Metallurgical Investigation & Testing Section 3 of 18 NDT section S. No. Name of the Tests Testing charges (Rs.) 1. Standardization of ultrasonic testing of axles, wheels, tyres, armature

Page 1 of 18

Revised Testing charges vide Joint Director/Finance’s note no. F/Fin/21/Test & Drawings/91-92

dated: 31.03.2015 and Procedure Order No.1 of 2015

Metallurgical Investigation & Testing Section

S. No. Name of the Tests Testing

charges(Rs.)

1. Visual Examination 5575.00

2. Tensile test/Compression test (Without preparation of

test piece)

5475.00

3. Hardness Test with preparation of test sample 7366.00

4. Impact Test (Without preparation of test piece) 4563.00

5.(a) Cold Bend Test (With preparation) 7300.00

5.(b) For additional bend test 3650.00

6. Macro Examination (Deep etching Test) 7456.00

7. Micro Examination (With preparation of sample) 16581.00

8. Chemical Analysis by Wet method (per element) 11214.00

9. Testing of galvanised coating

(a) Coating thickness (b) Uniformity of coating

6760.00

6916.00

11. Digital photomicrograph

(a) With three copies (Without preparation)

(b) For each extra copy

2942.00

678.00

12. Digital photograph

(a) With three copies

(b) For each extra copy

2029.00

678.00

13. Spectrographic analysis of elements in metals and

alloys per sample

8330.00

14. Analysis of results for metallurgical investigation and

report making

43800.00

15. Charges for sample preparation from welding

section/M&C or Central Workshop, RDSO

As per charges of

concerned section.

Page 2 of 18

COMPOSITE DEVELOPMENT CENTRE

S. No. Name of the Tests Testing charges (Rs.)

1. Sample Preparation 3650/-

2. Visual Examination 1825/-

3. Hardness (Rockwell ‘R’) 1825/-

4. Modulus of Elasticity 7300/-

5. Cross Breaking Strength 5475/-

6. Acetone Extraction test 11,490/-

7. Ash content 5475/-

8. Density/Specific Gravity 3650/-

9. Shear Strength 7300/-

10. Bending Strength 7300/-

11. Tensile Strength & Elongation at Break 5475/-

12. Toxicity Index 45,716/-

13. Limiting Oxygen Index 11,430/-

14. Polymer Identification by FTIR 11,622/-

15. Izod Impact Test 3,650/-

16. Izod Impact Test with preparation of notch 7300/-

17. Charpy Impact Test 3650/-

18. Falling Weight Impact Test + sample preparation 14,600/-

19. Smoke Density – Non flaming (by Optical Density Smoke Chamber) + sample preparation

21,900/-

20. Smoke Density – Flaming (by Optical Density Smoke Chamber) + sample preparation

24,300/-

21. Deterioration of visibility due to smoke+ sample preparation

18,850/-

22. Thermal Properties by AnterFlashline Thermal Analyzer + sample preparation

22,764/-

23. Thermal properties by DSC 16,905/-

24. Thermo gravimetric analysis by TGA 16,785/-

25. Melt Flow Index 7300/-

26. Dynamic properties by DMA + sample preparation 18,250/-

27. Melting Point 5475/-

28. Frictional properties by Tribometer + sample preparation

34,675/-

29. Checking of samples through Polarizing Microscope + sample preparation

18,250/-

Page 3 of 18

NDT section

S. No. Name of the Tests Testing charges

(Rs.)

1. Standardization of ultrasonic testing of axles, wheels, tyres, armature shafts etc

Rs 4,18,870/- plus visiting charges.

2. Magnetic particle testing of ferro-magnetic materials (wheels, tyres, bogie frames etc )

Rs 11,560/-

3. Dye penetrant testing of different compounds (wheels, tyres, bogie frames etc)

Rs 11,700/-

4. Ultrasonic testing of rails & welds (AT & FB) & butt welded plates of 300 mm length etc

a) up to sample of 2 meters length. Rs 7,480/-

b) AT, FB &butt welded plates (up to set of 02 nos of welds), for less than 2 welds charge will be the same Rs 3,790/-

5. Evaluation of radiographs of welds & steel castings (upto set of 6 radiographs), less than 6 radiographs charges will be same

