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Important Achievement of M & CDirectorate during Last Five Years


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Important Achievement of M & CDirectorate during Last Five Years

SN

Financial Year

Broad Area of Achievement

Title of Achievement

Description of Achievement

Likely Benefits

Current Status of Implementation

1.         

2007-08

Efficiency

Development of hard facing electrodes for reconditioning of points and crossings. 

By using those class of electrodes and technique the life of crossings have been enhanced to 50 GMT min from earlier existing service life of 35 GMT.

By using those class of electrodes and technique the life of crossings have been enhanced to 50 GMT min from earlier existing service life of 35 GMT.

Presently it is used in Indian Railway for reconditioning of Points & crossings.

2.         

2007-08

Efficiency

Development of Flux cored wire for reclamation of Tie Tamping Tools.

Reclamation procedure was prepared after laboratory evaluation and subsequent field trial at Kalyan & Bhusawal of CR Rly jointly by Track Machine Dte. & M&C Dte.

By using this consumable & technique the life of Tie Tamping Tools have been enhanced from 10 KM of Tamping to 50 KM.

Presently it is used in Indian Railway for reclamation of Tie Tamping Tool in Indian Railways.

3.         

2007-08

Reliability

Study on Characterization of Vanadium mico-alloyed rail steel manufactured by M/s BSP, Bhilai

To produce Vandium Microalloyed Rail with higher yield to permit higher axle load. Data so generated can be used to design safe

Indian Railway targeting for higher axle load

Data so generated can be used to design safe

4.         

2007-08

Reliability

Evaluation of Corrosion Inhibitor Admixture for concrete.

To evaluate Corrosion Inhibitor Admixture for concrete and assess its effectiveness in preventing corrosion and framing a RDSO Specification .B&S Dte advice for evaluation of Corrosion Inhibitor Admixture of M/s Krishna Conchem Mumbai to check the corrosion resitnat of bars insert in RCC.

Enhancement of corrosion resistance of steel bar in RCC and tentative spec M&C/PCN/126/2008 has been framed

To evaluate Corrosion Inhibitor Admixture for concrete and assess its effectiveness in preventing corrosion and framing a RDSO Specification.

5.         

2007-08

Safety

Standardization of Casting parameters of cast manganese Steel (CMS) crossings

Whenever any design modification is done by Track design Directorate on CMS crossings, the metal casting parameters in terms of moulding, control of chemistry of molten steel, gating and risering practices, solidification characteristics, heat treatment and weld repairs etc. are to be standardize at the time of producing the castings. The foundry technique to achieve stipulated metallurgical properties of seven varieties of CMS crossings were standardized and the crossings manufactured with standardized foundry parameters are successfully used on the railway track.

The foundry technique to achieve stipulated metallurgical properties of seven varieties of CMS crossings were standardized and the crossings manufactured with standardized foundry.

The foundry technique to achieve stipulated metallurgical properties of seven varieties of CMS crossings were standardized and the crossings manufactured with standardized foundry.

6.         

2007-08

Safety

Alternate chemistry for Corrosion Resistance Rail

A joint project on Corrosion Prevention of Rails with IITK is in progress under Technology Mission on Railway Safety. One of the alloys with alternate rail metallurgy micro alloyed with Ni, Cr and Cu has been found to show better. Corrosion Prevention property amongst the five alloys which were developed and Cu-Mo rail samples. Based on recommendation of project team, a proposal has been sent to Railway Board for field trial of 300 MT of the rails with this composition.

One of the alloys with alternate rail metallurgy micro alloyed with Ni, Cr and Cu has been found to show better. Corrosion Prevention property amongst the five alloys which were developed and Cu-Mo rail samples

Corrosion Prevention property amongst the five alloys which were developed and Cu-Mo rail samples. Based on recommendation of project team, a proposal has been sent to Railway Board for field trial of 300 MT of the rails with this composition.

7.         

2007-10

Safety

Development of specification for three-axle cast steel Tri-mount Bogie frams & flexi-coil bogie frame and Bolster for BG Locomotives.

