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North Central Railway

Central

Chemical and

Metallurgical

Lab

At a Glance

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CENTRAL CHEMICAL AND METALLUGICAL LABORATORY

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PREFACE

Quality is the jewel of production. When the work is judged with the whetstone of

quality this increases not only the credibility of the work but it also raises the

confidence of user. The C&M Laboratories established under Mechanical

department at Workshops, Sheds advise Railway about suitability/ unsuitability of

the material of Rolling stock components, spares by ascertaining the quality,

identification of materials the and its acceptability for intended use through

physical, chemical & metallurgical testing as per standards which in turn ensures

the safe running of the rolling stock.

Prior to constitution of the new zone of NCR the existing C&M Laboratories in

present divisions of JHS, AGC, ALD division were affiliated to zonal laboratories

of Central Railway and Northern Railway. After constitution of NCR the Railway

Board sanctioned a central C&M Laboratory for NCR at Jhansi. The estimated cost

for this project was 231 lakh in the year 2007-08. The building was handed over in

February 2012 after completion of civil construction work. The procurement of

different testing machines, instruments, equipment and apparatus is under process.

Having received some items some testing work has been started but the

unavailability of staff and funds for this Laboratory proved to be the main obstacles

for this project and they hampered its progress. In spite of all these odds the

important testing work like failure investigation, welding test and chemical testing

have been started. In the future this Central Chemical & Metallurgical Laboratory

is hoped to acquire an esteemed place in the realms of the quality testing and

standards and will play its important role as expected and needed by Railway.

Shivendra Mohan Manisha Goel B.P.S.Parihar

CWM/JHS Principal STC ACMT

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NORTH CENTRAL RAILWAY

CENTRAL CHEMICAL AND METALLUGICAL LABORATORY

PREAMBLE

The Chemical and Metallurgical Laboratories equipped with modern and

sophisticated testing instruments, machines and equipment are involved in carrying

out destructive, nondestructive, chemical and metallurgical testing of materials

used in railways. These labs are situated at different places like workshop, diesel

loco sheds, electric loco sheds ROH depots and sick lines to ensure the quality in

production/maintenance, to control on line failure causing derailment/accident and

thereby playing an important role in saving the valuable lives and revenue

ABSTRACT

Introduction

In the present scenario when Indian Railway is striving for high speed

transportation with a goal of online safety the quality assurance takes a place of

immense importance. For achieving this goal the quality assurance should

inevitably be kept on the top priority. For safe running of rolling stock the chemical

and metallurgical testing of material is must. This could not be achieved without

having a strong infrastructure capable of sound testing. This Central Chemical &

Metallurgical Laboratory of NCR is being setup as a tool of quality assurance to

furnishing the chemical and metallurgical testing requirement of entire NCR for

quality control aspect.

These labs serve the Railway in two ways -

(1) Public safety

(2) Quality assurance

Public safety -

A C&M laboratory pays its full contribution in the safe running of the trains by

performing nondestructive tests of motion components periodically.

Nondestructive test of the motion components includes ultrasonic testing of axles

of wagons, carriages, diesel and electric locomotives, cranes etc., testing of

armature shafts, cylinder head valve seats, inserts, bolts, nuts and radiator fans,

roller bearing, piston heads, valves, springs are examined by Dye penetrant,Zyglo

and MPI test for their serviceability. The quality of welding of different

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components is assured by X-Ray/ γ-Ray radiography testing in C&M Labs for safe

running of trains.

Quality Assurance -

The C & M lab assures the quality in production/maintenance/ repairs by various

physical as well as chemical methods of testing for materials. These items are

tested according to various IRS/ISS/BSS/EN/ISO/RDSO and other foreign

specifications.

Scope of Testing for different types of material -

Testing of all types of material purchased by Stores department as per

relevant specifications.

Testing of non-ferrous scrap for selling price valuation of costly material

according to their constituents and elements present for estimating correct

auction rates.

To make analysis and classification of all types of ferrous, non-ferrous

metallic and non-metallic material and scrap for correct tariff rates in case of

any dispute/claim.

To make analysis of material and produce witness in court of law for

prosecution of alleged culprits notified by RPF, GRP, Police as “technical

experts” to establish whether these are railway properties.

Testing of overhead crane axles, overhead wires, cadmium alloy, pantograph

tips, transformer oil, grease, copper wires, special aluminum conductors etc.

Quality check for steels used for bridges, reinforcement, rails, fish, plates,

permanent way tools, building material and thermite welding material.

Testing of components for microwave towers, testing of phosphor bronze

strips, steel wire ropes etc.

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To testing of ferrous, non-ferrous alloys, virgin metals, metallic and non-

metallic components, plastic, composite material, Teflon, mica, paints,

lacquers, varnishes, fuel, lube oil, grease, petroleum products, rubber

component, bricks, coal, coke, water, sand etc.

The above testing of material is classified in different section and requirement of

supervisors and supporting staff is given in annexure – 1.

Cost of Mechanical Engg. Work

Fig. in Rs.

Particulars Original

PWP Cost

Original

P.B. Cost

(in 2006)

Detailed

Estimate

Cost

(in 2008)

Revised

Estimate

Cost

(in 2012)

MECHANICAL

ENGG. WORK

1,66,00,000 1,61,588,04 1,76,51,029 1,88,260,80

PINK BOOK PARTICULARS

Plan Head - 42

Sr No. PINK BOOK YEAR ITEM NO.

1. 2007-08 143

2. 2011-12 483

3. 2012-13 501

4. 2013-14 539

5. 2014-15 (Interim) 488

General Setup Plan: Building

No. of floor - Two

Total Covered Area - 510 + 510=1100 sq. meter

Plan – 30.5 m X 17.0 m

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No. of Sections in Lab – 07 nos.

