Compendium June10

GOVERNMENT OF INDIAMINISTRY OF RAILWAYS

(RAILWAY BOARD)

COMPENDIUMOF

CORRECTION SLIPSTO CODES & MANUALS

PERTAINING TO ENGG. DEPTT.

(Incorporating all advance correction slips issued between 01st July 2009 to 30th June 2010)

For official use only

gË`_od O`Vo

Volume 7, Number 1 June 2010


(RAILWAY BOARD)

COMPENDIUMOF

CORRECTION SLIPSTO CODES & MANUALS

PERTAINING TO ENGG. DEPTT.

(Incorporating all advance correction slips issued between 01st July 2009 to 30th June 2010)

For official use only

gË`_od O`Vo

Volume 7, Number 1 June 2010

FOREWORD

The correction Slips (CSs) to various codes and manuals pertaining to the

Engineering Department are being issued by various nodal authorities, which have

been nominated by the Railway Board. There had been reports that the same were

not reaching the concerned officials down line.

It was, therefore, decided by the Railway Board (M.E) vide letter No. 2004/

CE-II/CS/1 dated 05-02-04 that in addition to the issue of CSs by nodal authorities

as per extant practice, the same shall also be compiled and published in the form

of a booklet twice a year, genrally i.e. on 30th June and 31st December by IRICEN

and re-circulated to the Railways, containing the CSs issued during the preceding

six months. Since number of Correction slips issued to various manuals from July

2009 to December 2010 were very less, it was decided that the compendium will

not be published in Jan. 2010. Therefore correction slips issued for July 2009 to

June 2010 have been included in the present compendium. Incidentally, the correction

slips to various codes and manuals are posted an IRICEN website also immediately

after reciept in IRICEN and the members can have an access to these after login

through their password.

This is the Seventh volume containing CSs issued during the period between

01st July 2009 to 30th June 2010. The pages have been printed on one side only, so

as to facilitate tearing/pasting/updating the codes and manuals by the concerned

officials. The contents are also available on the IRICEN website www.iricen.gov.in

in members area.

Director

Pune IRICEN

30th June 2010

S No. CODE / MANUAL PAGE NO.

1 INDIAN RAILWAYS PERMANENT WAY MANUAL 1(Second Reprint - 2004)

2 INDIAN RAILWAYS BRIDGE MANUAL - 1998 4

3 MANUAL OF INSTRUCTIONS ON LONG WELDED RAILS 2006 6(Second Reprint - 2005)

4 MANUAL FOR FUSION WELDING OF RAILS BY THE 7ALUMINO-THERMIC PROCESS - 1998

4 MANUAL FOR ULTRASONIC TESTING OF RAILS AND WELDS 9REVISED - 2006

No Correction Slips received to the following Codes & Manuals between1st July 2009 to 30th June 2010

1 INDIAN RAILWAYS WORKS MANUAL - 2000

2 MANUAL FOR FLASH BUTT WELDING OF RAILS (Reprint - 2004)

3 MANUAL FOR GLUED INSULATED RAIL JOINTS - 1998

4 INDIAN RAILWAYS TRACK MACHINE MANUAL - 2000

5 MANUAL OF INSPECTION SCHEDULES FOR OFFICIALS OFENGINEERING DEPARTMENT - 2000

6 INDIAN RAILWAYS SCHEDULE OF DIMENSIONS 1676 mmGAUGE (BG) REVISED - 2004

7 RAILWAYS (OPENING FOR PUBLIC CARRIAGE OFPASSENGERS) RULES, 2000

8 INDIAN RAILWAYS CODE FOR THE ENGINEERING DEPARTMENT(Third Reprint - 1999)

9 GUIDELINES FOR EARTHWORK IN RAILWAY PROJECTS2003

CONTENTS

Abstract of previous and current volumes of Compendium of Correction Slips toCodes & Manuals Pertaining to Engg. Deptt.

Code/ManualS.

No.

