1 | P a g e North Central Railway Central Chemical and Metallurgical Lab At a Glance 2 | P a g e CENTRAL CHEMICAL AND METALLUGICAL LABORATORY

3 | P a g e PREFACE Quality is the jewel of production. When the work is judged with the whetstone of qualitythisincreasesnotonlythecredibilityoftheworkbutitalsoraisesthe confidenceofuser.TheC&MLaboratoriesestablishedunderMechanical department at Workshops, Sheds advise Railway about suitability/ unsuitability of thematerialofRollingstockcomponents,sparesbyascertainingthequality, identificationofmaterialstheanditsacceptabilityforintendedusethrough physical,chemical&metallurgicaltestingasperstandardswhichinturnensures the safe running of the rolling stock. PriortoconstitutionofthenewzoneofNCRtheexistingC&MLaboratoriesin 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 February2012aftercompletionofcivilconstructionwork.Theprocurementof different testing machines, instruments, equipment and apparatus is under process. Havingreceivedsomeitemssometestingworkhasbeenstartedbutthe unavailability of staff and funds for this Laboratory proved to be the main obstacles forthisprojectandtheyhampereditsprogress.Inspiteofalltheseoddsthe important testing work like failure investigation, welding test and chemical testing have been started. In the future this Central Chemical & Metallurgical Laboratory ishopedtoacquireanesteemedplaceintherealmsofthequalitytestingand standards and will play its important role as expected and needed by Railway. Shivendra Mohan Manisha GoelB.P.S.Parihar CWM/JHSPrincipal STCACMT 4 | P a g e NORTH CENTRAL RAILWAY CENTRAL CHEMICAL AND METALLUGICAL LABORATORY PREAMBLE TheChemicalandMetallurgicalLaboratoriesequippedwithmodernand sophisticated testing instruments, machines and equipment are involved in carrying outdestructive,nondestructive,chemicalandmetallurgicaltestingofmaterials usedinrailways.Theselabsaresituatedatdifferentplaceslikeworkshop,diesel loco sheds,electric locoshedsROH depotsandsicklines toensure thequalityin 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 InthepresentscenariowhenIndianRailwayisstrivingforhighspeed transportationwithagoalofonlinesafetythequalityassurancetakesaplaceof immenseimportance.Forachievingthisgoalthequalityassuranceshould inevitably be kept on the top priority. For safe running of rolling stock the chemical andmetallurgicaltestingofmaterialismust.Thiscouldnotbeachievedwithout havingastronginfrastructurecapableofsoundtesting.ThisCentralChemical& MetallurgicalLaboratoryofNCRisbeingsetupasatoolofqualityassuranceto furnishingthechemicalandmetallurgicaltestingrequirementofentireNCRfor quality control aspect.These labs serve the Railway in two ways - (1) Public safety (2) Quality assurancePublic safety -AC&Mlaboratorypaysitsfullcontributioninthesaferunningofthetrainsby performingnondestructivetestsofmotioncomponentsperiodically. Nondestructive test of the motion components includes ultrasonic testing of axles ofwagons,carriages,dieselandelectriclocomotives,cranesetc.,testingof armatureshafts,cylinderheadvalveseats,inserts,bolts,nutsandradiatorfans, roller bearing, piston heads, valves, springs are examined by Dye penetrant,Zyglo andMPItestfortheirserviceability.Thequalityofweldingofdifferent 5 | P a g e components is assured by X-Ray/ -Ray radiography testing in C&M Labs for safe running of trains.Quality Assurance - TheC&Mlabassuresthequalityinproduction/maintenance/repairsbyvarious physicalaswellaschemicalmethodsoftestingformaterials.Theseitemsare testedaccordingtovariousIRS/ISS/BSS/EN/ISO/RDSOandotherforeign specifications.Scope of Testing for different types of material -TestingofalltypesofmaterialpurchasedbyStoresdepartmentasper relevant specifications.Testingofnon-ferrousscrapforsellingpricevaluationofcostlymaterial accordingtotheirconstituentsandelementspresentforestimatingcorrect auction rates. Tomakeanalysisandclassificationofalltypesofferrous,non-ferrous metallic and non-metallic material and scrap for correct tariff rates in case of any dispute/claim.Tomakeanalysisofmaterialandproducewitnessincourtoflawfor prosecutionofallegedculpritsnotifiedbyRPF,GRP,Policeastechnical 