MRT- 07, 08, 09 & 10 Question Bank with Solution.

Course Code- MJI (C) C, D, W-04 Ques-3 LONG TYPE QUESTIONS.

Ques-1 - What do you understand by tender? How many type of are tender are there? Explain.
MRT-07-Tender & Contract
Ans-1-A tender is a sort of bid or offer made by a party/ contractor/firm for the execution of work or supply
Ques-1 FILL IN THE BLANKS. of materials under certain specified conditions & within prescribed time limits.
1. Negotiation is done with Lowest 1 Firm. 1. Open Tender (Single / Two packet Tendering System):-It is a system of invitation of tender by public
2. JAG grade officer is the accepting authority for the tender value between 20 Lacs to 50 Lacs. advertisements in most open public manner. Any person on payment of the tender cost can purchase
3. Global tender can be called upon by Ministry of railways and Railways Board. tender document. These are resorted to get enough competition & rates for the work. As a general rule,
4. During disaster, annual limited tender limit of PHOD for single tender is 300 Crore. all the tenders must be the open tenders, except where the situation warrants. In open tenders, if a single
5. In critical condition limited tender up to 37.5 Lacs may be called upon by JAG/SAG Officer. offer has been received, it can be examined by Tender committee but in case of Limited tender, fresh
6. For tender for higher values Sudhir Chandra report should be followed. tender should be invited except in very urgent cases taking approval of SAG officer.
7. 10 % amount of total bill may be deducted from bill in form of SD. Check List in Tender-
8. There are 65 Clauses in GCC. Advertise high value tenders in National newspapers.
9. In failure of negotiation case may be Re-Tender. Minimum gap between publication & opening - 30 days.
10. In fixed delivery contract, contract rate, contract amount, and time is Fixed. Tender form to be available for sale 3 weeks before opening (Minimum 15 days before for small value
11. Generally contract is of Works and Supply types. Tenders).
12. The minimum cost of Tender document is Rs 1000. Curtailment of notice period (min. 21 days) with prior finance concurrence.
13. The PG amount should be submitted within 30 Days of LOA Reduction of NIT from 21 days (but not less than 12 days in any case) in rare exceptional cases of small
14. During negotiation 10 % rate variation is acceptable. value works shall be exercised by DRMs with concurrence of FA & CAO- Reason should be recorded.
15. While measuring the contract agreement from 140 to 150 Percent work gets done at 96% rate. Sale of tender form not to be denied.
16. In Limited tender, firms must be present in registration list. Date from which tender document would be available to be notified and not be less than 15 days before
17. For tender of Rs 2.4 Crore amount of EMD would be 2.70 Lacs tender opening date.
Corrigendum's to be published before original date of opening. Newspaper cutting must be pasted on
Ques-2 – Identify True & False. tender file Get estimate sanctioned before invitation. If specification after undergo a major change, re-
1. It is compulsory to upload the open tender on Internet----- TRUE. invite tender. Scope of work, completion time is known. Drawing / Site is ready. Requirement of all
2. For tender of more than 20 Lacs limited tender is called upon---- FALSE participating department have been taken care of in the scope of work.
3. Tender more than 50 Lacs, Sudhir Chandra report to be followed----TRUE
4. In general conditions SAG officer may call limited tender of more than Rs 1 Crore ---TRUE. 2. Limited Tender- Rly. May decide category of works for which list of approved contractors shall be
5. GM is competent authority to call Global Tender ---FALSE maintained for each monetary slab.
6. It is compulsory to verify EMD before signing the contract agreement----TRUE. The reasons for inviting limited tenders should be kept in record. There should be minimum 10 Firms
7. After Verification of SD and PG, Contract agreement should be issued ----TRUE. Registered for limited tender
8. For tender more than Rs 1 Crore, EMD amount availed on the basis of Rs 1 Lacs +0.5 Percent of In case of insufficient response & Ring formation is suspected, Railway may invite open tenders.
more that Rs 1 Crore ) ---FALSE. Monetary Slabs for calling Limited Tenders
9. TC is not followed by administrative officer ----FALSE
Sr. No Monetary Slab for LT Lowest Authority competent to approve
10. SD and PG is obtained at the rate of 5 Percent of the tender Price----FLASE
calling of LT
11. Before returning back SD issuance of NOC is compulsory ----TRUE.
12. Maximum 10 Percent of bill only, can be taken in form of SD from firm ----TRUE. 1. Up to Rs. 37.5 Lakhs JAG/ SG
13. Limited tender may be opened after 21 Days -----TRUE
2. More than Rs. 37.5 Lakhs & Up to Rs. 1.5 Crore SAG/ DRM
14. Negotiation can be done with L2 Firm ------FLASE.
15. During negotiation, retendering process is adopted after getting no consent from L1 Firm----TRUE. 3. More than Rs. 1.5 Crore & Up to Rs. 75 Crores HOD/ PHOD
16. After issuance of LOA work can be started -----FALSE.
17. MB can be signed only by supervisor---- FALSE
18. Contract can be extended by more than 150 Percent---- FALSE. 3. Special Limited Tender: - For important works, special limited tender can be invited.
19. When contract is extended from 140 to 150 percent work is executed at the rate of 96 Percent--- These tenders may be invited from specialized and reputed contractors/ agencies.
TRUE. Special limited tender be processed with finance concurrence and approval of competent authority under
20. As per the required extension upto 125 Percent only is done by a SAG or upper grade officer----- following situations –
TRUE Works of specialized nature (PHOD approval)
21. Delay and late tender are rejected----TRUE. Work of urgent nature (GM approval)
Consultancy works (GM approval)
Page 1 of 49 Page 2 of 49

Tenderers need not necessarily be borne on approved list. 03 Concurrence to proposal SE (Tender) Sr. DFM --
Offers for SLT should be invited from at least 6 firms but not less than 4. Each tenderer to fulfill eligibility
criteria. 04 Preparation of estimate/ Est. cost SE (Tender) SE( Tender) --
Board has decided that CAO(C) with the concurrence of FA&CAO (C) may invite SLT not only for specialized 05 Vetting of estimate SE (Tender) Sr. DFM --
nature of work, but all type of works depending upon the merit of the case...
06 Sanction to estimate SE (Tender) DRM/Sr DME --

4. Single Tender :- Single tender may be invited with CA’s Approval in case of:- 07 Tender booklet preparation with Terms and SE (Tender) ADME/DME/ Sr DME --
Emergent Situation, Accident, Breaches involving dislocation of traffic (separate powers) and AMC of Conditions, scope of work etc.
Equipment. 08 EMD (2% of the estimated tender value up By Tenderer SE (Tender) --
Limits of Single Tender- Up to Rs. 20 Lakhs per case per PHOD subject to annual limit of Rs. 1 Crore (prior to 1.0crores), above this, 2 lakhs + 0.5% of
finance concurrence at the level of FA& CAO). the excess of estimated cost
Up to Rs. 10 Lakhs per case per DRM subject to annual limit of Rs. 50 Lakhs (prior finance concurrence at the
09 Ensure Unit of Advertised Tender OS&SE (Tender) SE( Tender) --
level of Sr. DFM).
All Single Tender cases (other than stores) will require GMs personal sanction and FA & CAOs concurrence. 10 Preparation of tender notice for open SE (Tender)/OS Sr DME --
TC & Accepting authority should be one step higher. tenders/OEM
Note: GMs may delegate power to PHODs/DRMs in consultation with FA&CAOs to enter into Annual
Maintenance Contract (AMC) for equipment’s with authorized dealers on single tender basis based on 11 Loading of Tender Notice on website before SE (Tender) ADME --
35 days of opening of tender
justified local conditions.
5. Quotations: - Except where for reason which should be in public interest, it is not practicable or 12 Issuing of tender booklet before 25 days OS (Tender) ADME/DME --
advantageous to call for tenders, calling of tenders can be dispensed with by GMs.
In all other cases where it is decided not to call for tenders, the reason should be recorded and financial 13 Opening of tender OS (Tender) ADME 01 Day
concurrence obtained.
14 Submission of tender cost of down loaded OS (Tender) ADME 02 Days
Any work proposal value up to Rs. 5 Lakhs can be processed through work order by calling quotations. tender form to Sr. DFM (Same day)
Work order should be open to all contractors and minimum 3 quotations are required.
Attempt should not be made to split the work to bring the proposal under work order limit. 15 Verification of EMD submitted by Tenderer OS (Tender) ADME 07 Days

16 Preparation of brief note & tender SE/OS (Tender) ADME 01 Day

Ques-2 - What is difference between open tender and Limited tender? tabulation statement.
Ans-02-
Sr. NO Open Tender Limited Tender 17 Verification of brief note SO (Wks A/cs). OS (Tender) Engg. and accounts 05 Days
1 Open Tender is invitation of tender by Offers are invited from limited tenders from the 18 Nomination of TC members SE (Tender) Sr.DME/DRM 01 Day
public advertisements approved list to save the time for small value of
work and specialized in nature. 19 TC preparation SE (Tender) TC Members 05 Days
2 On payment of tender cost one can Limited tenders may be invited with concurrence 20 Verification of eligibility criteria SE (Tender) TC Members 07 Days
purchase tender document. of finance and approvals of competent authority.
3 These are resorted to get enough There should be minimum 10 forms registered for 21 TC Finalization TC Members TC Members 07 Days
completion rates for the work. limited tender.
22 Acceptance of TC recommendations SE (Tender) Sr DME/DRM 01 Day
4 All tenders must be the open tender, Such tenders are furnished before 21 days.
Except where situation warrants. 23 Issuance of Letter of Acceptance SE (Tender) DME/Sr DME 01 Day
5 Such tenders are published before 30 In limited tender we select one of the approved
days or min 35 days in news papers tenderer from the list of approved tenderers. 24 Submission of PG by the firm within 30 SE (Tender) ADME/ DME / 15 Days
Days[ 5% of contract value ] Sr. DME
6 Such tenders are published atleat 5r
national papers and local newspapers. 25 Verification of PG by law officer OS (Tender) SE (Tender) 02 Days

Ques-3 –Write down various type of tender proceedings in correct sequence? 26 Verification of BG by bank OS (Tender) SE (Tender) 05 Days
Ans-03- Tender Proceedings as follows:- 27 Preparation of Contract SE (Tender) ADME/DME/ 02 Days
SN Activity To be Initiated by Done by Time Limit Agreement Sr. DME

01 Preparing office note for approval SE (Tender) & ADME DRM/ADRM -- 28 Signing of Contract Agreement SE (Tender) With Rly. & Firm 03 Days

02 Calling for budgetary quotation from Firm SE (Tender) & ADME OEM/Any other firm --
Page 3 of 49 Page 4 of 49
 29 Dispatching of copy of Contract Agreement OS (Tender) SE (Tender) 01 Day 5 Tender Costing over Rs. 8 a) SG/JA Officer of the concerned Executive DRM/CWM
to concerned depot in charge. Crores and up to Rs. 12 Deptt. (Convener)
30 Updating of finalised tender on net for OS & SE (Tender) ADME 04 Days Crores b) SG/JA Officer of any other Executive Deptt.
value more than 1.0 crores. c) SG/JAG officer from Account Deptt.

31 Releasing of first on account bill by OS/SE (Tender) SE(T)/ADME/ --

preparing office note DME/Sr. DME S.N. Value of Tender Level of Accepting Level of TC Remarks
32 Completion report from depots. By Nominated By Nominated
Authority
Supervisor Supervisor Upto 4.0 Crores SG/JAG SS -
33 Refund of Performance Guarantee (PG) By Nominated Officer concerned Above 4.0 Crores & upto SAG/DRM/ ADRM/CWM JAG/SG -
after physical completion of work ( After Supervisor
20 Crores
completion certificate)
Above 20 Crores & upto CHOD in SA Grade SAG -
34 Refund of security deposit (SD) to the After getting No Officer concerned
contractor after expiry of maintenance Claim Certificate from
75 Crores
period and after passing the final bill. ( tenderer Above 20 Crores & upto AGM/PHOD in HAG CHOD -
After getting No Claim Certificate from 100 Crores
tenderer)
Above 20 Crores & upto CAO/Const. PHOD -
35 Arbitration, if any. By Firm/Tenderer Officer concerned
300 Crores

Ques-4- What do you understand by tender committee? Explain.

Ques-5- What is Negotiation and in what circumstances it is used?
Ans-04-Tender committee is a committee which is made up of three members
Ans-05- Negotiation is a method by people settled differences. It is process by which compromise or
A- Technical Member (Convener) which is from used department.
agreement is done while avoiding argument and dispute. In any disagreement, individuals understands aim
B- Finance memember- Which is from accounts department.
to achieve the best possible outcome for their position. It is strategic discussion that involves to or more
C- Third member from any department.
parties that resolves an issue.
COMPOSITION OF TENDER COMMITTEE (WORKS CONTRACTS) OPEN LINE
The circumstances of negotiation occur when two parties or groups of individuals disagree on a solution for
S Estimated Value of Composition of Tender Committee Tender accepting the problem or the goal for a project or contract. If successful negotiation requires the two parties to come
Tenders authority together and hammer out an agreement that is acceptable to both.

