Sampling & Acceptance Tests as per RDSO approved QAP for individual approved source.
(Ref. RDSO
Letter No. CT/JW/3 Dtd. 01/08/2019)
|
S. No. |
Acceptance Tests |
Sample Size & frequency of inspection |
AQL |
Ref. Cl. No. of QAP |
|
i. |
USFD
of rails (Only Head Hardened portion) |
10% |
If fail
then 100% inspection of rails & failed particular rail/rail piece will be
rejected. |
Cl. 2(A) |
|
ii. |
Hardness
on the top of heat treated portion of rails (Poldy
Hardness tester) |
10% |
If fail
then heat treatment process shall be reviewed. |
Cl. 2(B) |
|
iii. |
MPI
on heat treated portion of rails head |
10% |
If fail
then 100% inspection & failed particular sample will be rejected. |
Cl. 2(C) |
|
iv. |
(a)
Macro(HAZ), (b)
Microstructure, (c)
Hardness Survey & (d)
Tensile Test |
2% |
If fail
then heat treatment process shall be reviewed. |
Cl. 2(D-i) Cl.
2(D-ii) Cl. 2(E) Cl. 2(F) |
(As per Note-5 of QAP, tests mentioned in the QAP shall only to be
carried out.)
Document Verification : a) PO Description to be checked for the specific
Alt. No. of Drg.
b) Rail
Documents (Challan of Rails by Rly./Depot or RITES/CR/Bhilai IC).
c) RDSO
valid approval & new QAP approved by RDSO.
d)
Calibration record of measuring instruments, test equipments & Test
rail.
e)
USFD @100% internal report of New Rails (before head hardening)
&
heat treated portion of rails (after head
hardening) as per Chapter-10 of
RDSO Manual for Ultrasonic Testing of
Rails & Welds, Revised-2012).
f) Heat treatment (head hardening of rails) record/report.
Tests/Checks (to be witnessed/conducted by inspector):-
|
क्र.सं. S.No. |
पैरामीटर Parameter |
निर्दिष्ट मान Value
Specified |
अवलोकन Observations |
टिप्पणी Remarks |
|
(a) |
Visual |
i) Rails shall be free from visual surface
defect i.e. dent, lap, etc.
ii) RI stamp (RITES CR/Bhilai) at end face of
rail shall be verified randomly.
iii) ID
No. to be allocated/ marked (with
paint) on hardened Rails vis-a-vis branding (month/ year) shall be
verified with Internal Inspection Report randomly in spread-out condition.
iv)
Physical verification of Rails (52Kg/m- unhardened rails to be used for
making Check Rails*). |
|
*As per Note-3 of approved QAP, 1st
stage inspection could be carried out without the availability of check rail
as it is non-hardened rail. During final stage inspection availability & internal
USFD report/ documents to be verified by IE. |
|
(b) |
Rail
document’s verification |
Verification
of Challan issued by Zonal Railway/Depot against the subject P.O.
(for which Rails being offered for inspection of ISEJ
in 1st stage). |
|
Rail’s Challan in case Rails provided
by Rly. or IC
issued by RITES/CR/Bhilai in case Rails being directly lifted from SAIL by
the Vendor. |
|
(c) |
Verification
of Length-wise quantity of rails of section UIC 60 & IRS 52Kg |
Requirement
for 01 Set ISEJ:
i) Stock Rail - 02 Nos. (UIC60
Rail Sec. - 6180mm)
ii) Tongue Rail – 02 Nos. (UIC60 Rail Sec. - 6780mm)
iii)
Gap Avoiding Rail – 02 Nos. (UIC60 Rail Sec. - 2380mm)
iv)
Check Rail* – 02 Nos. (52Kg/m Rail Sec. -2700mm) |
|
Quantity of rails to be verified alongwith firm’s offer
list (& it’s Annexure) & for matching Rail’s Challan with physical
availability against the offered sets.
