upto a maximum depth of 3 mm of rails covered under
IRS:T-12-1994 and cupped A.T. Weld joints covered under IRS:T-19-1994. This
schedule also covers the technical requirements of Metal Spray Powder covered under
Specification No.M&C/W/103-2003.
1.2
Since sufficient number of manufacturers have not yet been developed, the scope of these
requirements shall be limited to R&D only and are open to be revised as and when
technique is fully developed and sufficient sources (at least two manufacturers under PartI category) of supply come into existence.
2.0
REQUIREMENTS
2.1
Vendors seeking approval shall have a minimum turn over of Rs.50 lakhs/annum.
2.2
The firm should have acquired ISO-9000 Series Certification.
2.3
All Infrastructural, Manufacturing, Quality Control and Work Execution facilities a
stipulated hereinafter.
2.4
All aspects of Comprehensive Procedure for Initial & Periodic Approvals of Micro flow
Spray Powder for Reconditioning of Scabs / Wheel Burns and Cupped A.T. weld joints
(Annexure ‘A’).
3.0
INFRASTRUCTURAL & MANUFACTURING FACILITIES
3.1
General
i)
ii)
iii)
3.2
3.2.1
Description of different departments in the factory/works to be specified by the
manufacturer.
Function of each department emphasising production and quality control to be
specified.
R&D – proper infrastructure for Research & Development related to Powder
Welding Technology.
Manufacturing
Mandatory requirements
3.2.1.1 Separate identified area for different raw material, finished product and enclosed room for
inspection.
3.2.1.2 Material handling facilities.
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3.2.1.3 Weighing machines
3.2.1.4 Vacuum Dryer
3.2.1.5 Sieving / Sizing Equipment.
3.2.1.6 Dry Blender
3.2.1.7 IS / BS sieves set
3.2.2
Desirable requirements
The following manufacturing facilities, if available shall be considered as ‘added
advantage’ and more weightage shall be given to such manufacturer’.
3.2.2.1 Atomising Chamber
3.2.2.2 Induction melting furnace
4.
Packaging:
To guard against ingress of moisture and accidental damage during transportation and
storage till its consumption, the packaging system of powder shall be as detailed below:
4.1
The powder shall be contained in suitable air tight plastic modules/hoppers capable of
being attached to the body of torch and to be fed for subsequent use for reconditioning.
4.2
Suitable arrangement shall be made to keep the contents moisture free like keeping Silica
Gel in the lid of the module.
5.
Marking:
The container (module) shall be marked with the manufacturer’s name, brand name, batch
number and the date of manufacture and any other information deemed necessary by the
manufacturer.
6.
WORK EXECUTION FACILITIES.
The manufacturer must possess proper and adequate infrastructure and facilities for an
effective and timely execution of work in site. The following are the minimum
requirements for the same:-
6.1
Standard Torch (es) with proper powder delivery system and safety checks as per RDSO’s
specification Noo.M&C./W/103-2003.
6.2
Standard oxygen and acetylene cylinders with Gas Pressure regulators.
6.3
Two stage gas regulators with high pressure hose pipes.
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6.4
Thermal-chalks / Contact Type Thermocouples / Pyrometer for measuring preheating
temperatures 200o C, 250o C, 300o C and 350 C.
6.5
Hammers and S.S. wire brush.
6.6
Eye protecting goggles.
6.7
Filler gauge set with 10 cm straight edge scale.
6.8
Magnifying glass
6.9
Dye penetrant test kit (cleaner, dye developer)
6.10
File
6.11
Portable grinder
6.12
Hand gloves
6.13
Spark lighter
6.14
Generators
6.15
Safety device (as per Specification No.M&C/W/103-2003).
6.16
Trained welder(s) duly certified for competency by the manufacturer.
7.
QUALITY CONTROL AND TESTING FACILITIES
7.1
General
In addition to the following testing facilities, the manufacturer must fulfill all the
requirements stipulated in Cl.6.1 to 6.17.
7.2
Testing
7.2.1 Hardness Testing Machine (Brinell / Vicker’s / Rockwell)
7.2.2 Optical Microscope
7.2.3 Carbon-Sulphur determination apparatus with transformer, furnace, oxygen cylinder and
other accessories.