1 Tender Costing over Rs.
10,000/-and up to Rs. 20
Lakhs
2 Tender Costing over Rs.20
lakh and up to Rs. 50 lakh
3 Tender Costing over Rs. 50
lakhs and up to Rs. 3
Crores
4 Tender Costing over Rs. 3
Crores and up to Rs. 8
Crores
a) Sr. Scale Officer of the concerned
Executive Deptt. (Convener)
b) Jr.Scale Officer from accounts Deptt.
a) Sr.Scale Officer of the concerned
Executive Deptt. (Convener)
b) Sr.Scale Officer of any other Executive
Deptt.
c) Jr. Scale officer from Account Deptt.
a) Sr.Scale Officer of the concerned
Executive Deptt. (Convener)
b) Sr.Scale Officer of any other Executive
Deptt.
c) Sr. Scale officer from Account Deptt.
a) SG/JA Officer of the concerned Executive
Deptt. (Convener)
b) SG/JA Officer of any other Executive Deptt.
c) SG/JA officer from Account Deptt.
SG/JAG Officer Quse-6- What points should be kept in mind while solving judicial disputes?
Ans-06- Following points should be kept in mind while solving judicial disputes.
1. Arbitrator (Mediator) should be appointed.
SG/JAG Officer 2. No dues are pending regarding contract (Ex SDGP, Regular bills).
3. Measurement book (MB should be completed.)
4. MB is insured that it is signed by concerned authorities.
Ques-7- Which documents are needed to be examined before verifying payment related documents?
Ans-07-
SG/JAG Officer 1. Collection of Security deposited ( SD& PG)
2. EMD (Earnest Money Deposited should be adjusted in Security deposit.
3. Bill will be verified as per measurement book.
4. Penalty details should be checked before verifying bills.
Recording of Measurements
1. Measurement are to be recorded in MBs.
SAG/ADRM
2. Prescribed checks on measurement should be conducted by officers.
3. Payment at full rates must not be made unless the item has been completed as per specs.
Upkeep of Measurement Books:

Page 5 of 49 Page 6 of 49

1. The pages should be machine numbered. • Credentials issued by private organization

2. The entries must be made clearly in MB books at site of the work. • Tenderers conditions
3. Each measurement book should be provided with an index-1325. – Financial implications to be evaluated
4. All quantities should be clearly traceable in to the documents. • Delay in finalization
Completion Reports: - Completion Report should be prepared in the form of E-1706 and brief explanation – Time and cost overrun
should also be furnished. – Source of corruption
Checking of Records for Payment • L1 ignored on flimsy ground
Whether the bill is in the prescribed format. – Favored contractor, high rates
Top sheet accompanying the bill is checked. • Comparative statement not prepared or checked
In case of final bill, whether no claims certificate from the contractor and no dues certificate from the – Other than L1
executive are enclosed. • Reasonability of rates
Whether any accounts or audit paras are pending against the agreement is verified. • Tender accepted during 2nd call
That there are no delays in making measurements or in preparing bills after the measurements are made. – 1st instance discharged on flimsy ground
The rates are verified with those given in the agreement. – Higher rates during 2nd call to favored firm
The currency of the contract. • Items deleted after opening
Validity of Bank Guarantee is verified. – To alter L1
Quantities in the bill are checked with those in the M. Book. • No verification of credentials
Whether test check has been done. – EMD mode not proper
Whether the bills are signed by the executive officer as well as the contractor. – False credentials
Whether the funds availability has been certified and has been allocated to proper heads of accounts.
Whether all deductions have been made and the bill is arithmetically accurate. Ques-10- What do you understand by contract? What are the type explain
Ans-10- Contract- In agreement which is enforceable by laws termed as contract. Types of contract
Ques-8- What are the guidelines of vigilance department while opening and inviting a tender? depending upon the size of project, Local conditions, resources and technology. There are many types of
Ans-8- Invitation and Opening of Tenders contracts
• Inadequate time Contracts mainly are of 3 types.
– Favored firms 1. Works contract & ;fn fdlh contract esa 50% ls vf/kd dk;Z dk ewY; “kkfey gksA
– High rates (a) Lump-sum contract
• Inadequate Publicity (b) Schedule contract
– Very less circulation in news papers (c) Piece work contract
– Not uploaded in websites 2. Supply contract- ;fn fdlh contract esa 50% ls vf/kd supply material dk ewY; “kkfey gksA
– Favored few firms (a) Running contract
• No Tender sale and opening Register (b) Rate contract
– For Fair & Transparent system (c) On delivery contract
• Open at prescribed time, place
Lump-sum contract-- bl dkUVªsDV ds vUrxZr dkUVªSDVj fdlh dk;Z dk fu’iknu ;k eSVsfj;y dh lIykbZ fuf”pr
• Presence of Tenderers
nj esa fuf”pr le; esa djrk gSA bl izdkj fdlh ek=k dh izkfIr ;k fdlh ek=k dk dk;Z fu’iknu mldh
• Rates to be read by Tender opening officer okLrfod ek=k rFkk fd;k dk;Z ;k lIykbZ dh x;h eVSfj;y dh ek=k mlds ifj.kke ds :Ik esa gksrk gSA
• Corrections/omissions not numbered & attested
– Possibility of Tampering of documents Schedule contract- bl izdkj ds dkUVªSDV ds vUrxZr Bsdsnkj fdlh dk;Z dk fu’iknu ;k eVSfj;y dh lIykbZ
• Rates not in words fuf”pr ek=k ,oa fQDl~M jsV ;k Qhl ds vk/kkj ij dh tkrh gSA fd;k x;k dk;Z ;k izkIr ek=k mldh okLrfod
– Tender opening authority should write in words dqy ek=k ds lkFk lfEcfZU/kr jgrk gSA fdUrq vyx vyx “ksM~;wy ds vk/kkj ij lIykbZ fd;k tkrk gSA
• Late/Delayed Tenders
– Not to be considered Piece work contract- bl izdkj ds dkUVªSDV ds vUrxZr fdlh dqy dk;Z ;k eVSfj;y lIykbZ dks VqdM+s VqdM+s
• Maintain sanctity of Tender system esa vyx vyx jsV ,oa le; ij fd;k tkrk gSA bl izdkj ds dk;Z ;k lIykbZ dk vkil esa dksbZ lac/k ugh
• Avoid malpractices gksrkA
Supply contract- bl izdkj dk dkUVªSDV LVksj foHkkx }kjk eSVsfj;y dh [kjhn ,oa lIykbZ ds fy, fd;k tkrk
Ques-9- What are guidelines of vigilance department during consideration of tender and award of
gSA ;s eq[;r% rhu izdkj dk gksrk gS&
Contract?
(a) Running contract- bl izdkj ds dkUVªSDV ds vUrxZr Bsdsnkj dks ,d fuf”pr ek=k dh vkMZj ekdsZV jsV ds
Ans-09- Tender Scrutiny and Award of works
vk/kj ij fn;k tkrk gSA vFkkZr iqu% vkMZj nsus ij jsV c<+ ;k ?kV ldrk gSA
Page 7 of 49 Page 8 of 49
 • EMD shall be applicable for all modes of Tendering.
(b) Rate contract- bl izdkj ds dkUVªSDV ds vUrxZr Bsdsnkj fdlh eSVsfj;y dh fQDlM ek=k dk fQDlM jsV • The tenders without EMD are liable to be rejected.
ij ,d fuf”pr le; esa lIykbZ djrk gSA ;g ,d izdkj dk Bsdsnkj ds lkFk jsV ,xzhesaV gSA • EMD should be in cash or can be remitted in the following forms
(c) On delivery contract- bl izdkj ds dkUVªSDV ds vUrxZr Bsdsnkj dks ,d fuf”pr ek=k dh lIykbZ ,d • Deposit receipts, Pay order, DD of SBI or any Nationalized Bank shall be rounded to the nearest Rs.
fuf”pr le; ij izkfIr ds fy, nh tkrh gSA bl izdkj ds dkUVSDV dk iz;ksx mUgh lIykbZ esa fd;k tkrk gS 10/-
tgkW eSVfj;y dh nj esa vf/kd varj vkus dh laHkkouk jgrh gSA
Ques-15- Explain in brief GCC?
SHORT NOTES- Ans-15- It is known as general conditions of contract.
Ques-11- What are the guidelines of CVC during tender proceedings? 1. GCC implemented to all type of contracts.
Ans-11- CVC Guidelines for tender opening: - Not only tender opening officer sign the envelopes but sign 2. For such quotations at least three quotations are required.
of two tenderers should also be obtained on all the envelopes containing price bid. 3. For such contracts attempts should not be made to split the work.
a. Ambit (Within the limit) – We don’t have to break any order or split it.
Ques-12- What are the various quantity in any tender and how it is done? b. Reasonableness of rates
Ans-12- Variation in quantities. c. Were experienced agencies.
(1) Operation of an item by more than 125% of the agreement quantity needs approval of an officer not less
than SA grade. Ques-16- What points must be kept in mind while preparing eligibility certificate?
1. In excess of 125% but upto 140% of the quantity shall be paid at 98% of the rate awarded Ans-16-
2. In excess of 140% but upto 150% of the quantity shall be paid at 96% of the rate awarded I. Similar work
3. Variation of individual item beyond 150% shall be prohibited and be permitted only in unavoidable II. One contract.
circumstances with the concurrence of finance and be paid at 96% of the rates awarded. III. 35 % of tender value
a) The variation in quantities as per the above formula will apply only to the individual items of the iV Last three Years,
contract and not on the overall contract value.
b) Execution of quantity beyond 150% of the overall agreement value should not be permitted, if found II- Tender cost amount 150 % of advertisement tender.
necessary, should be only through fresh tenders or by negotiating with existing contractor with Last three years.
concurrence of FA&CAO and approval of General Manager. From whom certificate can be considered.
(2) In case where decrease is involved during execution –
(a) Contract signing authority can decrease up to 25% of individual item without concurrence. Tender opening process.
(b) For decrease beyond 25% for individual items or 25% of contract agreement value, the approval of SA Verification of authenticity of documents.
grade officer may be taken after obtaining “No claim certificate” from contractor, with finance concurrence. Briefing notes and tabulation statements.
(c.) The limit of varying quantities for minor value items shall be 100% (as against 25% for other items).
Minor value of item is less than 1% of total contract agreement value. Ques-17- What is security deposit? At what time and how it can be availed?
Ans 17- - Security deposit is to be paid by contractor in token for the due fulfilment of a contract. The amount
Ques-13- Explain in brief Global Tender? of security deposit required will be as under:-–
Ans-13- It is a type of tender which has been opened for global level. No GM or SAG officer has the authority (a) Security deposit for each work would be 5% of the contract value.
to release such kind of the tender. (b) The rate of recovery will be @10% of the bill amount till the full security deposit is recovered.
(c) Security deposit will be recovered from the running bill of the contractor and no other mode of collecting
Ques-14- What is EMD? Where it is deposited and in which way it is returned back to tenderer? security deposit such as BG/FD etc. will be accepted towards security deposit.
Ans-14- Every tenderer is required to deposit EMD for due fulfillment of the conditions of the contract (to Refunding of SD:
be a security against loss in case of failure of contractor). The earnest money is required to test earnestness 1. Based on the completion report SD has to be refunded with the approval of competent authority.
of the tenderer and to discourage non serious parties. The EMD of the successful tenderers is adjusted in 2. Refund of SD is the last act in any contract. Returned after expiry of Maintenance period
the Security Deposit 3. SD refund should be linked with the performance for the work. After getting no claim certificate
Value of Work EMD
Ques-18- What is difference between Rate and running contract?
For works estimated to cost up to Rs. 1 Crore 2% of the estimated cost of the work. Ans-18- Rate Contracts. -The Rate Contract is a contract under which, during the period of its currency, the
contractor engages to supply materials on demand, irrespective of quantity, at fixed unit rates or prices,
For works estimated to cost more than Rs. 1 Crore Rs. 2 Lakhs + ½ % of the excess of estimated
within a given period of the receipt of such demand.
cost of work beyond Rs. 1 Crore
EMD Maximum Limit : 01 crore Running Contracts.-The Running Contract is one under which, during the period of its currency the
contractor engages to supply, and the other party to the contract to take, a specified quantity (with a

Page 9 of 49 Page 10 of 49

percentage tolerance either way) of materials, as and when ordered, at fixed unit rates or prices, within a
given period of the receipt of such order. MRT -08- Accident and Disaster Management (MRT-08) -----25 Marks.

Ques-19- What is Lump Sum Contract? Fill In the blanks.

Ans-19- "Lump Sum "Contracts. The Lump Sum Contract is a contract under which the contractor engages to
carry out a work or effect supply as specified and within a given period for a fixed total sum; his receipt of this
sum being dependent on his completing the work or supply to specification and time, irrespective of the
actual quantities and kind of work done or materials supplied in achieving his result.
In the case of such contracts a scale of rates or prices may be agreed upon by which enhancement of or
reduction from the lump sum may be regulated in the event of any departures from the work or supply as
specified being made subsequently under the orders of competent authority; or by which reduction may be
made, at the discretion of competent authority for failure on the contractor's part to conform to specification.
Ques-20- What is fixed delivery contract?
Ans-20- For a definite quantity of materials to be delivered in one or more installments, delivery of each
installment being completed by a definite date. It is type of contract which is done for store department
where the rate of the material the quantity of material and time fixed to unload the material is fixed that is
why it is called fixed delivery contract.
1. Capacity of crane with A class ART is 140 T.
2. Mechanical department is responsible for running of break down train.
3. Land slide is Natural Disaster.
4. TRD (Traction Rolling Department) is responsible for sending the tower wagon to accident site.
5. Commercial department is responsible for arrangement of private buses at the site of accident.
6. Signal & transmission (S&T) department is responsible for the arrangement of communications at
accident site.
7. During disaster the compensation amount is distributed by Commercial Department.
8. High level safety committee was formed in Year Sept-2002.
9. 3 Members were in High level committee.
10. Mechanical department is responsible for maintenance of ART and ARMV.
11. Cold cutting equipment’s are kept in ART.
12. There are 3 levels of disaster in Indian Railways.
13. High level committee provides 111 recommendations.
14. At zonal level, correct information about the disaster is conveyed to railway board by General Manager.
15. In disaster the compensation amount of Rs. 4 Lakhs is paid to relatives of Dead person.
16. A large vehicle which carries fire extinguisher equipment’s and has arrangement of throwing water is
called Fire Engine.
17. At Zonal Level, Chief public relation officer is nominated by General Manager.
18. Chief Safety Officer (CSO) is the chief of control room at zonal level during any accident.
19. Disaster management center is opened in the room of CSO officer at Headquarter.
20. Limit of Willkie talkie is 5 KM.
21. Medical report is necessary for any claim.
22. At division level ART remains under Sr. DME.
23. Time for Long Hooter is 90 Secs.
24. The compensation during rail accident is governed by rules inscribed in 124 Act.
25. Payment of interim help is made as per Section 125A of railway act.
26. In India there are 21 benches of railway claim tribunal.
27. Ex Officio officer of NDMA is Prime Minister.
28. First work of Railway employee who is travelling during disaster is to report to Guard.
29. EPLE box is kept nearby Electrical Portable light equipment.
30. While protecting line after accident, Distance between first and second Detonator is 600 Mtrs.
31. Unit of twist in track is mm/meter.
32. Maximum cant of 165 MM is permissible for broad gauge of Indian Railways.
33. Maximum Buffer height of rolling Stock is 1105 mm.
34. Ballast used between two sleepers is known as Crest Rib.
35. Ballast used under the sleeper is known as Cushion.