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.Qualitycheckforsteelsusedforbridges,reinforcement,rails,fish,plates, permanent way tools, building material and thermite welding material.Testingofcomponentsformicrowavetowers,testingofphosphorbronze strips, steel wire ropes etc.6 | P a g e Totestingofferrous,non-ferrousalloys,virginmetals,metallicandnon-metalliccomponents,plastic,compositematerial,Teflon,mica,paints, lacquers,varnishes,fuel,lubeoil,grease,petroleumproducts,rubber component, bricks, coal, coke, water, sand etc.Theabovetestingofmaterialisclassifiedindifferentsectionandrequirementof supervisors and supporting staff is given in annexure 1. Cost of Mechanical Engg. Work Fig. in Rs. ParticularsOriginal PWP Cost Original P.B.Cost (in 2006) Detailed Estimate Cost (in 2008) Revised Estimate Cost (in 2012) MECHANICAL ENGG. WORK 1,66,00,0001,61,588,041,76,51,0291,88,260,80 PINK BOOK PARTICULARS Plan Head - 42 Sr No.PINK BOOK YEARITEM NO. 1.2007-08143 2.2011-12483 3.2012-13501 4.2013-14539 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 7 | P a g e 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 Spectrographicanalysisofsteels,X-RayRadiographyofweldingjoints, Metallographic testing, Micrography, Electro-gravimetric analysis, Physical testing ofmetalsandpolymers,NDTofmaterial,RoutineChemicalTesting,Ultrasonic Testing and Failure investigation etc. Scope of testing Thescopeofthetestingencompassesthetestingofferrous&non-ferrousmetals andalloys,Rubber,Plastic,polymers,Composites,Paint,Lubeoil,grease,HSD, Chemicaltesting,non-destructivetesting,UST,DyePenetrantTesting(DPT), Magnetic Particle Inspection (Magnaflux),Zyglo, X-Ray and failure investigation ofcomponentsfailedinserviceasRails,HelicalCoilSprings,MainPistonPin, Camshafts, Connecting Rod Blades, Centre Buffer Coupler, Yoke, Knuckle, Brake Beam Hanger, Wheels, Cartridge TaperRoller Bearing etc. 8 | P a g e SET UP PLAN: CENTRAL C&M LABORATORY OF NCR (A)GROUND FLOOR S. NO. DESCRIPTION ACTIVITIES PROPOSED SET UP/ MACHINES TO BE INSTALLED 1Technical Library and InchargeLibrary of Technical Literature and Specifications Book shelves, reading tables & chairs, Catalogue, Computer table, Photo-copier m/c. 2MPI 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 developmentX-Ray testing of failed rails (rail fractures analysis), welding joints of tank wagon, trolley,carriage frame, welders competency test etc. X-Ray film development Apparatus Portable X-Ray Equipment, Instrument table, X-Ray film storagecabinet, Trolley, TLD card (BARC) cabinet, X-Ray film illuminator system, test bench, etc. 4Metallography & 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. 5Physical andMini 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. 9 | P a g e 6Instrumentation & 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.7Spectrography Lab Instrumental elemental analysis of metallic samples. Spectrograph for metals, Computer table, test bench, instrument table, inert gas dispensation system, inert gas cylinders. 8Staffs RoomAs per descriptionStaffs Seating arrangement 9Scrap & Lab General Store Room As per descriptionStorage cabinets, seating arrangement 10 Officersroom ACMT room (B)FIRST FLOOR S. NO. DESCRIPTION OF ROOM/HALL/LAB ACTIVITIES PROPOSED SET UP/ MACHINES TO BE INSTALLED 1Chemical, 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, Abels 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, 10 | P a g e Instrument tables, work benches, computer table, Wall mounting chemical & glassware storage cabinets. 2Meeting 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, Demonstrationof testingmethods 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. Cell3Balance RoomWeighing of samples & test products. Anti-vibration tables, analytical & other digital balances 4Paints storesStorage of paint drums received for testing Temporary given to AEN Staffs 5Supervisors RoomCommon room for supervisors Temporary given to AEE6Office of Dy. CCMT Personal related and general office work Temporary given to AEN7Chemical, Glassware, Apparatus StoresAs per descriptionTemporary given to AEN Staffs 8CMTs RoomAs per descriptionOfficers Seating arrangement 11 | P a g e CMT Cadre in N.C.Rly. Present scenarioThe N.C. Rly was reconstituted on 01-01-2003 by merger of Jhansi and ALD divisionincludingJhansiWorkshopandRSKWorkshop.Initiallythestrengthof chemicalandmetallurgicalLabstaff(non-gazettedposts)were64nos.