FBW Manual
FBW Manual
FBW Manual
Government of India
रे ल मंत्रा
MINISTRY OF RAILWAYS
संशो�धत)जनवर� (2012
(Revised January 2012)
अनस
ु ंधान, अ�भकल् एवं मानक संगठन, लखनऊ -11
Research, Design and Standards Organisation, Lucknow-11
CONTENTS
ii
ANNEXURES
iii
FIGURES
iv
CORRECTION SLIPS
v
MANUAL FOR FLASH BUTT WELDING OF RAILS
FOREWORD
1
MANUAL FOR FLASH BUTT WELDING OF RAILS
1. SCOPE
1.1 The manual gives details of the types and suitability of rails to
be welded by stationary Flash Butt Welding Plant, Mobile Flash
Butt Welding Plant, pre-welding inspection, preparation of rail
ends before welding, the general procedure of execution of
welding and finishing of welded joints. It also defines geometrical
tolerances for the finished joints and acceptance tests to ensure
quality control. It also defines process for procedure approval of welding
plants, procedure approval for other rail sections and grades and additional
transverse tests required to be performed on rectification of a welding
machine malfunction, machine overhaul or work other than normal
maintenance and change to another approved procedure.
1.3 All welding shall be carried out on a flash butt welding plant
using automatic, programmed welding sequence.
2
of handling during end unloading; only the second fishbolt hole
(one away from the rail end) need be drilled. In case, welding of
new rails with fishbolt holes cannot be avoided, it shall be
ensured that the outer edge of the hole nearest to the rail end is
at least 40mm away from the end to be welded to avoid the heat
affected zone of the weld extending up to the edge of the hole.
All fishbolt holes shall be chamfered before welding.
3
Rail Section Standard width of Minimum width of
the head of new rail the head of old rail
60kg 72.00 mm 66 mm
52 kg 67.00 mm 61 mm
90 R 66.68 mm 61 mm
75 R 61.91 mm 56 mm
60 R 57.15 mm 51 mm
4
Resulting step on non gauge face side after welding shall be
ground out to slope not steeper than 1:500.
5
4.3 END-CLEANING: Before welding, end faces of the rails
to be welded and electrode contact locations shall be thoroughly
cleaned of loose scales, rust, paint etc. by brushing and shot
blasting/grinding to bare metal finish for good electrical contact
to avoid arcing at the contact points on the rail and to eliminate
the possibility of rail failure near joint due to Copper penetration
and formation of brittle martensite structure. Cleaning of rail
bottom shall be ensured by placing a mirror and watching the
cleaned surface. The electrode contact locations should be
marked with chalk on each rail end to be welded to serve as
guidance for cleaning. Oil and grease, if present, shall be removed
by Carbon Tetrachloride or Benzene. If any internal defect such
as piping is noticed during end cleaning, the rail shall not be
welded.
5. PROCEDURE OF WELDING OF RAILS
5.1 ELECTRICAL CONTACT: The electrical contacts, i.e.
Copper/Melloroy electrode in the welding machine must be
cleaned by compressed air pistol to ensure freedom from loose
oxides and other foreign matter so that no arcing takes place at
the contact points on the rail and to eliminate the possibility of
rail failure near joint due to Copper penetration and formation of
brittle martensite structure. The electrodes must be replaced and
machined whenever surface depressions exceeding 1mm in depth
are formed due to wear. For this purpose, adequate spare
electrodes should be kept in the plant.
6
The mobile flash butt welders, however, give continuous
flashing instead of initial burn off, preheating and flashing cycles
separately.
7
The heaviest rail section which can be welded on plant
should be decided on this basis.
5.3.5 Stripping
8
5.5.1 Changing weld parameters arbitrarily like changing platte n
travel, increasing duration and/or number of preheat cycles so as
to increase interface temperature to achieve fusion with lower
butting pressure (wherever butting capacity of the plant is low) or
to retain heat in weld for easy upset metal removal when
stripping is done away from welding machine, shall strictly be
prohibited.