To develop cast steel bogie frame with adequate mechanical properties and improved weldability(low carbon equivalent) MP Dte advised about large no. of loco bogie frames are failing due to initiation of cracks at various location in service causing detenation of loco and higher maintenance cast.

Saving of Rs:30000000.00 per year by saving in terms of avoiding condemnationand evaluation of cast locobogie frames. Better than existing state of art

Saving of Rs.30000000.00 per year by saving in terms of avoiding condemnation and evaluation of cast loco bogie frames. Better than existing state of art

8.         

2008-09

Efficiency

Development of Cast Steel Wheels for EMU

The RWF’s proposal was examined at RDSO in details and technical comments for use of cast steel wheels on trial basis were sent to Railway Board vide this for use of cast steel wheels on trial basis were sent to Railway Board vide this office letter no. MC/EMU/WTA dated 3.3.2009. Railway Board vide their letter no. 2006/M(PU)/1/8 dated 13.4.2009 have permitted trial for 50 wheel sets on EMU trailer coaches having 16.25 t axle load bogies using cast steel wheels manufactured by RWF.

 

Railway Board vide their letter no. 2006/M(PU)/1/8 dated 13.4.2009 have permitted trial for 50 wheel sets on EMU trailer coaches having 16.25 t axle load bogies using cast steel wheels manufactured by RWF.

9.         

2008-09

Green Technology

Development of Rubber Pads with scrap material

Railway Board vide letter No. 2009/CE-II/MT-RDSO-3 dt. 18.05.2009 asked RDSO to explore the possibility of using rubber pads made from condemned BCM belts in turnout portion as these are being used by SC Railway. Accordingly, pads from SC Railway were collected and got tested at RDSO. Detailed report has been submitted to Railway Board vide letter No. CT/SRC/GRP dt. 16.07.2009.

Disposal of this scrap material creates pollution in environment. So this problem of disposal of scap material of used rubber pads may be solved.

Disposal of this scrap material creates pollution in environment. So this problem of disposal of scap material of used rubber pads may be solved.

10.      

2008-09

Safety

New corrosion Resistant Rails developed.

A new metallurgy has been developed as result of project on corrosion prevention of rails under technology Mission on Railway Safety. The Ni-Cr-Cu metallurgy has been developed jointly by RDSO, IIT Kanpur & SAIL. After laying of 500 MT of rails on South Eastern Railway and East Coast Railway, Railway Board has placed further trial order of 10,000MT of rails for laying in corrosion prone area

A new metallurgy has been developed as result of project on corrosion prevention of rails under technology Mission on Railway Safety.

Railway Board has placed further trial order of 10,000MT of rails for laying in corrosion prone

11.      

2008-12

Safety

Standardization of welding parameters of Flash Butt welding plants

A total of 17 stationary/mobile flash butt welding plants being used on  Indian Railways were standardized for welding parameters at site. The FB Welding of 52kg/60kg rails in the field is done accordingly to the weld parameters standardized by M&C Dte.

The FB Welding of 52kg/60kg rails in the field is done accordingly to the weld parameters standardized by M&C Dte.

A total of 17 stationary/mobile flash butt welding plants being used on  Indian Railways were standardized

12.      

2009-10

Safety

Development of Fire Retardant Coatings and Mastic Sealing Compound and Metallic Fire Barriers

