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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 regular production, 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 of prototype 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

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 measuring system 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.

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 advance so as to enable him to witness sampling of molten steel at different stages for chemical analysis and shall furnish details of charge, pouring temperature 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.

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 witness the 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, drawing number, 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. STAGES OF INSPECTION 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.

9.4 9.4.1

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 further purchase 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

Sr.no Stage of Offer memo no Condition for signing the offer memo Inspectio of Annexure II by RDSO inspecting official. n to be presented by firms Quality In charge to RDSO inspecting official by the firm 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, satisfactory machining, Straightening, Dye penetration test. Magnetic test, Satisfactory Radiography test results and Gross dimensional check. 4 Stage Offer Memo 7 1. Checking satisfactory -IV Straightening including DPT. 2. Detailed Dimension checking using approved gauges. 3. Satisfactory Quality (dimension,

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 AppendixII 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. Stage of Offer memo no Condition for signing the offer memo Inspectio of Annexure by RDSO inspecting official. n IIA to be presented by firms Quality In charge to RDSO inspecting official by the firm Stage-I Offer Memo 1 1. After verifying chemistry by witnessing 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. Stage-II Offer memo 2 1. After satisfactory heat treatment and shot blasting, satisfactory surface and gross dimension checking . 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

Sr.n o

Stage-III

Offer memo 2A

Stage -IV Offer memo 3

Straightening including DPT. 3. Satisfactory Quality(dimension, metallurgical)of components/fittings being supplied with CMS Crossing. 4. Observing satisfactory dimension 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. 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. 1. No unauthorized welding has been done. 2. After satisfactory Straightening, maching Dye penetration test. Magnetic test, Satisfactory Radiography test results. 3. Detailed Dimension checking using approved gauges. 4. Satisfactory Quality (dimension & ,metallurgical) of components/fittings being supplied with CMS Crossing 5. Satisfactory checking of all records pertaining to previous inspections. 6. Detailed Dimension checking using approved gauges. 7. Satisfactory Quality (dimension, metallurgical) of

components/fittings being supplied with CMS Crossing. 8. Satisfactory checking of all records pertaining to previous 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 in Appendix-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 mark shall be straight away rejected. 9.5.3 The crossing shall be checked for gross dimensions and discrepancies shall be 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. Metallurgical & Dimensional Inspection (Stage-II)

9.6

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 per corrigendum 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. Surface & Dimensional Inspection (Stage III) (After Removal / Rectification of casting defects only)

9.7

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

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 9.8.1 Final Dimensional check up & Magnetic Test (Stage-IV /Final Stage) 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 The each 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 electromagnet. 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

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. 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. All the inspections offer memos shown in Appendix-II and IIA shall be got printed 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.

14.2

15.1