1. NDT, 2. X-Ray, 3. Spectrograph, 4. Metallography, 5. Chemical &

Rubber testing, 6. Physical & 7. Paint testing

Technical Library – 01 no.

Mini workshop for Laboratory purpose – 01 no.

Section Stores – 03; Lab. General Store – 01 no.

Meeting Room- 01 no, Calibration room-1

Supervisors’ Room – 01 no, In-charge Room-1

Other Rooms for officers & office staff – 03 nos.

Core Testing Facilities to be available at this Lab

Spectrographic analysis of steels, X-Ray Radiography of welding joints,

Metallographic testing, Micrography, Electro-gravimetric analysis, Physical testing

of metals and polymers, NDT of material, Routine Chemical Testing, Ultrasonic

Testing and Failure investigation etc.

Scope of testing

The scope of the testing encompasses the testing of ferrous & non-ferrous metals

and alloys, Rubber, Plastic, polymers, Composites, Paint, Lube oil, grease, HSD,

Chemical testing, non-destructive testing, UST, Dye Penetrant Testing (DPT),

Magnetic Particle Inspection (Magnaflux), Zyglo, X-Ray and failure investigation

of components failed in service as Rails, Helical Coil Springs, Main Piston Pin,

Camshafts, Connecting Rod Blades, Centre Buffer Coupler, Yoke, Knuckle, Brake

Beam Hanger, Wheels, Cartridge Taper Roller Bearing etc.

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SET UP PLAN: CENTRAL C&M LABORATORY OF NCR

(A) GROUND FLOOR

S.

NO

.

DESCRIPTION

ACTIVITIES

PROPOSED

SET UP/ MACHINES TO BE

INSTALLED

1 Technical

Library and

Incharge

Library of Technical

Literature and

Specifications

Book shelves, reading tables &

chairs, Catalogue, Computer

table, Photo-copier m/c.

2 MPI Testing

R.D.P. , ZYGLO,

MAGNAFLUX

Testing Lab

Ultrasonic Testing, Red

dye penetrant test of

failed components &

stores samples, Testing

by magnetic methods.

Ultrasonic flaw Detector,

Permanent electromagnetic

yoke, Portable Electromagnetic

yoke, RDP test bench,

Instrument table.

3

Dark Room/

X-Ray

Radiography Lab

X-Ray film development

X-Ray testing of failed

rails (rail fractures

analysis), welding joints

of tank wagon, trolley,

carriage frame, welder’s

competency test etc.

X-Ray film development

Apparatus

Portable X-Ray Equipment,

Instrument table, X-Ray film

storage cabinet, Trolley, TLD

card (BARC) cabinet, X-Ray

film illuminator system, test

bench, etc.

4 Metallography &

Failure

Investigation Lab

Micrographic analysis of

failed jobs and fresh

metallic samples from

stores depots.

Inverted Metallurgical

Microscope, Specimen

Mounting Press, Image

analysis system, Specimen

Polishing m/c, Instruments

table, Stereo microscope,

Magnifiers, Instrument table,

Computer table.

5 Physical and

Mini Workshop

Hall

Sample preparation for

Ultimate tensile test

strength, Impact strength

Test, BHN & HRC test,

Drillings of metallic

samples for chemical

testing,

Universal Tensile Testing

(UTM) m/c, Lathe m/c,

Drilling m/c, Milling m/c,

Bench Grinder, Rockwell

hardness Tester, Brinell

Hardness Tester, Belt polisher,

Impact (30 kgm), Compression

Testing, Power hacksaw,

Abrasive Cut Off m/c.

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6 Instrumentation

& Calibration

Lab

In house calibration of

UFD, hardness testers of

metals & polymers,

thermometers,

pyrometers,

spectrograph, etc.

Instrument tables, anti

vibration tables, Storage

cabinet, different standards:

IIW blocks, hardness standard

blocks, ferrous and non ferrous

standard metal blocks, pH

meter, DPT test Ni-Cr standard

panels, etc.

7 Spectrography

Lab

Instrumental elemental

analysis of metallic

samples.

Spectrograph for metals,

Computer table, test bench,

instrument table, inert gas

dispensation system, inert gas

cylinders.

8 Staff’s Room As per description Staff’s Seating arrangement

9 Scrap & Lab

General Store

Room

As per description Storage cabinets, seating

arrangement

10 Officer’s room ACMT room

(B) FIRST FLOOR

S.

NO.

DESCRIPTION OF

ROOM/HALL/LAB

ACTIVITIES

PROPOSED

SET UP/ MACHINES TO

BE INSTALLED

1 Chemical, Rubber

& Plastic, Oil,

Paints ,

Miscellaneous

Testing Lab

Analytical testing of

ferrous and non ferrous

metals; physical,

chemical and

miscellaneous testing of

rubbers, polymers and

gaskets; testing of

paints, oils and

miscellaneous testing as

testing of coke, paint

brushes etc.

Chemicals, Ovens, Heaters,

Hot plates, Muffle furnace,

fuming chamber,

Centrifuge m/c, Stormer

viscometer, Humidity

cabinet, Ageing Oven,

Kinematic viscometer oil

tank bath, Abel’s flash

point Apparatus , Pensky –

Martins flash point

Apparatus , COC flash

point Apparatus, Tension

testing 2T with computer,

Penetrometer, Stirrer, Drop

point apparatus, Dean &

Stark apparatus, Distilled

water Plant, Island tables,

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Instrument tables, work

benches, computer table,

Wall mounting chemical &

glassware storage cabinets.

2 Meeting cum

Seminar, training,

demonstration Hall

Regular UST

coordination meeting of

UT operators from all

UT units as C&W

depots, Sheds,

workshops of entire

NCR, One year job

induction training of

CMAs recruited by

RRBs, Demonstration

of testing methods to

trainees other than C&M

cadre from STC

To be developed in future –

LCD projector system,

Lecture facilities, Seating

arrangement for meeting

Temporary given to Mod.