5.6.1 Procedure approval shall be carried out by RDSO for each individual
machine (no type approval) by testing weld samples produced in accordance
with procedure enumerated below.
Ten weld samples (two welds for each parameter) shall be prepared in
presence of RDSO representative.
All welds and rails shall be inspected visually for welding, trimming,
clamping or profile finish imperfections, such as tears, cavities, cracks,
damage and thermal damage, in particular, in the electrical contact areas.
9
5.6.4.2 Weld trimming and upset examination:
There shall be no sign of tearing, chisel mark or cavity in weld metal due to
trimming and upset shall not be raised more than 3mm and there shall be
no depression in accordance with item (v) of Annexure IV-A & B as
applicable.
Finished weld samples shall be checked for weld geometry and shall conform
to tolerance laid down in Para 8 and Annexure-IV of this manual.
Fusion
Line
RAIL
O P O H O H O P
O P O H O H O P
10
5.6.4.7 Transverse Testing:
Five welds (1 weld from each parameter) in as welded condition having met
the requirement of 5.6.4.1 to 5.6.4.6 shall be subjected to transverse test in
accordance with procedure laid down in 10.2.2.1 with following additional
provisions.
For the later case, the weld shall be notched to ensure that fracture occurs
in welding zone and the test weld shall be fractured. If the fracture occurs
about the weld line, the fracture surfaces shall be inspected. The details of
any weld imperfection shall be recorded. Lack of bond shall not be
permitted. Flat spots shall not be considered to be lack of bond.
If fracture occurs remote from weld, the fracture surfaces shall be checked
for the presence of die burn, which if detected shall cause the process to fail
approval.
If fracture occurs within rail for reasons other than die burn then another
test weld specimen shall be substituted for testing.
Five tested welds shall meet the requirement of given rail profile and grade
specified in table 1.
11
5 mm. This requirement shall apply equally to vertical axis cut through
full rail depth and those taken from each rail foot.
c) In case that flat spots are found, they shall be checked by micro
examination at 100 X magnification. If any cracks are found, the process
is rejected.
The joints showing minimum, uniform & parallel Heat Affected Zone (with
5mm difference between widest and narrowest points) along with satisfactory
mechanical test results will be considered satisfactory. By using welding
parameters of above satisfactory joints, again 6 joints shall be made. Out of
these, 3 joints shall be subjected for Transverse Testing and remaining 3
joints for Macro Examination after having met the requirements of 5.6.4.1 to
5.6.4.6. All 6 joints shall pass the requirements.
5.6.5.1 Following the initial approval with particular rail profile and grade,
other rail profiles and other rail grades as contained in IRS T-12 shall be
undertaken for approval as and when required.
12
5.7 Field approval of welding procedure –
For mobile flash butt welding plant having obtained procedure approval in
accordance with para 5.6 above, approval for field welding shall be granted
after execution of 30 welds on track (carried out in two shifts), if they satisfy
the weld acceptance criteria defined in 5.6.4.1, 5.6.4.4, 5.6.4.5, 5.6.4.7
above (visual, dimension, ultrasonic, transverse testing). This shall be
carried out in presence of Engineer in-charge and the approval shall be
granted by Chief Track Engineer/ Chief Engineer (construction).
8. FINISHING :
8.1 The top, side and bottom surfaces of the rail head shall be
ground smooth so that the weld surface is absolutely flush with
the parent rail surfaces. Particular care is necessary to ensure
that finish grinding does not burn or notch the rail surfaces.
After grinding, the top table and the sides of the rail head shall
comply with the geometrical standards given in Annexure IV.
Grinding shall be done preferably using a profile grinding trolley,
in the absence of which manual grinding can be done using a cup
13
grinder. Depending upon whether it is done mechanically or
manually, grinding may be done in stages.
XXXX MM YY AAA
The first four digits indicate the weld number starting from 0001
for first weld of every month, the next two digits month of welding
followed by last two digits of the year of welding. The end letters
shall be code of the Welding Plant. For example, 32810891 MGS
indicates that the particular weld is 3281 s t weld of August1991 of
Mughalsarai Flash Butt Welding Plant.
