Work challenges faced and

improvements suggested/implemented

Related to Flat Bottom Rail

Inspection at JSPL, Raigarh

Parveen Kumar (AM-Mech) 12826

RITES/QA/CR/Raigarh
Challenges Faced:
 UT(Ultrasonic Test) un-scanned length of Rails.
 Achieving hardness for HH Rails(Head Hardened).
 End straightness in HH short length Rails.
 Microstructure of Rail steel.
 Improvements suggested/implemented
1.)UT un-scanned length of Rails

• Problem: Internal defect in Rails can only be diagnosed at NDT lab, and un-scanned
part of Rails are highly dangerous.
• Reason diagnosed: To protect damage of Contact probe, UT probe are used after
and before 500-700mm on both ends of Rails. That’s why un-scanned part of 0.5m-
1.0m get passed in 13m Rails.
• Steps Taken to overcome:
– Technical session organised among RITES IEs(UT-II certified) to highlight this point among all.
– Problem conveyed to JSPL QC department(Quality Control Authority).
• Result:- UT scanning of Rails improved:
– Avoiding cutting of Short length pieces(13m) before NDT lab(Non Destructive Testing Lab).
– Long Rail (104m-118m) were cut after NDT lab.
 Improvements suggested/implemented
2.1)Achieving hardness for HH Rails(Head Hardened)

Problem: water jet quenching

process used for heat treatment
of HH Rails after rolling at 800°-
450°C. So water vapour film
formed on head of Rail, which
drastically decrease heat
treatment process. Due to this
Head hardness distribution is
not achieved.
Overcoming : Air Sweep Spray at
120° angle used to remove
vapour film.
Improvements suggested/implemented
2.2)Achieving hardness for HH Rails(Head Hardened)
• Problem : Hardness at point 45 sharply increase,
which violate the IRS-T-12 guidelines. (as per
specs- The cross sectional hardness distribution
of heat treated rails shall slope towards the
inside. No sharp drop in hardness should be
present.)
• Reason : Improper heat treatment of HH Rails.
• Overcoming : Quantity of water jet nozzle at
head surface increased than to side-head of
Rails.
Improvements suggested/implemented
3.) End straightness in HH short length Rails.
• Problem: Due to water quenching of Hot Rails, internal stress
develops in Long Rails(110m). After cutting them into 13m, the
stresses get released and produce bend-end, up-sweep & down-
sweep.
• Overcoming: Heat treatment of Rails increased when Rails are
above 600°C temperature and heat treatment decreased when
Rails are in between 600°C-450°C temperature. So this
optimisation of heat treatment have reduced internal stresses.
Improvements suggested/implemented
4.)Microstructure.
• As per IRS-T-12, the microstructure shall be fine pearlite without formation of any
martensite and bainite.
• As the production process of HH rail is heat treated, hence the above point is very
critical.
• Open sources of knowledge are not enough to differentiate between the
microstructure pearlite, martensite and bainite for rail steel.

Suggestion:- Training required for morphology of different structures of Rail-steel

to develop competency of IE.
Thank you….