7.2.4 Oxygen Analyser (for raw material testing to control oxygen level.
7.2.5 Muffle furnace with automatic temperature control (min. 800oC).
7.2.6 Hot plates
7.2.7 Electric Oven
7.2.8 Barometer
7.2.9 Hydrometer
7.2.10 Water distillation plant
7.2.11 Platinum crucible
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7.2.12 Burettes, Desicator, Measuring Cylinder, Washing Bottles, Funnels, Beakers, Filter
Papers, Silica Crucibles and other Glass Wares and chemicals of analytical-reagents
quality sufficient to analyse the elements relevant to the production range.
7.2.13 IS sieves set
7.2.14 Any other relevant facilities.
NOTE:
(1)
Availability of the following shall be considered advantageous special facilities for
exercising good Quality Control Measures.
•
Vacuum Emission Spectrometer
•
Carbon + Sulphur Analyser
(2)
All the equipment, wherever necessary should be properly calibrated and current
calibration certificates should be attached as a proof.
8.
8.1
QUALITY CONTROL REQUIREMENTS
There should exist a system of easy traceability of the product from initial stage to
finished product stage.
8.2
Quality assurance plan for the product detailing various aspects like
a)
Organisation chart
b)
Process flow chart
c)
Stage inspection details
d)
Various parameters to be maintained to ensure quality control and process control
charts.
e)
Policy of disposal of rejected raw materials and finished products.
f)
Process capability records and calculations to ensure that the process is under
quality control.
8.3
should be implemented and record maintained for documentary evidence.
A graduate Engineer or a Diploma holder with 5 years experience must head the
inspection / final quality control section for inspection of raw materials / finished
products.
8.4
There should exist a quality control manual i.e. QAP (Quality Assurance Plan) of the firm
indicating the extent of control over production and testing.
8.5
To ensure regular submission of rejection rate, cause of rejection corrective action taken
on quarterly basis.
8.6
There should exist a system of documentation in respect of rejection at customer end,
warranty replacement, to provide technical services to Railways and customer satisfaction
as per ISO norms.
8.7
There should exist a system of recording plant, machinery & control equipment remaining
out of service, nature of repair done etc.
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8.8
Welders engaged in welding works must be well qualified, trained and duly certified for
competency.
8.9
The production should be environment friendly as per ISO standards.
8.10
R&D facilities and Organisation.
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ANNEXURE ‘A’
COMPREHENSIVE PROCEDURE FOR INITIAL & PERIODIC APPROVALS OF
MICROFLOW SPRAY POWDER FOR RECONDITIONING OF SCABS / WHEEL
BURNS ON RAILS AND CUPPED A.T. WELD JOINTS.
Since the technique of reconditioning scabs and wheel burns on rails and cupped A.T.
weld joints by powder welding is still under development, it is a part of R&D. As such the
procedure for approval of this item shall be as stated below.
0.1
When sufficient sources of manufacturing are developed, the technique shall be finally
standardised for regular adoption and implementation.
1.
INITIAL APPROVAL :
1.1
Application, Scrutiny of Documents, Inspection and Sampling :
1.1.1
The manufacturer desirous of getting RDSO approval must be able to comply with the
stipulations of the detailed ‘Guidelines for Infrastructural, Manufacturing. Testing and
Quality Control Requirements for Microflow Spray Powder for reconditioning of Scabs,
wheel burns of Rails and Cupped A.T. weld joints.’
1.1.2
In case the manufacturer feels that all the stipulations are complied with, it will apply for
initial approval giving details of facilities as per 1.1.1 to the Director General, Track
Design, RDSO, Lucknow. Track Design Directorate will forward these proforma to M&C
Directorate for scrutiny.
1.1.3
The M&C Dte. will scrutinise the documents and if found satisfactory will inform the
manufacturer accordingly and ask them to deposit necessary inspection charges of RDSO
officials(theses charges vary from place to place).
1.1.4
An Officer each from M&C Dte. and Track Design Dte.will, then visit the factory
premises of the manufacturer and conduct thorough inspection to assess the capacity,
capability and quality control management etc. If things are in order as per the concerned
specification No.M&C/W/103-2003, and also as per the Guidelines of 1.1.1, necessary
samples shall be sealed for lab evaluation as well as field service trial. A total of 7 Kg.
Powder i.e. 14 modules (each of 500 gms) shall be sealed –1 for lab evaluation, 1 for
reference sample and 12 for field service trial.