(52nos. fromCentralRailway&12nos.fromNorthernRailway)andtwogazetteposts(onepostofCMTfromcentralrailwayandonepostofACMTfromnorthern railway). After restructuring and pin pointing of units/divisions, the staff strength is bringdownto57nos.videH.Q.LetterNo.707-E/Estt./Mech/C&Mdated02-12-2009. POSITION OF C&M SUPERVISORS On Date (11-06-2014) Sr no. Div/W.S. CMS SancOn RollCMA SancOn RollTotal Sanc Vac. 1HQ/ ALD(STC) 010101-- 2ALD/ DSL01000101 3JHS W/Jhansi Central Lab 14 W.C. 05 07 - 05 01 02 - 19 06 10 06 4JHS D/Shed080602011003 5JHS/ TRS0101010201 6JHS/ C&W010101-- 7CNB/ TRS0403030704 8CNB/ DSL010101-- 9CNB/ TM Shop0101010201 10GWL/ RSK040303010703 11GWL/ DSL010101- 12AGC/ Div.030302010501 Total45281856330 Vacant on Date171330 12 | P a g e 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. - 20150300 Total resultant vacancies 30 + 03= 33 TwoCMSwillbepromoteduptoendof2015AsACMT,hencethetotal 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. Thereforeitisrequestthatanotherindentof23CMAposts(Insteadof18 CMA) is required to be sent to RRB Allahabad by H.Q. ThereisnoanyHelperand/orArtisanstaffforC&Mcadresanctionedby HQ underrevenue. 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 1CMS460012+2*06050513 2CMA42000503010104 Total1709060617 GAZETTED ACMT4800---------010000 * 01 CMS from ALD/Diesel and 01 CMS from GWL/Diesel have been transferred to central lab Jhansi approved by competent authority. 13 | P a g e STAFF REQUIREMENT TO OPERATE CENTRAL C&M LAB Following staff is required to operate and manage the workof Central C&M Laboratory

NON-GAZETTED STAFF C&M SupervisorsSr. No.DesignationNo. of posts 1Chemical and Metallurgical Superintendent (CMS)14 2Chemical and Metallurgical Assistant (CMA)06 Total20

Staff other than C&M Supervisors Sr. No.DesignationNo. of posts 1Office Superintendent01 2Clerk02 3Steno01 4Artisan(Grinder, Welder, Machinist)03 5Helper 10 6TADK01 Total18 GAZETTED STAFF Sr. No. DesignationNo. of posts 1Deputy Chief Chemist & Metallurgist (Dy. CCMT)01 2Chemist & Metallurgist (CMT)01 3Assistant Chemist & Metallurgist (ACMT)01 Total03 Note Indents for above Gazetted and Non-gazetted staff under process at head quarter. Originallyaproposalfor40posts(03nos.C&Mofficers,20nos.C&M supervisorsand17nos.otherstaff)wasproposedasitisessentialtooperatethe lab.Atinitialstagetocommencetheworkfollowingtwoproposalshavebeen 14 | P a g e movedandfurthercreationofpostswillbeproposedinfutureasthetestingload increases. 1.Proposalforcreationofnon-gazetted10nos.postsofC&Msupervisors (CMS-7&CMA-3),01postofSr.Stenoand01postofTADKunder 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 workwhich is essential for safety of Railway. Roll of C&M Central Lab TheC&MOrganizationofIndianRailwaysisprimarilyresponsibleforquality control&consequentialsafetyonIndianRailways.Theirdutiesincludechecking & 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.SafetyitemslikeWheels,Axles,Springs,Rails,BogieFramesandSpringsRails 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: ChemicalandPhysicalTestingofFerrous/Non-Ferrousmetals,Rubber, Plastics,Plywood,Composites,FRPmaterials,Electricalcables,Adhesives, Sealants & all other materials used in Railways. TestingofWeldingConsumables,TrialsonWeldingprocessesforcoaches, bridges, tracks etc. RadiographictestingofWelds(Criticaljoints)(100%ofEMUBogieFrames), Castings, Forgings etc. 15 | P a g e 100% Ultrasonic Testing of Wheel & Axles of carriage, wagon and locos.100%MagneticParticleInspection(MPI)ofSpringSteelbars&springsfor detection of defects. Testing ofPaints& surfacecoatings used for corrosion prevention onRailway coaches & other useful assets. Testing of Oil, Grease, Coolants & other Lubricants in Production Units/Diesel Sheds for proper running of Locomotives. Process Control: