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K.L.V.S.VISWANADHAM
B.Tech, DCE, DCOM;PGDCA
SSE (P.WAY)
As per analysis of IIT/Kanpur, average annual loss due to premature rail replacements is about Rs.440 cr. Rail failures due to corrosion effects safety of trains and disturb normal traffic. Rails laid near coastal regions are more prone for atmospheric corrosion and warranting more frequent replacement than rails in dry climate.
How it forms
Substance disintegrates into atoms by chemical reactions with water and oxygen in the environment, resulting into an electron loss of the material. If an electrical circuit is completed, the metal atoms become positively charged ions, causing pitting or the development of a crack. Rate of pitting corrosion is more in portions where welding operations have caused micro structural transformation. Localized corrosion may initiate fatigue that can intensify by action with corrosive agents like sea water. Strength of iron reduces due to the oxidation of its atoms, called rusting, by which oxides are formed.
Atmospheric Corrosion
o Rust is formed when iron compounds corrode in the presence of oxygen and water which are available in atmosphere. This corrosion is the result of the oxidation reaction when iron metal returns to a more stable state. o Rust is formed on the rail table, more predominantly on the rail flange and in the rail web. o Rail corrosion, particularly at the base of the rail, is a serious problem in rail transit systems. Rail base corrosion compromises the integrity of the rail and could result in catastrophic failures. o The average rate of deterioration of rail foot in absence of application of any protective measures is around 1mm per year. This may be much more in corrosion prone areas. o The deposition of salts such as alkaline salts, chlorines and sulfates on rails creates a very detrimental effect on the reliability of the rails, because the salts form electrolytes promoting oxygen to react with the rails, thereby accelerates corrosion. o Places of salt Deposition noticed at; top of the slide chairs in P&C area, lugs of steel sleepers, bearing plates of wooden sleepers and very prominently near pit lines and coach maintenance lines. Most of these locations are usually humid and where there is consistent contact between the rail and ground.
Localized Corrosion
TYPES: TYPES:
Stray Current Corrosion Crevice Corrosion
CREVICE CORROSION
o The form of corrosion below and around the metal liner can commonly referred as crevice corrosion. o Localized corrosion in the form of corrosion pits and thinning of rail foot under the liner contact area are matter of serious concern.
o End result is premature failure of the rails, which is a great safety apprehension because this is failure. a major cause of rail failure.
o This is mainly due to collection of moisture from the atmosphere and discharge from the open lavatories of the coaches. o It is a localized form of attack, where there is a breakdown of the surface passive layer, in crevices or on shielded areas beneath surface deposits. o Crevice corrosion is more prominent in environments near sea coasts. The drawback is, this corrosion is not easily visible to the naked eye unless we remove the liners and examine. o Mostly the pit formation and crevice corrosion is observed on the gauge face side of the rails. Arrangement of the discharge pipe of the toilets provided in the trains is a main cause. The sullage water and the night soil will be highly saline in nature and entrapped near rail and liner contact area and at weld collars thus accelerates the corrosion and forming of corrosion pits.
Viable solution is
Adopt corrosion resistant Alloy. Elements like Cu, Cr, Ni, Mo, P, Si etc., will improve the sustainability against corrosion. Iron pillar at Qutub Minar is a great example of corrosion resistant ferrous. Increased phosphorous content made it possible.
TRIALS CONDUCTED Cu69C 24Cu 18Mo) Cutrial. SAIL developed Cu-Mo steel (0.69C-0.24Cu-0.18Mo) on trial. These rails shown promising results during field trials, but the high cost of molybdenum has became production. a hurdle in commercial production.
Cr, Mn, etc. Further trials Alloys like Cu and Cr, Cu and Mn, Cu, Cr and Ni etc., which abundant. Niare cheaper and abundant. Field trials have shown lower rusting in the case of Nisteels. CrCr-Cu rail steels. Once the symbiosis of these metals is proved satisfactory, general extent. corrosion can be get rid of to certain extent.
in highly corrosion prone locations such as platform lines, tunnels and extent. cuttings in the approaches of major cities and metros may help to some extent. Application of anticorrosive paints, oil, grease etc :
Can minimise formation of rust by exclusion of air and water from the surface of rails.
(b) For in-service Rails: Primary Coat: Anticorrosive Bituminous black paint confirming to IS 9862-1981 to a thickness of 100 microns. Secondary Coat: Anticorrosive Bituminous black paint confirming to IS 9862-1981 to a thickness of 100 microns.
inThe Painting of in-service rails shall be carried out depending upon condition, but not only. earlier than once in two years covering web and top flange only. However, platform painted. lines of station yards, Non gauge face side will also be painted. For locations other than painted. platform lines, only gauge face side shall be painted.
ERC greasing shall be done for all 4 ERCs on the sleeper. Sealing of liner contact area - In corrosion prone areas only on inside of the rail. Grease graphite to the specification IS 408 1981 Gr O (Aluminum soap based).
Use of galvanized metal liners, galvanized plate screws and stretcher bars in points and crossing areas.
Galvanized liners In all identified corrosion prone areas. Galvanized Plate screws and Stretcher bars - In all areas irrespective of corrosion Proneness.
nutshell: In a nutshell:
Average rate of corrosion at rail foot in absence of corrosion protective measures is @ 1mm/year. In severe corrosion prone areas, though protective measures adopted, within 3to4 yrs., corrosion pit is being formed.
Shifting of liner contact area is giving a promising result.
iii) iv)
v)
Right Lateral
5
Vertical
6
Lateral
(b) Anticorrosive Painting: (i) Anticorrosive painting of new rails before laying in the track as per procedure lay down. (ii) In-service rail painting with bituminous paint. (iii) Detailed procedure of surface preparation and procedure to be adopted while applying anticorrosive paint. (iv) Periodicity of rail painting. (c) Greasing and sealing of liner contact area (d) Shifting of liner locations.
Updates Warranted
1. Practically, Crevice corrosion is noticed on the gauge face side of the rail in the facing direction of the toilet droppings from the coaches. Modification to discharge pipe shall be done at the earliest to get rid of this menace. 2. Though it is a little costly, use of galvanized rails in highly corrosion exposed environments such as pit lines, platform lines, cuttings in the approaches of metropolitans etc., may reduce corrosion formation. SCR has taken initiative in this regard and galvanizing rails in FBWP/MLY.
From a paper submitted by ADENs of South Central Railway as a project work , Vijayawada division of this Railway alone could able to achieve Rs. a savings of Rs. 28 Crores per annum by adopting these corrosion control measures and thus contributing to the Railways and in turn to economy. countrys economy.
THANK YOU