1.1.5
If the samples have been sealed after assessing the capacity and capability of the
manufacturer, the estimate for testing charges shall be given to the manufacturer by the
M&C Directorate for effecting payment by means of a Demand Draft payable in favour of
‘Executive Director (Finance), RDSO, Lucknow’.
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1.1.6
The sealed samples as per instructions shall be sent to the Director General, M&C,
RDSO, Lucknow for lab. evaluation in the welding Research Section of M&C Directorate
along with testing charges.
1.2
Laboratory Evaluation
The laboratory evaluation shall be conducted on weld spray deposits on the rail head
sample having simulated defects (refer to Specification No. M&C/W/103-2003.
1.3
If the results of lab evaluation are found satisfactory, the M&C Dte. will advise the Track
Design Dte. accordingly and the Track Design Dte. shall arrange field service trials in
Zonal Railways.
1.4
Field Service Trial:
After successful laboratory evaluation, the M&C Dte. will refer the matter to the Track
Design Dte for conducting field service trial for which the following steps shall be taken
up.
1.4.1
The manufacturer shall be asked to deposit necessary field service trial charges (to be
decided by the Track Design Dte.).
1.4.2
Field trials shall be conducted in two different Railways under RDSO supervision. 25
wheel burnt/scabbed rail spots and 25 cupped AT weld joints shall be reconditioned
following code of procedure No. MC-47, already circulated earlier. Thus 50 spots in all,
shall be reconditioned in one Railway. The Zonal Railways shall be picked up by RDSO
for conducting trials, but the actual site/division will be allotted by the concerned
CE/CTC. However at the time of selecting the routes for service trial it should be ensured
that required GMT (25 min.) is earned as early as possible.
1.4.3
Reconditioning will be carried out by trained welder of manufacturer under their expert
supervision* in the presence of technical representatives of M&C and Track Design Dtes.
of RDSO. The RDSO representatives will fill up the requisite particulars as per proforma
enclosed at Annexure-III. Two copies of the same shall be handed over to the concerned
Zonal Railways – one for the concerned PWI and the other for Senior DEN. Inspection
proforma as per Annexure No. IV shall also be attached therewith.
*Note: Safety measures shall be adopted as per specification No. M&C/W/103-2003.
1.4.4
Monitoring of these reconditioned spots shall be done jointly by M&C & Track Design
Dte. every quarterly i.e. every three months from the time of reconditioning and
inspection reports submitted to the component authorities of M&C & Track Directorates.
1.4.5
Final inspection will be carried out jointly by M&C & Track Design Dtes. when the
reconditioned spots have earned 25 GMT (min.). The programme for final inspection
shall be planned well in advance so that joint inspection team is available at the site
around the time of completion of 25GMT.
1.5
*Acceptance Criteria:
1.5.1 Spots shall earn minimum 25 GMT satisfactorily with :
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No surface defects,
No metal chipping,
No cracks, and
No appreciable wear ( not exceeding 0.1 mm) when measured with filler gauge and a 10
cm straight gauge.
1.5.2
The reconditioned spots shall be reasonably smooth.
1.6
*Retest:
In case a maximum of one reconditioned wheel burnt/scabbed and/ or one cupped AT
weld joint fails on the basis of acceptance criteria, this clause shall be applied for
evaluation of performance before arriving at the final decision.
Double the number i.e two spots shall again be reconditioned and subsequently monitored
and finally inspected following the entire same
procedure afresh. Consequently both such spots must pass, only then the trial shall be
considered to be successful. If any one of these two spots fails, the trial shall be
considered to be unsuccessful and the product shall be rejected.
*Note: These stipulations are as per provisions of Clauses 8 & 9 of the Specification
No.M&C/W/103-2003.
1.7
Approval:
Once the field service trial is found to be satisfactory in both the railways, the product
shall be approved with joint consultation of ED (M&C) and ED (Track) and the product
shall be approved in part II for application for next two years.
2
PERIODIC APPROVAL:
2.1
The firm is to approach DG, Track Design/M&C Dte. at least six months before the
expiry of validity of approval for re-approval (periodic approval) with full details as done
earlier at the time of initial approval.
2.2
The Track Design Dte. will then arrange to get performance report of the product from the
consumer railways. On being satisfied with the performance, the matter will be referred to
M&C Dte. for subsequent periodic inspection and related sampling.