ProcesscontrolofweldingofBogieframes,Under-frames,Shelletc.atShop Floor for Conventional, Export and LHB coaches. Welder approval for SAW, MIG, TIG, Spot welding processes Processcontrolinheat-treatmentsofAnnealing,NormalizingofForged Components. Processcontrolinheat-treatmentsofHardeningandTemperingofCoiled 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: ChemicalandMetallurgicalEngineersensureeffectivequalitycontrolandsafety onRailways.Chemical&MetallurgicalOrganizationisengagedintestingand certifyingofallrawmaterials,finishedproducts&fueletc.assuringusageof standard materials and effective quality control of vital Safety required for Rolling stocks & Locomotives. Toensuretheeffectivequalitycontrolandsaferunningoftrainsfollowing 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 andefficiencyinproduction,repairandmaintenanceofRollingStockand punctualityofTrainservicesevenwhileensuringoptimumsafety&quality control. 16 | P a g e b)TheC&MEngineers(CMAs&CMS)conductFailureInvestigationof Railway components involved in derailment and accidents and making suitable recommendations for preventing further failures & deficiencies. c)TheC&MEngineersusetheNDE(Non-DestructiveEvaluation)ofcritical components and save crores of Rupees for Indian Railways. d)Testing of materials and components for mechanical &metallurgical properties and Chemical Compositions.e)TestingofWeldingconsumables,controlofWelding-processes,Periodical Assessment of Welders and advice of suitable welding techniques for Stainless Steel LHB / Sri Lankan coaches. f)Non-destructivetestingofBogieframes,Bogie/BodyBolsters,Axles(100%) SpringBars(100%),CoiledSprings(100%)etc.whicharecritical&safety items.g)Process control of Heat-treatment of Coiled Springs, Forged components etc.h)Process control of phosphating process. i)Assessthequalityoffuelandlubricantstoensuresmoothandsaferunningof rolling stocks and Locos. j)Checkthequalityofpaintstoavoidcorrosion,safety,durability&required finish.TestingofvariouspaintsusedforpaintingofDetail/Assembly Components&SystemPaints(Epoxy-cum-PU/otherHighPerformance Coatings)forpaintingofcoachesandControlofSystemPaintinginPaint-Booths. Inspection of outsourced components like Bogie Frames, Outer Doors, PVC flooring, Water Tanks etc. at Firm's premises.k)Measuring,monitoringandimprovingtheenvironmentcontrolaroundwork premisestocomplywiththeStandardsofEnvironmentManagementsystem (ISO-14001/2004)andOccupationalHealth&SafetyAssessmentservice (OHSAS - BS-18001/2007). Additional Duties:Standardization of new materials used for rolling stock. ConsultancytoDesignWingsofallEngineeringDepartmentsofIndian Railways for selection of proper raw material, process etc. Duties & responsibilities of C & M Staff have been continuously increasing and areboundtofurther increaseover theyears duetomodernizationofRolling Stock,Locomotives&allothersystemsontheRailways,introductionofhigh speed trains & qualitative change in technology. 17 | P a g e DUTY LIST OF ASST. CHEMIST & METALLURGIST (Gazzeted)Central Lab workshop Jhansi ASST.CHEMIST&METALLURGIST(ACMT/JHS)willcontrolandplanthe testingofmaterialbyUST,metallographic,physical,chemicalandmechanically andalsoplantoprocurementofthetestingmaterialsforallthesectionofmain laboratory.ThespecificresponsibilitiesofACMTinCentralLabWorkshop/JHSaregiven below: (1) ACMT will directly supervise metallurgical investigation of failed components.(2) ACMTwillcloselymonitorthemaintenanceofalllaboratoryequipment/ instruments/testingmachinesinworkingorderincludingprocurementof COFMOW/ M&P items.(3) ACMTwillserveasanodalinchargeforallUSTworkdonebyC&Mlab. Staff in entire NCR and summarized UST statement in MCDO. (4) ACMT will ensure 100 % testing of axles in workshop, diesel shed and electric locoshedandopenlinei.e.ROHdepotofJhansiandAllahabaddivisionof NCR.(5) ACMTwillco-ordinatethesafetymeetingonultrasonictestingofaxleswith all the UST operators of NCR.(6) ACMTwillsolvetheproblemsfacedbyultrasonicoperatorsinregardto 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) ACMTwillalsolookaftertheworkofindentsforstockandnon-stockitems with help of section in-charge Material control and stores.