Cell

3 Balance Room Weighing of samples &

test products.

Anti-vibration tables,

analytical & other digital

balances

4 Paints stores Storage of paint drums

received for testing

Temporary given to AEN

Staff’s

5 Supervisor’s Room Common room for

supervisors

Temporary given to AEE

6 Office of Dy.

CCMT

Personal related and

general office work

Temporary given to AEN

7 Chemical,

Glassware,

Apparatus Stores

As per description Temporary given to AEN

Staff’s

8 CMT’s Room As per description Officer’s Seating

arrangement

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CMT Cadre in N.C.Rly.

Present scenario

The N.C. Rly was reconstituted on 01-01-2003 by merger of Jhansi and ALD

division including Jhansi Workshop and RSK Workshop. Initially the strength of

chemical and metallurgical Lab staff (non-gazetted posts) were 64 nos. (52 nos.

from Central Railway & 12 nos. from Northern Railway) and two gazette posts

(one post of CMT from central railway and one post of ACMT from northern

railway). After restructuring and pin pointing of units/divisions, the staff strength is

bring down to 57 nos. vide H.Q. Letter No. 707-E/Estt./Mech/C&M dated 02-12-

2009.

POSITION OF C&M SUPERVISORS On Date (11-06-2014)

Sr

no.

Div/W.S. CMS Sanc On Roll CMA

Sanc

On Roll Total

Sanc

Vac.

1 HQ/ ALD (STC) 01 01 … … 01 --

2 ALD/ DSL 01 00 … … 01 01

3 JHS W/Jhansi

Central Lab

14

W.C. 05

07

-

05

01

02

-

19

06

10

06

4 JHS D/Shed 08 06 02 01 10 03

5 JHS/ TRS 01 01 01 … 02 01

6 JHS/ C&W 01 01 … … 01 --

7 CNB/ TRS 04 03 03 … 07 04

8 CNB/ DSL 01 01 … … 01 --

9 CNB/ TM Shop 01 01 01 … 02 01

10 GWL/ RSK 04 03 03 01 07 03

11 GWL/ DSL 01 01 … … 01 -

12 AGC/ Div. 03 03 02 01 05 01

Total 45 28 18 5 63 30

Vacant on Date … 17 … 13 30

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A.Gazetted - 02 (01 ACMT w. c. at Jhansi and 01 CMT* revenue at RSK)

B. Non Gazetted Cadre- 63 (45 CMS+18CMA) & 04 Lab Asstt.

Posts will be vacant till Dec. - 2015 03 00

Total resultant vacancies 30 + 03 = 33

Two CMS will be promoted up to end of 2015 As ACMT, hence the total

resultant vacancy will be 33+02 =35.

Panel of 12 CMA received from RRB/ALD. Out of these only 07 CMA have

joined and 05 CMA are still awaited.

The proposal for indent of 18 vacant CMA posts is already sent to H.Q. vide

this office letter no. B/12A/Lab/staff/III dated 06-04-2013.Copy Attached.

Therefore it is request that another indent of 23 CMA posts (Instead of 18

CMA) is required to be sent to RRB Allahabad by H.Q.

There is no any Helper and/ or Artisan staff for C&M cadre sanctioned by

HQ under revenue.

STATUS OF POST CREATION WORK ON DATE

STAFF POSITION ON DATE AT JHSW

NON GAZETTED

Sr.

No.

Desgn. Grade

Pay

Sanctioned

Strength

Vacant

Work

charged

Vacant

WC

Total

vacancy

1 CMS 4600 12+2* 06 05 05 13

2 CMA 4200 05 03 01 01 04

Total 17 09 06 06 17

GAZETTED

ACMT 4800 ----- ---- 01 00 00

* 01 CMS from ALD/Diesel and 01 CMS from GWL/Diesel have been transferred

to central lab Jhansi approved by competent authority.

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STAFF REQUIREMENT TO OPERATE CENTRAL C&M LAB

Following staff is required to operate and manage the work of Central C&M

Laboratory

NON-GAZETTED STAFF

C&M Supervisors

Sr. No. Designation No. of posts

1 Chemical and Metallurgical Superintendent (CMS) 14

2 Chemical and Metallurgical Assistant (CMA) 06

Total 20

Staff other than C&M Supervisors

Sr. No. Designation No. of posts

1 Office Superintendent 01

2 Clerk 02

3 Steno 01

4 Artisan (Grinder, Welder, Machinist) 03

5 Helper 10

6 TADK 01

Total 18

GAZETTED STAFF

Sr.

No.

Designation No. of posts

1 Deputy Chief Chemist & Metallurgist (Dy. CCMT) 01

2 Chemist & Metallurgist (CMT) 01

3 Assistant Chemist & Metallurgist (ACMT) 01

Total 03

Note – Indents for above Gazetted and Non-gazetted staff under process at head

quarter.

Originally a proposal for 40 posts (03 nos. C&M officers, 20 nos. C&M

supervisors and 17 nos. other staff) was proposed as it is essential to operate the

lab. At initial stage to commence the work following two proposals have been

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moved and further creation of posts will be proposed in future as the testing load

increases.

1. Proposal for creation of non-gazetted 10 nos. posts of C&M supervisors

(CMS-7 & CMA-3), 01 post of Sr. Steno and 01 post of TADK under

revenue is under process at HQs/ ALD.

2. Proposal for creation of 03 nos. gazetted posts (Dy. CCMT- 01, CMT- 01 &

ACMT- 01) has been vetted by associated accounts.

REQUEST – It is requested to sanction proposed gazetted and non- gazetted staff

along with Helper/ Artisan to manage quality control work which is essential for

safety of Railway.