1 INDIAN RAILWAYS PERMANENT WAY 120 Nil 100 101 to 104 to 109 to 114 to 116 & 118-

MANUAL (Second Reprint - 2004) dt. 16/4/10 103 108 113 115 117 120

2 INDIAN RAILWAYS BRIDGE 20 Nil Nil Nil 12 13 &14 15 to Nil 19 -

MANUAL - 1998 dt. 07/06/10 18 20

3 INDIAN RAILWAYS WORKS 10 Nil Nil Nil Nil Nil Nil Nil Nil

MANUAL - 2000 dt. 17/2/05

4 MANUAL OF INSTRUCTIONS ON LONG 13 9 10 & 11 Nil Nil Nil Nil 12 13

WELDED RAILS-2006 dt. 9/3/10

(Second Reprint-2005)

5 MANUAL FOR FLASH BUTT WELDING 7 Nil Nil 7 Nil Nil Nil Nil Nil

OF RAILS (Reprint - 2004) dt. 16/1/07

6 MANUAL FOR FUSION WELDING OF 10 5 Nil Nil 6 & 7 Nil 8 9 10

RAILS BY THE ALUMINO-THERMIC dt. 29/6/10

PROCESS - 1998

7 MANUAL FOR ULTRASONIC TESTING OF 5 N. A. N. A. Nil 1 2 & 3 Nil 4 5

RAILS AND WELDS - 2006 (Revised dt. 26/5/10

Including C.Ss. from 1 -17)

8 MANUAL FOR GLUED INSULATED 4 Nil Nil Nil NIL Nil Nil Nil Nil

RAIL JOINTS-1998 dt. 7/8/01

9 INDIAN RAILWAYS TRACK MACHINE 10 Nil 9 & 10 Nil Nil Nil Nil Nil Nil

MANUAL-2000 dt. 12/12/06

10 MANUAL OF INSPECTION SCHEDULES Nil Nil Nil Nil Nil Nil Nil Nil Nil

FOR OFFICIALS OF ENGINEERING

DEPARTMENT-2000

11 RAILWAYS (OPENING FOR PUBLIC Corrigandum Nil Nil Nil Nil Nil Nil Nil Nil

CARRIAGE OF PASSENGERS) dt. 16/2/05

RULES, 2000

12 INDIAN RAILWAYS SCHEDULE OF 5 1 & 2 Nil Nil 3 Nil Nil 5* Nil

DIMENSIONS 1676 mm GAUGE (BG) dt. 11/2/09

REVISED - 2004

13 INDIAN RAILWAYS CODE FOR THE 45 Nil 40 41 42 Nil 43 t0 Nil Nil

ENGINEERING DEPARTMENT dt. 10/7/08 45

(Third Reprint - 1999)

14 GUIDELINES FOR EARTHWORK IN 1 Nil Nil Nil Nil Nil Nil Nil Nil

RAILWAY PROJECTS - 2003 dt. 22/7/04

Serial Number of Correction Slips/Addendum &Corrigendum/ErrataVol. 3No. 2Dec. 06

Vol. 4No. 1

June 07

Vol. 5No. 1

June 08

Vol. 4No. 2

Dec. 07

Vol. 5No. 2

Dec.08

Vol. 3No. 1Dec. 06

LastCorrection

slips

Vol. 6No. 1

June09

* 4 not yetissued

Vol. 7No. 1

June10


(RAILWAY BOARD)

INDIAN RAILWAYSPERMANENT WAY

MANUAL

Second Reprint 2004

Embodying all advance correction slips uptonumber 93 dated 05-03-2004

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ADVANCE CORRECTION SLIP NO. 118 DATED 30-07-2010(Issued under Railway Board’s letter No. 2009/CE-II/CS-I Dated 30.07.2010)

A new sub-para 146 (vii) - may be added to Indian Railways Permanent WayManual to read as under :

Para 146 (vii) - Assist in supervision of pre and post machine attention, whenmachine is deployed in his gang beat.