2.3
The M&C Dte. will scrutinise the relevant technical papers and if the same are in order,
ask the firm to deposit inspection/visit charges of the RDSO officials (these charges vary
from place to place).
2.4
On receipt of Inspection/visit charges, representative of M&C Dte. and Track Design
Dte., will visit the firm premises for periodic inspection and shall verify that the original
infrastructures at the time of initial approval are existing in toto and in perfect condition.
If satisfied with the inspection, necessary samples shall be drawn and sealed for lab
evaluation. The samples shall be sent to Welding Research Section of M&C Dte. of
RDSO within 15 days along with necessary testing charges as advised.
2.5
On receipt of testing charges in the M&C Dte., the laboratory evaluation shall be
conducted by the M&C Dte. as per para 1.2 of this procedure. The outcome of the lab
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evaluation shall be communicated to the Track Design Dte. with the recommendations of
the competent authority of M&C Dte.
2.6
In case the results of laboratory evaluation have been found to be satisfactory the firm
shall be approved under Part-I by the Track Design Dte. in consultation with M&C for a
further period of three years.
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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
RESEARCH DESIGNS & STANDARDS ORGANISATION
APPLICATION FORM FOR REGISTRATION/RENEWAL
OF REGISTRATION WITH RDSO FOR SUPPLY OF MICRO-FLOW METAL SPRAY
POWDER TO INDIAN RAILWAYS
(To be prepared in duplicate)
Important :
This form is to be used for :
i)
Fresh registration in case of all the firms.
ii)
Renewal of registration for firms wherever necessary.
SECTION-I : GENERAL INFORMATION
1.
1.1
Name of the firm
Postal address:
i)
Head Office
ii)
Works/Factory
:
:
:
1.2
Telephone no. (with STD Code):
i)
Head Office
:
ii)
Works/Factory
:
1.3
E-mail/Fax Nos. :
i)
Head Office
ii)
Works/Factory
2.
:
:
Description of Factory/Works :
i)
Total land area (sq. mtrs.)
ii)
Total covered area
iii)
Different sub-units
iv)
Special features, if any
:
:
:
:
3.
Location
About____kms from _________Rly.Stn.
4.
Ownership Status (Lease deed, Article of
Memorandum etc. enclose copy) :
5.
Number of personnel employed
(Category-wise, with their qualification,
experience, duration of employment –
attach separate sheet in tabular form) :
i)
Managerial
:
ii)
Supervisory
:
iii)
Skilled/Artisans
:
iv)
Unskilled
:
6.
No. of shifts & weekly closed day
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:
:
7.
Hours of Works (both shifts)
8.
Please state whether this application
is for fresh registration or renewal of
registration? If it is for renewal, please
give details of last registration :
i)
Registration No. & Date
:
ii)
Date of expiry
:
9.
Financial standing of Company
:
(Attach audited balance sheet and
profit & loss account for past 3 years). :
10.
In case you have got more than one unit in
the same name or any other name give their
names and postal address.
11.
Name of sister concern, if any
:
12.
Status/item for which approval sought
:
13.
If application is for renewal of
registration, state whether any
additional items have been requested
for inclusions.
:
14.
Bankers reference certificate
:
15.
Current status of IT Clearance
Certificate (Attach copy).
:
16.
ISO-9000 Certificate status
(Attach photocopy).
:
17.
Present capacity of production
(per month) of item concerned.
:
Section-II
:
Technical Information
(Infrastructure for Production and Quality Control - Minimum requirements)
1.
Description of different departments
in the factory / works:
2.
Function of each department emphasising
production and quality control:
3.
Brief details of manufacturing process (es)
for the store(s), for which registration is sought :
Brief details of Quality Control facilities
(please submit a write up on QAP in ISO format
indicating source of raw materials, steps taken to
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ensure their quality, online inspection, routine
statistical inspection, documentation and record
keeping etc.. Rejection route of the powder found
unsatisfactory should be clearly indicated.)
4.
Manufacturing Facilities :
Items
No. Available & details
4.1
Atomising Chamber
4.2
Induction melting furnace
4.3
Vacuum Dryer
4.4
Sieving / Sizing Equipment
4.5
Dry Blender
4.6
Weighing Machine
5.