Rs 3,750/-

6. Radiographic examination of butt welded plates of size 300 mm length & up to 25 mm thick

Rs 7,640/-

7. Magnetic Particle testing of pin of lock arm of clamp point lock (Length – 150 mm & maximum dia 40 mm)

Rs 4,240/-

8. Certification of Ultrasonic equipments (Single Rail tester, Axle tester, Weld Tester- Up to 2 nos of ultrasonic equipments)

Rs 3,750/-

9. Certification of ultrasonic double rail- tester(01 No only)

Rs 3,750/

10. Evaluation of standard rail piece for calibration & sensitivity setting(SRT, DRT, AT weld) (01 no. only)

Rs 3,750/

Remarks:Validity- 1-4-2015 to 31-3-2017

Page 4 of 18

NDT Training Centre

S. No. Course Total Charges (up to 05 candidates) Rs.

Charges per additional candidate.Rs.

1. (a) Course for UST of AT & FB welded rail joints/ New rails. (b) Refresher Course on UST of Rails & Rail welds/ Axle & wheels

1,47,860/- 29,572/-

29,570/-

2. Certification of trainees for UST of rails / AT & FB welds (outsourcing)

58,900/- 11,780/-

3. Revalidation / Recertification of certificates

29,700/- 5,940/-

4. Regular Course on UST of Rails & Rail welds/ Axle & wheels

5,87,540/- 1,17,508/-

1,17,510/-

5. Orientation Course in UST of AT & FB welds (outsourcing)

89,180/-

17,836 /-

17,840/-

S. No. Details of works Total Charges

6. Checking & verification of quality Assurance plan (QAP)

of agency in connection with outsourcing of USFD testing

of Rails/ welds by zonal Railways

Rs 14,750/-

Remarks: Validity – 01.04.2015 to 31.03.2017.

