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INSPECTION OF RAW MATERIALS FOR ELASTIC RAIL CLIPS& FINISHED ERC AND CHECKING OF SERVICEABLITY OF ERC’s A presentation by:- Shri A.N.Sinha ATSO/HQ/E.Rly,Kolkata.

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Presentation on theme: "INSPECTION OF RAW MATERIALS FOR ELASTIC RAIL CLIPS& FINISHED ERC AND CHECKING OF SERVICEABLITY OF ERC’s A presentation by:- Shri A.N.Sinha ATSO/HQ/E.Rly,Kolkata."— Presentation transcript:

1 INSPECTION OF RAW MATERIALS FOR ELASTIC RAIL CLIPS& FINISHED ERC AND CHECKING OF SERVICEABLITY OF ERC’s A presentation by:- Shri A.N.Sinha ATSO/HQ/E.Rly,Kolkata Md. Mahamud Alam AXEN/CON/ADA/SE.Rly. Shri C.P.Raikwar AXEN/LM/HQ/WCR. under the guidance of Prof. A.K.Gupta.IRICEN

2 Scope * Indian Railway gradually transshipped from conventional system of maintenance to quality maintenance to suit the need of present day. * Indian Railway gradually transshipped from conventional system of maintenance to quality maintenance to suit the need of present day. * LWR & CWR is inevitable to suit the present demand. * LWR & CWR is inevitable to suit the present demand. * Function of LWR & CWR mainly depends upon i ) Ballast resistance. * Function of LWR & CWR mainly depends upon i ) Ballast resistance. ii) Toe load. ii) Toe load. * Elastic Rail Clip is the best design for the required toe load. * Elastic Rail Clip is the best design for the required toe load.

3 Types of ERC: At present three types of ERC’s are in vogue : At present three types of ERC’s are in vogue : 1ERC MK III - Toe load of 850 Kg Kg. 2ERC ‘J’ Clip - Used at joint sleeper having Toe load OF 300 Kg 3Anti-theft ERC- Used in theft prone area. Toe load of 850 Kg Kg 4ERC MK V -These are in trial stage Toe load 1200 Kg – 1500 Kg.

4 Functions of ERC : With stand vibrations induced in track With stand vibrations induced in track Sustain static and dynamic cyclic stresses. Sustain static and dynamic cyclic stresses. Provide creep and tortional resistance and keeps rail in position Provide creep and tortional resistance and keeps rail in position Able to resist lateral forces Able to resist lateral forces Reduces co-efficient of dynamic augmentation. Reduces co-efficient of dynamic augmentation. Longer life and economic maintenance. Longer life and economic maintenance.

5 INTRODUCTION TO ERC Mk-III Elastic Rail Clips (ERC Mk-III) Elastic Rail Clips (ERC Mk-III) Specification : IRS:T Specification : IRS:T Raw Material : mm dia. Silico manganese Raw Material : mm dia. Silico manganese steel to Gr. 55-Si7 steel to Gr. 55-Si7 Drawing No. : RDSO/T-3701 (Alt.4) Drawing No. : RDSO/T-3701 (Alt.4) Gauge Drg. No. : RDSO/T-3745 & 3746 Gauge Drg. No. : RDSO/T-3745 & 3746

6 DESIRED CHARACTERISTICS OF ERC MK III TO RDSO DRG. NO T-3701 APPROX. WEIGHT 910 gms HARDNESS RC MINOR AXIS 9.5 mm MAJOR AXIS 28.0 mm DEFLECTION 13.5 mm TOE LOAD Kg

7 INSPECTION OF RAW MATERIALS SPECIFICATION:- Silico Manganese Spring Steel of Silico Manganese Spring Steel of Grade 55 – Si7 confirming to IS :3195 of 20.64mm dia(+0.20mm to mm). Grade 55 – Si7 confirming to IS :3195 of 20.64mm dia(+0.20mm to mm). For ERC MK-V dia 23.00mm. For ERC MK-V dia 23.00mm. Hardness : 270BHN. Hardness : 270BHN. depth of decarburisation: Max.IS: depth of decarburisation: Max.IS: Inclusion rating : IS: Inclusion rating : IS: A : 2.5 Max (sulphides) B: 2.5 Max(alumina) A : 2.5 Max (sulphides) B: 2.5 Max(alumina) C : 2.5 Max (silicates) C : 2.5 Max (silicates) D : 2.5 Max (oxides) D : 2.5 Max (oxides) Grain size:- 6 or finer as per IS Grain size:- 6 or finer as per IS

