ACS 04 To FBW Manual (Reprint April 2022)
ACS 04 To FBW Manual (Reprint April 2022)
ACS 04 To FBW Manual (Reprint April 2022)
04
To
The Manual for Flash Butt Welding of Rails (Reprint-April 2022)
1
5. Existing Para 5.3.4.1(third line ) is replaced with the following:
- 110 U TS and R350HT Grade rails- 7 Kg/mm 2 on c ross s e ctional
area.
6. Existing Para 5.4 is replaced with the following:
5.4 POST WELD HEAT TREATMENT: 72 UTS and 90 UTS rails do
not require any spe cial post we ld heat treatme nt. He ad h ardened
and heat treated rails ne e d post weld he at tre atment to ensure the
vari ation in hardn ess within acce ptable limits in he at affecte d zone.
Typical post weld heat tre atments fo r head h ardene d/heat treated
rails are give n in Anne xure II. However, any other suitable adv ance
technique for post weld he at tre atment may be adopted and shall be
mentione d in the QAP of flash butt we lding plant.
7. Existing Table 1 of FBW Manual is replaced with the following:
Table 1
VALUES OF MINIMUM BREAKING LO AD AND D EFLECTI ON IN
TRANSVERSE LOAD TES T
S Rail Se ction Span Min. Minimum Frequency of testing
N & Grade (in breaking deflection at
me te r) load the ce nter at Stationary Mobile FBW
(in Ton) the actual FBW Pl ant Plant
transve rse (working as
breaking load mobile or in
(in mm) stationary
mode)
1 60E1 1.00 163 20 1 in 100* 1 in 100*
Grade-
(1600KN)
R350H T
2 60E1 1.00 150 20 1 in 100** 1 in 100*
Grade-
R260
3 60 kg (UIC)/ 1.25 115 30 1 in 500 1 in 100*
60E1,
Grade-
1080HH
4 60 kg 1.00 150 20 1 in 1000 1 in 100*
(UIC)/60E1
90 UTS
Grade-880/
R260NC
5 IRS-52 kg 1.00 115 20 1 in 1000 1 in 100*
90UTS
Digitally signed
2 AKHILES by AKHILESH
KUMAR
H KUMAR 2024.04.01
Date:
17:34:53 +05'30'
6 60 kg UIC 1.00 135 30 -do- 1 in 100*
MM
(72 U TS)
7 52 kg MM 1.00 100 30 -do- 1 in 100*
(72 U TS)
* Sample joints fo r first 1,000 joints will be te ste d at fre quency of 1
in 100 joints and s ubsequently at a fre que ncy of 1 in 500 joints.
** S ample joints for fi rst 1,000 joints will be te ste d at fre que ncy of 1
in 100 joints and subseque ntly at a freque ncy of 1 in 1000
joints.
8. Existing Para 13 is replaced with the following:
13. WELDING TEAM FOR MOBILE/STATIONARY FLASH BUTT
WELDING PLANT
13.1 We lding te am may consist of mi nimum one supe rvisor and two
welde rs. The e ducational quali ficatio n of supervisor sh ould be min.
Diploma in Me chanical/ Ele ctrical Engineering or BSc and that of
welde r should be minimum cl ass X or e quivale nt, pas se d. Welders
and supe rvisor al re ady working in Mobile/Stationary FBW Pl ant
may continue if Chief Track Engine er/Chie f Engine e r (construction)
is satisfie d about the quality of welds by the se operato rs. Zonal
Railways sh all also e nsure pe riodical training o f w e lde rs and
Supe rvisors of Mobile/Stationary Flas h Butt We lding Plants.