* * * *

INDIAN RAILWAYS PERMANENT WAY MANUAL

1

ADVANCE CORRECTION SLIP NO. 119 DATED 18-08-2009(Issued under Railway Board’s letter No. 2008/CE-II/CS/4 Dated 18.08.2009)

The existing para 220(3) of Indian Railways Permanent Way Manual shall be replacedby the following:-

Para 220(3) –

Maximum distance apart of trolly refuges on bridges will be as under:-

(i) On bridges with main spans of less than 100 metres – 100 metres.(ii) On bridges with main spans of 100 metres or more – A refuge over each pier.

* * * *ADVANCE CORRECTION SLIP NO. 120 DATED 16-04-2010

(Issued under Railway Board’s letter No. 2010/CE-II/CS-1 Dated 16.04.2010)

The existing para 151 (1) (a) of Indian Railways Permanent Way Manual shall be replacedby the following:-

Para 151 (1) (a) - Level-cum-gauge, square, hemp cord, metre stick, keying and/orspiking hammer, fish-bolt spanner, 2 sets of H.S. flags (2 H.S. lamps/Tricolour torchesin the night), 12 detonators, 2 no. whistle thunderers, marking chalk and Rail thermometer.

The following new sub-item may be added as (xiv) of para 232 (2) (c) to IndianRailways Permanent Way Manual as under:-

Para 232 (2) (c) (xiv) - 2 no. whistle thunderers.

* * * *

��


(RAILWAY BOARD)

INDIAN RAILWAYSBRIDGE MANUAL

1998


gË`_od O`Vo

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ADVANCE CORRECTION SLIP NO. 19 DATED 11-01-2010

Issued under Railway Board’s letter No. 99/CE-I/Misc.23 (IRBM) pt.II

Dated 11.01.2010

New para 318 inserted vide correction slip No. 17 dt.15.9.08 is modified as below:

Para 318: Approval of bridge drawings for Dedicated Freight Corridor lines:

i) "General Arrangement Drawings for bridges on Dedicated Freight Corridor lineswhere alignment is on de-tour, far off from the existing track, where linear waterwayis being reduced or vertical clearances are inadequate and where new bridge(during construction or during service) is likely to affect any of existing bridges,shall be approved by Chief Bridge Engineer.

(ii) General Arrangement Drawings for bridges on Dedicated Freight Corridor lineswhere alignment is near the existing track, all major bridges and bridges wherelinear waterway is being reduced or vertical clearances are inadequate andwhere new bridge (during construction or during service) is likely to affect any ofexisting bridges, shall be approved by Chief Bridge Engineer."

* * * *ADVANCE CORRECTION SLIP NO. 20 DATED 7.6.2010

(Issued under Railway Board’s letter No. 99/CE-II/Misc. 23(IRBM)pt.II

Dated 07.06.2010

Para 1104 (5) vide correction slip No.20 dt. 7.6.10 is replaced as below :

“Scrutiny by Territorial HOD & CBE and action thereon:

The registers should then be forwarded by the Divisional Engineer to TerritorialHOD by a specified date, who will examine each register, issue orders regardingmatters referred to him duly endorsing the registers to the effect.In caseswhere bridge matters are referred by divisional engineer to HQ’s office, thenthose bridge registers should also be seen by CBE after scrutiny by THOD. Theregisters should then be returned to the Divisional Engineer latest by a specifieddate, Subsequent action taken on the Territorial HOD’s and CBE’s orders shouldbe entered in the register by the Assistant Engineers,”

* * * *2

INDIAN RAILWAYS BRIDGE MANUAL

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(RAILWAY BOARD)

MANUAL OF INSTRUCTIONSON LONG WELDED

RAILS - 2006


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Second Reprint 2005

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MANUAL OF INSTRUCTIONS ON LONG WELDED RAILS - 2006

ADDENDUM & CORRIGENDUM SLIP NO. 13 of 2010(Issued under RDSO's letter No. CT/IM/LWR DATED 09.03.2010)