True and False.

1. The guard is the in charge of the accident site before any officer reaches at site---- TRUE.
2. The conductor/ rail superintendent ensures that no train passes through the accident site----TRUE.
3. National disaster management plan is updated in every 3 Years---- FALSE.
4. Rail disaster means, sudden incident that effects the rail passengers, staff and their family. ----TRUE.
Page 11 of 49 Page 12 of 49
5. Compensation amount is arranged by the welfare inspector----TRUE.
6. Damaged line is protected by means of Detonators---- TRUE.
7. Disaster management has 3 Levels ---TRUE.
8. The public relation officer is responsible for providing the information to the media regarding the
accident. -----TRUE.
9. The COM declares the disaster after affirmation from the General Manager. ----TRUE.
10. The very first hour after the accident is known as GOLDEN HOUR. ----TRUE
11. Sr. DOM Coordinates works from the division. ----TRUE.
12. The DRM relays information to headquarter about disaster----TRUE.
13. The prime motive of the public relation is to create coordination with the public----TRUE.
14. RS 25000 is given in case of minor injury. -----TRUE.
15. Compensation is given I n accordance to the section 11 and 12 of railway act,1989----TRUE
16. The process of inhaling and exhaling is known as breathing-----TRUE
17. Serious accident is considered when loss of more than 2 Crores occurs to railway property-----TRUE.
18. Bend in rail due to increase in length of rail as an effect of temperature is called Buckling-----TRUE.
19. Cross level is always measured on right rail in reference to left rail ------TRUE.
20. On 20M chord, Max limit of versine variation is 10 MM ----FALSE.
21. When point of mount is known the track reading upto 45 mtrs is taken on both sides ----TRUE.
Write SHORT NOTES –
1. GOLDEN HOUR- The golden hour, also known as golden time, refers to the period of time following
a traumatic injury during which there is the highest likelihood that prompt medical and surgical treatment
will prevent death. While initially defined as an hour the exact time period depends on the nature of the
injury and can be more than or less than this duration.
It is well established that the person's chances of survival are greatest if they receive care within a short
period of time after a severe injury; however, there is no evidence to suggest that survival rates drop off
after 60 minutes. Some have come to use the term to refer to the core principle of rapid intervention in
trauma cases, rather than the narrow meaning of a critical one-hour time period.
2. Derailment: - When a wheel or wheel set of rolling stock is leaved from the top surface of rail is called
derailment. The derailment are generally two types:-
a. Sudden derailment due to wheel jumping of the rails. - This type of derailment is characterized by no
mounting marks on the rail and only a drop mark on the sleepers. It occurs when the derailment force are
high enough to suddenly force the wheel to jump off the rails the probable cause of derailment of this
type are
i. Excessive speed particularly at the location of curve or turn out.
ii. Sudden shifting of load.
iii. Improper loaded vehicle.
iv. Sudden variation on draw bar forces cause due to braking or acceleration or improper train
operation.
v. Resonant rolling nosing or hunting
vi. Broken wheel or broken axle
vii. Failure of vehicle component
viii. Observation of track
ix. Failure of track component if both wheel drop inside there may be a case of track distortion or
spread of gauge
b. Gradually derailment by flange climbing. This type of derailment is characterized by wheel flange
gradually climbing the rail leaving mounting marks on the rail such a derailment occurs when derailing
forces do overcome the stabilizing forces but are not high enough to cause sudden derailment.
In this case due to unstable situation wheel climbing the rail rides over rail and finally slip and drop of
the rail.
It is difficult to established prima facial cause in this case and details investigation have to be done to
finally arrive at the exact cause.
The cause of accident may be singly or jointly any of the following
(a) Track defect
(b) Vehicle defect
(c) Unfavorable operating features.
3. Train Wrecking- This refers to the willful obstruction of or tampering with the permanent way, works or
rolling stock, resulting in an accident to a train with or without loss of life or damage. These include
accidents falling under category N-1, N-2 and N-3.
4. Serious accident. Accident to a train carrying passengers which is attended) with loss of life, or b) with
grievous hurt to a passenger or passengers in the train, or c) with damage to railway property, the value
of which exceeding 2 crore, and d) any other accident, which in the opinion of the Chief Commissioner of
Railway Safety or Commissioner of Railway safety requires holding of an inquiry by the Commissioner of
Railway Safety, shall be deemed to be a serious accident. However, the following shall be excluded from
the category of a serious Accident:
(a) Cases of trespassers run over and injured or killed through their own carelessness, or of passengers
injured or killed through their own carelessness.
(b) Cases involving railway servants or holding valid passes/tickets, or otherwise who are killed or
grievously injured while travelling outside the rolling stock of a passenger train such as on foot board, or
roof or buffer but excluding the inside of vestibules between coaches, or run over at a level crossing or
elsewhere on the railway track by a train, and
(c) Level crossing accident where no passenger or railway servant is killed or grievously hurt, unless the
Chief Commissioner of Railway Safety or Commissioner of Railway safety is of the opinion that the
accident requires the holding of an inquiry by the Commissioner of Railway Safety.
5. High Level Safety Committee- High level safety committee founded by the ministry of railways and
headed by the eminent scientist Dr. Anil Kakodhkar. This committee was constituted in year 2002 and
having 3 Nos of members. Major recommendations of this committee includes.
i. Elimination of all level crossings manned or unmanned in next 5 years.
ii. Maintenance of safety related infrastructure at cost of Rs 2000 Cr
iii. Implementation of advanced signaling system
iv. All new coached will be safer LHB type.
v. Total cost for implementing the safety committee report is of Rs 1lakh crore which has to funded
by safety cess on passengers and grant by the central government.
vi. High level safety committee gives 111 nos of recommendations
6. Corporate safety plan. Indian railways corporate safety plan was implemented in Indian railways
between years 2003-2013. The main findings of this plan is that 7% of total accidents account 35% of
total fatalities. Apart from it 75% accidents 14% of total fatalities. This data is related to collision or
Derailment type of accidents. Following suggestions are advised by a cooperative safety plan to
decrease the rate of accident and causalities.

Page 13 of 49 Page 14 of 49

i. Extensive use of anti-collision devices. It is only designed to make the victim, comfortable until help arrives. It is a help, which calms the victim’s
ii. Elimination of 4 Wagon trains which is accident prone. fears and reduces any chance of further injury. If a person is bleeding, further loss of blood is immediately
iii. Reduction of thermite welded joints in rails. stopped.
iv. Improve training facilities and enhancement of human skills. If a bone is broken, the area is immobilized and the patient is put at rest. In case of convulsion, the patient
v. Continuous track circuiting and use of state of the art spurt the rail flaw detection. is protected from injuring himself. If poison has been swallowed, either the poison is removed or it is
vi. Fire accidents are of only 2% of total fatalities. Fire accident will be reduced by 80% by neutralized without delay.
production of fire proof coaches and fire retardant material in existing coaches.
vii. Level crossing accidents- This type of accidents having 16 % of total accidents but account for 10. Rail Buckling. A rail track is liable to get distorted, particularly in hot weather when the compressive
46% of fatalities. Following methods are suggested corporative safety plan to decrease the rail forces in the track exceed the lateral or longitudinal resistance of the track. The buckling of the track is a
accidents. matter of grave concern as it may lead to derailments and even serious accidents.
viii. Social Awareness program. Causes
ix. Construction of rail under bridges and rail over bridges. A track can buckle due to the following reasons.
x. Provision of phones and interlocking level crossings gates. (a) Inadequate resistance to track due to deficiencies in the ballast
(b) Ineffective or missing fastenings
7. TWIST- The variation in two continuous cross levels is known as twist. or (c) Laying, distressing, maintaining, or raising the track outside the specified rail temperature range,
The algebraic variation in two continuous cross levels is known as twist. It is always measured in mm/m. especially is hot weather
(d) Failure to lubricate the SEJs in time
The allowed twist:-
(e) Excessive creep, jammed joints, sunken portions in a welded track
On straight and circular curve - 2.8 mm /m.
Symptoms
On transition curve - 1.0 mm/ m. Buckling in a track becomes noticeable when the track displays the following symptoms.
A class track (160 KMPH) – 1.37 to 1.41 mm/M (a) Presence of kinks in the track
B class track (130 KMPH) – 1.41 to 1.78 mm/M (b) Absence of gaps in the SWR portion of the track in the morning hours of hot days.
C class track (100 KMPH) – 1.78 to 2.41 mm/M (c) Expansion/contraction at SEJ is 20 mm more than the theoretical range given in the LWR manual
D class track (Main Line) – 1.78 to 2.41 mm/M (d) High percentage of hollow sleepers.
E class track (Branch line) –2.41 to 2.78 mm/M Precautions
Buckling can be avoided by taking the following precautions.
8. Rolling stock Parameters- The following parameters of rolling stock are to be taken during investigation (a) Proper expansion gaps as specified in the manual should be provided in the SWR portion of the track.
Wheel gauge - the wheel to be measured at four locations and average of them to be considered. (b) As buckling is likely to occur between the 11th and 17th hour of the day, rosters of key men should be
Wheel gauge – 1600+2/-1 MM so adjusted that there is proper patrolling of the LWR portions of the track when the temperature exceeds
tm + 20°C.
Wheel defects- Wheel defects will be examined by tyre defect gauge these defects are as under
(c) No work of track maintenance including packing, laying, aligning, major/ minor realignment of tracks,
Defects New Cond. limit
screening of ballast should be done outside the specified temperature.
(i) Thin flange - 28.5 16MM (Goods stock)
(d) Wherever the track structure is weak and vulnerable to buckling, immediate action should be taken to
,, 22 MM (Coaching stock) strengthen by the provision of extra shoulder ballast, increase in sleeper density, provision of adequate
(ii) Sharp flange - 14.5 less than 05mm anti creep fastenings, replacement and tightening of missing and loose fastenings, etc.
(iii) Deep flange - 28.5 More than 35 mm
(iv) Flat tyre - 50 mm (Coaching stock) 11. CANT- Cant or super elevation: - To maintain the center of gravity or to neutralize the effect of centrifugal
60 mm (Goods stock) force, the outer rail on curve is lifted in respect to inner rail, is known as cant. Or
(v) Root radius to small -16mm 13 mm The lifting of outer rail in reference to inner rail on curve on same point is known as cant or super
Buffer height- 1105mm (max.) elevation.
1030mm (min.) Cant is always measured on outer rail in mm.
Buffer projection- 635 mm (max) The max. Kant allowed in Indian Rly B.G. Is – 165mm.
584 mm (min) For A &B class track – 165 mm.
Displacement of buffer For C, D &E class track – 140 mm
(Goods) 35mm Variation in cant is possible due to: - Cant deficiency or Cant excess.
(Coaching) 38 mm Max. Cant deficiency permitted - 75mm (gen).
100mm (in spl. case).
9. First Aid- First aid is that treatment which is given, while waiting for the doctor to come. It is immediate Max. Cant excess permitted - 75 mm .
and temporary care, given to the victim of an accident or sudden illness. It is never meant to replace Causes of variation in cant:-
qualified professional care. 1. Due to poor maintenance of track by Engg. Dept. (excess or low cant)
Page 15 of 49 Page 16 of 49
 2. Due to poor engineman ship by the driver. (Excess or low speed)
The equilibrium cant
E = GV2/127R
Where G = 1676+74 mm (gauge + width of the rail)
V= speed in kmph
R = radius in mtr
12. VERSINE- The perpendicular distance drown at the center of chord from the midpoint of arc is known as
versine. Versine is always measured on outer rail in mm.
If the versine is measured on 11.8 mtrs chord basis, the allowed variation in versine is only 10mm. Or if
the versine is measured on 20 mtrs chord basis, the allowed variation in versine is only 29 mm. The
versine measured on 11.8 mtrs chord in cm, is tells directly the degree of curve.
Versine(V)=125 C2/R
Where :-
C =length of chord in mtr.
R =radius in mtr.
LONG TYPE QUESTIONS.
Ques-1- What are the duties of a supervisor at the accident site?
Ans-1- Protect the site of accident to restrict further movement on that line or yard as the case may be.
Ensure that the necessary message regarding the details of the accident and casualties have been relayed to
the SS/SM, control and civil authorities.
Make first-aid arrangements for the injured persons, if any.
• Examine and make a note of all evidence which may prove useful in ascertaining the cause of
accident.
• Try to save life and alleviate sufferings. Ensure everything possible is done. Provide security to the
injured and help to all other passengers.
• To relay the prima-facie cause of the accident with the expected time of restoration.
• Seize and freeze all records as laid down in accident manual.
• Arrange to take photographs from different angles to assist in reconstructing the scene of the
accident.
• Co-ordinate with train crew, station staff and control office for providing relief to the injured and
restoration of traffic.
• Record the statement of the concerned staff available at site for ascertaining the cause of the
accident.
• Take written evidences of as many witnesses as possible in case passenger train is involved. Their
names/addresses should be recorded (witnesses should not be from Railways).
• Ensure relaying the progress report to control after every one hour.
• Obtain clearance from civil/police before starting restoration in case of sabotage/doubt of sabotage.
• When a senior officer arrives at the spot, relevant records should be handed over to him and he
must be briefed about the situation.
• If the accident is within station limits, note down the condition of points, fixed signals, position of
levers, position of block instrument and SM control.
• Scrutinize as early as possible the train signal register, reply books, PN book and other relevant
records pertaining to the train movement.
• Make a rough sketch showing the position of derailed vehicles, marks on sleepers etc.
• To give fit certificate to the accident involve train up to the next examination point towards direction
of movement.
Page 17 of 49
Ques-2- Explain difference between relief, Rescue, Restoration?
1. Ans-02 Relief: - To provide first aid to injured passengers and arrange to send serious injured ones to
the nearest hospital.
2. Railway has self-medical facilities as medical van which is equipped with medicine, medical tools
with operation theatre.
3. In case matter is not solve by railway assistant may be taken from civil, private& defence hospital
also.
4. In case of emergency medical hospital can be established near at accident site.
Rescue: -
1. To bring out passengers from dangerous or unpleasant situations.
2. For this purpose all equipment’s are equipped in medical van like under water cutting equipment,
fire extinguisher, portable power cutting and straightening tools. Along with Rescue air bag.
3. For this purpose if situation is beyond under control of railway help may be taken from civil and
defence also.
To handle above situation Railway staff are trained for this purpose.
Restoration: -
1. To clear the route for traffic.
2. For this purpose various department like Mechanical, Civil and Electrical engineering, traffic are
involved.
3. Restoring of rolling stock is done by C&W department & restoration of track is done by engineering
department. Also restoration of OHE is done by TRD/Electrical department.
4. Any failure along SNT is attended by SNT department.
5. Above work is jointly handle by efforts of all involve department.
Ques-4- Explain on board staff duties at the accident site.
Ans-4- Duty of ON board Staff at accident site.
• ON Board staff means who is travelling by particular train which is involved in accident either, he is
ON duty or OFF duty. Even though he is proceeding on leave or so. As per Railway Board guideline he
has to immediate attend the site and failure will be treated as an action against him.
• Main Duties of ON Board Staff are as under: -
• After occurrence of the accident he has to immediate report to the guard who is the in-charge of the
train, and he should immediate disclose his identity to Guard, Nearest Station Master and Control
Office.
• Ensure protection of accident involve line as well as the beside track if infringed.
• Collect brief details of accident & communicate to nearest Station Master and Control Office for
assistance.
• Arrange to provide First Aid to the injured passengers immediately.
• Serious injured passenger should immediate direct to nearest hospital.
• Immediate evacuation of the passenger from badly damaged coaches involved in accident.
• Preserve all the clues pertaining to the accident.
• On arrival of Sr. Officer all collected information should be communicated to him immediately.
• He has to continue his work till completion of restoration.
Ques-5- What parameters of railway tracks should be noted at the time of derailment? Explain in proper
format?
Ans-05- Track Observation and Parameters at the time of derailment.
1. If point of mount is known.-the track length should be taken for measurement: - 45 m. In rear side of
the point of mount & 45 m in front side of the point of mount.
Page 18 of 49

