GOVERNMENT OF INDIA. MINISTRY OF RAILWAYS (RAILWAY BOARD) No.2008/Ii(W)/814/30 New Delhi dated 11/09/2015. Chief Mechanical Engineers All Zonal Railways. Sub:-Minutes of Seminar on Corrosion prevention and repair on ICF design coaches held at Garden Reach, S.E Railway Kolkatta on 30.07.2015. EDME /Chg./Railway Board official note no. 2005/M(C)/143/4 dated 25/08/2015 seein Vide above reference, it has been advised, among others, that the phosphating plants in the workshops have {o be made functional within two months time. This office may kindly be intimated upon commissioning of phosphating plants (if not functional already). \ = Tea (Gnirudh Kumar) Director Mechanical Engg. (P-1) Railway Board.Minutes of the Seminar on Corrosion prevention and repair on ICF Design coaches held at Garden Reach, S.E. Rly., Kolkata on 30.07.2015 The seminar was attended by the officials from Railway Board, ICF, RCF, RDSO and Zonal Railways. Parficulars of inspection Ration by | 10 ‘Address by ember Mechar v1 There have been cases of parting of coaches due to head stock breakage, sole bar eto, in the recent past. Coach parting is a very serious matter and should be taken not less than an accident. Any such case in future will be viewed very seriously and the responsibility will be fixed up at senior level AICMEs| 12 Corrosion repair has to be done strictly as per the procedure specified by RDSO by use of correct prescribed materials and electrodes. AILCMES | 13 MLR capacity has to be increased to match the requirement as the coaches featuring in cases of parting due to corrosion were not given MLR EDMENW RB 14 PUs have also to tighten up their processes of corrosion prev |, shot blasting of coaches and proper painting procedure as one of the coaches condemned prematurely was only 11 year old CMENCF CMEIRCF? REL Corrosion in coaches Is on the rise indicating the lack of attention/ adequate protection during manufacture and also not carrying out proper repairs during POH. All CMEs| Railways have also tendency to postpone corrosion repair during POH of coaches approaching the profile eligible for MLR. During visit to MLR shop at Bhopal, badly corroded coaches have been seen undergoing repairs. ‘AICMES: The laying of stainless sleel trough floor, side pillars, toilet inlays has to be done carefully and the stainless steel assemblies should also be fully painted to avoid corrosion. AICMEs ICF is using raised trough floor in non-AC coaches and the corrosion is excessive in such coaches. ICF may review the design. CMEVICF | 4 month Providing non-standard and over lapping patches during corrosion repair has to be stopped because it adds to further corrosion (crevice corrosion) AICMES | 40 within two months time. The corrosion has to be tackled by comprehensive strategy of design, maintenance, repair etc |The bogies of LHB ‘coaches should be cleaned thoroughly using high | pressure jets during the maintenance to clear the muck to avoid corrosion ! y sve mw) The phosphating plants in the ‘workshops and PUs have to be made functional ‘All CMEs EDMEM RB PAICMES | | pen | Line)20 Address by GMISER: | Corrosion in coach is @ very serious maller as the coach Is made of thin sheets and loss of section can affect the serviceability. The coach under frame in toilet area should be given special attention being prone to corrosion. VAILCMEs | 22 New technology/ processes for prevention and protection of coaches from corrosion should be explored and adopted. New lypes of paints and coating are now available in the market and their uses should be explored. The Process should be audited and the ideas should be exchanged to improve the situation of corrosion. ED(Carry/ RDSO ED(M&cy RDSO Discussions and decisions: ‘5mm thick tum-under to be provided in all conventional coaches, as the existing sheet of 2mm with smaller dia drain holes was reported to be resulting in corrosion. This shall be adopted by ICF/RCF on new coaches and by workshops during POH and MLR, whenever corrosion repair of turn under is done, All CMEs Itis highlighted that whenever SS items are introduced in the Corten Steel 7 Mild Steel assembles of coaches, galvanic corrosion at the contact area between SS and MS should be borne in mind. This contact area acts as galvanic ceil, To prevent this phenomenon, minimum requirement is to apply Paint over both the surfaces of stainless steel which should be made a standard procedure. All CME, 33 Presently, anti-corrosion epoxy coating (PCN-123) is applied on headstock, sole bar and sidewall upto window level. As galvanic corrosion between contact area of SS trough floor with MS cross members is reported, anti- | corrosion epoxy coating shall be applied on both sides of trough floor as well as cross members. All CME. ICF has switched over to raised trough floor from middle trough floor design of under frame for non-AC coaches since 1991. As there are reports of high corrosion due to changing over to raised trough floor, ICF shall explore reverting back to middle trough