Roll of C&M Central Lab

The C & M Organization of Indian Railways is primarily responsible for quality

control & consequential safety on Indian Railways. Their duties include checking

& testing & certifying the Raw materials used in the manufacture of Rolling stocks

to exact specifications to avoid the use of sub-standard materials in the production

repair & maintenance of Railway Coaches, Wagons and Locomotives.

Safety items like Wheels, Axles, Springs, Rails, Bogie Frames and Springs Rails

etc. supplied to the Production & Repair Shops by Firms & Suppliers etc. are tested

and certified by CMT Staff and ensuring safety of travelling public.

The Railway Board Management Services has considered C & M Organization as

the back bone of entire Quality Control and preventive maintenance exercise of all

Engineering Departments.

Material Testing:

• Chemical and Physical Testing of Ferrous/ Non-Ferrous metals, Rubber,

Plastics, Plywood, Composites, FRP materials, Electrical cables, Adhesives,

Sealants & all other materials used in Railways.

• Testing of Welding Consumables, Trials on Welding processes for coaches,

bridges, tracks etc.

• Radiographic testing of Welds (Critical joints) (100% of EMU Bogie Frames),

Castings, Forgings etc.

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• 100% Ultrasonic Testing of Wheel & Axles of carriage, wagon and locos.

• 100% Magnetic Particle Inspection (MPI) of Spring Steel bars & springs for

detection of defects.

• Testing of Paints & surface coatings used for corrosion prevention on Railway

coaches & other useful assets.

• Testing of Oil, Grease, Coolants & other Lubricants in Production Units/Diesel

Sheds for proper running of Locomotives.

Process Control:

• Process control of welding of Bogie frames, Under-frames, Shell etc. at Shop

Floor for Conventional, Export and LHB coaches.

• Welder approval for SAW, MIG, TIG, Spot welding processes

• Process control in heat-treatments of Annealing, Normalizing of Forged

Components.

• Process control in heat-treatments of Hardening and Tempering of Coiled

Springs.

• Process control in Corrosion prevention &Phosphating.

• Process control in Paint shop.

Quality Management System (ISO-9001/ 2000):

• Calibration of Measuring & Testing Equipments.

• Updating of Quality Manuals and related documents.

• Co-ordination for Process Qualification Requirements.

• Co-ordination for Process Validation Requirements.

• Periodical Internal Audits and Subject to External Audits.

MAIN FUNCTIONS OF CMAs & CMSs:

Chemical and Metallurgical Engineers ensure effective quality control and safety

on Railways. Chemical & Metallurgical Organization is engaged in testing and

certifying of all raw materials, finished products & fuel etc. assuring usage of

standard materials and effective quality control of vital Safety required for Rolling

stocks & Locomotives.

To ensure the effective quality control and safe running of trains following

important functions are performed by CMAs & CMS working in the Chemical and

Metallurgical Labs on the Railways:

a) All the testing has to be done on a time bound basis to ensure productivity and

efficiency in production, repair and maintenance of Rolling Stock and

punctuality of Train services – even while ensuring optimum safety & quality

control.

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b) The C & M Engineers (CMAs & CMS) conduct Failure Investigation of

Railway components involved in derailment and accidents and making suitable

recommendations for preventing further failures & deficiencies.

c) The C & M Engineers use the NDE (Non-Destructive Evaluation) of critical

components and save crores of Rupees for Indian Railways.

d) Testing of materials and components for mechanical & metallurgical properties

and Chemical Compositions.

e) Testing of Welding consumables, control of Welding-processes, Periodical

Assessment of Welders and advice of suitable welding techniques for Stainless

Steel LHB / Sri Lankan coaches.

f) Non-destructive testing of Bogie frames, Bogie/Body Bolsters, Axles(100%)

Spring Bars (100%), Coiled Springs(100%) etc. which are critical & safety

items.

g) Process control of Heat-treatment of Coiled Springs, Forged components etc.

h) Process control of phosphating process.

i) Assess the quality of fuel and lubricants to ensure smooth and safe running of

rolling stocks and Locos.

j) Check the quality of paints to avoid corrosion, safety, durability & required

finish. Testing of various paints used for painting of Detail/Assembly

Components & System Paints (Epoxy-cum-PU / other High Performance

Coatings) for painting of coaches and Control of System Painting in Paint-

Booths. Inspection of outsourced components like Bogie Frames, Outer Doors,

PVC flooring, Water Tanks etc. at Firm's premises.

k) Measuring, monitoring and improving the environment control around work

premises to comply with the Standards of Environment Management system

(ISO-14001/2004) and Occupational Health & Safety Assessment service

(OHSAS - BS-18001/2007).

Additional Duties:

Standardization of new materials used for rolling stock.

Consultancy to Design Wings of all Engineering Departments of Indian

Railways for selection of proper raw material, process etc.

Duties & responsibilities of C & M Staff have been continuously increasing and

are bound to further increase over the years – due to modernization of Rolling

Stock, Locomotives & all other systems on the Railways, introduction of high

speed trains & qualitative change in technology.

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DUTY LIST OF ASST. CHEMIST & METALLURGIST (Gazzeted)

Central Lab workshop Jhansi

ASST. CHEMIST &METALLURGIST (ACMT/JHS) will control and plan the

testing of material by UST, metallographic, physical, chemical and mechanically

and also plan to procurement of the testing materials for all the section of main

laboratory.

The specific responsibilities of ACMT in Central Lab Workshop/JHS are given

below:

(1) ACMT will directly supervise metallurgical investigation of failed components.

(2) ACMT will closely monitor the maintenance of all laboratory equipment/

instruments/ testing machines in working order including procurement of

COFMOW/ M&P items.

(3) ACMT will serve as a nodal in charge for all UST work done by C&M lab.