8 SPECIFICATION OF RAW MATERIALS Chemical compositionIS:228 Chemical compositionIS:228 % Tolerance % Tolerance Carbon 0.50 to 0.60% ± 0.03% Silicon 1.50 to 2.0% ± 0.03% Manganese 0.80 to 1.0% ± 0.04% Sulphur 0.04% (max) ± 0.005% Phosphorus 0.04% (Max) ± 0.005%

9 QUALITY CHECKS Silico manganese spring steel round are to be procured by the supplier from Rashtriya Ispat nigam limited (VSKP) as per RDSO’s guideline (test certificates of production unit i.e from RINL/VSKP)Silico manganese spring steel round are to be procured by the supplier from Rashtriya Ispat nigam limited (VSKP) as per RDSO’s guideline (test certificates of production unit i.e from RINL/VSKP) Before actual production of ERC the raw material will be tested as follows:Before actual production of ERC the raw material will be tested as follows: a) Dimensionally. (Heat wise) b) Chemically. (Heat wise) c) Metallurgically. c) Metallurgically.

10 Testing of Raw Materials 20 nos. of bars shall be checked for dimension as per heat wise, and to be compared with test certificates (supplier: RINL/VSKP) and Technical specification.20 nos. of bars shall be checked for dimension as per heat wise, and to be compared with test certificates (supplier: RINL/VSKP) and Technical specification. 2 nos. of bars chemically tested either in laboratory or by spectrometer heat wise. Micro structure of two nos. of bars are to be checked for : (a) ‘D’ curb i.e. loss of carbon (b) Inclusion rating i.e. A, B, C, D2 nos. of bars chemically tested either in laboratory or by spectrometer heat wise. Micro structure of two nos. of bars are to be checked for : (a) ‘D’ curb i.e. loss of carbon (b) Inclusion rating i.e. A, B, C, D These result will be compared with test certificates and technical specifications.These result will be compared with test certificates and technical specifications.

11 PRODUCTION PROCESS Heat wise stacking:- The bars shall be stacked heat wise.Heat wise stacking:- The bars shall be stacked heat wise. Cutting/Shearing:-The bars shall be cut, squared and chamfered in proper length i.e. 350mm +1.5mm to – 0 mm and the same are to be kept in proper way in front of heating furnace heat wise.Cutting/Shearing:-The bars shall be cut, squared and chamfered in proper length i.e. 350mm +1.5mm to – 0 mm and the same are to be kept in proper way in front of heating furnace heat wise. Heating in Furnace:- The cut bars shall be heated systematically at a controlled temp of 900 °c to 950 °c. Temperature monitoring recorder shall always in working order during operation.Heating in Furnace:- The cut bars shall be heated systematically at a controlled temp of 900 °c to 950 °c. Temperature monitoring recorder shall always in working order during operation.

12 PRODUCTION PROCESS Forming of clips:-After completion of heating operation, the ERCs are formed in three stage of strokes.Forming of clips:-After completion of heating operation, the ERCs are formed in three stage of strokes. Quenching:- After forming the ERCs the same is to pass through Quenching oil tank through conveyor belt for a period of 12 minutes at a temp of 70 ◦ c(max). After taking out of bars from heating furnace to dipping in the quenching oil (including ERC forming), the time specified is 20 seconds (max). The quenching oil bath to be cleaned and oil to be filtered at regular interval preferably after production of every one lakh of clips.Quenching:- After forming the ERCs the same is to pass through Quenching oil tank through conveyor belt for a period of 12 minutes at a temp of 70 ◦ c(max). After taking out of bars from heating furnace to dipping in the quenching oil (including ERC forming), the time specified is 20 seconds (max). The quenching oil bath to be cleaned and oil to be filtered at regular interval preferably after production of every one lakh of clips.

13 PRODUCTION PROCESS Tempering:- After quenching operation the ERCs shall be passed through tempering furnace with automatic temperature control device and continuous temperature recorder at a temp of 400 ◦ c to 500 ◦ c for a period of minutes. Auto cut is to be provided for keeping the temp in the permissible limit. A graphical chart shall be maintained.Tempering:- After quenching operation the ERCs shall be passed through tempering furnace with automatic temperature control device and continuous temperature recorder at a temp of 400 ◦ c to 500 ◦ c for a period of minutes. Auto cut is to be provided for keeping the temp in the permissible limit. A graphical chart shall be maintained. Application test:- All the ERCs so produced shall pass through an application test.Application test:- All the ERCs so produced shall pass through an application test.