13.2.1.2 Interview
ANNEXURE-I
(Para-5.4)
------Deleted------
Digitally signed
AKHILES by AKHILESH
KUMAR
H KUMAR Date: 2024.04.01
17:36:40 +05'30'
6
14. Existing Annexure-X is replaced with the following:
ANNEXURE-X
(Para-5 .6.2 )
Procedure to be followed for approval of Quality Assu rance
Program (QAP ) for Mobile F lash Butt Welding Plan ts
1.0 The mobile flash butt welding plants used on Railways are
mostly outsource d. In orde r to expedite the approval of QAP and
minimize the time gap be twee n award of contract and start of
work, the following proce dure shall be followe d.
2.0 Submission of General Quality Ass urance Programme:
2.1 The ge ne ral QAP, containing the information as pe r Anne xure-XI
of Manual shall be submitte d in soft copy in pdf format of
size<20MB to RDSO by the agency/ Plant owne r se parately for
e ach Mobile Flash Butt welding Plant proposed to be deployed.
Availability of Railways’ o rde r (Lette r of acce ptance ) will not be
required at this stage.
2.2 The comple te QAP (e xcluding de tails of we lding team, an d
standardize d we lding paramete rs) so submitte d by the firm will
be scrutinize d and approve d by RDSO afte r e nsuring compliance
of re le vant provisions of this manual .
2.3 Approve d soft copy of Ge ne ral Qual ity Assurance Programme
will be issue d to the concerne d agency, which has approache d
for approval .
3.0 Approval of Welding Team:
3.1 Once the contract is awarded, the fi rm will approach co nce rned
Zonal Railway/PSU /Metro Railway for approv al o f welding team
as per Para 13 o f Manual.
3.2 The compe tency certific ate to welding ope rators and supe rvisors
will be issued by Chie f Trac k Enginee r/Chief Enginee r
(Construction) of Zonal Railway/GM (e quivalent to SA grade
office r and above ) of PSU /Metro Railway after conducting
necessary test as pe r Manual and other instructions on the
subject.
4.0 Submission of Fin al Qu ality Assurance P rogramme:
4.1 After the agency has got the welding team approve d by
concerned Zonal Railway/PSU/Metro Railway , the fi rm will
unde rtake inte rnal te st to provisionally fix the we lding
Digitally signed
AKHILES by AKHILESH
7 KUMAR
H KUMAR Date: 2024.04.01
17:37:00 +05'30'
parame te rs fo r rails of different sections/ metallurgy as
required to be welded.
4.2 Afte r comple ting above e xe rcise , the age ncy will submit the
final Quality Assurance Prog ramme (Duly updating the e arlier
approve d General QAP with de tails of welding te am approved by
Zonal Railway/PS U/Me tro Railway with compe tency certificates
and welding parame te rs as decided by the firm during i nte rnal
te st) to RDSO through conce rne d Railway/PSU/Me tro Railway
Administration fo r s tandardization of we lding parameters
and approval o f fin al QAP.
5.0 Standardization of Weldin g P arameters and approval of QAP:
5.1 Afte r the final Q AP submitte d is found satis facto ry during
scrutiny, the standardization of we lding parame te r for
concerned Rail section/ U TS as re quested by age ncy/ Zonal
Railway/PSU/ Metro Railway will be undertake n by RDSO as
pe r Para 5.6 of Manual.
5.2 The standardized we lding parame ters and marking code allotte d
by RDSO will be attached with the fi nal QAP submitte d by the
agency/ Zonal Rail way/PSU/Metro Railway. The fin al QAP duly
containing the standardize d welding parame te rs shall be
approve d by RDSO and issue d to the conce rned Zonal
Railway/PSU/Metro Railway and the fi rm for undertaking the
Flash Butt we lding work as pe r provis ions of this M anual.
5.3 The adhere nce to provisions of Manual and QAP will be e nsured
by the concerned Zonal Railway /PSU/Me tro Railway.