2. If point of mount is unknown/ disputed. - 90 m. In rear side of the point of mount & 45 m in front side Where:-
of the point of mount. C =Length of chord in mtr.
Point of mount: - The first wheel flange climb marks found on rail table is known as point of mount. R =Radius in mtr.
If there is more than one point of marks found on rail table. The rear most 1st point of mount mark will Ques-6- Explain difference between cross level and Twist.
be treated as actual point of mount. No any point of mount is found in case of sudden derailment. Ans-06- Cross level: - The variation in top level of the both rails on same point on straight track is known as
cross level.
Point of drop: - The wheel flange drop marks shown on sleeper and ballasts is known as point of drop. In
Variation in rail height at particular point on any track is known as cross level.
case of gradual derailment, the point of mount &point of drop both are found on rail table .but in case
Cross level is always measured on left rail in reference to right rail as per direction of the train.
of sudden derailment only point of drop is found
Unit of cross level is in mm. Permitted cross level is - 13 mm/station.
Track gauge:-The distance between two running rails is known as track gauge. the track gauge should be Twist: The variation in two continuous cross levels is known as twist.
measured 13mm below from the top of the rail Or
Track gauge should be :- The algebraic variation in two continuous cross levels is known as twist. It is always measured in mm/m.
1. on straight track - 1676±6mm. Twist can be calculated as the difference between two cross level. For example.
2. up to 5 degree curve - 1676 +15/-6 mm If cross level on 1 station is +5 mm and on station 2nd is – 5 mm, Then twist will be:- Twist = or or = 3.3mm/m.
3. above 5 degree curve - 1676 +20/-0 mm The allowed twist:-
Cross level :- The variation in top level of the both rails on same point on straight track is known as On straight and circular curve - 2.8 mm /m.
cross level cross level is always measured on left rail in reference to right rail as per direction of the train On transition curve - 1.0 mm/ m.
Permitted cross level is - 13mm/station A class track (160 kmph) – 1.37 to 1.41mm/m
One station is 3 meter B class track (130 kmph) – 1.41 to 1.78 mm/m
Twist:- The variation in two continuous cross levels is known as twist. or C class track (100 kmph) – 1.78 to 2.41 mm/m
The algebraic variation in two continuous cross levels is known as twist. It is always measured in mm/m. D class track (Main Line) – 1.78 to 2.41 mm/m
The allowed twist:- E class track (Branch line) –2.41 to 2.78 mm/m.
On straight and circular curve - 2.8 mm /m.
On transition curve - 1.0 mm/ m. Ques-7- Define Disaster? Write down its various levels.
A class track (160 KMPH) – 1.37 to 1.41 mm/M Ans-07- DISASTER---Railway Disaster is a serious train accident or an untoward event of grave nature, either
B class track (130 KMPH) – 1.41 to 1.78 mm/M on railway premises or arising out of railway activity, due to natural or man-made causes, that may lead to
C class track (100 KMPH) – 1.78 to 2.41 mm/M loss of many lives and/or grievous injuries to a large number of people, and/or severe disruption of traffic
D class track (Main Line) – 1.78 to 2.41 mm/M etc, necessitating large scale help from other Government/Non-government and Private Organizations.
E class track (Branch line) –2.41 to 2.78 mm/M
Cant or super elevation: - To maintain the center of gravity or to neutralize the effect of centrifugal Disaster in the Railway context was traditionally a serious train accident, caused by human/equipment failure,
force, the outer rail on curve is lifted in respect to inner rail, is known as cant. Or which may affect normal movement of train services with loss of human life or property or both. This is now
The lifting of outer rail in reference to inner rail on curve on same point is known as cant or super extended to include natural and other manmade disasters. Different types of disasters are described along
elevation. with a few examples, below:
Cant is always measured on outer rail in mm. (a) Natural Disaster: - Earthquakes, Floods, Cyclones, Land Slides, Snow Avalanches, Tsunami etc.
The max. Cant allowed in Indian Rly B.G. Is – 165mm. (b) Train Accident related Disaster 5 Collisions (with a huge number of casualties), Train marooned (flash
For A &B class track – 165 mm. floods), derailments on a bridge over a river and coaches falling down, train washed away in cyclone,
For C, D &E class track – 140 mm derailment of a train carrying explosives or highly inflammable material, tunnel collapse on a train, fire or
Variation in cant is possible due to: - Cant deficiency or Cant excess. explosion in trains, and other miscellaneous cases etc.
Max. Cant deficiency permitted - 75mm (gen). (c) Manmade Disasters Acts of Terrorism and Sabotage, i.e. causing deliberate loss of life and/or damage to
100mm (in spl. case). property, which includes: - Setting a Train on fire, Railway installations etc., bomb blast at Railway
Max. Cant excess permitted - 75 mm. Station/Train, Chemical (Terrorism) Disaster, Biological, Radiological and Nuclear Disaster.
VERSINE:- Levels of Disaster-
The perpendicular distance drown at the center of chord from the midpoint of arc is known as versine. 1. National level- National Disaster Management Authority, abbreviated as NDMA, is an agency of
Versine is always measured on outer rail in mm. the Ministry of Home Affairs whose primary purpose is to coordinate response to natural or man-made
If the versine is measured on 11.8 mtrs chord basis, the allowed variation in versine is only 10mm. Or if disasters and for capacity-building in disaster resiliency and crisis response. The Prime Minister is the ex-
the versine is measured on 20 mtrs chord basis, the allowed variation in versine is only 29 mm. The versine officio chairperson of the same.
measured on 11.8 mtrs chord in cm, is tells directly the degree of curve. 2. State level
Versine (V) =125 C2/R 3. District level

Page 19 of 49 Page 20 of 49
 Ques-11- Explain various signal aspects that are recorded at the accident site?
Ques-8- What do you understand by Medical Rescue technique? What first aid will you provide to injured Ans-11- Signal Aspects at the site of Accident
person during a road accident?
Ans-8- It is an emergency lifesaving procedure that is done when someone is breathing or heartbeat has In case of accidents, the following observations are helpful to know the cause of accident by which the
stopped. This may happen after an electric shock, heart attack or drowning. CPR combines rescue breathing responsibility can be fixed. S&T department also required to maintain the following locking and sealing the
and chest compressions. Rescue breathing provides oxygen to person’s lungs. equipment’s properly to avoid misuse or interference of the same which may result in accident.
Following first aid should be provided to injured person during a road accident.
1. Check yourself first. 1. Type of Interlocking
2. Check the other person who is injured. a. Standard 1: Manually operated
3. Look for signs of breathing. b. Standard 2: Manually operated. Signal of interlocking will be displayed at cabin
4. Call for help. c. Standard 3: Electro – mechanically operated.
5. Check for obstructions in the person’s mouth & throat. d. Standard 4: Modified non interlocking system (speed 15 kmph)
2. Visibility of Concern Signal & where necessary repeater provided or not – Starter, Advanced
6. Perform life saving techniques.
Starter and Repeater signals should be provided at appropriate locations.
7. Ways to help him/her in grave situations.
3. Lighting of Signal & Indicator.
8. Deal with open wounds. 4. Testing report by the committee for the signal points and slot.
9. Always suspect spinal injuries. 5. Last maintenance date of concern signal & point.
10. Keep the person warm. 6. Condition of seal (Crank handle box, Block instrument, Location box of panel)
11. Avoid feeding the person. 7. Locking position & Relay room.
8. Panel Counter as per record & at panel.
Ques-9- Write down the procedure to put off the fire in a burning coach? 9. Position of Indication at panel.
Ans-9- Fire in Coach: - The following precautions should be taken immediately:-
i. First of all pull the alarm chain to stop the running train. Ques-12- What do you understand by accident? Write down its categories given by Indian railways.
ii. Switch off all lights and fans from the junction box. Ans-12- Accident is an occurrence in the course of working of Railway which does or may affect the safety
iii. Cut off electrical connection from next coach through EFT at both the ends. of the Railway, its engine, rolling stock, permanent way and works, fixed installations, passengers or servant
iv. Cut off battery fuse/ terminals. or which affect the safety of others or which does or may cause delay to train or loss to the Railway.
v. After stopping of train, coach should be isolated and detached immediately to avoid spreading of Classification of Accident:- Accidents are classified into 16 parts which are following:
fire to adjacent coaches. 1. A’ class: Collision: Collisions are of 3 types – ¬ Head on collision. ¬ Side on collision. ¬ End on collision.
vi. Disconnect the AC generator (Alternator) to remain the generator dead. Collision involving a train carrying passenger, resulting in loss of human life & damage to railway property
vii. Then apply necessary fire extinguishing methods on the coach. exceeding Rs. 25 lakhs.
2. ‘B’ class: Fire in Train Fire in a train carrying passenger resulting loss of human life & damage to railway
Ques-10- What do you understand by First Aid? What first aid will you provide to a person injured during property exceeding Rs. 25 lakhs.
the road accident? 3. ‘C’ class: Train running in to road traffic at Level crossing. The road surface meeting with railway track on
Ans-10- First is the first and immediate service given to any person suffering from either a minor or serious same level is known as ‘Level Crossing’. The most causes of accident turns on account of an unmanned level
illness or injury. With care provided to preserve life. Also we can say first aid is help given to a sick or injured crossing resulting into loss of human life.
person until full medical treatment is available. First aid course prepares individuals to respond in emergency 4. ‘D’ class: Derailment is of two types – 1) Sudden, 2) Gradual Derailment of trains carrying passengers
situations. resulting in loss of human life.
1. Check yourself first. 5. ‘E’ class: Other train Accident Train running over any obstruction (land slide, flood, & earthquake) fined
2. Check the other person who is injured. structure other than resulting in loss of human life or damage in railway property.
3. Look for signs of breathing. 6. ‘F’ class: Averted Collision Averted collision between trains at least one of which carrying passengers &
4. Call for help. obstruction.
5. Check for obstructions in the person’s mouth & throat. 7. ‘G’ class: Breach of Block Rules Train carrying passengers, entering a block section without any authority
6. Perform life saving techniques. or entering a wrong line a station.
7. Ways to help him/her in grave situations. 8. ‘H’ class : Train Passing signal at Danger. Train carrying passengers running past a stop signal at danger
8. Deal with open wounds. without proper authority.
9. Always suspect spinal injuries. 9. ‘J’ class : Failure of Engine & Rolling Stock Failure in rolling stock such as failure of tyres, wheels, axles.
10. Keep the person warm. Etc. on passenger carrying train.
11. Avoid feeding the person. 10. ‘K’ class : Failure of Permanent Way Buckling of track, weld failure, rail fracture. 199