Packing Arrangement:
5.1
State whether shrink wrapping and
locking of the module lid is possible or not :
5.2
Type of module and the capacity of the same
5.3
State whether arrangement is available to keep
the contents of the module moisture free, like Silica Gel etc..
6.
Marking:
State whether available on the module
as per RDSO’s instructions.
7.
YES / NO
YES / NO
Quality Control:
General:
7.1
IS / BS sieves set
7.2
A standard Torch with proper powder delivery system and safety
checks as per RDSO’s specification no. M&C/W/103-2003.
7.3
Standard Oxygen and Acetylene Cylinders with Gas pressure
regulators.
7.4
Two stage Gas regulators with high pressure hose pipes.
7.5 Thermal-chalks / Contact Type Thermocouples /Pyrometers for
measuring preheating temperatures (2000C, 2500C, 3000C, and 3500C.)
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No. Available &
details
7.6
Ball Pen Hammers ½ Kg weight
7.7
7.8
Chipping hammer
SS wire brush
7.9
Eye protector goggles
7.10 Filler gauge set with 10cm straight edge scale.
7.11 Magnifying glass
7.12 Dye penetrant test kit (cleaner, dye and developer)
7.11
File
7.12
Portable grinder
7.13 Hand gloves
7.14 Spark Lighter
7.15 Generators
7.16 Safety device(as per Specification No.M&C/W/103)
7.17 Protective cloth apron
7.18 Templates of Rail Heat (different rail section)
7.19 Spherometer
8.
Testing:
8.1
Hardness Testing Machine ( Brinell / Vicker’s / Rockwell)
8.2
Optical Microscope
8.3
Carbon Sulphur determination apparatus with transformer, furnace,
oxygen cylinder and other accessories
8.4
Oxygen Analyser (for raw material testing to control oxygen level)
8.5
Muffle furnace with automatic temperature control
8.6
Hot plates
8.7
Electric Oven
8.8
Barometer
8.9
Hygrometer
8.10 Water Distillation plant
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No. Available &
details
8.11 Platinum crucible
8.12 Burettes, Desecrator, Measuring cylinder, washing bottles, funnel,
beakers, filter papers, silica crucible, and other glass wares and
chemicals of Analytical Reagents quality sufficient to analyse the
elements relevant to the production range.
8.13 Any other relevant facilities
Note :
(1)
Availability of the following shall be considered advantageous special facilities for exercising
good Quality Control Measures
• Vacuum Emission Spectrometer
• Carbon + Sulphur analyzer
• Flame spraying equipment
(2)
All the equipment, wherever necessary should be properly calibrated and current calibration
certificates should be attached as a proof.
UNDERTAKING
I / We undertake that information given above are true to the best of my / our knowledge. We
understand that if during inspection / on some other later date, these are found to be incorrect, the firm will
not be approved / approval will be withdrawn.
I / We also undertake to maintain routine inspection to ensure consistent quality. In case of
customer complaint regarding poor quality of supply or non-adherence to delivery schedule causing
inconvenience to consignee, approval of the firm will be summarily rejected and it will be debarred from
reapplying for the approval for at least 2 years from the date of withdrawal of approval.
Place:
Date:
Signatures of authorised signatory
Name (in Capital letters)________________
Designation__________________________
Stamp of the firm applying for registration
NOTE :
1) Please read procedure for approval and re-assessment of Microflow Spray Powder for reconditioning
of scabbed / wheel burnt and for cupped AT weld joints before filing up the application form.
2) Where the space provided against any item is insufficient, the information should be furnished on a
separate sheet of paper which should be appended to this form and marked in appropriate place.
D:\for_web\Expression of Interest for Powder.doc
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
RESEARCH DESIGNS & STANDARDS ORGANISATION
QUESTIONNAIRE FORM IN CONNECTION WITH ASSESSMENT OF MICROFLOW POWDER
1)
Name & Address of Manufacturer :
2)
Particulars of the brand offered for
assessment (Please enclose technical
leaflet.)
a) Name of Brand
:
b) AWS Specification and code no. :
3)
Whether offered for initial or periodic
assessment :
4)
Gas Pressure requirement (Min.)