14 PRODUCTION PROCESS Oiling:- All the ERCs manufactured and tested shall be oiled before packing. Oiling:- All the ERCs manufactured and tested shall be oiled before packing. Packing:- ERCs shall be packed in double plastic/gunny bags and stitched with knotless thread and sealed. Each bag contain 50 nos of ERC’s. Packing:- ERCs shall be packed in double plastic/gunny bags and stitched with knotless thread and sealed. Each bag contain 50 nos of ERC’s.

15 Stage inspection during production Check two clips after hardening in the oil bath for dimension in the standard gauge to RDSO Drg No T-3746 in every one hour from the running production and to be recorded. Check hardness of the above two clips every one hour and record the observation and see that the result are consistent.Check two clips after hardening in the oil bath for dimension in the standard gauge to RDSO Drg No T-3746 in every one hour from the running production and to be recorded. Check hardness of the above two clips every one hour and record the observation and see that the result are consistent. Check the stamping on the product (ERC) is clearly readable.Check the stamping on the product (ERC) is clearly readable. Use the raw material of the second heat only when the cut bars of first heat fully consumed.Use the raw material of the second heat only when the cut bars of first heat fully consumed.

16 Marking on heel of clips and packing and sealing All clips shall bear clear identification mark. As per example LG 6/5 it means LG=Manufactures code given by RDSO,6= last digit of the year of manufacture and 5= lot noAll clips shall bear clear identification mark. As per example LG 6/5 it means LG=Manufactures code given by RDSO,6= last digit of the year of manufacture and 5= lot no Before packing the clips shall be protected with one coat of boiled linseed oil. After inspection the bags to be sealed with lead seal with identification mark of the Inspecting official.Before packing the clips shall be protected with one coat of boiled linseed oil. After inspection the bags to be sealed with lead seal with identification mark of the Inspecting official.

17 Final inspection Random sampling as per specification shall be collected, if the sample are failed in any of the test, double sample is to be drawn, if doubled sample failed, the lot to be rejected.Random sampling as per specification shall be collected, if the sample are failed in any of the test, double sample is to be drawn, if doubled sample failed, the lot to be rejected. Following test to be carried out:-Following test to be carried out:- Application & deflection 100% of the sample size.Application & deflection 100% of the sample size. Gauging 100% of the sample size.Gauging 100% of the sample size.

18 Final inspection Contd. Sampling:-Sampling is to be drawn as per IS2500,generally double sampling method adoptedSampling:-Sampling is to be drawn as per IS2500,generally double sampling method adopted Lot size/ heat wise ( in Nos) Code sampleSize cumulative Acceptance Rejection Up to 3000 K First Second Second to 10000L First Second Second to 35000M First Second Second to N First Second Second

19 Final inspection Contd. Hardness: 100% of the sample SIZE in RC method, value should be 40 to 44.Hardness: 100% of the sample SIZE in RC method, value should be 40 to 44. Toe load: 100% of the sample SIZE, value should be within 850Kg to 1100 Kg for ERC MK- III.Toe load: 100% of the sample SIZE, value should be within 850Kg to 1100 Kg for ERC MK- III. Calibration of Hardness & Toe load machine to be checked and the validity of the machine is also to be checked.Calibration of Hardness & Toe load machine to be checked and the validity of the machine is also to be checked. Major axis and Minor axis of the ERC i.e. flat surface/contact area to be checked. major axis min 28.5mm, minor axis 9.5mm and deflection 13.5 mm.Major axis and Minor axis of the ERC i.e. flat surface/contact area to be checked. major axis min 28.5mm, minor axis 9.5mm and deflection 13.5 mm.

20 Final inspection Contd. Chemical composition:- One sample to be checked per lot per heat, value should be as stated above mentioned in Raw materials.Chemical composition:- One sample to be checked per lot per heat, value should be as stated above mentioned in Raw materials. D ’ curb to be checked 5% of the sample size. value within 0.25%.D ’ curb to be checked 5% of the sample size. value within 0.25%. Inclusion rating to be checked 5% of the sample size. value should be within 2.5 of A,B,C,D as specified in the Raw material.Inclusion rating to be checked 5% of the sample size. value should be within 2.5 of A,B,C,D as specified in the Raw material.