Note- Rail can be cut to length before heat
treatment & marked for identification. |
|
Note:- Combination of 13/12/11m of UIC-60 & 13/12/11m
of 52 Kg rails to be evaluated as per Qty. offered & Rail Challan for
physical verification. |
||||
|
क्र.सं. S.No. |
पैरामीटर Parameter |
निर्दिष्ट मान Value
Specified |
अवलोकन Observations |
टिप्पणी Remarks |
|
(d) |
USFD
testing on heat treated (Head Hardened) portion of Rails
|
No indication of
flaw echo beyond acceptable limits.
i)
Calibration with 300mm long Std. Test Rail
(preferably head hardened) of UIC60 rail section with 03 FBH for sensitivity
setting).
ii) USFD
Testing of Heat treated portion of sampled rail as per Chapter 10 of RDSO Manual for
Ultrasonic testing of Rails & Welds, Revised-2012.
iii) UT to be done by RDSO certified UT personnel (UT Level-II) only.
iv) Threshold at 60% of FSH.
v) Head & web to be scanned from head top
& one side surface and foot from head top. |
|
Ref. Cl. No 2.A of
approved QAP (Table)
(Sample Size: 10%) If fail then 100% inspection of rails & failed
particular rail/rail piece will be rejected.
|
|
|
Hardness |
Hardness
on the top of heat treated portion of rails (By Poldi
Hardness tester)
Hardness:
330-360BHN (for
80mm gap ISEJ) |
|
Ref. Cl. No 2.B of
approved QAP (Table) (Sample Size:10%) If fail then heat
treatment process shall be reviewed. |
|
(e) |
MPT
on Heat treated portion of Rails |
No crack
of surface or subsurface.
i) MPT on Heat treated portion of rail as per
IS:3703/2004.
ii) Magnetizing force of equipment to be
checked using 4.5Kg test weight (max. prods spacing 300mm for AC) or 18Kg
(yoke at poles/legs spacing 150mm max. for HWDC).
iii) Performance/Sensitivity shall be checked by
Magnetic Field Indicator (Pie indicator).
iv) MPT to be done by ASNT Level-II certified MPT personnel only. |
|
Ref. Cl. No 2.C of
approved QAP (Table)
Preferably, standard kit of Wet
Magnetic Particles & White Contrast to be used.
(Sample
Size:10%) If fail then 100% inspection & failed particular sample will be rejected. |
|
क्र.सं. S.No. |
पैरामीटर Parameter |
निर्दिष्ट मान Value
Specified |
अवलोकन Observations |
टिप्पणी Remarks |
|
(f) |
Macro
Examination on
head hardened cross-section of Rails
|
HAZ
distance (on macro-etched cross-section surface) from –
Head
top (b) ≥ 15mm
Side
heads (a & c) ≥ 10mm
|
|
Ref. Cl. No 2.D(i) of approved QAP
(Table) (Sample Size: 2%) If fail then heat treatment process shall be reviewed. |
|
(g) |
Micro
Examination of
head hardened cross-section of Rails |
Microstructure
of head hardened zone (cross-section) shall be Fine Pearlite (without any
formation of Martensite & Bainite) at 100X or 500X magnification. |
|
Ref. Cl. No 2.D(ii)
of approved QAP
(Table) (Sample Size: 2%) If fail then heat treatment process shall be reviewed. |
|
(g) |
Hardness
Survey on
head hardened cross-section of Rails |
Hardness at head
top: 330-360BHN
Hardness on
Cross-Section- At 12mm from head
top: 290-310
BHN At 15mm from head
top: 260-280
BHN Note: The variation
in hardness from top surface to a depth of 15mm shall be gradual. Sudden
variation in hardness of more than 20 BHN/mm shall not be allowed as measured
at every 3mm. |
|
Ref. Cl. No 2.E of
approved QAP (Table)
Hardness
of Std. hardness test block shall be checked before start of test &
continue test at same dwell time between 10 to15 seconds. Ref. IS:1500/ 2005.
(Sample
Size: 2%) If fail then heat treatment process shall be reviewed. |
|
(h) |
Tensile
Test |
Tensile
properties: (head hardened portion of rails)
UTS-
1080 MPa (min.)
0.2%
Proof Stress/YS- 460 MPa (min.)
%Elongation- 10% (min.) |
|
Ref. Cl. No 2.F of
approved QAP (Table)
(Sample
Size: 2%) If fail then heat treatment process shall be reviewed. |
|
(i) |
Marking |
ID
No. with paint on head top of head hardened rails.
|
|
|
|
|
Stage Clearance: Clearance
shall be given, if the rails offered for inspection in 1st stage
found conforming to the specified requirements of relevant specifications
& RDSO approved QAP. |
|||
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