Staff in entire NCR and summarized UST statement in MCDO.

(4) ACMT will ensure 100 % testing of axles in workshop, diesel shed and electric

loco shed and open line i.e. ROH depot of Jhansi and Allahabad division of

NCR.

(5) ACMT will co-ordinate the safety meeting on ultrasonic testing of axles with

all the UST operators of NCR.

(6) ACMT will solve the problems faced by ultrasonic operators in regard to

testing of axles.

(7) ACMT will plan a code for procedure for ultrasonic testing of axles if the same

is not available with RDSO/LKO.

(8) ACMT will plan the procurement of UST flaw detectors and its accessories on

age basis for effective UST testing over NCR.

(9) ACMT will also look after the work of indents for stock and non-stock items

with help of section in-charge Material control and stores.

(10) ACMT will control over staff management in central lab including personal

and DAR matters. He will look after the work of CMT in his absence.

(11) Supervise the duty of all section in-charges and authorized for sending the

reports to other depots & railways.

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DUTY LIST OF ASST. CHEMIST & METALLURGIST (Gazzeted)

Rail spring Karkhana, Sithouli, Gwalior

ASST. CHEMIST &METALLURGIST (ACMT/RSK) will control and plan the

testing of materials by UST, metallographically, physical, chemical and

mechanically and will also plan for procurement of the testing materials for RSK

lab, Diesel lab AGC, GWL MTJ and Baad. The specific responsibilities of ACMT

in RSK Workshop/GWL are given below:

(1) ACMT will directly supervise metallurgical investigation of failed components

and manufactured springs heat wise.

(2) ACMT will closely monitor the maintenance of all laboratory

instruments/equipment/ testing machines in working order including

procurement of COFMOW/ M&P items.

(3) ACMT will closely keep a watch over entire heat treatment and manufacturing

process of conventional and fiat bogie springs.

(4) ACMT will ensure 100 % testing of springs by Magnaflux and 3 samples per

batch for decarburization depth, core to case hardness, grain size, inclusion

rating, almen test and 10 samples per batch for surface hardness test.

(5) ACMT will ensure appropriate chemical composition as per material

compositions referred in concerned IS/EN/ISO as per RDSO directives.

(6) ACMT will plan to prepare a code of procedure/reliable drawings and

specifications for different parts/ components used in spring manufacturing at

RSK.

(7) ACMT will plan the procurement of new testing machines/instruments/

equipment/ apparatus and accessories on requirement.

(8) ACMT will also look after the work of stock and non-stock items with help of

Lab in-charge and stores.

(9) ACMT will look after the staff matter including indent of posts and DAR.

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DUTY LIST OF CHEMIST & METALLURGIST (Gazzeted)

The Indian Railways is planning for huge improvement in its infrastructure,

technology and service on account of “Vision 2020”, which will further add to the

burden & responsibilities of C&M Engineers.

The chemist and Metallurgist will control and plan the testing and other activities in

various sections of Central Laboratory and other field Laboratories situated at all

divisions of N.C. Railway including RSK Sithouli Karkhana and MLR workshop.

CMT will be responsible for proper functioning of Central Laboratory.

The specific responsibilities of CMT in NCR are given below:

(1) CMT will issue the testing certificates for materials tested in laboratory and will

have quality check to relevant specifications. He will also carry out the

metallurgical investigation of failed components and will suggest the remedial

measures.

(2) CMT will monitor the maintenance of all laboratory equipments/instruments

testing machines in working order.

(3) CMT will plan for recruitment, selection promotion and transfer of C&M staff.

CMT will plan to conduct the induction training to new recruits and arrange for

periodic training of other staff.

(4) CMT will ensure the implementation of quality system procedure in compliance

to quality policy and quality objectives.

(5) CMT will ensure and get maintained safety environment in the laboratory work

place.

(6) CMT will control over the quality control on the manufacturing and repair and

maintenance operations in the workshop diesel shed, electric loco shed and C

&W ROH depots.

(7) CMT will recommend the alterative specifications and materials with respect to

foreign specifications and transfer of technology projects.

(8) CMT will keep closely liason with PHOD’s of mechanical dept. and with

RDSO/LKO for special tasks. He will also act as an advisor to mechanical,

electrical, civil, S&T, stores, operating and safety deptt. Of NCR.

(9) CMT will have regular inspection of other laboratories over NCR.

(10) CMT will conduct the co-ordination meeting of its technical staff and will

organize in house training programme to increase the efficiency to laboratory

staff.

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DY. CHIEF CHEMIST & METALLURGIST (Gazetted)

No. of post – 01(one)

Grade- Rs. 14300-18300(pre revised )

Dy. Chief Chemist & Metallurgist (Dy. CCMT) attached to the major work shop

of NCR in Jhansi will work as an advisor on chemical and metallurgical aspect of

repairs, productions and other activities for all the work shop, Diesel shed, Electric

loco shed ,and sick line /ROH depots at JHS, GWL, AGC, CNB and ALD. The

specific responsibilities of Dy. CCMT. in North Central Railway are given below.

(1) MONITORING UST WORK - He will be responsible for carrying out the

ultrasonic testing of rolling stock axle, wheel and other components in all the

workshops, divisions, loco sheds ensuring availability of required flaw detectors

and consumables, RDSO trained operators man power as and when required. He

will be making tentative code of procedure for ultrasonic testing of components and

keep liasoning with RDSO for preparation of final UST code of procedure. He will

be responsible for compiling the statistical data on UST and time to time taking

necessary corrective action to tackle up the failure prone areas and to send the

statistical data of UST to RDSO for further analysis. He will also be conducting

regular meeting with UST operators of the zonal railways to sort out the problems

related to ultrasonic and refresh their knowledge so that the UST work in zonal can

be carried out effectively. Roughly 1.5 lack axles and others items are examined

yearly in this zonal railway ultrasonically to ensure the safety and reliability of

rolling stock.