(10) ACMTwillcontroloverstaffmanagementincentrallabincludingpersonal and DAR matters. He will look after the work of CMT in his absence.(11) Supervisethedutyofallsectionin-chargesandauthorizedforsendingthe reports to other depots & railways. 18 | P a g e DUTY LIST OF ASST. CHEMIST & METALLURGIST (Gazzeted) Rail spring Karkhana, Sithouli, GwaliorASST.CHEMIST&METALLURGIST(ACMT/RSK)willcontrolandplanthe testingofmaterialsbyUST,metallographically,physical,chemicaland mechanicallyandwillalsoplanforprocurementofthetestingmaterialsforRSK lab, Diesel lab AGC, GWL MTJ and Baad. The specific responsibilities of ACMT in RSK Workshop/GWL are given below: (1) ACMTwill directlysupervisemetallurgical investigation offailedcomponents and manufactured springs heat wise.(2) ACMTwillcloselymonitorthemaintenanceofalllaboratory instruments/equipment/testingmachinesinworkingorderincluding 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) ACMTwillensure100%testingofspringsbyMagnafluxand3samplesper batchfordecarburizationdepth,coretocasehardness,grainsize,inclusion rating, almen test and 10 samples per batch for surface hardness test.(5) ACMTwillensureappropriatechemicalcompositionaspermaterial compositions referred in concerned IS/EN/ISO as per RDSO directives.(6) ACMTwillplantoprepareacodeofprocedure/reliabledrawingsand specificationsfordifferentparts/componentsusedinspringmanufacturingat RSK. (7) ACMTwillplantheprocurementofnewtestingmachines/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. 19 | P a g e DUTY LIST OF CHEMIST & METALLURGIST (Gazzeted)TheIndianRailwaysisplanningforhugeimprovementinitsinfrastructure, 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 varioussectionsofCentralLaboratoryandotherfieldLaboratoriessituatedatall divisionsofN.C.RailwayincludingRSK SithouliKarkhanaandMLRworkshop. 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 havequalitychecktorelevantspecifications.Hewillalsocarryoutthe metallurgicalinvestigationoffailedcomponentsandwillsuggesttheremedial measures.(2) CMTwillmonitorthemaintenanceofalllaboratoryequipments/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 maintenanceoperationsintheworkshopdieselshed,electriclocoshedandC &W ROH depots.(7) CMT will recommend the alterative specifications and materials with respect to foreign specifications and transfer of technology projects.(8) CMTwillkeepcloselyliasonwithPHODsofmechanicaldept.andwith RDSO/LKOforspecialtasks.Hewillalsoactasanadvisortomechanical, electrical, civil, S&T, stores, operating and safety deptt. Of NCR. (9)CMT will have regular inspection of other laboratories over NCR.(10)CMTwillconducttheco-ordinationmeetingofitstechnicalstaffandwill organizeinhousetrainingprogrammetoincreasetheefficiencytolaboratory staff.20 | P a g e DY. CHIEF CHEMIST & METALLURGIST (Gazetted) No. of post 01(one) Grade-Rs. 14300-18300(pre revised ) Dy.ChiefChemist &Metallurgist (Dy.CCMT)attachedto themajorwork shop ofNCR 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 locoshed,andsickline/ROHdepotsatJHS,GWL,AGC,CNBandALD.The specific responsibilities of Dy. CCMT. in North Central Railway are given below. (1)MONITORINGUSTWORK-Hewillberesponsibleforcarryingoutthe ultrasonictestingofrollingstockaxle,wheelandothercomponentsinallthe workshops,divisions,locoshedsensuringavailabilityofrequiredflawdetectors andconsumables,RDSOtrainedoperatorsmanpowerasandwhenrequired.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 beresponsibleforcompilingthestatisticaldataonUSTandtimetotimetaking necessarycorrectiveactiontotackleupthefailureproneareasandtosendthe statisticaldataofUSTtoRDSOforfurtheranalysis.Hewillalsobeconducting 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 becarriedouteffectively.Roughly1.5lackaxlesandothersitemsareexamined yearlyinthiszonalrailwayultrasonicallytoensurethesafetyandreliabilityof rolling stock. (2) FAILUREANALYSIS-TheDy.CCMTwillberesponsibleforcarryingout themetallurgicalandchemicalinvestigationoffailedcomponentsreceivedform divisions&workshopsandsuggestremedialmeasures.Everymonthabout70to 100failedcomponentswillbesubjectedtofailureanalysisinvolvingthe knowledge