Page 5 of 18

R & P Section

A:RUBBER


1 Visual Examination 1825

2 Dimensional Check 1825

3 Hardness(Shore 'A') 1825

4 Tensile Strength & % Elongation at

Break 5475

5 Modulus 5475

6 Compression Set 5475

7 Tension Set 5475

8 After Ageing

i) Tensile Strength & Elongation at Break 7300

ii) Modulus 7300

iii) Hardness(Shore 'A') 1825

9 Electrical Resistance 7300

10 Resistnce to Fluid & Chemicals(by volume) 7300

11 Specific gravity 3650

12 Polymer Identification (i) By flame Test 3650

13 Load deflection 5475

14 Adhesion 5475

15 Extended ageing 1825 Per day

16 Extraction 7300

17 Ash content 5475

18 Tear Strength 5475

19 Dynamic Properties of rubber pad 10950

20 Stretch test for 'O' ring 1825

21 Stretch test for Rolling ring 5475

22 Secant stiffess 5475

23 Shear Bond test 5475

24

Before Durability test

i) Tensile strength 5475

ii % relaxed modulus 5475

iii) impact attenuation test 7300

Page 6 of 18

25 After Durability

i) Tensile strength /(per pad) 62050

ii % relaxed modulus/(per pad) 62050

iii) impact attenuation /(per pad) 63875

B: PLASTICS


2 Hardness (Rockwell 'R')/Shore 'D' 1825

3 Dimensional check 1825

4 Melting point/Vicat Softening Point 5475

5 Specific gravity/Density/Bulk density 3650

6 Water absorption 7300

7 Resistance to Boiling water 7300

8 Inherent viscosity/MFI 7300

9 Tensile Strength & Elongation at Break 5475

10 Cross breaking strength 5475

11 Fire resistance/flammability 3650

12 Izod Impact strength 3650

13 Compressive strength Proof Load 5475

14 Compressibility & Recovery 5475

15 Polymer Identification (IR) 7300

16 Ash content/Glass content(%) 5475

17 Electric Resistance 3650

18 Internal Cavity 3650

19 Crushing Test on Bush 1825

20 Annealing test 3650

21 TS & EB after hydroysis of PU sample 5475

22 Chemical test 3650

C: FRP & OTHER COMPOSITE MATERIALS


2 Dimensional Check 3650

3 Hardness (Rockwell 'R') 1825

4 Ash content (%) Glass content 7300

5 specific graviy 3650

6 insert pull out 3650

7 bolt pull out 3650

8 bending test 5475

9 impact strength/indentation 3650

10 Tensile strength and % elongation at

break 7300

Page 7 of 18

11 resistance to boiling water 7300

12 fire resistance/flambility 5475

13 adhesion 3650

14 resistance to flexing 43800

15 dynamic fatigue test 36500

16 pull belt tensile strength 7300

17 weight square meter 3650

18 construction/count/no of plies 3650

19 breaking strength treated fabric 7300

20 adhesion of laminated or treaed fabric 5475

21 annealing test 3650

22 staining test 3650

23 weldability test of PVC 7300

24 Mandrel flexibility 3650

25 crushing test on bush 1825

D: TEXTILE

1 weight /square meter 3650

2 construction/count/no of plies 3650

3 adhesion 5475

Tribology Section

(A) Grease:-

S. No.

Name of the Tests Testing charges (Rs.)

1. SKF-V2F Test Rig 121500

2. 760 hrs Rig Test 752550

3. 4-ball Weld Load Test 11700

4. EMCOR Test 19150

5. ETRS 74550

6. Vibration Rig Test 95700

7. Seal Compatibility Test 14600

Page 8 of 18

(B) Lubricating oil:-

(C) HSD/Kerosene/Petrol

S.

No.


1. CFPP 3750

2. Total contamination 3800

3. Sediment content in HSD oil 7400

4. Total Sediment in HSD 15250

5. Gum Content 7400

(D) Lube oil Filter

S. No.


1. Rig. life of filter element for ALCO/DLW

locomotive

114450

2.

