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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 divisions were affiliated to zonal laboratories of Central

Railway and Northern Railway. After constitution of NCR, the Railway Board sanctioned

a New 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, equipments and apparatus

are required for managing quality system with production. Most of the items are received

and some are under process. Having received some items, the 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 investigations of different components, welder’s

efficiency test and chemical testing by spectrometer 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 components is assured by X-Ray/ γ-Ray radiography

testing in C&M Labs for safe running of trains.

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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.

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.

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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

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.

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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.

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.

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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.

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

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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,

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

To be developed in future –

LCD projector system,

Lecture facilities, Seating

arrangement for meeting

Temporary given to Mod.

Cell

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of testing methods to

trainees other than C&M

cadre from STC

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

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.

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

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.

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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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.

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

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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 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.

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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.

• 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.

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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.

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.

DY. CHIEF CHEMIST & METALLURGIST (Gazetted)

No. of post – 01(one)

Grade- Rs. 14300-18300(pre revised )

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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 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.

20 | P a g e

(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.

(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

21 | P a g e

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.

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.

22 | P a g e

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

Electrode

RSK/STLI,

SSE/Welding/JHS

W

02

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

23 | P a g e

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,

power hacksaw blade, bolt,

WS/JHS,

RSK/STLI

24

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

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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

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

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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 --- --- ---

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

Dy.CMM/JHS 86

27 | P a g e

28 mm, Steel Samples, Rivet

Snap Head 20X100 mm long,

Hot Forged Rivet, MS Steel

Rivet Snap, H.S. Steel samples

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,

Roller, Brush Paint & Varnish

ADME(DSL)/JHS,

AMM(G)/ALD

07

11 Feb’13 Foundry Coke Dy.CMM/JHS 01

12 Mar’13 Brush Paint & Varnish SMM ALD 18

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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

Welder’s competency test. During 2012-13

30 | P a g e

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

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

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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

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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.