CRS/SCR’s enquiry report No.T.13018/1/2008-SCC dated 14.08.2008 received vide Railway Board’s letter No.2006/M(C)/137/20 Vol.I dated 14.07.2009 has recommended that the material of the handle and the latches should be modified having thermal insulating properties so that it is possible to grab the handle even when the coach becomes hot due to fire. RDSO has developed an STR No. RDSO/2009/CG-20 for fire retardant coatings and mastic sealing compound which can lower the temperature of handles and latches. The fire retardant coatings can be used on both metallic and nonmetallic surfaces. The fire retardant coatings will restrict the surface spread of flame by formation of carbonaceous char. The mastic sealing compound can be used on coach door handles and door latches followed by a coat of fire retardant coating to get thermal insulation property. To restrict the propagation of fire from SLR’s luggage portion to other portion, RDSO has developed metallic fire barrier for SLR coaches to Drawing No.CG-K9127. The effectiveness of fire barrier has been verified on Fire Simulation Facility and fire barrier is able to hold fire and the fire extinguished automatically after 9 minutes. To enhance the safety of coaches against fire, the Railways &PUs have been advised to use the fire retardant coatings and mastic sealing compound vide this office letter No.MC/FR/Paint dated 26.03.2010. The drawing No.CG-K9127 for the fire barrier and STR No.RDSO/2009/CG-20 for fire retardant coatings and mastic sealing compound have also been circulated to railways and PUs.

The effectiveness of fire barrier has been verified on Fire Simulation Facility and fire barrier is able to hold fire and the fire extinguished automatically after 9 minutes. To enhance the safety of coaches against fire, the Railways & PUs have been advised to use the fire retardant coatings and mastic sealing compound vide this office letter No.MC/FR/Paint dated 26.03.2010. The drawing No.CG-K9127 for the fire barrier and STR No.RDSO/2009/CG-20 for fire retardant coatings and mastic sealing compound have also been circulated to railways and PUs.

The effectiveness of fire barrier has been verified on Fire Simulation Facility and fire barrier is able to hold fire and the fire extinguished automatically after 9 minutes. To enhance the safety of coaches against fire, the Railways & PUs have been advised to use the fire retardant coatings and mastic sealing compound vide this office letter No.MC/FR/Paint dated 26.03.2010. The drawing No.CG-K9127 for the fire barrier and STR No.RDSO/2009/CG-20 for fire retardant coatings and mastic sealing compound have also been circulated to railways and PUs.

13.      

2010-11

Reliability

Study of the metallurgical and chemical behavior of duplex stainless steel and exlore possibilities for using it as a material for manufacturing superstructure of wagons in place of present ferritic stainless steel of ASTM -409 M grade.

To evaluate mechanical properties, weldability & corrosion resistance property of Duplex stainless steel (ASTM S 32101) and assess its suitability for use in wagon superstructure Indian Railways are using Cu-bearing low carbon structural steel (IS: 2062) for superstructure of wagons. Year 2000 onwards Indian Railways have started switching over to ferritic stainless steel wagons of ASTM-409M grade. Since the corrosion of stainless steel is less, corrosion allowances designed for the wagons are also minimized causing reduction of tare weights of the wagons. The payload of the BCN wagon has increased by reducing the tare weight and counter-adjusting this benefit in the dimensions of the wagons. The payload capacity of the BCN wagon rack has been increased by 78% and that of open wagon rack has been increased by 22%. This has generated a massive increase in revenue. Ferritic stainless steel is having better mechanical strength compared to that of austenitic stainless steel. On the other hand, Austenitic stainless steel is having better corrosion resistant property compared to that of Ferritic stainless steel. In the case of duplex stainless steel, the word duplex is based on the concept of austenite and ferrite formulated in the same material. Because of their fine austenitic-ferritic microstructure they offer an excellent combination of mechanical and corrosion resistance properties. With the higher mechanical & corrosion resistance property, the duplex stainless steel appears to be a better material in place of ASTM-409M (Ferritic) stainless steel. The application of Duplex stainless steel may give rise to further reduction of tare weight of the wagon and thus may fetch high revenue to Indian Railways. M/s Outu Kumpu, India has proposed Duplex stainless steel as per ASTM S 32101 as a substitute of ASTM 409M for use in Indian railways. They have estimated that there will be a weight saving of around 1370Kgs per wagon. This may give a huge opportunity of increasing pay load of wagon Director Wagon vide his letter No: MW/STL, dated 03.02.2010 has requested M&C to undertake testing on samples of duplex stainless steel of ASTM S 32101 for assessing suitability for use of this material in wagon superstructure.