Initial / Periodic
a) For Oxygen Gas :
c) For Acetylene gas :
5)
Whether any torch of standard make can be used
or it is a tailor made one, i.e. company made only :
6)
Minimum deposition in thickness :
7)
Deposition efficiency :
8)
Whether the brand has been approved by
NTH / BIS / LLOYDS Shipping or other approving
agency, if yes, submit, a copy of approval certificate :
9)
Whether the brand offered is in regular production
if yes, please indicate average annual production
Metric Tonnes
10)
Price per Kg (for information & cost economy purpose)
:Rs.
11)
Whether the offered brand in being checked
at periodic intervals for production control, If
yes, please furnish batch test certificates which
should contain the following –
D:\for_web\Expression of Interest for Powder.doc
per kg
a) Name of the brand
:
b) AWS specification and code no., :
if any
c) Tap Density
:
d) Grain size distribution
:
e) Chemical composition
:
f) Hardness:i) With 3.00mm deposit
ii) With 2 layer deposit on mild
steel plate (IS:2062)
12)
Special characteristics / recommendations for the powder,
if any. Please enclose technical leaflet of the brand
(Strike out which ever is not applicable)
Place :
Date :
__________________
D:\for_web\Expression of Interest for Powder.doc
Signature
Designation
Company’s Seal
Government of India
Ministry of Railways
Guidelines for
Infrastructural, manufacturing, work execution, testing & quality control requirements
for
Micro flow Spray Powder for reconditioning of scabs, wheel burns of
Rails and Cupped A.T. weld Joints.
(R&D Project)
M&C Directorate
Research Designs & Standards Organisation
Manak Nagar, Lucknow – 226 011
(Price Rs.800/-)
D:\for_web\Expression of Interest for Powder.doc
SPECIFICATION FOR RECONDITIONING
OF SCABS, WHEEL BURNS OF RAILS AND CUPPED A.T. WELD
RAIL JOINTS BY SPRAY POWDER WELDING TECHNIQUE
( Specification No.M&C/W/103-2003)
0.
Foreword:
It is a common phenomenon of track that certain shallow surface defects like scabs and
wheel burns develop on rail during service, the occurrence of which is almost
unavoidable. In addition to such problems, many a time cupping occurs on A.T. weld
joints arising out of various reasons. These surface defects create hindrance in smooth
passage of traffic on rails and if allowed to remain there, these may give rise to initiation
of transverse cracks which may propagate further resulting in ultimate catastrophic failure
of rails. Therefore, acute need has, of late, been felt for repairing such defects by means
of a suitable welding technique. Keeping the depth and overall geometry of these defects
powder welding technique has been found to be most suitable for such reclamation. A
number of laboratory tests followed by actual service trials have successfully been
conducted and a methodology evolved.
0.1
However, an important point of caution is to be taken care of and that relates to deep
scabs and wheel burns i.e. beyond 3 mm depth. Reconditioning, at least by powder
welding is not recommended and such problems are to be taken up separately.
0.2
For the purpose of deciding whether a particular requirement of this standard
is complied with, the final value, observed or calculated, expressing the result
of a test or analysis, shall be rounded off in accordance with IS:2-1960
(Revised) – Rules for rounding off numerical values. The number of
significant places retained in the rounded of value, should be the same as that
of the specified value in this standard.
1.
Scope:
It covers the technical requirements for the technique which shall be applicable for
reconditioning of wheel burns, scabbings and cupping of rail joints and any other shallow
surface defects upto 3 mm depth for all rails covered under IRS:T-12-94 and A.T. weld
joints covered under IRS:T-19-94. Depending upon the size and shape of a defect, extent
of spread of powder may be the entire width* of rail head.
*Note: For reconditioning a defective spot on rail head, especially when shape and size is
large, surface preparation by grinding has to be done mostly over the entire width
for an effective bonding of powder with parent metal. Therefore, whole width
should be covered.
D:\for_web\Expression of Interest for Powder.doc
Specification No. M&C/W/103-2003)
2.
Requirement:
The surface defects as mentioned above when reconditioned by using the technique shall
be capable to serve without any significant wear, chipping & flaking off, cracking etc. for
a minimum of 25 GMT.
3.
Chemical Composition:
Normally, it should be a Nickel based alloy with strong carbide/boride former so as to get
a tough matrix with finely dispersed hard intermetallic carbides/borides. This gives very
good wear resistance with good impact
resistance. The formulation of the chemical composition of the alloy powder is basically
the prerogative of the manufacturer. However, the following basic
elements form the basic composition of the actual powder and as such their presence or
otherwise shall be checked:Elements to be checked – Carbon, Boron, Silicon, Iron, others and Nickel (balance).