6.0 Validity of QAP :
6.1 The Final Quality Assurance Programme (QAP) of a particular
Mobile Flash Butt We lding Plant nee d not be re -approve d by
RDSO unle ss the firm h as faile d to ge t the qual ity audit
conducted by RDSO within stipulate d time as me ntione d in Para
15 or there is major change in Quality Control se tup or new
type of rail to be welded or the re is a revision/ame ndment to
FBW M anual to provisions related to qu ality assessment of FB
welds/proce dure of welding/ me thodology of standardization of
welding parameters. The final decision whe the r there is majo r
change in Quality Control se tup or n ot will re st with the Chief
Track Engineer/ Chief Enginee r of Zonal Railway and GM
(e quivalent to SA grade officer and above) of PS U/Metro
Railway, where plant is being de ployed.
6.2 In c ase of change of ope rator/ supervisor or e xpiry of their
competency ce rtificates, concerned Zonal Railway/PS U/Metro
Railway shall take action for approval of we lding team.
8 AKHILES Digitally signed by
AKHILESH KUMAR
ANNEXURE-XI
(Para-5 .6.2 )
Information to be provided in Quality Assurance Programme for
Mobile/Stationary Flash Butt Welding Plants
1. Cover page of the QAP
This shall indicate the Name and relevant details of the Agency; Details of
Flash Butt Welding machine (Make, Model & Serial no. etc. and carrier vehicle
registration no. in case of Rail-cum-Road Vehicle type Mobile Plant).
2. Index.
3. Brief description about the firm/ company and General information about the
addresses and contact numbers of office and work stations, branches and
sister concerns and the details of ISO certification, if firm is already a ISO
certified company having Operation and maintenance of Mobile/ Stationary
Flash Butt Welding Plant in scope. If firm is not already ISO certified, ISO
certification including Operation and maintenance of Mobile/ Stationary Flash
Butt Welding Plant in scope shall be ensured before submission of Final QAP.
4. If firm is ISO certified,
(a) Quality policy of the company as per ISO certification.
(b) Certificate to this effect that the approved QAP is a controlled document
and a quality record of ISO quality control system of the vendor.
5. Organization chart emphasizing quality control set-up.
6. Qualification and experience of key personnel and officials deployed for
operation and in quality control cell including supervisor and welders of the
machine.
Details of competency certificate of the welders and supervisor issued by Zonal
Railway/PSU/Metro Railway as per clause 13.2 of Manual shall be
specifically indicated.
7. Brief description on the Mobile/Stationary Flash Butt Welding Machine and
other machinery & plant deployed. (Serial no., model no., make, date of
manufacturing, AMC details and brief working procedure of the machine).
(Mobile/Stationary Flash Butt Welding machine must have facility for display
and storage of all the welding parameters in re-producible electronic forms at
the time of F.B. welding of rail joints. A certificate in this regard along with
brief on the facility for display/ storage capacity of the machine must be
specifically mentioned in the QAP).
Digitally signed
9 AKHILES by AKHILESH
KUMAR
H KUMAR Date: 2024.04.01
17:37:45 +05'30'
8. Recommended Welding parameters for various rail sections and rail
metallurgies as per operating manual of FBW machine specified by
Manufacturer.
9. Process flow chart for complete process (from receipt of rail to dispatch of
welded panels).
10. Procedure for Standardization of welding parameters as per clause 5.6 of the
manual.
11. Procedure of the field approval of welding procedure as per clause 5.7 of
Manual in case of MFBWP.
12. Quality Assurance System covering the following:
(a) Scope
(b) List of standards, codes and reference documents.
(c) Inspection & Testing process of incoming rails as per clause 2 to 4 of
Manual.
(d) Detailed description of procedure of regular welding of rails.
(i) Welding Process and In process check:
- Inspection of Copper/ Melloroy electrodes for electrical contact.
- Rail alignment.
- Welding sequence including stripping.
(ii) Weld Record for each joint duly indicating actual weld parameters
vis-à-vis parameters standardized by RDSO.
(iii) Post weld heat treatment for 110 UTS, HH & R350HT rails, if
applicable.