As per the firm’s estimation, the use of duplex steel will reduce the tare weight of one wagon considerably. With our existing state of art, one wagon weighs around 6940Kgs. The new design with duplex stainless steel, may reduce the weight of the wagon to the range of 5570Kgs. Hence there is a possibility of reduction of tare weight of a wagon by 1370Kgs. It is, in general, assessed that one Kg reduction in Tare weight of a wagon gives rise to the saving of around Rs.45.50 annually. Thus saving of 1370Kgs will give rise to saving of Rs.62335 annually. Cost of of ferritic stainless steel (Present material) is around Rs.80/- per Kg and that of Duplex stainless steel ( proposed material) is around Rs.185/- per Kg. The application cost will be increased by around Rs. 2,45,250/-. Since it is onetime cost, it is recoverable in 3.93 or 4 years. Moreover, duplex stainless steel is supposed to have higher corrosion resistance property than that of existing ferritic stainless steel. Hence repair/maintenance cost (if any) may also be reduced. A tentative financial benefit has been calculated based on above approximation and same is given below. The life cycle of stainless steel wagon has been considered to be 30 years. It must be better than ASTM 409M

As per the firm’s estimation, the use of duplex steel will reduce the tare weight of one wagon considerably. With our existing state of art, one wagon weighs around 6940Kgs. The new design with duplex stainless steel, may reduce the weight of the wagon to the range of 5570Kgs. Hence there is a possibility of reduction of tare weight of a wagon by 1370Kgs.

14.      

2010-11

Safety

Development of Digital Single & Double Rail Testers

An additional source has been developed for supply of digital single rail tester and double rail tester during the month. This will facilitate zonal railways in expediting phasing out of analogue rail testing machines by digital rail testing machines.

This will facilitate zonal railways in expediting phasing out of analogue rail testing machines by digital rail testing machines.

This will facilitate zonal railways in expediting phasing out of analogue rail testing machines by digital rail testing machines.

15.      

2011-12

Safety

Development of Forged Junction Rails:

Railway Board has approved TSC’s recommendations and directed that zonal railways should firm up requirement of Forged Junction Rails and advise the same to Railway Board so that its manufacturing can be discussed with Bhilai Steel Plant. Junction Forged Rails have been developed as an alternative of combination fish plated joint of 60 kg and 52 kg rail. Since RDSO does not have any facility for production of Forged Junction Rail, Railway Board has been requested to issue an order to Bhilai Steel Plant, Bhilai for trial production of Forged Junction Rails as per provisional specification already submitted by RDSO to Railway Board to confirm that production as per provisional specifications is achievable.

Forged Rails have been developed as an alternative of combination fish plated joint of 60 kg and 52 kg rail.

Railway Board has been requested to issue an order to Bhilai Steel Plant, Bhilai for trial production of Forged Junction Rails as per provisional specification already submitted by RDSO to Railway Board to confirm that production as per provisional specifications is achievable.

16.      

2011-12

Safety

Development& Trial of Corrosion resistant NCC rails

A new metallurgy has been developed as a result of project on corrosion prevention of rails under Technology Mission on Railway Safety. This metallurgy has been developed jointly by RDSO, IIT Kanpur and SAIL. 10,000 MT of NCC rails were ordered for trial. 10084 MT of NCC rails have been rolled by BSP and supplied to SE Railway (2398 MT), WR (1747MT) and SCR (2902 MT), SR & SWR (3037MT) for laying in track and conducting trial as per trial scheme circulated. Chief Track Engineers / Southern, South Western, South Central, South Eastern and Western Railways have been requested for advising current status of welding/laying of these rails and expediting laying of balance quantity. Reminders have been issued to SR, SCR, SER, WR and SWR to advise performance of NCC rails in the prescribed proforma on half yearly basis and to send the latest position of NCC rails laid in track and planned to be laid. Replies are awaited.

