6400mm OVER-RIDING CURVED DERAILING SWITCH FOR 1 IN 8.5 TURNOUT B.G. (1673MM) FOR 52 KG -UIC- RT- 8153, RT- 4866 & RT- 5836
1. Specification /Drawing: RDSO Drg. No. T-8153 Alt.NIL (UIC-52)
- Assembly
RDSO Drg.
No. T-4866/2 (UIC-52) - Stock & Tongue Rail
RDSO
Drg. No. T-4773
Alt.1 (UIC-52) – Check Rail
Spec.
No. IRS T-10/2000 & IRS T-12/2009
2. Date of Inspection :
3. Place of Inspection :
4. Size
of lot :
5. Sample Size :
Sampling Plan & Acceptance
Tests, as stipulated in approved QAP may be applicable.
6. Document Check : a) Internal
Inspection Reports
b)
Documents (Challan of Rails by Rly./Depot or RITES/CR/Bhilai IC).
c) RDSO
valid approval, approved QAP & 01 set of approved sample
d) Calibration
record of gauges, measuring instruments & test equipment.
e)
Endorsement to be done on invoices of bought out items (procured
from
RDSO Source) with red ink, for proper
accountal as per SI-79.
f)
Declaration regarding non-use of any heating device &/or
drilling
tools for cutting of rails, to
be obtained from firm.
7. Tests/Checks (to be witnessed/verified
by inspector):
|
S. No. |
Parameter |
Value Specified |
Observation |
Remarks |
|
(a) |
Visual |
i) Rails shall be free from visual surface
defects i.e. dent, lap, etc. ii) Any Oxy-Acetylene or any
other flame/heating device should not be used for any kind of Cutting,
Drilling & Bending of these rails. iii) The presence of deep cutting marks at the
curve surface of foot of rail should be avoided & machining smoothness at
foot cut & other places may be as per IS:3073 (Reaffirmed 2006). iv) Holes of Ø26.5mm at the ends of Rails used
for manufacture of switches shall be chamfered with standard chamfering tool. Slide Blocks shall be bolted to the respective Stock Rail & C.I.
Heel Blocks bolted in place & the toe end of the Tongue Rail shall be
lashed to the Stock Rail, with stout wire. |
|
Note-
Rails having deep corrosion, pitting especially at foot shall not be used for
fabrication of Switches. ---- Ref.
Note-1 &3 (Pg.3) of IRS T-12/2009 ---- As
per Cl. No. 3.3.2 of IRS T 10/2000 Holes
in Check, Tongue & Stock rails shall be drilled with approved drilling
jigs with hardened bushes. |
|
S. No. |
Parameter |
Value Specified |
Observation |
Remarks |
|
(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) |
|
Rail’s Challan in case Rail supply by Rly.
or IC issued by RITES/ CR/Bhilai in case of Rails being directly lifted from
SAIL by the Vendor. |
|
(c) |
Verification
of Length-wise quantity of rails of section UIC60 |
01
Set of Curved Switch: i) Stock Rail(Straight & Curved) - 01
No. each (UIC52-12800 mm) ii)
Tongue Rail (Curved & Straight)– 01 No. each (UIC52-11900 mm straight
length) iii)
Check Rail -02 Nos.(UIC52-4330mm) |
|
RI
stamp (RITES CR/Bhilai) at end face of rail shall be verified randomly. |
|
Note:-
13m/12m/11m of 52 Kg rails to be evaluated as per Qty. offered & Rail
Challans, for physical verification. |
||||
|
(d) |
USFD
of Rails for manufacture of Switches |
As
per Note 22 of RDSO Drg. No. T-4866 The
head, web & foot of each rail shall be ultrasonically tested by the
manufacturer (before manufacturing) through a competent person using the
rails for manufacture. |
|
Ref.
Cl. 3.3.1 of IRS T-10/2000 Switch
manufacturer’s USFD report to be verified/ reviewed. |
|
(e) |
*USFD
of Stock/ Tongue/ Check Rails |
i)
Calibration with 250 or 300mm long Std.