XXXX MM YY OO PP EE
The first four digits indicate the weld number starting from 0001
for first weld of every month, the next two digits month of welding
followed by next two digits of the year of welding. The letters OO
denotes the code for owner of the plant, PP denotes the code for
14
the plant of that particular owner and EE stands for the code of
agency executed the welding work.
15
stacked. The defective joint shall be cut and removed before the
panel is dispatched from the Flash Butt Welding Plant. Another
panel of matching length should be welded and the short panels
(minimum 3 rail lengths) dispatched in pairs.
Fusion
Line
RAIL
O P O H O H O P
O P O H O H O P
16
10.2.2 Transverse Test: The finished test weld samples, not less
than 1.5 metre long with the weld at the centre shall be subjected
to transverse load test in a transverse testing machine in the
following manner:-
Table 1
17
VALUES OF MINIMUM BREAKING LOAD AND DEFLECTION IN
TRANSVERSE LOAD TEST
S Rail Section Span Min. Min. Frequency of testing
N breaking deflection
load at centre Stationary Mobile
(tonnes) (mm) FBW Plant FBW
Plant
1 60 kg (UIC), 1.25 115 30 1 in 500 1 in
Grade- m 100*
1080HH
2 60 kg (UIC), 1.25 110 12 -do- 1 in
Grade- m 100*
1080Cr.
3 60 kg (UIC) 1m 150 20 1 in 1000 1 in
90 UTS 100*
4 52 kg 90 UTS 1m 115 20 -do- 1 in
100*
5 60 kg UIC 1m 135 30 -do- 1 in
MM (72 UTS) 100*
6 52 kg MM 1m 100 30 -do- 1 in
(72 UTS) 100*
7 90R MM 1m 80 30 -do- 1 in
(72 UTS) 100*
8 75R MM 1m 70 30 -do- 1 in
(72 UTS) 100*
9 60 R MM 1m 60 25 -do- 1 in
(72UTS) 100*
* Sample joints for first 1,000 joints welded by mobile flash butt
welding plant will be tested at frequency of 1 in 100 joints and
subsequently at a frequency of 1 in 500 joints.
18
10.2.3 Macro examination: One test joint for every 5000 joints
welded in case of stationary Flash Butt welding Plant and one tes t
joint for every 1,000 joints welded in case of Mobile Flash Butt
Welding Plant shall be subjected to macro examination as per
Cl 5.6.4.8 and micro examination as per Cl 5.6.4.10. 100mm
length of rail with weld at centre shall be cut and the sample
shall be sectioned in vertical longitudinal direction through the
weld. One of the sections shall be etched with 5-10% Nitric acid
and for confirming any defect found in Macro Examination, Magna
flux test should also be carried out. Extent of heat affected zone
shall be measured for head, foot and web of the rail. The visible
heat affected zone shall be of a normally symmetrical shape about
the weld line and fall within the width of 40 mm maximum and 20
mm minimum. The permissible deviation between the maximum
and minimum dimension on any weld shall not exceed 5 mm in
general. However the limit shall be guided by the value
standardized during the procedure for standardization of welding
parameters. This requirement shall apply equally to the vertical
axis cut through the rail depth and each rail foot tip.
In case that flat spots are found, they shall be checked by micro examination
at 100 X magnification. If any cracks are found, the process is rejected.
11.1 The 90 UTS head hardened and 110 UTS rails are
comparatively brittle having less fracture toughness as compared
to 72 UTS (MM) rails. Therefore, such rails require special car e
in handling. Provisional guidelines for handling and
maintenance of such rails are given in Annexure-VII. Flash Butt
Welding Plants shall create adequate handling facilities to follow
these guidelines.
19
In order to ensure proper quality of Flash Butt Welds, a list of
minimum equipment and machines to be provided in each Flash
Butt Welding Plant is placed at Annexure-IX.
13.2.1.2 Interview
20
machine, welding defects, their causes and remedies. The
candidate found suitable in interview shall be allowed for further
tests.