4.
Mechanical & Physical Properties:
The sprayed weld deposit shall be sound, free from welding defects like porosities, blow
holes and other defects. It shall have satisfactory bonding with base metal.
The weld metal shall possess the following mechanical and physical properties:
i)
Hardness
(as deposited)
-
Rc 24 – 35
ii)
**Tap Density
-
7.5 – 8.5 gms/cc (min.)
iii)
Deposition Efficiency -
45% (min.)
iv)
Macro Examination
-
The spread weld deposit shall be sound and
porosity free with satisfactory bonding with base material
(to be inspected by sectioning the job)
v)
Micro Structure
-
The micro structure should show inter-metallic
Carbide & Boride compounds distributed in Nickel alloy
matrix.
vi)
**Average co-efficient
of thermal expansion.
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-
15.55 x 10 –4 cm/cms/0 C
( Specification No. M&C/W/103-2003)
vii)
**Limitations of depth
The powder should be able to be
deposited at a thickness of 0.075 mm (max.) in
a single pass.
Maximum thickness of deposit shell be 3 mm.
viii)
**Powder Grain Size
ASTM Mesh #
+100
-100 + 140
-140 + 325
- 325
**Note:
-
Nil
5% max.
Balance
30 to 50%
These tests are to be verified in the manufacturer’s premises at the time of
initial/periodic inspection for related approval only. These are not
applicable in checking of bulk supply.
5.
Equipments/Tools:
a)
Details of Powder Delivery System:
The system consists of specially designed oxy-acetylene torch with powder delivery
hopper or module to meet its specific requirement. The system should consist of
following safety checks:
i)
Quick shut – off lever which cuts the supply of gases to the torch.
ii)
Proper arrangement to avoid excess heating in the torch which causes
fusion of nozzles thus blocking the passage of gases.
iii)
Longer blow pipe to keep the operator at safe and comfortable distance
while working at higher flame setting for thicker deposition.
iv)
Heat shield for maximum protection at different working angles.
NOTE: A standard torch developed by any manufacturer taking care of safety
measures as per Clause 6 of this specification may be used for this purpose. The torch
may have different nozzles operating under different oxygen and acetylene pressure to
suit different types of jobs. The firm’s instructions in this regard may be consulted for
guidance.
b)
Standard oxygen and acetylene cylinders only. No alternate gas such as LPG etc. should
be used.
D:\for_web\Expression of Interest for Powder.doc
( Specification No.M&C/W/103-2003)
c)
Two stage gas regulators with high pressure hose pipes.
d)
Thermal-chalks/Contact Type Thermocouples/Pyrometer for measuring preheating
temperatures 200 C, 250 C, 300 C and 350 C.
e)
Hammers and S.S. wire brush.
f)
Eye protector goggles.
g)
Filler gauge set with 10 cm straight edge scale.
h)
Magnifying glass
i)
Dye penetrant test kit (cleaner, dye developer)
j)
File
k)
Portable grinder
l)
Hand gloves
m)
Spark lighter
n)
Generators
NOTE: Operating Manual of the torch manufacturer should be referred to and strictly followed.
6.
Safety Measures:
The above process involves oxy-acetylene gas, the hazardous nature of which
can cause many serious accidents, if proper safety measures are not used. There is always a
danger of leaking hoses, cylinders and even torches, therefore suitable device such as ‘Flash
Back Arrester’ must always be used to check such accidents. The salient features of
requirements of the same are given in Annexure-I of this specification.
7.
Execution of Work:
The defective spots viz. scabs and wheel burns on rails and cupped A.T. weld joints shall
be reconditioned by trained welder(s) of the manufacturer under their own supervision.
The total work shall be executed by the manufacturer on '‘Turn Key Basis’ and the
manufacture shall have to stand a guarantee for the satisfactory performance of the
reconditioned spots for a minimum of 25 GMT when evaluated on the basis of clause 8 of
this specification.
D:\for_web\Expression of Interest for Powder.doc
( Specification No.M&C/W/103-2003 )
8.