Page 21 of 49 Page 22 of 49

11. ‘L’ class : Failure of Electrical Equipment Snapping or any damage to OHE wire requiring switching of 10. According to Renny Licurts third theory of leadership management is best----FALSE.
OHE for more than 3 minutes. 11. It is not necessary for leader to sincere himself---- FALSE
12. ‘M’ class : Failure of S & T Failure of block instrument, interlocking, signal, station communication for 12. Stress may be reduced by Yoga---- TRUE.
more than 15 minutes. 13. Staff and management should have faith on supervisor---- TRUE
13. ‘N’ class : Train Wrecking Attempted wrecking of or sabotage to train carrying passengers. 14. Work may not be completed within time by team management--FALSE.
14. ‘P’ class : Causalities Person falling out of a running train resulting loss of human life or grievous hurt. SHORT NOTES—(MRT-09)
15. ‘Q’ class : Other Incidents Murder or suicide in a train, robbery, attempted robbery or attempted theft in 1. Diseases by stress-
railway premises, & blockage to train services due to agitation. i. Heart Problems.
16. ‘R’ class : Miscellaneous i) Train running over cattle ii) Floods, breaches & landslides etc., were resulting ii. Weakness in immunity.
interruption of an important through line of communication more than the threshold value. • Most serious iii. Diabetes.
class ‘A’ • Least serious class ‘R’ • I & O is not included iv. Asthama
v. Poor Digestion.
vi. Ulcer.
vii. Depression.
viii.Depression.
ix. Headache.
x. Migraines.
2. Factors which increase stress at workplace-
i. Chasing success abruptly at any cost.
ii. Change in the working nature.
MRT-09 SUPERVISORY SKILLS iii. Change in working circumstance.
iv. Excess work
Fill In the blanks- (MRT-09)
v. Lack of work.
1. Supervisors comes under the Lower level of Management.
3. Centered Leadership- At very high level leadership is defined by the ability of a person to motivate and
2. There are 3 Levels of Management.
inspire a group of people to achieve a common set of objective.
3. Development of workers are done by training.
Main Functions of Centralized leadership are as follows.
4. This is also a work of supervisor to Co-ordinate with other departments.
1. Planning of Work
5. Good Supervisor makes quick decisions about nay work.
2. Management of work & resources.
6. Good supervisor manage works with Available resources.
3. Notification to workers.
7. Distribution of works by supervisor with Fair manner.
4. Control over the pace & Quality of Work.
8. X-Y motivation theory is given by Douglas MacGrigore.
5. Minute observations of work.
9. According to reney licurts Sharing is the best theory of management.
6. Necessary changes as and when required.
10. The person which gives correct leadership to others is called Leader.
4. Human Skill- Human skill is one of the important part of personality development, it involves the ability
11. All attention to pay with Production in automatic autocratic leadership.
to communicate and build relationship with others. Effective human skills helps anyone during the job
12. Sudden increase in income may also increase Stress.
and it will give a positive impact to his personality. Some important human skills includes active listening,
13. Team management theory is given by Robert & Mutton.
Team Work, Leadership, Motivation and patience, flexibility.
14. Capacity of a person enhancement by positive stress.
5. Objectives of Management- The main objective of management is to secure the maximum output with
minimum efforts and the goal is to achieve the task with the help of available resources. The goal must
TRUE & FLASE- (MRT-09) be achieved within the given time. Likewise it also ensured that the economic cost of this goal achieving
1. Supervisor not comes under management---- FLASE process is not too high.
2. Failure investigation is carried out by supervisor---- TRUE Simultaneously the main objective of management is also to ensure the welfare of the staff is giving them
3. Supervisor should take responsibility of failure---- TRUE. there due to salary & other perks.
4. Supervisor should attentive to about new technological information----TRUE
5. Manager should not work done with corporation & Coordination. ----FALSE LONG TYPE ANSWERS- (MRT-09)
6. Manager should think about work not about workers---- FLASE
Ques-1- Who is the supervisor what is the works of Supervisor?
7. Workers are used like machine in autocrative leadership---- TRUE
Ans-1- Role of Supervisor: - Supervisor is the chain between management and workers, which completes
8. Reany Licurts gives theory of Center leadership----- TRUE
the works in time with quality within limited resources.
9. Leadership means to motivate others --- TRUE

Page 23 of 49 Page 24 of 49
Maintenance of rolling stock within prescribed time and ensures to make available for the traffic 4. Sangathan Manav Prabandh: - In this type of methodology, the attitude of management is sometimes
department and maintain the reliability of rolling stock. To fulfill this, the mechanical supervisor has to do favourable to the workers and sometimes focused on the production. This way, the efficiency of the
the following. organization can’t be utilized completely and production will be effected.
1. Planning of work 5. Team management: - In this type of Methodology, the team work attitude can be developed among the
2. Do the contributed work. workers by motivation. Both, production and welfare of workers are focused by the organization. This is
3. To ensure punctuality. considered most success methodology.
4. Motivate the workers and to create team work theme. Ques-3- Any person in stress, what are the symptoms to diagnose it Explain in detail?
5. Technical help. Ans-03- If any person in stress, the following experience he feel.
6. To implement the policies of administration. 1. Lack of confidence.
7. Control over motion of work. 2. Lack of work ability
8. Co-ordination with others sections/ departments. 3. Feeling himself guilty.
9. Inspection/close watch. 4. Creating doubts.
10. Material Management. Symptoms of Stress
11. Failure investigation. i. Physical Stress
12. Staff Counselling. a. Feeling Sad
13. Implement of special drives if required. b. Feeling stressed.
14. Close watch on data analysis. c. Feeling Fatigued.
15. Knowledge of new technology and curiosity. d. Getting angry.
16. Take responsibility in case of failure. ii. Mental Stress.
17. Share success with staff. a. Lack of concentration
18. To maintain discipline. b. Loss of memory.
19. Neutrality. c. Difficulty in taking decisions.
20. To encourage /promote good workers in front of all. d. Getting confusion.
21. Make provision for penalty for careless / undisciplined workers. iii. Behavioral Stress
22. No one matter should made ego problem. a. Un- Balanced food.
23. Temperate language. b. Addicting alcoholic.
24. Consider /Solve /forward the problems of the workers to administration. c. Chain Smoking.
25. Maintain faith between administration and workers. d. Restless
26. Availability for administration and workers. e. Biting Nails.
27. Care of workers. Ques-4- What is stress why it is necessary in life? Explain performance and stress level graph.
Ques-2-Explain in details about managerial grid of Robart Black and J.S Mutton. Ans04- Stress – When we feel the everything seems to be have become too much , We are over loaded and
Ans-02- The behavior of management to the workers may be of two types. wonder whether we are really can cope with the pressures placed up on us is called stress.
1. Favorable attitude on the workers relations. S= P>R (Stress is equal to Pressure >Resources).
2. Ideal attitude to workers of production. There are two type of stress
Following management grid may be defined as per the Robert R. Bleck and Jen S. Mutan. 1. Positive Stress.
1. Ineffectual (Unable) Management –The attitude of management regarding the production and relation 2. Negative Stress.
between workers, both are insensible. Management neither focus attentively on the production or the Causes of Negative Stress- When our efficiency is continuously decreased due to the work pressure and
welfare of workers. Due to the production level is not achieved as well as the workers also feels abundance of work this type of stress is known as Negative stress.
unsatisfactory & desperation. This management system is not succeeded. The organization will not Following are the main reasons of Negative stress.
remain stable for long time. i. Decreases in self confidence
2. Country Club Management:- The attitude of management regarding workers is friendly the trade unions ii. Decrease in work efficiency
become success to create pressure on the management to make policies in their favor, due to which the iii. Feeling Guilty
production is affected , finally the organization collapses. iv. Creates doubts.
3. Adhikar Agya Patra: - The management forces on the workers to obey the orders and connive their Importance of Stress
welfare. High production can be gained by this methodology but, dis-satisfaction & thoughts of 1. Due to the stress we can accept the challenges in our life and grab the opportunities in future.
exploitation live in workers. Such dissatisfaction of workers is not realistic for organization. 2. Without stress the life becomes hopeless and spiritless.

Page 25 of 49 Page 26 of 49

3. Social Needs: - Social needs of an employee to know one another encouraging cooperative team work
and kind promoting a good work life balance.
4. Esteem Needs: - Esteem Needs of employee by offering praise and recognition when the employee does
well and offering promotions and additional responsibility to reflect employee belief.
5. Self-Actualization Needs- Self-actualization needs describes a person need to reach his / her full
potential.

Ques-8- Write In detail about X-Y theory douglas MacGregor.

Ans-08- Theory X-Managers Believe employee.
Need to be control
Don’t like work
Ques-5- Describe the methods to reduce the stress. Need to be pushed.
Ans-5- In Stress management ABC technique is very useful. To be more productive.
A- Awareness- ( Reason of Stress ) Need incentive schemes
B- Balance- ( There is minute difference between Positive & Negative Stress) Have to be directed to do things that they don’t enjoy.
C- Control- (By which method how will you control the stress) Theory Y managers believe employees.
By Following methods / Steps one can reduce stress. What to be involved.
1. Evaluate the strength and the weakness of the body. Can think themselves and make decisions.
2. Set the goal Share ownership of tasks.
3. Study the reasons behind the stress Will find work more rewarding if given responsibility and a variety of tasks.
4. Perform Yoga per day. Have good ideas.
5. Perform physical exercise per day Can engage in some level of self-management.
6. Live in present,
7. Not make too much actions with the future and past. Ques-9- What are the Indian thoughts about motivation?
8. Meet with old friends. Ans-9- Traditional theories of motivation comes under Indian Thoughts.
9. Hear old songs and create interest in comedy films. 1. Fear and punishment theory- This process of motivation is one of the oldest process. In this type of theory
10. Do not eat excessively also say no. managers shows his fear factor, scold to and shows their strengths top the people to get maximum work
11. Avoid excessive public relation. from them. This theory works on the basis of solders order.
2. Reward Theory- In this type of theory the manager provides rewards to the workers those who work
Ques-6- What is motivation? What is the five points to remember about motivation? outstandingly. As per this theory the person works efficiently or at his best for reward. This theory also
Ans-06- Motivation- The effect leading to make the human work progressively is called motivation. It is tells if the reward is given to the worker he /she works hard along with dedication.
introduced to increase the effort of human manpower and its efficiencies to increase the productivity. 3. Carrot & Stick Theory - In this type of theory the manager reward to those workers those are doing / job
Points to be considered for motivation. on time. And punishment to those workers are not working properly or becoming the cause of delay in
1. Feel that the work they do has meaning or importance. production. In this theory we can say the factor of fear and profit both are hidden. Also according to Mc
2. Believe that good work is rewarded. Gregore the theory of carrot and stich only withstand upto the level of a person’s life satisfaction.
3. Believe that they are treated fairly.
4. Recognize the individual ability of employees to motivate. Ques-10 – What is the leadership write guidelines of good leader?
5. Appraisals policies according to the performance to the employees. Ans-10- Leader is the person who guides his colleagues to achieve a common goal with in definite time.
6. Invest in training and development. Following are the qualities of good leaders are as followings.
7. Empowerment of the team. 1. Healthy – A leader should have good health.
8. Recognizing the achievements. 2. Having Objectives.
Ques-7- Write the motivation theory of Abrahim maslo. 3. Friendly.
Ans-07- Maslo proposed the motivation is the result of a person’s attempts at fulfilling 5 basic needs which 4. Learned.
are as under. 5. Faithful
1. Physical Needs- Physical needs are by providing comfortable working conditions, reasonable working 6. Technically competent.
hours, and necessary breaks to use bathrooms and eat or drink. 7. Having good teaching skills.
2. Safety Needs- Employee should be provided safe working conditions secure compensation and job 8. Take prompt decisions.
security which especially important in bad economy. 9. Self-confident.

Page 27 of 49 Page 28 of 49
10. Sincere towards self and for organization. 21. Solder is an alloy of Tin and lead.
11. Charming personality & honest. 22. Welding joint is permanent type joint.
23. Fusion welding is also called Non Pressure welding.
24. Arc eye defect is produced due to flashing in eyes by arc welding.
25. Tungsten electrode is used in TIG Welding.
26. The full form of MAG welding is metal active Gas welding.
27. In general welding process, Manual Metal Arc Welding is used.
28. The chemical formula of acetylene gas is C2H2
29. The specific gravity of acetylene gas is 0.91.
30. The temperature of oxy-acetylene gas flames is 3200 C.
31. Helium is an Inert Gas.
32. Air cooling is done in D.C generator set.
33. The pressure of oxygen cylinder is 120-150 kg/cm2.
34. The pressure of gas in acetylene gas cylinder is 15- 16 Kg/cm2.
35. The unit of current is Ampere.
36. The full form of AWS is American Welding Society.
37. Oil cooling is done in A.C generator set.
38. The efficiency of component is not effected by Non Destructive Testing.
39. In dye penetrant test, Only Surface cracks are detected.
40. In ultrasonic testing internal cracks in axle are detected.
41. Sound testing is a Non Destructive type of test.
42. In Ultrasonic testing of axle, frequency of waves are above 20000 MHz.
43. Non Destructive testing is done 100% components.
44. In radiography testing Radium & Cobalt radioactive isotope is used.
45. Internal defects are detected by –Ray testing method.
Question Bank Paper -1 46. Magnetic powder is sprayed in magnetic particle inspection test.
NDT and Welding (MRT-10) ---Marks--25 47. 100% of components are detected by NDT testing.
Fill In the blanks TRUE & FLASE.
1. In submerged Arc welding, arc is covered. 1. The pressure of gas cylinder is increased with increase in temperature-----TRUE.
2. The length of electrode is between 250 to 450 mm. 2. Left hand threads are found in acetylene cylinder------TRUE.
3. Acetylene is an inflammable gas. 3. In acetylene cylinder, The pressure of the gas is 21kg/cm2.---FALSE
4. Oxygen is a nonflammable gas. 4. Spattering defect is produced due to the Long arc. ----TRUE
5. In Cylinder, acetylene gas remains in dissolved state. 5. Up to which depth job is melt is called Penetration-----TRUE.
6. Argon is an inert gas. 6. To weld plate having thickness more than 10 mm, butt welding is done by making double v groove---
7. Inert gas is used for shielding of welding bead. TRUE.
8. Carbon-di-oxide is an Active gas. 7. Weight of the holder should be less than 750 grams---TRUE.
9. Acetylene cylinder is also called DA cylinder. 8. In Ac transformer we can choose polarity----FALSE
10. Manifold system is used to save gas. 9. To increase welding bead is called weaving----TRUE.
11. In welding operation Flux is used to prevent oxidation. 10. Filler rod is used in resistance welding----FALSE
12. The color of oxygen cylinder is Black. 11. Resistance welding is used to weld thick plates----FALSE
13. The color of acetylene gas cylinder is Maroon. 12. Generally , Resistance welding machines works on D.C ---FALSE
14. In straight polarity, electrode is connected to negative terminal. 13. Non-ferrous materials could be welded by A.C transformers---FALSE.
15. The cutting of stainless steel is done by Plasma-arc cutting. 14. In welding process step down transformer is used. ----TRUE
16. M4 electrode is used to weld stainless steel with mild steel. 15. Seam welding is also called stich welding-----TRUE
17. M2 electrode is used to weld stainless steel with stainless steel. 16. Welding joint is permanent joint -----TRUE
18. M5 electrode is used to weld liner in trolley. 17. Oxygen cylinder must be placed in vertical position ----FALSE.
19. The electrodes of resistance welding are made up of copper Chromium. 18. D.A cylinder must be always remain in standing position ----TRUE.
20. The shape of seam welding electrodes is Roller. 19. Carbon di- oxide is inert gas----FALSE.
Page 29 of 49 Page 30 of 49