21
Annexure-I
(Para 5.4)
The rails being 60 Kg. Cr-Mn alloy steel rails are required to be
subjected to controlled post weld cooling treatment, as detailed below, so as
to avoid formation of undesirable micro-structure and cracks in weld and
HAZ.
(i) Asbestos cement pipe of internal dia. 250mm – 300mm, wall thickness
15 to 25mm and length not less than 1 metre shall be installed after the
flash butt welding machine along the welding line. Necessary arrangement
to roll the rail through this pipe shall be made so that the pipe walls are not
damaged due to movement of rails. Two holes of 30mm dia. (to suit the
burner head of kerosene blow lamp) on the horizontal diameter are to be
made as shown in Fig.5.4(a), in such a way that the holes are staggered by
25-30 mm with respect to the mid length of the pipe. Two nos. kerosene
blow lamps of about 1.5 litres capacity are fixed through these holes in such
a way that flames from the burners strike at the centre of the web on each
side. The air pressure in the burners is to be adjusted in such a way that
blue flame is always available from these. Asbestos cloth/asbestos lined
mild steel gadget are to be always kept ready to cover both the ends of the
pipe, to the extent possible so that cool air draught is not allowed to enter
inside the pipe. The blow lamp burners are kept in ‘ON’ position at least 10
minutes before the flash butt welded joint enters the pipe to ensure warming
up of the pipe and the enclosed air pocket to retard the rate of cooling.
(ii) After stripping, the welded joint should be quickly moved forward and
brought exactly at the mid length of the A.C. pipe. This operation is to be
completed within 120 seconds of butting. At this time, the temperature of
the weld is generally above 850 degree C. Depending upon the travel speed
of the rail panel, the mid length of the pipe may be located at about 13m (rail
length) from the welding head to facilitate setting up of the next rail joint to
be welded during the period the rail joint already welded is being slowly
cooled. The flash butt welded joint shall be kept inside the A.C. pipe for not
less than 10 minutes till the weld temperature drops to about 400-450
degree C. Two standby kerosene blow lamp burners in perfect working
condition shall be kept ready to be utilised in case of necessity.
22
Annexure-II
(Para 5.4)
23
Annexure-III
(Para 6)
RECORD OF WELDS
MACHINE
1. Date of welding
2. Shift (day/night)
3. Joint No.
4. Length of rail
5. Section of rail
6. Welding current (primary, amps)
7. Primary voltage (volts)
8. Clamping pressure Kg/cm 2
9. Butting pressure Kg/cm 2
10. No. of pre-heats
11. Pre-heating time On……………..Off………….
12. Burn off time (sec.)
13. Flashing time (sec.)
14. Post welding heat treatment if any
15. Whether automatic weld record chart available
16. Remarks (Any change of voltage during welding etc.)
17. Signature of welder
18. Signature of Foreman
24
ANNEXURE – IV
(Para 8)
(iii) Head finishing (in width): Side of rail head should be finished
to :-
+ 0.25 mm on gauge side at the centre
of 10 cm straight edge.
(v) Web zone (under side of head, + 3.0 mm of the parent contour
web, top of base, both fillet - 0.0 mm
each side):
(vi) Upper sides, under surfaces and edges of rail foot shall be
ground smooth. The edges of foot should be rounded and
bottom of rail foot ground smooth without any minus
tolerances to ensure proper seating on sleepers, unhindered
movement of welded panels on end unloading rakes, avoid damage
to elastic rail pads and eliminate stress riser.
NOTE: Tolerances for BSP rail rolled as per Explanatory Note to IRST-
12/2009 shall be as under:-
25
B. Welds with old rails
(vi) Upper sides, under surfaces and edges of rail foot shall be
ground smooth. The edges of foot should be rounded and
bottom of rail foot ground smooth without any minus
tolerances to ensure proper seating on sleepers, unhindered
movement of welded panels on end unloading rakes, avoid damage
to elastic rail pads and eliminate stress riser.