of mechanical metallurgy, mechanical behavior, stress analysis, fracture analysis,design,chemicalcompositionand testingof variousotherparametersby destructiveandnon-destructivemethodsThefailureanalysisreportsareusedas guidingtobythemechanicalandelectricalofficersoftheworkshops,shedsand divisions for taking corrective and preventive actions to work improving safety and reliabilityofcoaches,wagonsandlocos.Failureanalysisrevealsarerequiredto be metallurgicallytestedforidentifyingthecauseoffailuresuggestive remedial measures.Thermiteweldingandbuttweldingofrailsisanimportant 21 | P a g e activitywhere thendepthknowledgeofmetallurgyisrequiredtimetotimefor obtaining soundweld joints having maintaining desire strength under functioning, conditionofenvironmentaltemperature.About25to30casesoffailedrailswill be investigated in laboratory under guidance. (3)MODIFICATIONINTHEMATERIALSPECIFICATION-TheDy.CCMT willberequiredtotechnicallyexaminetheexisitingfailurepronematerial specificationofthecomponentsofcoaches,wagonsandlocomotivesandsuggest appropriatematerial/processtothetechnicalofficersofheadquarteraswellas officers working in the field. (4)FAILUREANALYSISOFELECTRICALCOMPONENTSLargenumber ofcomponentssuchascomponentsofOHE,electricloco,railcars,isrequiredto beanalysedandremedialmeasuressuggestedforpreventionoffailure.About20 componentsrelatedtotheelectricaldepartmentreceivedfromdivisionand electricaldept.willbesubjectedtofailureanalysisundertheguidanceand supervision of Dy. CCMT. (5)DEVELOPMENTOFIMPORTSUBSTITUTION TheservicesoftheDy. CCMT are required for in demising the components of electric loco diesel loco and coachesbytestingthematerialandfindingoutequivalentIndianstandardsothat the vendors for the same could be developed indigenously. (6)DEVELOPMENTOFWELDINGPROCEDUREANDtestingMorethen 50%ofactivitiesofrepairandmaintenanceinvolvewelding.Weldingmetallurgy playsanimportantroleinachievingthesoundandstrongweldjoint.Dy.CCMTwillcontributeindevelopmentofweldingprocedures,suggestingeffectiveways incarrying outwelding proceduresemphasizing on preweldingandpostwelding heattreatmentrequirements.Itisalsoessentialtohaveapanelofproficient weldersforcriticalapplications.Dy.CCMTwillorganizetheproficiency examinationofweldersaspermandatoryrequirements.Hewillalsomaintaina fullyequippedX-rayradiographyexaminationlaboratorywithallessentialsafety measures. (7)QUALITYASSURANCECHECK-Stockaswellasnon-stockitemsare procured/purchasebystoresdepartmentofworkshopaswellasdivisionallevel, Dy. CCMT will carry out the quality assurance check on purchase item as apart of purchase inspector. This will help ineliminating / rejecting of sub-standard items. Thus improving the reliability of rail services. 22 | P a g e (8)QUALITYCHECKINWORKSHOP-Dy.CCMTthroughsubordinate 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 shedsandtwoelectriclocosheds.Dy.CCMTwillrequiretoplanthepreventive maintenance check/ tests for smooth functioning of diesel loco and electric loco of respectiveshedssothatnopointoftimeoutturnoflocosisaffectedwhichis 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 isresponsibletoprocureandmaintainallthenecessarytestequipments/ instrumentsultrasonicflawdetectorsprobeetc.inworkingconditionandin calibrated status. (11) NONGAZETTEDLABORATORYCADRECONTROLLINGDy.CCMT willberesponsibleforrecruitment,promotionandtransferoflabcadrenon gazetted staff. He will also require to human resource development by identifying areasoftraining.Hewillplanandimparttrainingtoalllaboratorystaffsoasto have fully trained and proficient man power He will also plan induction training for apperentices recruited through RRB. (12) MONITORINGOFENVIRONMENTALRELATEDISSUES-Withthe latestdirectivesfromRly.Bd.regardingsetting ofanenvironmentalmanagement system for mechanical workshop. Dy CCMT. will be require to put up for effective implementationofenvironmentalmanagementsystem.Inviewoflegislative requirement and of the setting up efficient treatment plans etc. The advisory role of Dy.CCMTwillbeverymuchrequired.OntheotherrailwayDy.CCMTis functioningasamanagementrepresentative(MR)intheISO14000certification programme.