Performance & Acceptance Criteria:
In addition to the tests laid down earlier in this specification, the service trial
shall be carried out and the performance shall be evaluated as below:
8.1
The reconditioned spots shall earn minimum 25 GMT satisfactorily with:
No surface defects
No metal chipping
No cracks, and
No appreciable wear (not exceeding 0.1 mm) when measured with a filler gauge and a 10
Cm straight gauge.
8.2
The reconditioned spots shall be reasonably smooth.
NOTE: Field service trial is not applicable in periodic approval and also in
bulk supply. But the manufacturer shall give a guarantee for satisfactory
performance upto a minimum of 25 GMT.
9.
Re-test:
In case a maximum of one reconditioned wheel burnt/scabbed and/or one cupped A.T.
weld joint fails on the basis of acceptance criteria, this clause shall be applied for
evaluation of performance before arriving at the final decision. Double the number i.e.
two spots shall again be reconditioned and subsequently monitored and finally inspected
following the entire same procedure afresh. Consequently both such spots must pass,
only then the trial shall be considered to be successful. If any one of these two spots fails,
the trial shall be considered to be unsuccessful and the product shall be rejected.
10.
Packing:
The powder shall be contained in suitable air tight plastic modules/hoppers capable of
being attached to the body of torch and to be fed for subsequent use for reconditioning.
Suitable arrangement shall be made to keep the contents moisture free like keeping Silica
Gel in the lid of the module.
11.
Marking:
The container (module) shall be marked with the manufacturer’s name, brand name, batch
number and the date of manufacture and any other information deemed necessary by the
manufacturer.
D:\for_web\Expression of Interest for Powder.doc
ANNEXURE – I to Specification No.M&C/W/103-2003
The salient features of requirements for Flash Back Arrestors
Cylinder End – Oxygen & Fuel Gas
1.
Dry type with Filter, Non return valve, flame arrestor & automatic thermal
gas cut out.
2.
Suitable for Inlet pressure of Oxygen: 20 bars, Acetylene: 1.5 bars,
Hydrogen: 3.5 bars, LPG: 5.0 bars.
3.
Flow rate: 31.35 cu meter/hour at 5.0 bar for oxygen & 12.6 cu meter for
DA at 1.5 bar.
4.
BAM* approved & certificate to be given before supply.
5.
Connection: as per BSP standards (British Standards for Piping) .
6.
All aspects of manufacturing to be as per EN 730** of BS.
7.
Minimum ISO 9001 manufacturing company.
8.
Gas flow direction to be indicated on each Flash back arrestor.
9.
The working manual to be enclosed in each packing.
Label:
Oxygen blue and fuel gas red.
Threading: Oxygen 3/8 inch, right hand, fuel gas 3/8 inch left hand.
Torch End
1.
Cylinder End – Oxygen & Fuel Gas.
2.
Dry type with Filter, Non return valve & flame arrestor.
3.
Suitable for Inlet pressure of Oxygen: 20 bars, Acetylene: 1.5 bars,
Hydrogen: 3.5 bars, LPG: 5.0 bars.
4.
Flow rate: 21.85 cu meter/hour at 5.0 bar for oxygen & 8.67 cu meter for
DA at 1.5 bar.
D:\for_web\Expression of Interest for Powder.doc
ANNEXURE – I to Specification No.M&C/W/103-2003
5.
BAM* approved & certificate to be given before supply.
6.
Connection: as per BSP standards (British Standards for Piping) .
7.
All aspects of manufacturing to be as per EN 730** of BS.
8.
Minimum ISO 9001 manufacturing company.
9.
Gas flow direction to be indicated on each Flash back arrestor.
10.
The working manual to be enclosed in each packing.
Label:
Oxygen blue and fuel gas red.
Threading: Oxygen 3/8 inch, right hand, fuel gas 3/8 inch left hand.
* The Federal Institute for Materials Research and Testing (BAM) is a technical and
scientific senior federal institute under the authority of the Federal Ministry of Economics
and Labour, (Germany).
** Gas Welding equipment, equipment used in gas welding, cutting and allied process,
safety devices for fuel gases and oxygen or compressed air. General specification
requirements and tests.
Important Note: If required, the manufacturer will have to arrange practical
demonstration of working of the Flash Back Arrestor before the consumer to its full
satisfaction.
D:\for_web\Expression of Interest for Powder.doc