(vii) The above tolerances are finished tolerances of welds
inclusive of tolerances of rail.
26
Annexure-V
(Para 10)
27
6. Use of treated water for cooling system – The pipes/tubes for
circulation of water for cooling purpose are, generally, of small
diameter. Due to presence of impurities in water, scaling on the
inner side of the pipe takes place resulting in less circulation of
cooling water and consequent problems. Therefore, suitably
treated water should be used for cooling system. The welding
plant should not be operated if the cooling system is non-
functional.
11. Minimum and nearly parallel Heat affected Zone of the joint
should be achieved by setting the weld parameters.
28
Annexure-VIA
(Para 10.1.2)
29
Annexure-VIB
(Para 10.1.3)
1. Joint No.
2. Rail section & chemistry
3. Day Night shift
4. Result of testing
5. If defective, details of flaw Defective zone Flaw peak pattern
Head/Web/Foot Probe Trace
6. Remarks
7. Signature
30
ANNEXURE-VIC
(Para 10.2.1)
5. Remarks
6. Operator’s Signature
31
ANNEXURE-VID
(Para 10.2.2)
No. of joints welded during the month (Rail section & UTS-wise)
32
ANNEXURE-VIE
(Para 10.2.3)
Head
Web
Foot
33
ANNEXURE-VII
(Para 11)
AVOID
- Sudden impact
DO
34
AVOID
DO
AVOID
DO
35
AVOID
DO
AVOID
DO
36
6. Safety of Personnel
AVOID
DO
37
ANNEXURE-VIII
(Para 12)
Yes No Not
Appli
cable
1. ITEMS TO BE CHECKED DAILY
1.1 UNLOADING OF LOOSE RAILS
1.1.1 Rails of same section and UTS are
stacked together
1.1.2 Spacers are provided between successive
layers of rails.
1.1.3 Rail are stacked in head up position
1.1.4 Numbers of layers in each stack is not
exceeding 15.
1.2 FEEDING OF RAI LS
1.2.1 Rails ends have been checked for –
(a) Straightness
(b) Squareness
(c) Width of head and height
1.2.2 Fish bolt holes/any other drilled are
chamfered.
1.2.3 Rail ends are cleaned of rust, scales,
paint etc.
1.2.4 Top of rail head and bottom of rail foot
are clear at electrode position.
1.2.5 Grease/oil at rail ends, if present has
been removed with carbon tetrachloride/
Benzene.
1.3 WELDING
1.3.1 Alignment of rail ends is proper and
checked with 1m straight edge.
1.3.2 Electrodes surfaces are clean (cleaning
after every welding operation)
1.3.3 Stipulated oil and air pressure is
available in the welding machine.
1.3.4 Record of each weld is kept in prescribed
proforma.
1.4 FINISHING OF JOINT
1.4.1 Stripping/trimming of entire weld cross
section has been done.
1.4.2 Notches/undercuts are avoided while
stripping with pneumatic chisel
38
1.4.3 Post weld controlled cooling is done for
Cr-Mn/head hardened rails.
1.4.4 Joint has been checked for –
(a) Straightness on
(i) 10 cm st. edge
(ii) 1 m st. edge
(b) Dimensional tolerances
39
2.6 While unloading, the rails are held at
two points 6-6.5m apart and overhang of
ends does not exceed 3-3.5m.
2.7 Rails/panels are stacked on leveled and
well drained platform and they have no
contact with soil.
2.8 Transverse testing & macro
examinations of test welds is done at
prescribed frequency and records are
maintained.
2.9 Transverse testing machine is calibrated.
2.10 Workmen are provided with required
protective clothing.