(2) FAILURE ANALYSIS-The Dy. CCMT will be responsible for carrying out

the metallurgical and chemical investigation of failed components received form

divisions & workshops and suggest remedial measures. Every month about 70 to

100 failed components will be subjected to failure analysis involving the

knowledge of mechanical metallurgy, mechanical behavior, stress analysis, fracture

analysis, design, chemical composition and testing of various other parameters by

destructive and non-destructive methods The failure analysis reports are used as

guiding to by the mechanical and electrical officers of the workshops, sheds and

divisions for taking corrective and preventive actions to work improving safety and

reliability of coaches, wagons and locos. Failure analysis reveals are required to

be metallurgically tested for identifying the cause of failure suggestive

remedial measures. Thermite welding and butt welding of rails is an important

21 | P a g e

activity where the n depth knowledge of metallurgy is required time to time for

obtaining sound weld joints having maintaining desire strength under functioning,

condition of environmental temperature. About 25 to 30 cases of failed rails will

be investigated in laboratory under guidance.

(3) MODIFICATION IN THE MATERIAL SPECIFICATION- The Dy. CCMT

will be required to technically examine the exisiting failure prone material

specification of the components of coaches, wagons and locomotives and suggest

appropriate material/ process to the technical officers of headquarter as well as

officers working in the field.

(4) FAILURE ANALYSIS OF ELECTRICAL COMPONENTS – Large number

of components such as components of OHE, electric loco, rail cars, is required to

be analysed and remedial measures suggested for prevention of failure. About 20

components related to the electrical department received from division and

electrical dept. will be subjected to failure analysis under the guidance and

supervision of Dy. CCMT.

(5) DEVELOPMENT OF IMPORT SUBSTITUTION – The services of the Dy.

CCMT are required for in demising the components of electric loco diesel loco and

coaches by testing the material and finding out equivalent Indian standard so that

the vendors for the same could be developed indigenously.

(6) DEVELOPMENT OF WELDING PROCEDURE AND testing – More then

50% of activities of repair and maintenance involve welding. Welding metallurgy

plays an important role in achieving the sound and strong weld joint. Dy. CCMT

will contribute in development of welding procedures, suggesting effective ways

in carrying out welding procedures emphasizing on pre welding and post welding

heat treatment requirements. It is also essential to have a panel of proficient

welders for critical applications. Dy. CCMT will organize the proficiency

examination of welders as per mandatory requirements. He will also maintain a

fully equipped X-ray radiography examination laboratory with all essential safety

measures.

(7) QUALITY ASSURANCE CHECK- Stock as well as non-stock items are

procured / purchase by stores department of workshop as well as divisional level,

Dy. CCMT will carry out the quality assurance check on purchase item as apart of

purchase inspector. This will help in eliminating / rejecting of sub-standard items.

Thus improving the reliability of rail services.

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(8) QUALITY CHECK IN WORKSHOP- Dy. CCMT through subordinate

officers shall maintain the quality control checks on the manufacturing, repair and

maintenance activities in workshop related to metallurgical and chemical aspects.

(9) PREVENTIVE MAINTENANCE CHECKS-In NCR there are two diesel loco

sheds and two electric loco sheds. Dy. CCMT will require to plan the preventive

maintenance check/ tests for smooth functioning of diesel loco and electric loco of

respective sheds so that no point of time out turn of locos is affected which is

related to the punchuality of running trains.

(10) PLANNING AND IMPLEMENTATION OF UST –ultrasonic examination of

rolling stock is a prime activity on NCR under technical control of Dy. CCMT . He

is responsible to procure and maintain all the necessary test equipments /

instruments ultrasonic flaw detectors probe etc. in working condition and in

calibrated status.

(11) NON GAZETTED LABORATORY CADRE CONTROLLING – Dy.CCMT

will be responsible for recruitment, promotion and transfer of lab cadre non

gazetted staff. He will also require to human resource development by identifying

areas of training. He will plan and impart training to all laboratory staff so as to

have fully trained and proficient man power He will also plan induction training for

apperentices recruited through RRB.

(12) MONITORING OF ENVIRONMENTAL RELATED ISSUES- With the

latest directives from Rly. Bd. regarding setting of an environmental management

system for mechanical workshop. Dy CCMT. will be require to put up for effective

implementation of environmental management system. In view of legislative

requirement and of the setting up efficient treatment plans etc. The advisory role of

Dy. CCMT will be very much required. On the other railway Dy. CCMT is

functioning as a management representative (MR) in the ISO14000 certification

programme.

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ACTIVITIES

At present no staff is available for this Lab and the proposal for creation of ten (10)

nos. of posts of Chemical and Metallurgical supervisors is under process. Despite

the lack of the technical staff a few of the Chemical & Metallurgical testing

activities has been started anyhow with the extra efforts of CMT staff of Jhansi

workshop over their regular duties there. Their contribution is really appreciable as

they are already over burdened due to heavy vacancy at Jhansi workshop. The

activities started are summarised below –

(i) Spectrographic analysis of different components/ jobs for their chemical

composition/ chemistry.

April 2012 to March 2013

Sr.

No.