A new metallurgy has been developed as a result of project on corrosion prevention of rails for Coastal regions.

10084 MT of NCC rails have been rolled by BSP and supplied to SE Railway (2398 MT), WR (1747MT) and SCR (2902 MT), SR & SWR (3037MT) for laying in track and conducting trial as per trial scheme circulated. Chief Track Engineers / Southern, South Western, South Central, South Eastern and Western Railways have been requested for advising current status of welding/laying of these rails and expediting laying of balance quantity. Reminders have been issued to SR, SCR, SER, WR and SWR to advise performance of NCC rails in the prescribed proforma on half yearly basis and to send the latest position of NCC rails laid in track and planned to be laid. Replies are awaited.

17.      

2011-12

Safety

Development of corrosion resistant (Cu-Mo) rails

In order to prevent rail corrosion, RDCIS/Ranchi had developed corrosion resistant Cu-Mo rails which were laid in Waltair Division of East Coast Railway for initial field trial. On finding the encouraging performance of Cu-Mo rails, Railway Board ordered rolling of 1,000 MT of rails for extensive field trial. Trial scheme for trial of corrosion resistant (Cu-Mo) rails has been prepared and sent to concerned Railways Railway Board has also been  advised of locations of trial and consignee. Railways for advising Bhilai Steel Plant to dispatch 1000MT rails accordingly.

In order to prevent rail corrosion, RDCIS/Ranchi had developed corrosion resistant Cu-Mo rails which were laid in Waltair Division of East Coast Railway for initial field trial

Railway Board ordered rolling of 1,000 MT of railsf or extensive field trial. Trial scheme for trial of corrosion resistant (Cu-Mo) rails has been prepared and sent to concerned Railways Railway Board has also been  advised of locations of trial and consignee. Railways for advising Bhilai Steel Plant to dispatch 1000MT rails accordingly.

18.      

2011-12

Safety

Development & Field Trial of 110 UTS Rail

High strength 110 UTS rails have been developed by RDCIS/Ranchi for use on high density/heavy axle load routes. On approval of its rail chemistry. Railway Board ordered rolling of 600 MT of 110 UTS rails for field trial vide letter no.Track/21/ 2010/0504/7 dated 27-09-2010 addressed to SAIL/Kolkata. Trial will be conducted on Hatia-Orga section of Ranchi Divn.(Km 529/17-534/17=5.0km) of South-Eastern Railway. Trial scheme for trial of high strength 110 UTS rails has been prepared and sent to South Eastern Railway for conducting trial alongwith proforma for monitoring trial vide letter no.CT/RG/RIC dated 15-09-2010. Initial trial production of one heat no. 124320 of about 100MT of 110 UTS rails as per the approved chemical composition recommended by the Committee constituted by Railway Board has been rolled by BSP in 60kg profile in the month of Feb. 2012 and after conducting qualifying criteria tests and other acceptance tests as per IRST-12-2009 further production will be taken up.

High strength 110 UTS rails have been developed by RDCIS/Ranchi for use on high density/heavy axle load routes.

Railway Board ordered rolling of 600 MT of 110 UTS rails for field trial vide letter no.Track/21/2010/0504/7 dated 27-09-2010 addressed to SAIL/Kolkata. Trial will be conducted on Hatia-Orga section of Ranchi Divn.(Km 529/17-534/17=5.0km) of South-Eastern Railway. Trial scheme for trial of high strength 110 UTS rails has been prepared and sent to South Eastern Railway for conducting trial alongwith proforma for monitoring trial vide letter no.CT/RG/RIC dated 15-09-2010. Initial trial production of one heat no. 124320 of about 100MT of 110 UTS rails as per the approved chemical composition recommended by the Committee constituted by Railway Board has been rolled by BSP in 60kg profile in the month of Feb. 2012 and after conducting qualifying criteria tests and other acceptance tests as per IRST-12-2009 further production will be taken up

  

 



Source : WELCOME TO RDSO CMS Team Last Reviewed on: 06-12-2012  

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