Topic 1 1 Codification Of Defect Codification of

Topic – 1. 1 Codification Of Defect

Codification of Rail & Weld Defects § It is necessary to device a suitable coding system for reporting rail failures. § UIC has adopted an Alphanumeric system of codification of rail failures § In view of its international status and the facility afforded for computerized statistical data analysis, this system, has been adopted by Indian Railway for reporting rail failures. § The code of reporting rail failure consists of two parts viz. ALPHABETIC- consisting of three code letters and NUMERICconsisting of three or four digits.

First Part – Alphabetic Codes Type of rail Reason for withdrawal O- Plain rail F- Fractured X- Points & Xing rail C- Cracked D- Defect other than F & C Probable cause of failure R- Inherent in rail S- Fault of rolling stock C- Excessive corrosion J- Badly maintained joint M- Other maintenance conditions D- Derailment (failure developed later) O- Other causes

Second Part – Numeric Codes 1 st Digit Location & characteristics 2 nd Digit 3 rd Digit 4 th Digit Origin/type of welding i. For Internal Defects if 2 nd digit is 1, 3 or 5 Further details 0 1 Unknown Within fish Plated Limit 1 Transverse 1 At rail seat 2 Horizontal 2 Not at rail seat 1 Top fillet 1 Within Head 3 Vertical longitudinal 2 Bottom Not at fillet 3 radius

1 st Digit 2 nd Digit 3 rd Digit 2. Surface of rail head 5. Diagonal at hole 8. Diagonal not at hole 3. Web For Surface Defects if 2 nd Digit is 2, 3 or 5 1. Corrugation Other 2 Location 5. Foot 2. Shallow surface defects 2. 3. 4. 5. Breaking out Crushing Continuous Battering local Wheel burns 9. Lap, seam, roll marks 4 th Digit 1. 2. Short pitch Long pitch Running surface Gauge corner 1. Isolated 2. Repeated

1 st Digit 2 nd Digit Location & characteristics Origin/type of welding 3 i. For Internal Defects if 2 nd digit is 1, 3 or 5 1 Brushing or arcing Damage done 0 2 Incorrect machining, drilling or flame cutting Type of welding Direction of fracture 1 FB weld 4 3 rd Digit 1. Transverse 2. Horizontal Associated 2 AT weld 3 Electric arc welding 5. Diagonal at hole with welding 4 Oxy- acetylene 7 Building up 8. Diagonal not at hole 8 Traction bond 5 Corrosion 0 0 4 th Digit Further details

Failure Code Group § On the basis of the system of codification, a list of the failure code group to be followed is given as under: Within Elsewhere Description FP Limit On Rail 100 200 111 112 113 1211 135 -- 211 212 213 2211 235 238 Transverse breakage without apparent origin eg. Sudden failure Internal flaw in head, transverse breakage Internal flaw in head, horizontal crack Internal flaw in head, vertical longitudinal split Head, surface, shallow surface defect (flaking) Web, cracks at hole Web, diagonal cracks not at hole

Failure Code Group Within Elsewhere FP Limit On Rail 153 253 301 302 --- 411 422 481 500 ------ Description Foot vertical longitudinal split Damage to rail by brushing or arcing Damage to rail by bad machining, drilling or flame cutting Welding, Flash Butt joint, transverse crack Welding, Thermit joint. Transverse crack Welding, Thermit joint. Horizontal crack Welding, traction bond welding, crack at weld Corrosion

Failure Code Group § For more Failure Codes please refer Revised ISFD Manual -2012, Para No. 1. 3. 1. 4 and Para No. 1. 4