20. Filler rod is not used in TIG welding -----FALSE. 2. M.I.G Welding- Metal Inert Gas (MIG) welding (also known as Gas Metal Arc Welding [GMAW]) is an arc
21. Gas welding is the fusion welding process---TRUE. welding technique in which a consumable electrode is used to weld two or more work pieces. A
22. Argon is an inert gas----TRUE diagrammatic representation of metal inert gas welding is shown below:
23. In gas welding the temperature of oxy-acetylene flame is maximum -----TRUE
24. The flame blow out with the sound of cracker is called back fire ----TRUE.
25. In neutral flame the amount of oxygen and acetylene is approx. equal-----TRUE.
26. If the amount of oxygen is increased then it becomes oxidizing flame----TRUE
27. Stainless steel cannot be cut with the oxy-acetylene flame ----TRUE.
28. In Metal, With the increase of carbon amount its melting point increases--- FALSE
29. Generally, tin and lead are used as alloy in solder-----TRUE.
30. Thin sheets are joined by brazing process------TRUE.
31. Thick components are joined by brazing process----TRUE.
32. In A.C transformer set we can change the polarity of -----FALSE. Working:
33. In straight polarity electrode is connected to positive ------FLASE The work piece to be welded and the consumable electrode (in the form of wire) are connected to the
34. The length of undercoated section in electrode is 20 to 30 mm ----TRUE. Power Supply (D.C or A.C). Whenever the consumable electrode is brought near the work piece (with a
35. The size of electrode is taken from the diameter of coated rod. -----FALSE. small air gap), an arc is produced. This arc melts the electrode. The melted electrode fills uniformly over the
36. A.C welding set is generally like a step down transformer-----TRUE. required regions of the work piece.
37. When electrode is connected to negative and job to positive, then it is called reverse polarity---FALSE. An inert gas supply is provided around the electrode (hence the name ‘Metal Inert Gas Welding’) during the
38. The plastic components can be inspected by the magnetic particle inspection test----FALSE. welding process. It forms a gas shield around the arc and the weld (See the diagram above). This is intended
39. Only surface cracks can be detected by DPT testing -----TRUE. to protect the weld from the external atmosphere.
40. X-Radiography is used to determine the welding quality-----TRUE. The type of electrode used and the shielding gas used primary depends on the material to be welded. In
41. Zyglo testing is done is done on small components----TRUE. many cases the shielding gas used is a mixture of many gases.
42. To detect internal defects of axles D.P.T testing is done----FALSE. If many work pieces are to be welded continuously an electrode spool (in the form of coil) is used.
43. In Gama ray radiography testing, Radium is used----FLASE. Consumable electrode is continuously supplied from this spool by a suitable feeding mechanism.
Commonly, servo mechanisms are used for feeding long electrodes.
44. After ultrasonic testing, the first two digits in punching denotes the railway division----FALSE.
In MIG Welding, consumable electrode itself acts as filler metal. So, no separate filler rod or filler wire is
45. The ultrasonic testing of diesel loco Axles is done on the duration of each 6 Months -----TRUE.
needed.
46. In axles, the speed of ultrasonic waves is 5.9x10 m/s-----TRUE
47. Cleaner, Dye and developer are used in DPT testing Kit. -----TRUE. 3. Seam Welding- Seam welding is similar to the spot welding except that the roller copper alloy electrodes
in the form of circular roller carries current continuously the over lapping sheets are held constant
SHORT NOTES: --- pressure between roller electrodes which rotates at constant speed and carries current. A series of spot
1. T.I.G Welding- In this process an arc is struck between a non-consumable tungsten electrode and the welds whose nuggets overlap each other is formed which gives a continuous weld seam. A common
base metal the inert gas ARGON and helium mixture shields the arc of filler wire may or may not be application of seam welding is in the manufacturing of steel drums.
used. When it is used the welder feeds it’s externally into the arc in the form of rod. The welder also has
to control the arc length & arc speed. An AC power source ids used for welding aluminum & its alloys,
while a DC source is used for other metals. This is an ideal process for wielding non-ferrous metal &
stainless steel of limited thickness. TIG is also preferred for depositing the root pass in the pressure
piping where welding from inside is not possible.

4. Spot Welding- In this process as spot of weld is made between overlapping sheets by means of two
cylindrical copper alloys electrodes one on the top and other at the bottom which carries a high current.
The electrode also clamps the work piece and apply pressure when the metals at the joint sufficient heat
by electrical resistance the current is switched and more pressure is applied through the electrodes. A
tiny bottom of fused metal resist at the sheet interface which is called as nugget. The electrodes are
retracted after the weld is completed .The spot welding is performed with a machine in which all the

Page 31 of 49 Page 32 of 49
 parameters can be controlled and preset. The process is used on a large scale in ICF for fabrication of
superstructure automatic production and in sheet metal fabrication.

7. Different Types of Welding joints. There are five different types of welded joints for bringing two parts
together for joining.
Five types of welded joints are butt joint, corner joint, and lap joint, tee-joint and edge joint.
5. Plasma Cutting- Butt joint:
Principle: In Butt welded type, the parts lie in the same plane and are joined at their edges.
The hot ionized gases are known as plasma. When a sufficient amount of energy provided to any inert Corner joint:
gas, some of its electrons breaks free from its nucleus but travel with it. After the electrons leave, the The parts in a corner joint form a right angle and are joined at the center of the angle.
atoms are converted into hot ionized state. It is most common state of matter which is known as fourth Lap joint:
state of matter. These ionized atoms have high heat contain which is further used to join two plates. This Lap joint consists of two overlapping parts.
is basic principle of plasma arc welding. This welding is extended form of TIG welding in which, a non-
consumable tungsten electrode is used to produce arc. This arc heats up the inert gases which are
provided from inner orifice around tungsten electrode. The heating temperature is about 30000 degree
centigrade at which the gas converts into ionized form. This hot ionized gas further used to create a
welding joint by fusion.

4. Tee-joint:
In a Tee-joint, one joint is the right angle to the other joint in the approximate shape of the letter “T”
5. Edge joint:
The parts in edge joint are parallel with at least one of their edges in common and the joint is made at the
common edge(s).

8. Polarity -- The electrical circuit that is created when you turn on the welder has a negative and a positive
pole – this property is called polarity. Polarity matters greatly in welding because choosing the right
6. Manual Metal Arc welding- This is the group of process in which heat required of fusion is generated by
polarity affects the strength and quality of the weld. Using the wrong polarity will lead to lots of spatter,
the electrical arc formed between a metallic electrode & base metal. The electrode is consumed in the
bad penetration, and a lack of control of your welding arc.
arc and provides the filler metal for the joint, the electric arc is an ideal source of welding heat. The
Reverse polarity
extremely high arc temperature is over 5000 C permits it to supply a large amount of heat at a small area.
Straight and “reverse” polarity are common terms for “electrode-negative” and “electrode-positive”
It is a manual process and hence depend on the skill and experience of the welder it makes use of flux
polarity. Welding currents with electrode-positive (reverse) polarity result in deeper penetration, while
coated electrodes having a core of solid wire diameter of 6.3 mm to 1.6 mm and length 450 to 250 mm.
electrode-negative (straight) polarity has the benefit of faster melt-off and faster deposition rate.
It need a power source either a transformer supplying A.C or generator Supplying D.C. the process suitable
Different shielding gases may further affect the weld as well.
for the range of plate thickness and for the almost all metals and alloys. It is used for joining as well as
surfacing. It can be used in all welding options.
9. Magnetic Particle Test- One of the most widely utilized NDT methods Very simple, easy, highly sensitive
to detect surface or subsurface cracks (below surface up to 6 mm deep) in ferro- magnetic material such
as steel, iron, cobalt, nickel & some of their alloys .Deeper subsurface defects are not satisfactorily
detected because influence of the distorted lines of magnetic flux on the magnetic particles spread over

Page 33 of 49 Page 34 of 49

the job surface becomes weaker with the distance, so that sensitivity falls away with the depth. Defects 13. Radiography Testing. In Radiography test high frequency radiations are need to fall on the material
located on the surface appear as sharp and distinct lines whereas subsurface defects appear as irregular while passing through the material the radiography are also absorbed and scattered along different
& rough indications. directions. This leads to variations in the intensity of the transmitted radiations which are usually
recorded on a sensitive photographic film. The darker region on photographic film corresponds to the
10. Ultrasonic Testing- When the ultra-sonic waves produced by the ultrasonic probe is subjected under the defective region and less dark region corresponds to perfect regions. It is due to the more radiations
component then these ultrasonic waves reflected back by the fillets and come back to the probe. In the passes through the defective area then the perfect one. The developed image in photographic film is
probe by the action of reverse piezo electric effect these waves again converted into the electrical signal called radiography.
and shows an echo (Signal) on the screen of ultrasonic flaw detector. As an echo or signal the height of The Radiography may be broadly classified in two categories.
the echo or signal of this flaw is depend upon the orientation size and distance from the probe end. This 1. X-Ray Radiography- in X-Ray radiography X- rays are used as high frequency radiations and the
flaw signal is not describe in all the standard signals mentioned in the code of procedure technique is used to detect the defects i.e. as gas porosity or other casting defects.
Types of UTS- 1- Far end. 2. NELA, 3. HA, 4 Trace delay. 2. Y-Ray Radiography- In Y-Ray radiography the radioactive elements i.e. radium, cobalt are used
as a source of producing a very high frequencies .this type of radiography test is most suitable
11. Difference b/w Destructive and non-Destructive testing. for the inspection of medium sized parts.
Sr.No Destructive Welding Non-Destructive Welding Additional safety features are required to carry out radiography examinations.
1 In destructive testing the component The component subjected under non Thick concrete wall having lead sheets with in built for the radiographic examinations chamber. In
subjected under testing is destroyed and its Destructive testing is not destroyed and its order to stop the exposure of radiations likewise radiographic personals are also undergoes a specific
serviceability is adversely affected. serviceability remains the same. training at BARC (BHABHA ATOMIC RESEARCH CENTER) regarding operations and maintenance and
2 Testing is done on sampling basis. 100% testing is done accept the radiography preservation of radiographic instruments.
testing (done 10 % only). It gives mire reliability
to user shop. 14. Dye Penetrant Testing- this type of testing is non-destructive type testing process. Most widely used
3 In destructive testing sample preparation is No sample preparation is required.
NDT. A method to detect surface discontinuities such as:
required according to specifications.
Crack, Shrinkage, blow holes, porosities, pin-holes, Seams, Cold shuts, etc.
4 Testing carried out in sophisticated Testing is done in shop floor as well as i.e. SITU
Application: Ferrous, non-ferrous and also other materials such as plastics, glass, ceramics, glasses, rubber
laboratories only inspection is possible.
etc.
5 Testing equipment’s are more expensive & Testing requires less expensive equipment’s &
requires skilled manpower require minimum labor skills. TESTING PROCEDURE:-
• Surface preparation--- All coatings, such as paints, varnishes, plating and contaminants such as oil,
12. Xyglo Test -Zyglo is the registered trade mark of “Magnaflux Corporation” grease, water, dirt, heavy oxides etc. must be removed
Zyglo test is used to detect defects in ferrous and non-ferrous materials such as: They should be removed by cleaning agents such as: Acetone, Perchlorate ethylene,
Aluminum, Magnesium, Brass, Copper, Titanium, Bronze, Stainless steel, cast iron, Non-magnetic alloys, Methylene chloride, etc.
Ceramics, Plastic, welded structures etc. • Application of penetrant-- The main feature of DPT: Visibility of indication.
A quick and accurate process for locating surface flaws such as: The liquid penetrant contains a color dye (usually brilliant red in color) which is easily visible in the white
Shrinkage cracks, Porosity, Cold shuts, fatigue cracks, Grinding cracks, heat treatment cracks, seams, light.
forging laps, forging bursts, etc Applied to the cleaned surface by: Spraying, Swabbing, Brushing, Dipping, Most effective method is
Essential steps- spraying.
• Surface preparation—cleaning the surface to be tested. For general application penetrants are available in convenient spray can.
• Application of penetrant- Water washable fluorescent penetrant is applied on the surface of the
component either by: Dipping, Spraying or, Brushing. The component is kept in the penetrant for 15 – • Dwelling time--- The penetrant is left on the surface for a sufficient time to allow as much penetrant as
30 mts. cleaning in running water. possible to be drawn from a defect.
• Heating the component- The component is then dried in an oven maintained at 700C for some time.
Temp should not exceed 830C. Penetrant Dwelling time: “The period of time during which the penetrant is permitted to remain on the
• Application of Developer-- The dry developer is then sprinkled throughout the surface of the surface”.
component. After sometime the excess developer is then removed by using soft wire brush. Dwelling time:
The developer acts like a blotter to draw penetrant out of the crack & enlarges the size of the area of The minimum time required to enter the penetrant into defects is determined by the following:
penetrant indication. Manufacturer’s recommendation
• Observation--The surface is viewed under ultraviolet ray or black light. Ultraviolet/black light causes Type of defects expected
penetrant to glow in dark. Since fluorescent penetrant inspection is performed in dark environment & Type of material tested
the excited dyes emit brilliant Yellow-Green light that contracts strongly against dark back ground. Temp of the specimen Humidity of the environment
Yellow-Green fluorescent is chosen because the human eye reacts best to these colours. Tight crack may require as high as 30 mts where gross defects may require 3-5 mts