23 | P a g e ACTIVITIES At present no staff is available for this Lab and the proposal for creation of ten (10) nos.ofpostsofChemicalandMetallurgicalsupervisorsisunderprocess.Despite thelackofthetechnicalstaffafewoftheChemical&Metallurgicaltesting activitieshasbeenstartedanyhowwiththeextraeffortsofCMTstaffofJhansi workshop over their regular duties there. Their contribution is really appreciable as theyarealreadyoverburdenedduetoheavyvacancyatJhansiworkshop.The activities started are summarised below (i) Spectrographicanalysisofdifferentcomponents/jobsfortheirchemical composition/ chemistry.April 2012 to March 2013 Sr. No. MonthItem Name/ Particulars Item recd. fromNo. of samples 1Apr12Steel SamplesRSK/STLI04 2May12ScrewCouplingShacklePin, Springforcutoffanglecock, Steel Samples Dy.CMM/JHS, RSK/STLI 16 3June12AngleIronFillet,RoundBar 28mm,SteelSamples,Rivet SnapHead20X100mmlong, HotForgedRivet,MSSteel RivetSnap,TopSideWear Liner,SpringSteel,PinFlat Head for Break Gear Type A Dy.CMM/JHS, RSK/STLI 53 4July12Steel SamplesRSK/STLI05 5Aug12Shearing BladeSSE/Panel Plate/JHSW 01 6Sept12Steelsample,WeldingRSK/STLI, SSE/Welding/JHS02 24 | P a g e ElectrodeW 7Oct12Steel SamplesRSK/STLI09 8Nov12SteelSamples,Welding Electrode, Roller RSK/STLI, SSE/Welding/JHSW,CMS/ Metallography 04 9Dec12SteelSamples,Coupler,MS Bush Bar, Welding Electrode RSK/STLI,CMS/ Metallography, SSE/Welding/JHSW 06 10Jan13WeldingElectrode,RailPiece, Head stock SSE/Welding/JHSW , CRWS/BPL 03 11Feb13Steel Samples, CTRB RollersRSK/STLI,CMS/ Metallography 13 12Mar13WeldingElectrode,Steel Samples,JournalThrower, Knuckle, Lug Liner SSE/Welding/JHSW,RSK/STLI, CMS/ Metallography, ADME(DSL)/JHS 14 Spectrographic analysis April 2013 to March 2014 Sr. No. MonthItem Name/ Particulars Item recd. fromNo. of samples 1Apr13Steel SamplesSSE/weld.&XEN TMC3 2May13Waterpump,bolt,welding electrodeT-barhanger& samples of spring Dy.CMM/JHS, RSK/STLI 12 3June13Springmaterialelectrode,WS/JHS,24 25 | P a g e power hacksaw blade, bolt, RSK/STLI 4July13Springrodssamples,tapered shank portionRSK/STLI and tool room JHSW10 5Aug13--------- 6Sept13FailedSteelsample,Welding Electrode ADME/Baad SSE/Welding/JHSW 07 7Oct12SteelSampleselectrodeand hexa nippleSSE/JHS & RBL 02 8Nov12--------- 9Dec12Keyforbrakeblock,bracket pillar for LHB coaches Dy CME/RBL Dy CME/JHS,18 10Jan13Electrode, CBC and knuckle SSE/Welding/JHSW , M&P05 11Feb13Hexagonalcapscrew, equalizing lever, bend cutter Sr.DME/D,SMM ELS/JHS 06 12Mar13Draw-barhook,cattleguard, couple body knuckleDyCMM/ELE, SR.DME/AGC, DRM/JHS07 26 | P a g e Failure investigation of components as CTRB, CBC, J/Thrower 2012-13 Sr. No. MonthItem Name/ Particulars Item recd. fromNo. of samples 1Sept12CTRBSSE/M/c&Wheel Shop/JHSW 02 2Dec12CTRBSSE/M/c&Wheel Shop/JHSW 01 CBC bodySSE/C&W/GMC/CNB 01 3Feb13CTRBSSE/M/c&Wheel Shop/JHSW 01 4Mar13KnuckleDRM(M) JHS01 Journal throwerSr.DEE/RS/CNB01 Failure investigation of components as CTRB, CBC, J/Thrower 2013-14 Sr. No. MonthFailure CTRB Total No. of samples 1Apr13--------- 2May13---0202 3June13030205 4July1301---01 5Aug13---0101 6Sept13---0101 7Oct13--------- 27 | P a g e 8Nov13---0101 9Dec13---0202 10Jan14---0202 11Feb14010506 12Mar1403---03 Total tested 24 28 | P a g e Chemical and Miscellaneous testing as Paint brush testing of tender samples, chemical testing of store samples, Hard coke, Welding Electrodes, etc. Sr. No. MonthItem Name/ Particulars Item recd. fromNo. of samples 2May12Punchset,ScrewCoupling ShacklePin,Springforcutoff anglecock,SteelSamples, AngleIronFillet,RoundBar 28mm,SteelSamples,Rivet SnapHead20X100mmlong, HotForgedRivet,MSSteel Rivet Snap, H.S. Steel samples Dy.CMM/JHS86 3June12TopSideWearLiner,Spring Steel,PinFlatHeadforBreak GearTypeA,Punch,Hand Brake Sleeve Dy.CMM/JHS, RSK/STLI 14 4July12BK beam Spring WasherDy.CMM/JHS05 