floor design for non-AC coaches. | ICF has pointed out that 80% of the corrosion problem is in curved portion of rolled sections. RDSO should examine this issue CME/ICF ED/Carr/ RDSO 35 ' Drain holes shall be compulsorily provided on tum under near door corners as this area is reported to be corroding heavily due to water stagnation AICMEs 36 37 [ Non-AC window sill The water sealing arrangement presently provided Is not adequate. This should be studied by RDSO and PUs and leak proof design | needs to be worked out BEML type window frame design may be adopted on ICF coaches also because corrosion in window frame area of BEML coaches is much lower | Corrosion shall be made as a check point in inspection and a rejectable defect as per IRCA rules, | Only the specified coach cleaning compounds with neuiral behavior should be T EOiCarr/ RDSO CDE/RCF CDENCF CDEIRCF | used during the cleaning proces:Workshops reported that anti-corrosion coating (PCN-123) is peeling off which is due to poor surface preparation. As per the specification, the anti-corrosion coating has to be applied only after through surface cleaning as given in the specification (ST3). AIL CMES: Jagadhari workshop reported that Fiat bogies originally imporled trom LHB are still working without corrosion. However, IR made Fiat bogie frames are corroding. There should not be any dilution in grade of material used for bogie and bogie components. It should be ensured that material specified by LHB is followed. RDSO should conduct audit of FIAT Bogie manufacturing at PUs. RCF should pull up quality control as JUDW has received bogies without primer. These should be investigated and responsibility for such lapse to be fixed up. GMIRCF ED/Car/ RDSO 3.10 The Railways should stop flooding of coach during intemal cleaning and Topping of coaches by wet cloths/ sponge! mop should be done. All CEs: 311 | The welding of PVC flooring should be done in Such a way that the joints are property sealed. AllCMES: 3.12, The use of epoxy flooring in place of PVG flooring in the toilets should be promoted to avoid the seepage of water through joints. EDICarr] RDSO CDE/RCF CDE/ICE Only stainless steel fittings should be used for securing the component made of stainless steel. All CES: The sealed window design should be explored both for ICF and LHB non AC coaches. | CDEIRCF CDEICE RCF has not provided drain holes in the trough floor of AC coaches. Drain holes in the trough floor have to be provided in a staggered manner so that the minimum required cross sectional area is maintained. CME/RCF | Bituminous painting of sole bar and other structural members has to be done without fail, All CMEs| | FRP tissue has (0 be used for corrosion protection of under frame structural members as specified. VAICMEs | Filling of pully between the window frame and window opening in the shel | should be stopped as it blocks the drainage of water for which the slope has been provided in the window frame. CMENCF CME/RCF — Shri D. Ray, Ex. CME/SER the guest Speaker highlighted that during the | Schedule, rust, oi, metal oxides shall be removed before fresh repainting | ——— Railways must maintain the corrosion diagram. Instruction for computerization of corrosion diagram already exists and this should be used as a guide for the next corrosion repair schedule RCF must revert to imporied ferrule fitlings to avoid detention of trains in opan | line Ul such time quality of indigenous sources is improved. Railways have been reporting that there are frequent failures of indigenous ferrule fillings | being provided by RCF. [All CMEs All CMES: CMEIRCF3.22 RCF & ICF should switch over to seamless slainiess steel tubes for av brake | CDENGE system, CME/RCF EDICarr/ RDSO| made by RCF because of the bad quality materials supplied. RCF should identity coaches fitted with the pipes of this particular firm and replace them and claim the warranty as per the terms and conditions of the contract. There have been many instances of failure of metalic brake pipes in coaches | CME/RCF 3.24 Putting patch over the joints of the sole bar ‘should be quality of the weld of the original joint of the sole bar cannot be seen after covering it with the patch. liscontinued as the | All CMs 325 related issues during design and manufacturing in PUs. Other Expert Group repair in workshops. Report by 20" October 2015. ‘Two standing expert group consisting oF EDME/Chg, CDE/ICF, ED(Carriagey’ | EDME/WI RDSO, Additional ED(M&CYRDSO are appointed to look into the corrosion | RB Consisting of EDMEN, CWM/BPL, CWM/LLH, CWMIJHS & ED/CAMTECH is | EOME/ also appointed which will focus on the maintenance in coaching depot and | Chg /RB 3.26 Feedback on the action taken should be given in one montis lime to Board. TANGMES No. 2005/M(Cy/143/4 To Gou.g OF (SHAILENDRA SINGH) EDME (Chg)/ Railway Board DG/IRDSO CMES/All Zonal Railways & Open Line RCF/Kapurthala & RBL, ICF Copy for kind information to; AM(ME), AM(PU) EDMEtW), OME(Chg.) Sr. PPS to MM -4 (= dated 25.08.2015