Rig. life of filter element for EMD

locomotive

173800

3. End load 1850

4. Fabrication integrity 4400

5. High temperature for ALCO/DLW

locomotive

31400

6. High temperature for EMD locomotive 20350

7. Resistance to water 59650

8. Bursting strength of filter 3650

9. Pore size of filter paper 14600

10. Tensile strength of paper 5500

11. Thickness of filter paper 1850

12. Ash content of filter paper 7350

13. Basic weight of filter paper 1850

14. Visual examination & dimension 7300

S. No.


1. 4-ball Weld Load Test 11700

Page 9 of 18

Lubricant & Tribology Section

(A) Grease :--


1. Acidity/ alkalinity 5845

2. Ash content 7350

3. Cu- strip corrosion 3725

4. Drop Point 4155

5. Evaporation loss of grease 14650

6. Flash point of extracted oil 5575

7. Graphite content 18515

8. K.V. and VI of extracted oil 9345

9. Leakage tendency 27400

10. Mineral oil content 15465

11. Moisture /volatility 14650

12. Non graphite carbon content 11000

13. Oil separation on storage 5500

14. Penetration at 25 C 9225

15. Resistance to break down 3750

16. Soap base by flame test 10980

17. Structural stability 22070

18. Sulphated ash 14700

19. Visual Examination 1825

20. Water Content 7495

21. Oxidation Stability of Lubrication Grease by the Oxygen Bomb for 500 Hrs.

18770

(B) Lubricating oil:-


1. Aniline Point 9320

2. Ash content 7375

3. Asphaltene content 14915

4. ASTM Colour test 3725

5. Carbon residue Ramasbottom 9260

6. Cast iron corrosion test 7400

7. Emulsion characteristics 7385

8. Flash Point (ABEL), oC 5620

9. Flash Point (COC), oC 5610

10. Flash Point (PMCC), oC 5610

11. Foaming characteristics 14690

12. Frothing test 7400

13. Insoluble Hexane & Toluene 15060

14. Kinematic Viscosity at 100oC, cst 3760

Page 10 of 18

19 Saponification value 7660

20 Shear stability 5450

21 Specific Gravity 3700

22 Sulphated Ash 14675

23 Thermal stability 14650

24 Total acidity inorganic & organic 7660

25 Viscosity Index 1825


27 Water content 7495

28 Reactive Sulpher 2045

29 Evaporation loss by nocks’ method 7410

30 Air Release Value 11145

31 RBOT 14880

32 Demulsibility 14795

33 Bacterial Resistance 15705

34 Conradson C-Residue 9225

35 Oxidation stability of Turbine oil 37220

36 Low temperature pumping viscosity of Engine oil 37020

37 Low temperature cranking viscosity 11215

38

Incipient wear of engine components in used engine oil 7375

39

Wear debris pattern of engine components in used

engine oil

16380

40 Oxidation Stability of Inhibited Mineral Oils for 1000 Hrs. 30240

(C) HSD/Kerosene/Petrol

15. Kinematic Viscosity at 40oC, cst 3760

16. Neutralization Number (pH, TAN, TBNE) 15320

17. Pour Point oC 5585

18. Rust Preventive Characteristics 11025


1 Visual examination 1825

2 Density 3710

3 Flash Point 5620

4 Pour Point 5585

5 Carbon Residue (Rams bottom) 9260

6 Distillation (Atmospheric) 7615

7 Distillation (Vacuum) 14820

8 Diesel Index 11095

9 Aniline Point 9320

Page 11 of 18

Bio-diesel & its blends:-

10 Cetane Index 11050

11 Smoke Point 7400

12 Ash Content 7350

13 Water Content 7495

14 Copper Strip Corrosion 3725

15 Acidity Organic 3890

16 Acidity Inorganic 3890

17 Calorific Value (P7 of IS:1448) 3740

18 Kinematic Viscosity 3870

19 Oxidation stability of HSD Oil 24430

20. Sulphur in HSD 7375

21. Cetane No. 7565


1 Visual examination 1825

2 Density 3710

3 Kinematic Viscosity 5695

4 Flash Point 5620

5 Sulfur 7375

6 Carbon Residue (Rams-bottom) 9260

7 Sulfated Ash 14675

8 Water Content 7495

9 Total contamination 3820

10 Copper Strip Corrosion 3725

11 Cetane No. 3915

12 Acid Value 3725

13 Oxidation Stability of Bio-diesel 29200

14 Moisture content in Bio-diesel 11960

15 Methanol % by mass, Max 11430

16 Ethanol % by mass, Max 11430

17 FAME content % by mass, Max 13135

18 Free Glycerol % by mass, Max & Total Glycerol % by mass, Max

13375

19 Iodine value 8380

Page 12 of 18

Paint Testing and Corrosion Engg. Lab.