(iv) Post weld straightening.
(v) Finishing of joints to achieve geometrical standards given in
Annexure IV of Manual.
(vi) Marking of joints for Mobile/Stationary FBW plants. (Marking code
shall be assigned by RDSO at the time of approval of final QAP).
The formats duly indicating the frequency of in process check shall
be part of QAP.
(e) Product Control:
(i) Tests for every flash butt welded joint.
- Visual inspection.
- Dimensional check.
- Ultrasonic test.
(reprocessed/ scrapped)
Standard format no. for
Reference documents
Method/measuring/
wherever applicable
maintaining results
inspection/testing
Acceptance limit/
Rejection details
inspection/tests
Sample size and
Parameters for
specified value
frequency of
equipments
Accuracy
Process
S. No.
14. List of tools & plants and testing equipments available with FBW machine for
execution of rail welding along with calibration status and plan.
15. List of Registers maintained and their standard formats with unique number.
Following registers/records are mandatory:
11 AKHILES by
Digitally signed
AKHILESH
KUMAR
H KUMAR Date: 2024.04.01
17:38:31 +05'30'
1. Record of Weld Register (Proforma as per Annexure –III of Manual),
2. Dimensional Check Register (Proforma as per Annexure–VIA of
Manual),
3. USFD Test Register (Proforma as per Annexure – VIB of Manual),
4. Hardness Test Register (Proforma as per Annexure – VIC of Manual),
5. Transverse Load Test Register (Proforma as per Annexure– VID of Manual),
6. Macro Examination Register (Proforma as per Annexure– VIE of Manual),
7. Micro Examination Register (Proforma as per Annexure– VIF of Manual).
8. Daily Progress Register (Proforma as per Annexure–‘A’ attached),
9. Joint Rejection Register (Proforma as per Annexure –‘B’ attached),
10. Customer Complaint Register (Proforma as per Annexure– ‘C’ attached).
16. A blank format as given below shall be part of the final QAP of mobile flash
butt welding plant for entering the details regarding movement of the machine
and work executed. This format shall be placed after Index page of QAP. While
submitting initial QAP for approval, Column no. 1, 2, 3 & 6 shall be filled by
the firm. During movement of the machine from one work site to another work
site against a contract agreement/ different contract agreement details shall be
filled and signed by firm and Railway/PSU officials in the proforma.
Movement details of Mobile Flash Butt Welding Plant
Period Signature
FB
and
FB Welds executed
Division/ Section
Name of welder
welds executed
Firm’s Railway
Cumulative FB
welds ordered
of
CA/WO No.
official officials
with
(Plant
quantity
Railway
designat
Sl. No.
in-
From
ion
charge)
To
1 2 3 4 5 6 7 8 9 10 11
17. The QAP covering all the information must be given in the form of single
document indicating name of the firm, effective from, document no., revision
number and page no. ‘x’ of ‘y’ on each page. QAP shall be digitally signed by
(with name and designation) ‘Prepared by’, ‘Checked by’ (QC in-charge) and
‘Approved by’ by competent authority. All certificates/supporting documents
shall be attached as Annexure to the QAP. In case of General QAP, details of
welding team, and standardized welding parameters need not to be included.
Digitally signed
AKHILES by
12
AKHILESH
KUMAR
H KUMAR Date: 2024.04.01
17:38:49 +05'30'
16. A new Annexure-XII is adde d as under:
Annexure-XII
(Para 13.2)
COMPETENCY CERTIFICATE
(Signature of Welder/Supervisor)
Date: ______
(Signature)
Chief Track Engineer/Chief Engineer (Construction)
_______Railway,
or
(in case of PSUs/Metro Railway)
Name:
Designation with Grade:
Name of Organization
Seal:
Digitally signed
AKHILES by AKHILESH
KUMAR
H KUMAR Date: 2024.04.01
17:39:11 +05'30'
13