Page 35 of 49 Page 36 of 49
 The exact time has to be determined by trial & error method.
• Removal of excess penetrant-- After sufficient dwell time, the excess penetrant from the surface is to
be removed by using clean clothes moist with solvent. This has to be done without disturbing
any penetrant which has entered into the discontinuities. The component is then allowed to
dry by normal evaporation.
• Application of developer-- After the excess penetrant has been removed, thin layer of developer is
applied to pull the trapped penetrant back to the surface
The developer draws the penetrant out from each side of the openings by reverse capillary
action.
After a short time, indications appear in the developer which are wider than defect and
therefore, can be seen directly in normal light due to enhancement of the contrast between
the penetrant and the developer.
Ques-02- Explain Working process of Oxy- acetylene gas welding.
• Surface inspection--After applying the developer, the surface is inspected for flaws either by normal
Ans-02- In this process, the melting of the base metal is achieved by means of a gas flame, which delivers its
light or artificial white light to detect indications from any flaws
intense heat from the combustion of a fuel with oxygen. The most commonly used fuel is acetylene, and
Post cleaning--Done immediately after inspection to avoid adhesion of the developer to the surface of
hydrogen is sometimes used. Hence appropriate term of this process is oxy acetylene welding. Filler may or
the component.
may not be used.
Carried out by suitable technique such as: simple water rinsing, m/c washing, etc.
The oxyacetylene depends on the chemical reaction which occurs in two stages.
Primary Stage-- C2H2+O2 −> CO+H2+Heat (105 kcal)
LONG TYPE QUESTIONS.
The primary combustion provides the actual flame for the welding, with temperature up to 3000 C
Ques-01- Define welding list out the different type of Welding processes & explain any one in detail?
Ans01- Definition of Welding- The American welding society defines welding as a localized coalescence of
Secondary Stage. 2CO+H2+1.5 O2 −> CO2+H2O+Heat (68 kcal)
metal or non- metal produced either by heating the materials to suitable temperatures with or without
2H2+O2 −> 2H2O+58 kcal
application of pressure ,or by the application of pressure alone and with or without the application of filler
The secondary combustion occurs at the outer portion of the flame. It produces the molten puddle from
materials.
attack by air and helps to preheat the base metal.
Indian Standard I.S 812-1957 defines the weld as “union between two pieces of metal at faces rendered
Gas welding is limitedly application in industrial production purposes, because it is much slower than the
plastic or liquid by heat or by pressure or both, filler metal may be used to affect the union.
arc welding process. It is used considerably more maintenance work including thin sheet welding, hard
facing, welding metals of low melting points( especially nonferrous metals) and performing such operations
Welding & Allied Processes- Welding has large number of variations and diversity. However welding and
as brazing, soldering and thermal spraying.
allied activities may be broadly classified in four distinct categories.
1. Welding.
2. Brazing.
3. Soldering
4. Thermal Cutting.
5. Thermal Spraying etc.
Manual Metal Arc welding- This is the group of process in which heat required of fusion is generated
by the electrical arc formed between a metallic electrode & base metal. The electrode is consumed in
the arc and provides the filler metal for the joint, the electric arc is an ideal source of welding heat. The
extremely high arc temperature is over 5000 C permits it to supply a large amount of heat at a small Ques-03- Explain plasma cutting process with figure?
area. It is a manual process and hence depend on the skill and experience of the welder it makes use of Ans-03- Plasma Cutting-
flux coated electrodes having a core of solid wire diameter of 6.3 mm to 1.6 mm and length 450 to 250 Principle: The hot ionized gases are known as plasma. When a sufficient amount of energy provided to any
mm. It need a power source either a transformer supplying A.C or generator Supplying D.C. the process inert gas, some of its electrons breaks free from its nucleus but travel with it. After the electrons leave, the
suitable for the range of plate thickness and for the almost all metals and alloys. It is used for joining as atoms are converted into hot ionized state. It is most common state of matter which is known as fourth state
well as surfacing. It can be used in all welding options. of matter. These ionized atoms have high heat contain which is further used to join two plates. This is basic
principle of plasma arc welding. This welding is extended form of TIG welding in which, a non-consumable
tungsten electrode is used to produce arc. This arc heats up the inert gases which are provided from inner
orifice around tungsten electrode. The heating temperature is about 30000 degree centigrade at which the
gas converts into ionized form. This hot ionized gas further used to create a welding joint by fusion.

Page 37 of 49 Page 38 of 49

4 Undercut (It is the cutting ofToo fast welding speed. Use proper current & polarity in
a groove into the base metal Long arc length. case of D.C.
parallel to the weld) High current. Use proper diameter electrode.
Higher diameter of electrode Proper angle of electrode.
used.
Wrong electrode angle.
5 Slag Inclusion Faulty Electrode. Proper current and heat input.
Wrong current. Proper design & Technique.
Rapid rate welding. Proper cleaning of Weld.
Defective weld design.
Improper technique.
Ques-04- Explain the precautions used in electric arc welding. Improper manipulation of flux.
Ans-04- Be sure the welder is properly installed and grounded. Bad tack weld.
Never weld without adequate ventilation. Improper removal of slag.
Take proper precautions to prevent fires. 6 Porosity (It is a development Wrong arc length. Maintain proper arc length &
Protect your entire body with fire retardant clothing, shoes, and gloves. of a group of small gas Inadequate gas shielding due to correct polarity when welding
Wear eye protection at all times. packet in the weld.) clogging, Jamming or hose leaking. with DC
Too high current. Clean the surface properly.
Weld only in a fire safe area.
Excessive moisture in the Check for proper gas supply &
Never do any welding, cutting, or hot work on used drums, barrels, tanks, or other containers.
electrode. leakage.
Mark metal "HOT" with a soapstone. High rate weld freezing.
Keep a well-stocked first aid kit handy. Dirty Joint.
7 Blow holes (Porosity or Improper electrode.
Ques-05- What are different welding defects. Write the down there causes and remedial action. cavities are called blow Less current.
Ans-05- There are a number of welding defects which are observed when checking the quality of weld holes) Excessive moisture in electrode. ---Do---
joints. These welding defects result in poor weld appearance and reduction in strength of weld joint. These Improper groove formation in
defects very be divided in to tow types 1. External Defects. 2 Internal Defects. butt joint.
Welding procedure is the important for fabrication /manufacturing of rolling stock due to improper 8 Cracks. Rapid cooling. Avoid rapid cooling by
welding. There are many reasons of poor performance of rolling stock. Improper composition of parent preheating.
Following are important welding defects, Reasons /cause of defect and there remedial actions. metal. Maintain proper welding
SR DEFECT Causes Remedies High welding speed. parameter.
No Electrode with high H2 Use low hydrogen electrodes.
1 Lack of fusion (it is the i. Dirty Surface i. Cleaning the edges to be Excessive localized stress.
failure of the adjacent layer ii.Improper cleaning of weld bead. welded. High rigidity of the joint.
of weld metal) iii. Excessive welding speed. ii.Proper cleaning of each bead. Concave, wide or shallow bead.
iv. Current too low. iii. Maintenance proper current High carbon sulphur and silicon
v. Long arc length & Welding Speed. content.
vi. Indigent removal of slag. 9 CRATER (It is depression High current. Set proper current.
2 Lack of penetration (It is Inadequate joint preparation. Proper joint preparation. caused at the termination of Wrong size of electrode. Select proper size of electrode
caused when the weld metal Wrong size of electrode. Suitable size of electrode as per weld bead) Wrong electrode angle. as per the thickness of plate &
does not completely fill the High welding speed. the root gap. Rapid withdraw of electrode. proper angle.
cavity. Long arc length. Proper heat input and welding 10 SPATTER (It consists of metal High current. Proper current.
Wrong polarity of D.C supply. speed. particles expelled from Moisture in electrode. Select proper size of electrode
Too large dia of electrode. welding) Long arc length. set proper arc length.
3 Overlap (It is the overlapping Wrong angle of electrode. Keep correct angle of electrode. 11 Warping (To twist from true Improper sequence of welding
of weld metal beyond the Too large deposition in a single Use proper sixe of electrode. direction) and presetting as per sequence of
toe or root of weld) run. welding.
Faulty electrode manipulation. Incorrect edge preparation.
Insufficient current.
Ques-06- Explain stainless steel welding process?
Ans-06- The stainless steel welding process varies depending on the thickness and finish of the material, as
well as the use of the finished product. While there are a variety of methods for welding stainless steel, there
Page 39 of 49 Page 40 of 49
are three that are used most commonly by welders in the United States. These stainless steel welding
methods are TIG welding, resistance welding and MIG welding.
They are TIG welding, resistance welding, and MIG welding.
1. TIG WELDING OR GAS TUNGSTEN ARC WELDING
Offering high quality, versatility and longevity, TIG is the most commonly used stainless steel welding
process. This welding process creates a low heat input, which makes it perfect for thin material. The argon
gas is often mixed with other gases, depending on the needs of the specific project, including helium,
hydrogen and nitrogen. To prevent oxidation and increase resistance to corrosion, a single-sided welding
process can be used creating inert backing gas protection between the interior and exterior welds.
2. RESISTANCE OR SPOT WELDING
Resistance or “spot” welding, as it is often called, is one of the most economical types of welding. The
resistance welding (RW) equipment is incredibly versatile, which means it can be used on both small and
large projects.
RW uses an electrical current to heat frayed metal edges and seal them together. This type of welding is
exceptionally productive on metal with a low melting point because it can be tailored to prevent distortion
of the metal.
3. MIG WELDING OR GAS METAL AC WELDING
MIG welding is a semi-automatic process that when done correctly offers a strong joining of two pieces of
stainless steel. This process uses an argon rich shielding gas and a solid wire electrode.
MIG welding is popular because it allows the welder to utilize a pulsed current supply, which can make it
easier to weld those tough-to-reach spots on complex stainless steel projects. Other gases mixtures,
including those with helium, oxygen and carbon dioxide, are often used to stabilize the arc and improve the
quality of the weld.
Ques-07- What are different welding positions. Explain with the help of figure.
Ans-07-
Page 41 of 49
SAW is usually operated as a mechanized process. Welding current (typically between 300 and 1000
amperes), arc voltage and travel speed all affect bead shape, depth of penetration and chemical composition
of the deposited weld metal. Since the operator cannot observe the weld pool, great reliance must be placed
on parameter setting and positioning of the filler wire.
Although SAW is normally operated with a single wire using either AC or DC current, there are a
number of variants including the use of two or more wires, adding chopped wire to the joint prior to welding,
and the use of metal powder additions. Additional productivity may be gained by feeding a small diameter
non-conducting wire into leading edge of the weld pool. This can increase deposition rates by up to 20%.
These variants are used in specific situations to improve productivity through increasing deposition rates
and/or travel speed. Replacing the wire with a 0.5mm thick strip, typically 60mm wide, enables the process
to be used for surfacing components.
SAW is ideally suited to the longitudinal and circumferential butt welds required for
the manufacture of line pipe and pressure vessels. Welding is normally carried out in the flat (BS EN ISO 6947
PA) position because of the high fluidity of the weld pool and molten slag and the need to maintain a flux
layer. Fillet joints may also be produced, welding in either the flat or horizontal-vertical (PB) positions.
Ques-10- Explain the working process of TIG Welding with figure.
Ans-10- TIG Welding- In this process an arc is struck between a non-consumable tungsten electrode and the
base metal the inert gas ARGON and helium mixture shields the arc of filler wire may or may not be used.
When it is used the welder feeds it’s externally into the arc in the form of rod. The welder also has to control
the arc length & arc speed. An AC power source ids used for welding aluminum & its alloys, while a DC source
is used for other metals. This is an ideal process for wielding non-ferrous metal & stainless steel of limited
thickness. TIG is also preferred for depositing the root pass in the pressure piping where welding from inside
Is not possible.
Ques-11- Explain the working process of MIG/MAG welding with figure.
Ques-12- Define nondestructive testing, explain any one of nondestructive testing process in detail.
Ans-12- NDT may be defined as the science of examining materials or manufactured articles in order to
determine their fitness for certain purposes without impairment of the desirable properties. Does not alter
the structure or appearance of the component, used to ensure the quality of, raw material, during fabrication
and processing, pre-service and in service, makes the component more reliable, safe & economical, No single
NDT method works for all defects. Each method has advantages & disadvantages, when compared to other
methods.
MAGNETIC PARTICLE INSPECTION TEST- (MAGNAFLUX TESTING)- One of the most widely utilized NDT
methods Very simple, easy, highly sensitive to detect surface or subsurface cracks (below surface up to 6 mm
deep) in ferro- magnetic material such as steel, iron, cobalt, nickel & some of their alloys .Deeper subsurface
defects are not satisfactorily detected because influence of the distorted lines of magnetic flux on the
magnetic particles spread over the job surface becomes weaker with the distance, so that sensitivity falls
away with the depth. Defects located on the surface appear as sharp and distinct lines whereas subsurface
defects appear as irregular & rough indications.
Applied to:
Page 43 of 49
Ques-08- Explain the principle of manual metal arc welding why this process is so much popular explain it
reasons?
Ans- is on page no 37 .
Ques-09- Explain the Working process of submerged arc welding with figure.
Ans-09 Submerged-arc welding (SAW) is a common arc welding process that involves the formation of an
arc between a continuously fed electrode and the work piece. A blanket of powdered flux generates a
protective gas shield and a slag (and may also be used to add alloying elements to the weld pool) which
protects the weld zone.
A shielding gas is not required. The arc is submerged beneath the flux blanket and is not normally visible
during welding. This is a well-established and extremely versatile method of welding.
The electrode may be a solid or cored wire or a strip made from
sheet or sintered material. The flux may be made by either fusing constituents to form a glassy slag (which is
then crushed to form a powder) or by agglomerating the constituents using a binder and a corning process.
The chemical nature and size distribution of the flux assists arc stability and determines the mechanical
properties of the weld metal and the shape of the bead.
Page 42 of 49
Finished components
Billets
Hot rolled bars
Forgings
Castings, etc
Can also be used to check processing operations:
Machining
Grinding
Heat treatment
PRINCIPLE--Magnetic particle testing is based on the principle that when the material under test is
magnetized, magnetic lines of force is created. Any defect in the material will set up magnetic poles as well
as leakage field. The presence of leakage field (therefore the presence of defect) is detected by use of
ferromagnetic fine particles applied over the surface which tend to be attracted at these leakage fields and
pile up over such defects.
The magnetic fields spread out when it encounters the small air gap created by the crack because the air
cannot support as much magnetic field as the magnet can.
STEPS OF TESTING---
Surface preparation--Heavy built-up of paints, rusts, grease, excess scales, ripples, slag etc are to be
cleaned.
Magnetization of the component under test--Two general types of magnetic fields that can be established
within a component:
• Longitudinal: it has magnetic lines of force that run parallel to the longitudinal axis of the part
• Circular: it has magnetic lines of force that run circumferentially around the perimeter of the part Magnetic
field is set up in the test piece in any of the following ways:
• By passing electric current directly through all or part of the test specimen
• Both AC & DC are suitable for magnetizing parts. AC should not be used for detecting subsurface defects
• By passing electric current through a conductor surrounding the specimen
• By magnets
• The primary difference between the two currents (AC & DC) is the fields generated by DC penetrate the
cross section of the part & the field generated by the AC is confined to the metal at or near the surface of
the part. Therefore, AC should not be used for subsurface discontinuities.
• Application of magnetic ink over the surface--The particles used in magnetic ink (Key ingredient) should be
finely divided ferromagnetic materials [milled pcs of iron oxide high magnetic permeability & low
retentivety & bonded with pigment to their surfaces to give the particles color (black or brown). Particle
mean size shall be 6 µm & shape can be a mixture of roughly spherical & columnar.
• High permeability (component with low C-steel) is imp because it makes the particles attract easily to small
leakage field from flaws low receptivity is imp because the particles themselves never become strongly
magnetized so they do not stick to each other or surface of the part Apply magnetic particle while the
magnetic field is present or while current is flowing through material.
• Application of dry powder should be such that it settles gently in a fine dispersion on the material surface.
Page 44 of 49
• Dry powder is very sensitive towards subsurface & tiny flaws. Ques-14- Write down the difference between destructive and non-destructing testing. Explain dye
• Magnetic particles suspended in water [(less expensive, no fire hazard, no petrochemical fumes & formulated penetrant testing process.
with corrosion inhibitors)] or kerosene (superior corrosion protection) is more useful because the suspension Ans-14- Difference between the Destructive and Non Destructive Process.
provides the particle with more mobility. It also makes easy to apply the particles uniformly to a relatively Sr.No Destructive Welding Non-Destructive Welding
large area. 1 In destructive testing the component The component subjected under non
• Both visible & fluorescent particles (coated with pigments that fluoresce when exposed to UV light) can be subjected under testing is destroyed and its Destructive testing is not destroyed and its
used serviceability is adversely affected. serviceability remains the same.
Interpretation of the surface for powder patterns or indications--The magnetic particle indications are 2 Testing is done on sampling basis. 100% testing is done accept the radiography
observed in visible light or ultraviolet ray/black light depending on the process followed. The powder is testing (done 10 % only). It gives mire reliability
accumulated around the defects, if any to user shop.
3 In destructive testing sample preparation is No sample preparation is required.
Demagnetization--Since all ferromagnetic materials possess retentively, there will be certain amount of
required according to specifications.
residual magnetism depending on the magnetizing current & its strength. Essentials for components to use
4 Testing carried out in sophisticated Testing is done in shop floor as well as i.e. SITU
in bearings etc. where pick up of iron particles cause damage to the part. Done by passing the component
laboratories only inspection is possible.
through an AC field of gradually reducing current or by periodically reversing and reducing the DC Current.
5 Testing equipment’s are more expensive & Testing requires less expensive equipment’s &
Post cleaning---When the test is completed, the components are cleaned of the magnetic powder particles. requires skilled manpower require minimum labor skills.
It may be done by:
– use of air
– wiping etc Dye Penetrant test—this type of testing is non-destructive type testing process. Most widely used NDT. A
method to detect surface discontinuities such as:
Crack, Shrinkage, blow holes, porosities, pin-holes, Seams, Cold shuts, etc.
Ques-13- What are ultra-sonic waves, Explain the ultrasonic process of an axle. Application: Ferrous, non-ferrous and also other materials such as plastics, glass, ceramics, glasses, rubber
Ans-13- Ultrasonic Testing- UST is used to detect the internal and surface flaws of a component, it can be etc.
applied over ferrous & Non Ferrous. In Indian Railways UST is used to detect flaws in rails, axles, wheel discs, TESTING PROCEDURE:-
Armature shafts, etc. The frequency of ultrasonic waves is above 20000 Hz • Surface preparation--- All coatings, such as paints, varnishes, plating and contaminants such as oil,
Ultrasonic waves are created by the effect of Piezo-electric effect. When an artificial or natural crystal grease, water, dirt, heavy oxides etc. must be removed
is subjected under the current the crystal produces the mechanical vibrations which turned into the ultrasonic They should be removed by cleaning agents such as: Acetone, Perchlorate ethylene,
waves. This is known as Piezo Electric effect. The crystals which shows piezo-electric crystals. Quartz Lead Methylene chloride, etc.
titinate, Zirconate, are the important piezo electric crystals. • Application of penetrant-- The main feature of DPT: Visibility of indication
Working Principle: - When the ultra-sonic waves produced by the ultrasonic probe is subjected under the The liquid penetrant contains a color dye (usually brilliant red in color) which is easily visible in the white
component then these ultrasonic waves reflected back by the fillets and come back to the probe. In the probe light.
by the action of reverse piezo electric effect these waves again converted into the electrical signal and shows Applied to the cleaned surface by: Spraying, Swabbing, Brushing, Dipping, Most effective method is
an echo (Signal) on the screen of ultrasonic flaw detector. spraying.
As an echo or signal the height of the echo or signal of this flaw is depend upon the orientation size and For general application penetrants are available in convenient spray can.
distance from the probe end. This flaw signal is not describe in all the standard signals mentioned in the code
of procedure. • Dwelling time--- The penetrant is left on the surface for a sufficient time to allow as much penetrant as
possible to be drawn from a defect.
Types of Ultrasonic Testing… There are 4 types of Ultrasonic testing.
1. Far end scanning- Through scanning of whole length of axle using normal probe from axle end. Penetrant Dwelling time: “The period of time during which the penetrant is permitted to remain on the
2. Near End Low angle - Scanning near to the wheel seat using angular probe between 5degree to 20.5 surface”.
degree these are normal probes converted into low angle probes by providing a suitable Perspex. Dwelling time:
3. High Angle- Scanning near to the wheel seat across the diameter using angular probe with an angle higher The minimum time required to enter the penetrant into defects is determined by the following:
than 35 to 80 degree. Manufacturer’s recommendation
4. Trace Delay: - Scanning in fraction by using normal probe to overcome congestion of signals and Type of defects expected
confirmatory techniques in case of doubt. Type of material tested
Temp of the specimen Humidity of the environment
Tight crack may require as high as 30 mts where gross defects may require 3-5 mts
The exact time has to be determined by trial & error method.