Month Item Name/

Particulars

Item recd. from No. of

samples

1 Apr’12 Steel Samples RSK/STLI 04

2 May’12 Screw Coupling Shackle Pin,

Spring for cut off angle cock,

Steel Samples

Dy.CMM/JHS,

RSK/STLI

16

3 June’12 Angle Iron Fillet, Round Bar

28 mm, Steel Samples, Rivet

Snap Head 20X100 mm long,

Hot Forged Rivet, MS Steel

Rivet Snap, Top Side Wear

Liner, Spring Steel, Pin Flat

Head for Break Gear Type A

Dy.CMM/JHS,

RSK/STLI

53

4 July’12 Steel Samples RSK/STLI 05

5 Aug’12 Shearing Blade SSE/Panel

Plate/JHSW

01

6 Sept’12 Steel sample, Welding RSK/STLI,

SSE/Welding/JHS

02

24 | P a g e

Electrode W

7 Oct’12 Steel Samples RSK/STLI 09

8 Nov’12 Steel Samples, Welding

Electrode, Roller

RSK/STLI,

SSE/Welding/JHS

W,CMS/

Metallography

04

9 Dec’12 Steel Samples, Coupler, MS

Bush Bar, Welding Electrode

RSK/STLI, CMS/

Metallography,

SSE/Welding/JHS

W

06

10 Jan’13 Welding Electrode, Rail Piece,

Head stock

SSE/Welding/JHS

W , CRWS/BPL

03

11 Feb’13 Steel Samples, CTRB Rollers RSK/STLI, CMS/

Metallography

13

12 Mar’13 Welding Electrode, Steel

Samples, Journal Thrower,

Knuckle, Lug Liner

SSE/Welding/JHS

W, RSK/STLI,

CMS/

Metallography,

ADME(DSL)/JHS

14

Spectrographic analysis April 2013 to March 2014

Sr.

No.

Month Item Name/

Particulars

Item recd. from No. of

samples

1 Apr’13 Steel Samples SSE/weld.&XEN

TMC

3

2 May’13 Water pump, bolt, welding

electrode T-bar hanger &

samples of spring

Dy.CMM/JHS,

RSK/STLI

12

3 June’13 Spring material electrode, WS/JHS, 24

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power hacksaw blade, bolt, RSK/STLI

4 July’13 Spring rods samples, tapered

shank portion

RSK/STLI and tool

room JHSW

10

5 Aug’13 --- --- ---

6 Sept’13 Failed Steel sample, Welding

Electrode

ADME/Baad

SSE/Welding/JHS

W

07

7 Oct’12 Steel Samples electrode and

hexa nipple

SSE/JHS & RBL 02

8 Nov’12 --- --- ---

9 Dec’12 Key for brake block, bracket

pillar for LHB coaches

Dy CME/RBL

Dy CME/JHS,

18

10 Jan’13 Electrode, CBC and knuckle SSE/Welding/JHS

W , M&P

05

11 Feb’13 Hexa gonal cap screw,

equalizing lever, bend cutter

Sr. DME/D, SMM

ELS/JHS

06

12 Mar’13 Draw-bar hook, cattle guard,

couple body knuckle

Dy CMM/ ELE,

SR. DME/AGC,

DRM/JHS

07

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Failure investigation of components as CTRB, CBC, J/Thrower 2012-13

Sr.

No.

Month Item Name/

Particulars

Item recd. from No. of

samples

1 Sept’12 CTRB SSE/M/c &Wheel

Shop/JHSW

02

2 Dec’12 CTRB SSE/M/c &Wheel

Shop/JHSW

01

CBC body SSE/C&W/GMC/C

NB

01

3 Feb’13 CTRB SSE/M/c &Wheel

Shop/JHSW

01

4 Mar’13 Knuckle DRM(M) JHS 01

Journal thrower Sr.DEE/RS/CNB 01

Failure investigation of components as CTRB, CBC, J/Thrower 2013-14

Sr.

No.

Month Failure CTRB Total

No. of

samples

1 Apr’13 --- --- ---

2 May’13 --- 02 02

3 June’13 03 02 05

4 July’13 01 --- 01

5 Aug’13 --- 01 01

6 Sept’13 --- 01 01

7 Oct’13 --- --- ---

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8 Nov’13 --- 01 01

9 Dec’13 --- 02 02

10 Jan’14 --- 02 02

11 Feb’14 01 05 06

12 Mar’14 03 --- 03

Total tested 24

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Chemical and Miscellaneous testing as Paint brush testing of tender samples,

chemical testing of store samples, Hard coke, Welding Electrodes, etc.

Sr.

No.

Month Item Name/

Particulars

Item recd. from No. of

samples

2 May’12 Punch set, Screw Coupling

Shackle Pin, Spring for cut off

angle cock, Steel Samples,

Angle Iron Fillet, Round Bar

28 mm, Steel Samples, Rivet

Snap Head 20X100 mm long,

Hot Forged Rivet, MS Steel

Rivet Snap, H.S. Steel samples

Dy.CMM/JHS 86

3 June’12 Top Side Wear Liner, Spring

Steel, Pin Flat Head for Break

Gear Type A, Punch, Hand

Brake Sleeve

Dy.CMM/JHS,

RSK/STLI

14

4 July’12 BK beam Spring Washer Dy.CMM/JHS 05

5 Aug’12 Foundry coke, Rivet 22X100

mm

WM(R)/JHSW 02

6 Sept’12 Brush Paint & Varnish, Sash

Tool, Steel sample, Welding

Electrode, Bush Metallic, Pin

Flat Head

Dy. CMM/JHS,

SSE/Welding/JHS

W

09

7 Oct’12 Brush Paint & Varnish, AMM(G)/ALD 04

8 Nov’12 Welding Electrode SSE/Welding/JHS

W

01

9 Dec’12 Brush Paint & Varnish Dy.CMM/JHS 05

10 Jan’13 Hanger Block, Metal Piece, ADME(DSL)/JHS, 07

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Roller, Brush Paint & Varnish AMM(G)/ALD

11 Feb’13 Foundry Coke Dy.CMM/JHS 01

12 Mar’13 Brush Paint & Varnish SMM ALD 18

Chemical and Miscellaneous testing as Paint brush testing of tender samples,

chemical testing of store samples, Hard coke, Welding Electrodes 2013-14.