Test Rail of UIC 60Kg rail section with 03 FBH for sensitivity setting. ii) USFD
Testing of rail as per *Chapter 10 of RDSO Manual for Ultrasonic testing of Rails & Welds,
Revised-2012. iii) Threshold at
60% of FSH. iv) Head & web to be scanned from head top
& one side surface and foot from head top. |
|
*If
& as specified in PO/QAP. A person possessing a competency
certificate issued by Director General (M&C) RDSO shall be deemed to be a
competent person for USFD testing. |
|
S. No. |
Parameter |
Value Specified |
Observation |
Remarks |
|
(f) |
Magnetic
Particle Test (after
bending) |
As
per Cl. 3.3.1 of IRS T-10/2000 The
Rails after bending shall be tested by Magnetic Particle Test & shall be
free from cracks. The
Curved Tongue & Stock Rails shall be given the correct bend as per Drg.
No. T-8153 & shall be bent accurately as specified without
any injury to the material. |
|
Note-
The Rails shall be bent cold. No drilling & cutting by hand shall be
permitted. Test
method as per IS:3703/2004
may be referred for MPI. |
|
(g) |
Dimension |
As
per RDSO Drg. No. T-4866
(UIC52) for Assembly &
RDSO Drg. No. T-4866/2 (UIC52) for Stock
& Tongue Rail. As per Cl. No. 3.3.3
& 3.3.4
of IRS T-10/2000 i)
The correctness of hole spacing shall be checked with a single template made
specifically for this purpose. ii)
All the holes for fish bolts shall be chamfered with a standard chamfering
tool & shall be within tolerance of ±0.8mm in diameter. As per Cl. No. 4.1 of i)
The tolerance on length of Stock/Tongue Rail shall be within ±3mm or as
specified in Drg. ii)
Maximum clearance between Switch & Stock Rails in assembled position:- ·
0.5mm
between inner head & between over-riding surfaces at the toe end, heel
end & at the heel. ·
1.5mm
between over-riding surfaces at the center. |
|
Std.
chamfering kit (EDO/T-1760) for chamfering of holes may be used. |
S. No. |
Parameter |
Value Specified |
Observation |
Remarks |
|
(h) |
MAJOR
FITTINGS / FASTENERS MASTER
ITEM LIST in IBS to be referred for component’s check sheets (duly linked
with Drg. & Spec.), if any. NOTE: Inspection/tests may be conducted as
per the respective Inspection & Test plan (hyperlinked) & detailed observations may also be recorded
in the relevant check sheets. |
|||
|
h.1 |
Reinforcing Straps
(LH & RH) |
As per RDSO Drg.
No. T-2610
Alt.4 MS
Flat:75x10 mm &
shall confirm to Specification IS:2260 i)
All holes are 19mm except where otherwise shown in Drg. ii)
The ‘A’ marked inner straps to be machined (LH & RH). iii)
The first 10 holes from the toe require mushroom head rivets as indicated in
the Drg. The remaining holes except where otherwise indicated require snap
head rivets. iv)
The Reinforcing straps are to be riveted to the Tongue Rails shown on Drg. T-4325/1
by the manufacturer. v)
Outer Reinforcing straps shall be made shorter by 260mm at the toe to
accommodate the switch extension brackets. vi)
Outer Dia. of finished 1st mushroom head rivet on outer side be
kept as 35 mm to avoid infringement for switch extension bracket. |
NA |
|
|
h.2 |
Heel Blocks |
As per RDSO Drg.
No. T-15592 Material
shall confirm to IS:210/1962 (Grade-20) along with Dimension Report |
|
Part
No. to be cast as indicated in the Drg. Doc.
to be review by IE |
|
S. No. |
Parameter |
Value
Specified |
Observation |
Remarks |
|
h.3 |
Distance Blocks |
As per RDSO Drg.
No. T-15591, T-5355 Material
shall confirm to IS:210/1962 (Grade-20) along with Dimension Report |
|
Part
No. to be cast as indicated in the Drg. Doc.
to be review by IE |
|
h.4 |
Slide Blocks |
As per RDSO Drg.
No. T-4347
to T-4358 Material
shall confirm to IS:210/1962 (Grade-20) along with Dimension Report |
NA |
Part
No. to be cast as indicated in the Drg. Doc.
to be review by IE |
|
h.5 |
Leading Stretcher
Bar (Insulated) |
As per RDSO Drg.