Para-1.11 of Manual be replaced by the following :

Para 1.11 Destressing Temperature (td) is the average rail temperature duringthe period of fastening the rails to the sleepers after destressing LWR withoutthe use of rail tensor. If rail tensor is used, td for all practical purpose isequal to to as defined in Para 1.13. Range of td or to shall be within the limitsof rail temperature shown below :-

a) Temperature Zone - I, II & III

Rail Section Range

i) All Section tm to tm + 50C

b) Temperature Zone - IV

Rail Section Range

i) 52 Kg & heavier tm + 50C to tm + 100C

ii) Others tm to tm + 50C

* * * *

3


MANUAL FOR FUSION WELDING OF RAILSBY THE ALUMINO - THERMIC PROCESS

gË`_od O`Vo

Printed SEPTEMBER 1998

RESEARCH DESIGNS AND STANDARDS ORGANISATIONLUCKNOW - 226 001

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MANUAL FOR FUSION WELDING OF RAILS BY THE ALUMINO - THERMIC PROCESS - 1998

ADDENDUM & CORRIGENDUM SLIP NO. 10 OF 2010(Issued under RDSO's letter No. CT/AT/Welding/sub - committee dt. 29.06.2010)

1. Following Note shall be inserted at the end of Para 4.

Note: For upgraded AT Welding Techniques approved in terms of Part E ofIRS:T:19:1994, the parameters such as preheating time, pressure, type ofmoulds, crucibles, tapping system etc. shall be mentioned in the approvalletter issued by RDSO. These shall be ensured while welding."

2. Following Note shall be inserted below Para 6.3:

Note: For upgraded AT welding techniques approved in terms of Part E ofIRS:T:19:1994, the AT welds shall exhibit less than 0.4% cumulative failurerate during execution, acceptance, acceptance ultrasonic testing and duringservice upto 12OGMT or 3 years whichever is earlier including weld failuresand welds declared defective during regular ultrasonic testing up to 120GMTor 3 years of installation whichever is earlier. 'A penalty of three times the unitrate of supply and execution of joints shall be payable by the firm for eachjoint failing in above criteria."

3. Following note shall be inserted below Para 7.3.1:

"Note: For upgraded AT welding techniques approved in terms of Part E ofIRS:T:19:1994, the guarantee period applicable shall be 3 years or passageof 120GMT traffic whichever is earlier. For joints welded in cess or forconstruction projects, the above period/traffic shall commence from the datetraffic commences on these welds."

4. New para 6.3.2 is added as follows :"

6.3.2Defective/ Fractured joints:

In case, total no. of USFD defective joints (under initial USFD testing) /fractured joints welded against a particular contract exceeds 2% :

i) Action as per contract conditions be initiated.

ii) Railway shall be at liberty to suspend further welding.

iii)The details of welds executed against a particular contract, % defective /fractured welds against total no. of welds executed be compiled as per thefollowing format :

S. Name of Total No.Welds No.of welds No.of fract- No. of USFD Total %No welding for which executed ured welds defective defective /

agency/ contract was against a & their % welds & fracturedwelders awarded (Rail particular w.r.t. (3) their % [(5)+(6)]

section wise) contract w.r.t. (3)

(1) (2) (3) (4) (5) (6) (7)

4

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iv) All defective joints shall be broken with the help jim crow in the presence of firmsof represenatative and a joint report be prepared. Defects observed on fracturedfaces shall be recorded in form of photograph/ sketch.

v) Sectional DEN/ Sr. DEN shall carry out investigation / analysis for all in trackfractured joints and joints broken as per iv) above. Information shall be compiled inthe format indicated below :

S. Km Rail Year joint USFD defective joints Fractured RemarksNo. / section/ of no (in intial acceptance testing)

Post UTS rolling (marking probe Peak Defects Defectspunched * pattern observed (if obeservedon the (travel & any) on fractu- on fractureweld peak red faces of faces

height)* defective AT (if any)welds (brokenwith the helpof jim crow)

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

* If defective in flange testing, supporting calculation be also enclosed in termsof Note in Chapter 8 of 'Manual for Ultrasonic testing of rails and welds,Revised 2006'.

vii) The investigation report prepared by sectional DEN/ Sr. DEN be sent toExecutive Director/Track-I, RDSO, Lucknow through Chief Track Engineerfor appraisal and suggesting further action.

viii) The defective joints taken out of track and fractured joints be preservedfor undertaking investigation by RDSO, if required."