Page 45 of 49 Page 46 of 49

• Removal of excess penetrant-- After sufficient dwell time, the excess penetrant from the surface is to Ques-16- Explain magnetic particle testing in detail.
be removed by using clean clothes moist with solvent. This has to be done without disturbing Ans-16- MAGNETIC PARTICLE INSPECTION TEST- (MAGNAFLUX TESTING)- One of the most widely utilized
any penetrant which has entered into the discontinuities. The component is then allowed to NDT methods Very simple, easy, highly sensitive to detect surface or subsurface cracks (below surface up to
dry by normal evaporation. 6 mm deep) in ferro- magnetic material such as steel, iron, cobalt, nickel & some of their alloys .Deeper
subsurface defects are not satisfactorily detected because influence of the distorted lines of magnetic flux on
• Application of developer-- After the excess penetrant has been removed, thin layer of developer is
the magnetic particles spread over the job surface becomes weaker with the distance, so that sensitivity falls
applied to pull the trapped penetrant back to the surface
away with the depth. Defects located on the surface appear as sharp and distinct lines whereas subsurface
The developer draws the penetrant out from each side of the openings by reverse capillary defects appear as irregular & rough indications.
action. Applied to:
After a short time, indications appear in the developer which are wider than defect and Finished components
therefore, can be seen directly in normal light due to enhancement of the contrast between Billets
the penetrant and the developer. Hot rolled bars
• Surface inspection--After applying the developer, the surface is inspected for flaws either by normal Forgings
light or artificial white light to detect indications from any flaws Castings, etc
Can also be used to check processing operations:
Post cleaning--Done immediately after inspection to avoid adhesion of the developer to the surface of
Machining
the component.
Grinding
Carried out by suitable technique such as: simple water rinsing, m/c washing, etc.
Heat treatment

• ADVANTAGE-- Highly sensitivity to small surface discontinuities.

• It can be used to inspect almost any material:
– Metallic and nonmetallic, magnetic and non-magnetic & conductive and non-conductive
provided that the surface is not extremely rough or porous.
• Materials of large surface areas & large volumes of material can be inspected rapidly at low cost.
• Parts with complex geometric shapes can be routinely inspected.
• Indications are produced directly on the surface of the part providing a visual image of the
discontinuity.
• Equipment investment is minimal.

Ques-15- Explain radiography testing process in detail.

Ans-15- In Radiography test high frequency radiations are need to fall on the material while passing through
the material the radiography are also absorbed and scattered along different directions. This leads to
variations in the intensity of the transmitted radiations which are usually recorded on a sensitive
photographic film. The darker region on photographic film corresponds to the defective region and less dark
region corresponds to perfect regions. It is due to the more radiations passes through the defective area
then the perfect one. The developed image in photographic film is called radiography.
The Radiography may be broadly classified in two categories.
3. X-Ray Radiography- in X-Ray radiography X- rays are used as high frequency radiations and the
technique is used to detect the defects i.e. as gas porosity or other casting defects.
4. Y-Ray Radiography- In Y-Ray radiography the radioactive elements i.e. radium, cobalt are used
as a source of producing a very high frequencies .this type of radiography test is most suitable
for the inspection of medium sized parts.
Additional safety features are required to carry out radiography examinations.
Thick concrete wall having lead sheets with in built for the radiographic examinations chamber. In
order to stop the exposure of radiations likewise radiographic personals are also undergoes a specific
training at BARC (BHABHA ATOMIC RESEARCH CENTER) regarding operations and maintenance and
preservation of radiographic instruments.
PRINCIPLE--Magnetic particle testing is based on the principle that when the material under test is
magnetized, magnetic lines of force is created. Any defect in the material will set up magnetic poles as well
as leakage field. The presence of leakage field (therefore the presence of defect) is detected by use of
ferromagnetic fine particles applied over the surface which tend to be attracted at these leakage fields and
pile up over such defects.
The magnetic fields spread out when it encounters the small air gap created by the crack because the air
cannot support as much magnetic field as the magnet can.
STEPS OF TESTING---
Surface preparation--Heavy built-up of paints, rusts, grease, excess scales, ripples, slag etc are to be
cleaned.
Magnetization of the component under test--Two general types of magnetic fields that can be established
within a component:
• Longitudinal: it has magnetic lines of force that run parallel to the longitudinal axis of the part
• Circular: it has magnetic lines of force that run circumferentially around the perimeter of the part Magnetic
field is set up in the test piece in any of the following ways:

• By passing electric current directly through all or part of the test specimen

Page 47 of 49 Page 48 of 49
• Both AC & DC are suitable for magnetizing parts. AC should not be used for detecting subsurface defects
• By passing electric current through a conductor surrounding the specimen
• By magnets
• The primary difference between the two currents (AC & DC) is the fields generated by DC penetrate the
cross section of the part & the field generated by the AC is confined to the metal at or near the surface of
the part. Therefore, AC should not be used for subsurface discontinuities.
• Application of magnetic ink over the surface--The particles used in magnetic ink (Key ingredient) should be
finely divided ferromagnetic materials [milled pcs of iron oxide high magnetic permeability & low
retentivety & bonded with pigment to their surfaces to give the particles color (black or brown). Particle
mean size shall be 6 µm & shape can be a mixture of roughly spherical & columnar.
• High permeability (component with low C-steel) is imp because it makes the particles attract easily to small
leakage field from flaws low receptivity is imp because the particles themselves never become strongly
magnetized so they do not stick to each other or surface of the part Apply magnetic particle while the
magnetic field is present or while current is flowing through material.
• Application of dry powder should be such that it settles gently in a fine dispersion on the material surface.
• Dry powder is very sensitive towards subsurface & tiny flaws.
• Magnetic particles suspended in water [(less expensive, no fire hazard, no petrochemical fumes & formulated
with corrosion inhibitors)] or kerosene (superior corrosion protection) is more useful because the suspension
provides the particle with more mobility. It also makes easy to apply the particles uniformly to a relatively
large area.
• Both visible & fluorescent particles (coated with pigments that fluoresce when exposed to UV light) can be
used
Interpretation of the surface for powder patterns or indications--The magnetic particle indications are
observed in visible light or ultraviolet ray/black light depending on the process followed. The powder is
accumulated around the defects, if any
Demagnetization--Since all ferromagnetic materials possess retentively, there will be certain amount of
residual magnetism depending on the magnetizing current & its strength. Essentials for components to use
in bearings etc. where pick up of iron particles cause damage to the part. Done by passing the component
through an AC field of gradually reducing current or by periodically reversing and reducing the DC Current.
Post cleaning---When the test is completed, the components are cleaned of the magnetic powder particles.
It may be done by:
– use of air
– wiping etc

Page 49 of 49