Signature of XEN/Dy.CE
40
ANNEXURE-IX
(Para 12)
LIST OF MINIMUM EQUIPMENTS & MACHINES REQUIRED
FOR FLASH BUTT WELDING PLANTS
I. TESTING FACILITIES
1. Transverse Load Testing Machine of 200t capacity.
2. Hardness testing machine.
3. USFD testing machine (preferably on line tester).
4. Equipment for Macro and Magna flux examination.
II. PREWELDING EQUIPMENTS
1. Pre-straightening machine.
2. Portable grinders.
3. Shot blasting machines.
4. Mechanical rolling system for feeding of single rails for welding.
5. Abrasive rail cutting machines.
III. POST WELDING MACHINE
1. Weld stripping machine.
2. Profile grinders.
3. Post straightening machine.
4. Equipments and fixture for post weld controlled cooling.
5. Equipments and fixture for post weld air quenching.
6. Automatic weld recorders.
7. Arrangements for availability of treated water for cooling system.
IV. HANDLING/TRANSPORTATION AND OTHER EQUIPMENTS
1. Electric Hoists/Gantries in adequate numbers for unloading of
single rail from wagons.
2. Electric Hoists/Gantries in adequate numbers with centralised
control panel capable of loading/handling of rails up to 20 rail
panels.
3. Motorized conveyor line for feeding and welding of rails.
4. Arrangement of stacking of single rails and 20 rail welded panels
with capability of mechanical handling (capacity to handle to
match with plant production).
5. Generating Diesel sets of adequate capacity for standing
arrangements.
6. Independent water supply and water cooling system.
7. Provision of chilling plant for cooling of oil to maintain hydraulic
pressure specially for summers.
8. Adequate number of End Unloading Rakes.
9. Adequate line capacity for receiving rails and for dispatch of
welded rail panels.
10. Other minor tools and plants required for day to day repair and
maintenance.
41
42
43
44
45
46
47
48
49
50
51
52
53
FAC E
OSITE
GA T OPP
AR M ARKIN
SIMILL
300mm
AAA*
MM YY
XXXX
10mm m
6mm 300m
eld
FB w
PP EE
M M YY OO nt
X
*X bile Pla
for Mo
54
55
Addendum & Corrigendum Slip No.1 of 2012
To
Manual for Flash Butt Welding of Rails (Revised Jan 2012)
1
Addendum & Corrigendum Slip No. 2
To
Manual for Flash Butt Welding of Rails (Revised Jan 2012)
(a) For stationary welding Plant, the Quality Assurance Programme (QAP)
shall be submitted to RDSO through concerned railway administration,
who shall scrutinize and approve by ensuring compliance to this manual.
(b) For Mobile Flash Butte welding Plants, the procedure given in Annexure-
X of this Manual shall be followed.
The Quality Assurance Programme (QAP) shall contain the information given
in Annexure-XI.
1
ANNEXURE-X
(Para 5.6.2)
Procedure to be follow ed for approval of Quality Assurance
Program (Q AP) for Mobile Flash Butt Welding Plants
1.0 The mobile flash butt welding plants used on railways are mostly
outsourced. In order to expedite the approval of QAP and
minimize the time gap between award of contract and start of
work, the following procedure shall be followed.
2
earlier approved General QAP with details of welding team
approved by Zonal Railway with competency certificates,
proposed welding parameters as decided by firm during
internal test and details of contract agreement) in
quadruplicate to RDSO through concerned Railway
Administration for standardization of welding parameters
and then approval of final QAP.
3
ANNEXURE-XI
(Para 5.6.2)
Information to be provided in Quality Assurance Programme for Mobile
Flash Butt Welding Plants
1. Cover page of the QAP
This shall indicate the Name and relevant details of Agency; Details of Mobile
Flash Butt Welding machine (Make, Model & Serial no.etc.); Details of
Contract along with agreement no. & name of Zonal Railway awarded the
Contract.
2. Index.
3. Brief description about the firm/ company and General information about the
addresses and contact numbers of office and work stations, branches and
sister concerns and the details of ISO certification, if firm is already a ISO
certified company having Operation and maintenance of Mobile Flash Butt
Welding Plant in scope. If firm is not already ISO certified, ISO certification
including Operation and maintenance of Mobile Flash Butt Welding Plant in
scope shall be ensured before submission of Final QAP.