No. T-4885 & T-4886 MS
Flat:75x12 mm &
shall confirm to Specification IRS T-10/2000 & IS:226 |
NA |
i)
All holes on the Stretcher Bars are to be 18mm Dia. exact where otherwise
shown in the relevant Drg. ii)
2nd 18mm Dia. holes for lug T083(M), with Turned Bolts T-11634 are
to be drilled only in Leading Stretcher Bars RDSO/T-3650 & 3rd
Following Stretcher Bars RDSO/T-3654 iii)
Two slotted holes are to be made in the 3rd Following Stretcher
Bar RDSO/T-3655 as shown in the relevant Drg. iv)
Synthetic Adhesive may be applied on the threads of Turned Bolts after
tightening the nut to prevent loosening of nuts. Alternatively, split pins
may be provided. |
|
h.6 |
1st
Following Stretcher Bar (Insulated) |
As
per RDSO Drg. No. T-4887 & T-4888 MS
Flat:75x12 mm &
shall confirm to Specification IRS T-10/2000 & IS:226 |
NA |
|
|
h.7 |
2nd
Following Stretcher Bar (Insulated) |
As per RDSO Drg.
No. T-4889 & T-4890 MS
Flat:75x12 mm &
shall confirm to Specification IRS T-10/2000 & IS:226 |
NA |
|
|
|
|
|
|
|
|
S. No. |
Parameter |
Value
Specified |
Observation |
Remarks |
|
h.8 |
M.S. Plates |
As per RDSO Drg.
No. T-3901, T-3902 Plate thickness:14 mm
Specification IRS T-10/2000 & IS:2062/1999 Gr. B |
|
Part
No. to be stamped on MS plates as per Drg. |
|
h.9 |
Slide Chairs |
As per RDSO Drg.
No. T-5813 Plate
thickness:14, 6, 20 mm &
shall confirm to Specification IRS T-10/2000 & IS:226 |
|
Rivet
head soundness, rivet flushing at Counter sunk side, weld size & Bkt.
profile (by Rail Profile template) to be checked on samples. |
|
h.10 |
Bearing
Plates |
As per RDSO Drg.
No. T-4869 to T-4871 As per RDSO Drg.
No. T-5837 to T-5839 As per
RDSO Drg. No. T-4604
to T-4609 Alt.2 As per
RDSO Drg. No. T-4597
Alt.1 Plate
thickness:12, 20 mm &
shall confirm to Specification IRS T-10/2000 & IS:226 & IS:2062/1999 Gr. B |
|
Part No. to be
stamped on each bearing plate as per relevant Drg. *(instead of T-4601
to T-4603 against T-4219 Alt.6) Rivet
head soundness, rivet flushing at Counter sunk side, weld size & Bkt.
profile (by Rail Profile template) to be checked on samples. |
|
h.12 |
Plate
Screw |
As per Drg. No. RDSO/T-3912 Alt.2 Plate screw shall
confirm to Spec. IRS-T-16/1981 &
IS:226/1975
Structural Steel (Standard Quality) |
|
Check Sheet: Doc.
No. QA/ER/CIV-08 (hyperlinked) |
|
h.13 |
Single Coil
Spring Washer |
As per Drg. No. T-10773 Single coil Spring
washer shall confirm to Specification IRS-T-42/1988 & IS:4072/1988 Grade-6;
Designation- 55Si7 |
|
Check Sheet: Doc.
No. QA/ER/CIV-06 (hyperlinked) |
|
S. No. |
Parameter |
Value
Specified |
Observation |
Remarks |
|
h.14 |
Fish Bolts |
As per RDSO Drg.
No. T-1899 Alt.1 (18x140mm) Track bolts &
nuts shall confirm to Specification IRS-T-23/1967 |
|
Track Bolt Check
Sheet: Doc. No. QA/ER/CIV-10 (hyperlinked) Fish plate to be used as per RDSO
Drg. T-5916 instead of T-1898. |
|
h.15 |
Turned Bolts |
As per RDSO Drg.
No. T-11627 (18x65mm) Track bolts &
nuts shall confirm to Specification IRS-T-23/1967 |
|
Track Bolt Check
Sheet: Doc. No. QA/ER/CIV-10 (hyperlinked) |
|
h.16 |
Bolts & Nuts |
As per RDSO Drg.
No. T-11623
(25x80mm)*, T-11624 HH (25x80mm)*, T-11522
(25x270mm), T-11523
(25x280mm), T-11525 (25x300mm), T-11531
(25x360mm), Track bolts &
nuts shall confirm to Specification IRS-T-23/1967 |
|
Track Bolt Check
Sheet: Doc. No. QA/ER/CIV-10 (hyperlinked) *As per Note-6 of Drg. T-4219 Alt.6 Thickness of bolt head to be reduced
from 22 to 8mm for slide chairs on sleeper No. 3 to 13. |
|
h.17 |
Extended Tie Plates |
As per RDSO Drg.