5. Para 7.4 is re-worded as follows :

"7.4 The welded joints with the extended period of guarantee shall be punchmarked 'X' on the right of markings for month/year in addition to the markingsprescribed in Clause 5.6. Such marked joints shall be kept under carefulobservation by the purchaser."

5

Printed SEPTEMBER 1998


MANUAL FOR ULTRASONIC TESTINGOF RAILS AND WELDS - 2006

gË`_od O`Vo

RESEARCH DESIGNS AND STANDARDS ORGANISATIONLUCKNOW - 226 001

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MANUAL FOR ULTRASONIC TESTING OF RAILS AND WELDS - 2006

ADDENDUM & CORRIGENDUM SLIP NO. 05 OF MAY 2010

(Issued under RDSO's letter No. CT/USFD dt. 26.05.2010)

1. Para 8.2.2(d) is modified as follows :

"8.2.2 (d) A pair of two 700/2 MHz probes at 200 side looking with respectto usual beam path. Side looking angle of both probes shall be in oppositedirection to each other.

2. Para 8.8 is modified as follows:

8.8 700/2MHz Side Looking (SL) probe:

This procedure shall be used for the detection of half moon shapedtransverse defect with a pair of 700 side looking probes using trans-mitter-receiver method.

8.8.1 Range calibration: The equipment shall be set for a depth range of150mm shear wave.

8.8.2 Sensitivity setting: Set Range - 150 mm, Velocity- 3250 mm/sec, Mode-Double crystal and Angle — 700. Connect cables of side looking probes totransmitter & receiver socket in such a way that direction of side lookingcrystal face is inward i.e. towards simulated half moon shaped defect.Place the 700 side looking ( Tx and Rx) probes on the upper zone of theflange at a distance of 85 mm on either side of flange (Fig.25). Move theprobes slowly in slight zigzag manner towards the weld upto a distance of 20mm from weld collar. Set the signal obtained from simulated half moondefect to 60% of full screen height with the help of gain control switch. Thisgain setting will be utilized during testing of the weld.

8.8.3 Test procedure: Place the transmitter and receiver 700 side looking probesat positions as mentioned in Para 8.8.2. Move the probes slowly in zigzagmanner towards the weld. The position of transmitter and reciever probesfrom a defect signal may vary depending upon the location of half moon defect.This exercise shall also be done from other side of the weld.

8.8.4 Defect Clasification : The defect signal of height 20% of full screen heightor more shall be treated as defective AT welded joint (DFW).

3. 700 2 MHz (8mm x 8mm) probe' is replaced by '700/2MHz SL probe' in Para6.5.2, Para 6.6, table of Para 6.6 & Para 6.8.2.1, Para 8.1(b) and Para 8.11.1.

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4. Existing Fig. 25 is replaced with modified Fig 25 enclosed.

5. Para 9.4 (vi) is modified as follows :

"vi) The equipment is now calibrated for death range of 50mm per main scaledivision (for machine having 5 main division on horizontal scale) of longitudinalwave and gain of the UFD is set separately for conducting the test using 450

and 700 probes."

Published by :INDIAN RAILWAYS INSTITUTE OF CIVIL ENGINEERING, PUNE

For Ministry of Railways (Railway Board), New Delhi

Typeset & Printed by :KALYANI CORPORATION

1464 Sadashiv Peth, "Mangesh-Shree", Pune 411 030, Tel : 020-24486080

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Compendium June10