A. Oil & Alkyd based Paints


1. Drying Time 4306/-

2. Finish 609/-

3. Viscosity By Ford Cup No. 4 2513/-

4. Humidity Test (168 hrs. ) 14298/-

5. Salt spray test (96 hrs.) 13198/-

6. Scratch hardness 5211/-

7. Flexibility & Adhesion test 3651/-

8. Stripping test 5211/-

9. Resistance to water 5171/-

10. Non volatile vehicle content 13830/-

11. Resistance to acid test 5381/-

12. Resistance to alkali test 5446/-

13.. Colour 614/-

14 Consistency 609/-

15 Flash point 5550/-

16. Fineness of grind 2772/-

17. Gloss 3193/-

18. Spreading capacity 7031/-

19. Mass in Kg / 10 lit. 3132/-

20. Water content 7455/-

21. Volatile matter 3791/-

22. Pigment content 8825/-

Page 13 of 18

23. Pigment Analysis 25381/-

24. Phthallic Anhydride content 27206/-

25. DFT 790/-

26. %Volume solid test 13720/-

27. Leafing properties 7941/-

28. Presence of rosin & rosin derivative 3650/-

29. Resistance to kerosene 5507/-

30. Accelerated storage stability test 21433/-

31. Ash content 7107/-

32. Wet abrasion resistance – 5000 cycles 5738/-

33. % Fe2O3 26576/-

34. %CrO3&ZnO 28468/-

35. Hold out properties 3682/-

36. Flattening properties 1857/-

37. Resistance to Chlorine 5171/-

38. Freedom from coarse particles 609/-

39. Freedom from lead 1825/-

40. Reaction with white paint 6996/-

41. Resistance to heat 12884/-

42. Resistance to lube oil 5769/-

43. Resistance to salt water 12940/-

Page 14 of 18

B. Epoxy Polyurethane based Paints


1. Drying Time 4306/-

2. Finish 609/-

3. Viscosity By Ford Cup No. 4 2513/-

4. Humidity Test (500 hrs. ) (2000hrs.)

14298/- 36198/-

5. Salt spray test (500hrs.) 13198/-

6. DFT 790/-

7. Resistance to chemical for 1800hrs. 34000/-

8. Pot life 18250/-

9. Identification of polyisocynate 1857/-

10. Scratch hardness 5211/-

11. Flexibility & adhesion 3651/-

12. Resistance to alkali test 5446/-

13.. Color 614/-

14 Consistency 609/-

15 Flash point 11025/-

16. Fineness of grind 2772/-

17. Gloss 3193/-

18. Spreading capacity 7031/-

19. Mass in Kg / 10 lit. 3132/-

21. Volatile matter 4401/-

22. Pigment content 8608/-

25. DFT 790/-

26. %Volume solid test 13720/-

Page 15 of 18

C. Other materials & Preparation of Test Reports


1. Corrosion test of Butt Welded test pieces as per IRS -M-28 , Appendix-1

27105/-

2. Preparation of test Report 3650/-

D. Liquid Cleaning Composition for Exterior of Railway Coaches


1 Visual Appearance 1217/-

2 Odor 609/-

3 Skin Irritation 913/-

4 PH after recommended dilution 1825/-

5 Demulsifying Capacity 3650/-

6 Abrasion Test 7563/-

7 Immersion Test 29200/-

8 Freedom from visible impurities 3650/-

9 Specific Gravity 1825/-

10 Foaming Power 7300/-

11 Lab. Performance test for Cleaning Efficiency 14709/-

12 Effect on metals 5475/-

13 Data Collection & Calculation 3650/-

14 Field Performance test 14600/-

Total 96190/-

Page 16 of 18

Welding Section

Annexure-I

Charge for MMAW electrodes in welding section w.e.f 01.04.2015

S No Description of test/sample preparation Charges

1. All Weld Tensile Sample preparation 22525.00 2. All Weld Charpy Sample preparation 16425.00 3. Butt Weld Sample preparation 8577.50 4. Transverse Bend sample preparation 7300.00 5. Transverse Tensile Sample preparation 3650.00 6. Usability Test 12254.00 7. Weld pad Preparation 8537.00 8. Fillet Weld test 11099.00 9. Fillet Weld (SS) test 11365.00 10. Corrosion Sample preparation 9457.00 11. Cutting & Gouging test 10676.00 12. Storage Stability Test 7300.00 13. Performance Test 14600.00 14. Deposition Efficiency test 7300.00 15. Filling from core wire sample preparation. 3650.00 16. Diffusible Hydrogen Content test 5541.00

Page 17 of 18

Annexure-II

Charge for SAW wire & flux in welding section w.e.f 01.04.2015


1. Multi Run Tensile Sample preparation 34603.00 2. Multi Run Charpy Sample preparation 16425.00 3. Two Run Bend test Sample preparation 10878.0 4. Two Run Transverse Tensile Sample

preparation 3650.00

5. Two run charpy Sample preparation 16425.00 6. Copper coating content test 3870.00 7. Weld Pad Sample preparation 8624.00 8. Filling from core wire Sample

preparation 3650.00

9. Visual examination of wire test 1825.00 10. Storage stability test 7300.00 11. Cast & helix test 3650.00 12. Grain size for flux test 7300.00 13. Tap density test 3650.00 14. Moisture content test 3650.00 15. Corrosion Sample preparation 9457.00

Page 18 of 18

Annexure-III

Charge for MIG/MAG FILLER WIRE in welding section w.e.f 01.04.2015


1. All Weld Tensile Sample preparation 22575.00 2. All Weld Charpy Sample preparation 16425.00 3. Corrosion Sample preparation 9457.00 4. Weld Pad for flux cored wire Sample

preparation 8597.00

5. Fillet Weld test 11099.00 6. Fillet Weld (SS) test 11365.00 7. Macro/Visual examination test 1825.00 8. Cast and Helix test 3650.00 9. Copper coating content test 3870.00 10. Filling from core wire for chemical

analysis Sample preparation 3650.00

11. Performance Test 14600.00 12. Diffusible Hydrogen Content test 5541.00 13. Storage stability test 7300.00

Documents

Metallurgical Investigation & Testing Section 3 of 18 NDT section S. No. Name of the Tests Testing charges (Rs.) 1. Standardization of ultrasonic testing of axles, wheels, tyres, armature