4. If firm is ISO certified,
1. Quality policy of the company as per ISO certification.
2. Certificate to this effect that the approved QAP is a controlled document
and a quality record of ISO quality control system of the vendor.
5. Organization chart emphasizing quality control set-up.
6. Qualification and experience of key personnel and officials deployed for
operation and in quality control cell including supervisor and welders of the
machine.
Details of competency certificate of the welders issued by Zonal Railway as
per clause 13.2 of Manual shall be specifically indicated.
7. Brief description on the Mobile Flash Butt Welding Machine and other
machinery & plant deployed. (Serial no., model no., make, date of
manufacturing, AMC details and brief working procedure of the machine).
(MFBW machine must have facility for display and storage of all the welding
parameters in re-producible electronic forms at the time of F.B. welding of rail
joints. A certificate in this regard along with brief on the facility for display/
storage capacity of the machine must be specifically mentioned in the QAP).
8. Recommended Welding parameters for various rail sections and rail
metallurgies as per operating manual of FBW machine specified by
Manufacturer.
9. Process flow chart for complete process (from receipt of rail to dispatch of
welded panels).
10. Procedure for Standardization of welding parameters as per clause 5.6 of
manual. (The parameters finally approved by RDSO shall be included in final
QAP).
4
11. Procedure of field approval of welding procedure as per clause 5.7 of Manual.
5
(ii) Periodical maintenance of mobile flash butt welding machine as per
procedure and frequency laid down by OEM (Original Equipment
Manufacturer).
(iii) Periodical inspection of mobile flash butt welding machine by OEM
or his authorized representative at an interval of two years or
execution of 20,000 joints whichever is earlier to conduct technical
audit of its health, as per clause 14.1 of Manual.
(iv) Availability of sufficient stock of genuine spares.
(g) List of various gauges/ templates e.g. feeler gauge, straight edge etc. along
with their calibration status and plan.
13. Quality Assurance System- Inspection & Testing covering the following:-
of
and
for
details
limit/
(reprocessed/ scrapped)
Reference documents
Method/measuring/
li bl
maintaining results
inspection/testing
size
inspection/tests
specified value
Acceptance
Parameters
equipments
frequency
Rejection
Accuracy
Process
Sample
S. No.
14. List of tools & plants and testing equipments available with MFBW machine for
execution of rail welding alongwith calibration status and plan.
15. List of Registers maintained and their standard formats with unique number.
6
16. Welding parameters to be approved by RDSO:- A blank format as prescribed
in operating manual of FBW machine shall be part of final QAP for entering the
welding parameters to be standardized by RDSO.
17. The QAP covering all the information must be given in the form of single
document indicating name of the firm , effective from, document no., revision
number and page no. ‘x’ of ‘y’ on each page. Each page shall be signed by
(with name and designation) ‘Prepared by’, ‘Checked by’ (QC in-charge) and
‘Approved by’ by competent authority. In case of General QAP, details of
welding team, details of contract agreement and standardized welding
parameters need not to be included.
7
Annexure-VI F
(Para-5.6.4.10)
Micro Examination of Welded Joints
9. Date, month and year
10. Joint No.
11. Rail section
12. Date of Testing
13. Remarks on Microstructure at 100X magnification with grain size
14. Signature
15. Summary – (at the end of the month)
Annexure-‘ A’
(of Annexure -XI)
Dail y Progress
Total No. of joints
Joint No.
found defective
Joints
Joints
welded on date
Rail Section
with reason
From To
Signature
Remarks
of
of
Tested
Date
No.
No.
8
Annexure-‘B’
(of Annexure -XI)
Joint Rejection
1. Date, month and year
2. Joint No.
3. Date of Testing of joint
4. Cause of Rejection
5. Date of Re-welding
6. Re-weld joint No.
7. Remarks
8. Signature
Annexure-‘C’
(of Annexure -XI)
Customer Complaint
work executing
Designation of
the Customer
Action Taken
Complainant
Signature of
Signature of
by the work
Corrective
Complaint
executing
Name &
agency
agency
Sl. No.
Date