5Aug12Foundrycoke,Rivet22X100 mm WM(R)/JHSW02 6Sept12BrushPaint&Varnish,Sash Tool,Steelsample,Welding Electrode,BushMetallic,Pin Flat Head Dy.CMM/JHS, SSE/Welding/JHSW 09 7Oct12Brush Paint & Varnish,AMM(G)/ALD04 8Nov12Welding ElectrodeSSE/Welding/JHSW 01 9Dec12Brush Paint & VarnishDy.CMM/JHS05 10Jan13HangerBlock,MetalPiece,ADME(DSL)/JHS,07 29 | P a g e Roller, Brush Paint & VarnishAMM(G)/ALD 11Feb13Foundry CokeDy.CMM/JHS01 12Mar13Brush Paint & VarnishSMM 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. MonthPass FailureTotal No. of samples 1Apr13070714 2May13--------- 3June13030104 4July1301---01 5Aug1301---01 6Sept13040206 7Oct13131124 8Nov1303---03 9Dec13060208 10Jan1402---02 11Feb1402---02 12Mar14--------- Total tested 65 30 | P a g e Hardness testing of temping tools and store samples 2012-13 Sr. No. MonthItem Name/ Particulars Item recd. fromNo. of samples 1June12Hand Brake SleeveDy.CMM/JHS, 02 2July12BKbeamSpringWasher ,Tamping tools SSE/TD/JHS51 3Aug12Rivet 22X100 mmWM(R)/JHSW01 4Oct12Tamping toolsSSE/TD/JHS25 5Nov12Spindle, Welding ElectrodeDy.CMM/JHS, SSE/Welding/JHSW 02 6Dec12Tamping toolsSSE/TD/JHS18 Hardness testing of temping tools and store samples 2013-14 Sr. No. MonthItem Name/ Particulars Item recd. fromNo. of samples 1May 13Misc.----11 2Nov 13Misc. ----06 31 | P a g e Welders competency test. During 2012-13 Sr. No. MonthItem Name/ Particulars Item recd. fromNo. of samples 1Jan13Weldedpieceforwelders competency test BTC/JHSW35 2Feb13---do------do---17 3Mar13---do------do---14 Welders competency test. During 2013-14 Sr. No. MonthItem Name/ Particulars Item recd. fromNo. of samples 1Apr13Weldedpieceforwelders competency test BTC/JHSW 03 2May13---do------do---05 3June13---do------do---09 4July13---do------do---07 5Aug13---do------do---03 6Sept13---do------do---04 7Nov13---do------do---02 8Dec13 ---do------do---05 9Jan14---do------do---04 Total tested42 32 | P a g e UST SUMMARY OF C&M LAB JHSW 2012-13 Sr.NoMonthAxle TypeNo of axles tested Total No of axles tested No ofaxles rejectedRejection percentage 1Apr12CTRB187222800000 RB & Others336 2May12CTRB2442272408029 RB & Others282 3June12CTRB24812741070.26 RB & Others260 4July12CTRB23382533060.24 RB & Others195 5Aug12CTRB22232486120.48 RB & Others263 6Sept12CTRB24692748100.36 RB & Others279 7Oct12CTRB24182635120.46 RB & Others217 8Nov12CTRB20372204090.40 RB & Others167 9Dec12CTRB23192587110.43 RB & Others268 10Jan13CTRB23882703130.48 RB & Others315 11Feb13CTRB23312625100.38 RB & Others294 12Mar13CTRB21662505110.44 RB & Others340 Total tested 306991090.35 33 | P a g e Rejection percentage in UST 34 | P a g e UST SUMMARY OF C&M LAB JHSW 2013-14 Sr.NoMonthAxle TypeNo of axles tested Total No of axles tested No ofaxles rejectedRejection percentage 1Apr13CTRB23412631120.45 RB & Others290 2May13CTRB26002919220.75 RB & Others319 3June13CTRB22342523120.48 RB & Others289 4July13CTRB24002732140.51 RB & Others332 5Aug13CTRB23762645050.19 RB & Others269 6Sept13CTRB25762866150.58 RB & Others290 7Oct13CTRB23572671080.30 RB & Others314 8Nov13CTRB24382800080.28 RB & Others362 9Dec13CTRB25302873100.34 RB & Others343 10Jan14CTRB24852797050.18 RB & Others312 11Feb14CTRB24322724060.22 RB & Others292 12Mar14CTRB24262761090.33 RB & Others335 Total tested 329421260.38 35 | P a g e 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.NondestructivetestingofcomponentsbyZYGLO,MAGNAFLUXand DPT. 6.Failure investigations of Couplers, CTRB etc. 7.Chemical composition determination by Spectrometer. 8.Physical&Metallurgicalexamination,Macro,Micro,T.S.,Bendtest, Compression test. 9.X-ray radiography of weld joints. 10. Material chasing, Indents, Stores, Post creation proposals, Staffing proposals, Installation,Commissioning,PTC,PersonnelrelatedmattersofC&Mstaff, 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.