Sr.

No.

Month Pass Failure Total

No. of

samples

1 Apr’13 07 07 14

2 May’13 --- --- ---

3 June’13 03 01 04

4 July’13 01 --- 01

5 Aug’13 01 --- 01

6 Sept’13 04 02 06

7 Oct’13 13 11 24

8 Nov’13 03 --- 03

9 Dec’13 06 02 08

10 Jan’14 02 --- 02

11 Feb’14 02 --- 02

12 Mar’14 --- --- ---

Total tested 65

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Hardness testing of temping tools and store samples 2012-13

Sr.

No.

Month Item Name/

Particulars

Item recd. from No. of

samples

1 June’12 Hand Brake Sleeve Dy.CMM/JHS, 02

2 July’12 BK beam Spring Washer

,Tamping tools

SSE/TD/JHS 51

3 Aug’12 Rivet 22X100 mm WM(R)/JHSW 01

4 Oct’12 Tamping tools SSE/TD/JHS 25

5 Nov’12 Spindle, Welding Electrode Dy. CMM/JHS,

SSE/Welding/JHS

W

02

6 Dec’12 Tamping tools SSE/TD/JHS 18

Hardness testing of temping tools and store samples 2013-14

Sr.

No.

Month Item Name/

Particulars

Item recd. from No. of

samples

1 May 13 Misc. ---- 11

2 Nov 13 Misc. ---- 06

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Welder’s competency test. During 2012-13

Sr.

No.

Month Item Name/

Particulars

Item recd. from No. of

samples

1 Jan’13 Welded piece for welder’s

competency test

BTC/JHSW 35

2 Feb’13 ---do--- ---do--- 17

3 Mar’13 ---do--- ---do--- 14

Welder’s competency test. During 2013-14

Sr.

No.

Month Item Name/

Particulars

Item recd. from No. of

samples

1 Apr’13 Welded piece for welder’s

competency test

BTC/JHSW 03

2 May’13 ---do--- ---do--- 05

3 June’13 ---do--- ---do--- 09

4 July’13 ---do--- ---do--- 07

5 Aug’13 ---do--- ---do--- 03

6 Sept’13 ---do--- ---do--- 04

7 Nov’13 ---do--- ---do--- 02

8 Dec’13 ---do--- ---do--- 05

9 Jan’14 ---do--- ---do--- 04

Total tested 42

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UST SUMMARY OF C&M LAB JHSW 2012-13

Sr.

No

Month Axle Type No of

axles

tested

Total No

of axles

tested

No of

axles

rejected

Rejection

percentage

1 Apr’12 CTRB 1872 2280 00 00

RB & Others 336

2 May’12 CTRB 2442 2724 08 029

RB & Others 282

3 June’12 CTRB 2481 2741 07 0.26

RB & Others 260

4 July’12 CTRB 2338 2533 06 0.24

RB & Others 195

5 Aug’12 CTRB 2223 2486 12 0.48

RB & Others 263

6 Sept’12 CTRB 2469 2748 10 0.36

RB & Others 279

7 Oct’12 CTRB 2418 2635 12 0.46

RB & Others 217

8 Nov’12 CTRB 2037 2204 09 0.40

RB & Others 167

9 Dec’12 CTRB 2319 2587 11 0.43

RB & Others 268

10 Jan’13 CTRB 2388 2703 13 0.48

RB & Others 315

11 Feb’13 CTRB 2331 2625 10 0.38

RB & Others 294

12 Mar’13 CTRB 2166 2505 11 0.44

RB & Others 340

Total tested 30699 109 0.35

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Rejection percentage in UST

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UST SUMMARY OF C&M LAB JHSW 2013-14

Sr.

No

Month Axle Type No of

axles

tested

Total No

of axles

tested

No of

axles

rejected

Rejection

percentage

1 Apr’13 CTRB 2341 2631 12 0.45

RB & Others 290

2 May’13 CTRB 2600 2919 22 0.75

RB & Others 319

3 June’13 CTRB 2234 2523 12 0.48

RB & Others 289

4 July’13 CTRB 2400 2732 14 0.51

RB & Others 332

5 Aug’13 CTRB 2376 2645 05 0.19

RB & Others 269

6 Sept’13 CTRB 2576 2866 15 0.58

RB & Others 290

7 Oct’13 CTRB 2357 2671 08 0.30

RB & Others 314

8 Nov’13 CTRB 2438 2800 08 0.28

RB & Others 362

9 Dec’13 CTRB 2530 2873 10 0.34

RB & Others 343

10 Jan’14 CTRB 2485 2797 05 0.18

RB & Others 312

11 Feb’14 CTRB 2432 2724 06 0.22

RB & Others 292

12 Mar’14 CTRB 2426 2761 09 0.33

RB & Others 335

Total tested 32942 126 0.38

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Rejection percentage in UST

36 | P a g e

TARGETS

TARGETS

1. Quality test of stores materials.

2. Improvement of welding quality and material.

3. Quality test of paint and painting quality monitoring.

4. Ultrasonic testing of Axles & Wheels

5. Nondestructive testing of components by ZYGLO, MAGNAFLUX and

DPT.

6. Failure investigations of Couplers, CTRB etc.

7. Chemical composition determination by Spectrometer.

8. Physical & Metallurgical examination, Macro, Micro, T.S., Bend test,

Compression test.

9. X-ray radiography of weld joints.

10. Material chasing, Indents, Stores, Post creation proposals, Staffing proposals,

Installation, Commissioning, PTC, Personnel related matters of C&M staff,

Miscellaneous testing.

FUTURE PLAN

1. MLR shop related testing facility development.

2. To arrange technical C&M staff by filling vacant posts and by proposing for

creation of new posts with increasing workload in different units of NCR.