21 Placing/Maintenance of ERC Hammer driving is prohibited. mechanical device to be used. Hydraulic clip applicator and extractor to be used. It should be driven in such a way so that end of central leg flushes with the outer face of insert to achieve required toe load.Hammer driving is prohibited. mechanical device to be used. Hydraulic clip applicator and extractor to be used. It should be driven in such a way so that end of central leg flushes with the outer face of insert to achieve required toe load. ERC is susceptible for static load and hence loose packing is prohibited.ERC is susceptible for static load and hence loose packing is prohibited.

22 Placing/Maintenance of ERC Contd. Rotation of central leg is inevitable to reduce the stress on deflection during service, hence greasing on central leg and insert is must to avoid seizure. as per IRPWMRotation of central leg is inevitable to reduce the stress on deflection during service, hence greasing on central leg and insert is must to avoid seizure. as per IRPWM Once in Two years in ordinary area.Once in Two years in ordinary area. Once in a year in corrosive prone area.Once in a year in corrosive prone area. Grease to IS sleepers should be done by Key man daily.Grease to IS sleepers should be done by Key man daily.

23 Placing/Maintenance of ERC Contd: ERC is susceptible for static load, hence loose packing is prohibited ERC is susceptible for static load, hence loose packing is prohibited Eye estimation for Toe load is not possible, hence Toe load testing is inevitable, Eye estimation for Toe load is not possible, hence Toe load testing is inevitable, Frequency;-Four years or passage of 200 GMT which ever is earlier and Two years or 100 GMT which ever is earlier in non- corrosive or corrosive prone area respectively. Frequency;-Four years or passage of 200 GMT which ever is earlier and Two years or 100 GMT which ever is earlier in non- corrosive or corrosive prone area respectively.

24 Placing/Maintenance of ERC Contd: Sample size:- one presentSample size:- one present if 20% or more of sample size records toe load below 600KG but >400KG both frequency and sample size to be double.if 20% or more of sample size records toe load below 600KG but >400KG both frequency and sample size to be double. If <400KG to be confirmed by 5% sample size proposal for Through fastening Renewal (TFR) to be initiated.If <400KG to be confirmed by 5% sample size proposal for Through fastening Renewal (TFR) to be initiated.

25 ANTI -THEFT ERC RDSO DRG NO T-6254 & T-6255 IT IS MAINLY USED IN THEFT PRONE AREA.ONLY DIFFERENCE IS THAT THE CENTRAL LEG IS SOME HOW LONGER THAN MK III FOR PROVISION OF CIRCLIP AS PER DRG NO T-6255.THE CIRCLIP IS TO BE MANUFACTURE FROM SILICO MANGANESE SPRING STEEL TO GRADE 55 Si 7IT IS MAINLY USED IN THEFT PRONE AREA.ONLY DIFFERENCE IS THAT THE CENTRAL LEG IS SOME HOW LONGER THAN MK III FOR PROVISION OF CIRCLIP AS PER DRG NO T-6255.THE CIRCLIP IS TO BE MANUFACTURE FROM SILICO MANGANESE SPRING STEEL TO GRADE 55 Si 7

26 CONCLUSION BEST QUALITY STANDARDS CAN BE ACHIVED THROUGH:BEST QUALITY STANDARDS CAN BE ACHIVED THROUGH: > CONSCIOUS MONITORING AT VARIOUS MANUFACTURING STAGES > TESTING DESIRED PARAMETERS AS PER FREQUANCY > MAKING SHOP FLOOR WORKERS CONSCIOUS OF THE QUALITY OF END PRODUCT > ADOPTING CORRECT METHOD OF INSPECTION > To achieve the game training of officials at every capital level is inevitable.

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31 THANK YOU

32 INSPECTION OF RAW MATERIALS FOR ELASTIC RAIL CLIPS& FINISHED ERC AND CHECKING OF SERVICEABLITY OF ERC’s A presentation by:-A presentation by:- Shri A.N.Sinha ATSO/HQ/E.Rly,KolkataShri A.N.Sinha ATSO/HQ/E.Rly,Kolkata Md. Mahamud Alam AXEN/CON/ADA/SE.Rly.Md. Mahamud Alam AXEN/CON/ADA/SE.Rly. Shri C.P.Raikwar AXEN/LM/HQ/WCR.Shri C.P.Raikwar AXEN/LM/HQ/WCR. under the guidance of Prof. A.K.Gupta.IRICENunder the guidance of Prof. A.K.Gupta.IRICEN


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