No. T-5812 to T-5812/2 Material shall
confirm to Specification IRS T-10/2000 & IS:2062/1999 Gr. B |
|
Rivet
head soundness, rivet flushing at Counter sunk side, weld size & Bkt.
profile (by Rail Profile template) to be checked on samples. |
|
h.18 |
M.S. Flat Tie Bar |
As per RDSO Drg.
No. T-4711 MS
Flat:75x12 mm &
shall confirm to Specification IS:226 Note-
Only on hole of Ø26mm to be drilled at 70mm from the end. |
|
Remaining
holes (marked in the Drg.) to be drilled at site as per sleeper spacing. |
|
S. No. |
Parameter |
Value
Specified |
Observation |
Remarks |
|
(i) |
Marking |
As per IRS T-10/2000 Cl. No. 6.2.2 i)
The marking on end faces of switch Rails (at lower central portion of head)
:- ·
For
LH Turnout C
/ST or CR/ LL (on LH Side) C
/ST or CR/ RL (on RH Side) ·
For
RH Turnout C
/ST or CR/ LR (on LH Side) C
/ST or CR/ RR (on RH Side) ii)
The serial number of each Switch shall be punch marked with 10mm high &
0.5mm deep letters vertically on the web of the rails to identify Switch. iii)
The punch mark will have 6 digits consisting of last 03 digits of PO No. as 1st
3 digits and last 3 digits indicating the S. No. of Switch at heel end of
stock & tongue rail. iv)
04 digits shall be punch marked at foot below S.No. indicating initial of
firm in 5mm size letter punch. Cl. No. 6.2.4 The
marks shall be punched on various components of switches at the location
indicated below- Check
Rails- At both end faces of rail head. Tongue
Rails- At the heel end face of rail head. Stock
Rails- At both end faces of rail head Cl. No. 6.2.5 i)
The markings detailed above (at Cl. No. 6.2.2) shall also be stamped in 10mm
high letters on G.I. Sheet/Aluminium Sheet of size 80x30x1mm. ii)
The sheets shall then be fixed with the help of specified epoxy resin on the
web of rails at 300 mm (towards toe) from 1st heel block bolt hole
on the open face of tongue rails. |
|
As per Cl. No. 6.1 All
component parts of Switches shall be marked with maker’s initials/ mark &
IRS part No. shown on the drawings either stamped or cast thereon. The sample sketch of markings
appears as Annexure-III of IRS T-10/2000 for Switches. |
|
S. No. |
Parameter |
Value
Specified |
Observation |
Remarks |
|
(j) |
Painting |
Priming as per
Cl. No. 8.1 of IRS T-10-2000 after inspection. Primer
coats of DFT 40µ (min.):- i)
01 heavy coat of Ready mixed paint Red lead priming to IS:102/1991 OR ii)
01 coat of Ready mixed paint, Zinc Chrome priming to IS:104/ 1988 followed by 01 coat of Ready mixed paint; Red
Oxide Zinc Chrome, priming to IS:2074/1989. OR iii)
02 coats of Ready mixed paint; Red Oxide Zinc Chrome, priming to IS:2074/1989. OR iv) 02 coats of Red
Oxide Zinc Chromate primer to IRS Spec. No. P31-71. |
|
Declaration
to be obtained from vendor regarding priming requirement/ application &
DFT (internal check for primer) along with verification of Batch TC of Primer
used |
|
Painting as per
Cl. No. 8.2 of IRS T-10-2000
after priming i)
01 finishing coat of Ready Mixed Paint Verdigil Green ISC 280 to IS:117/1988 ii)
Overall DFT 80 microns (min.) after finishing coat of paint inclusive of
primer coats. iii)
The following shall be written on open face of web by stencil of 50mm size with white paint:-
10125mm
O.R. Curved Switches on PSC Sleepers BG, 60 Kg., RT/TA (Drg. No.), Name of
firm, monogram of firm.
LH
Side- LH Switch for LH or RH Turnout. RH
Side- RH Switch for LH or RH Turnout.
Check
Rails for 1 in 12 crossing BG 60 Kg, RT/TA (Drg. No.), Name of firm, monogram
of firm. |
|
Verification
of Batch TC of Paint used |
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