GOVERNMENT OF INDIA

{Ministry of Railways)

SPECIFICATION FOR
POURING TUBE CERAMIC
(PL No.84980916)

MECHANICALDRAWING OFFICE
RAIL WHEEL FACTORY
YELAHANKA, BANGALORE-560 064
I ND I A

Issued by
SSE/D

Page 1 of 8
 SPECIFICATION FOR POURING TUBE CERAMIC

INTRODUCTION

The pouring tube ceramic is a very vital consumable in the manufacturing of cast
steel wheels. The process employed is the patented Griffin's controlled pressure
pouring technique. The ladle containing about 20 tons of molten steel at
about 1620 -1640 °C is placed in a pit, which is sealed by a cover, which
also carries the pouring· tube at the centre. The relevant process detailed is
given elsewhere in the specification. Considering the critical nature of the item,
it is necessary that the tenderer possesses adequate knowledge of the
pouring process and has proven experience of having supplied such
pouring tubes to any plant manufacturing Cast Steel Railway Wheels.

The tenderers are therefore required to furnish details of supplies made

by them to any such plants in the world and also to enclose performance reports
in support of satisfactory and consistent supplies having been made.

SCOPE

The specification covers the design and supply of Pouring Tube Ceramic.
1.0
GENERAL DESCRIPTION
1.1
Pouring tube as per enclosed Drawing No. C/MO-12/9, Alt.' k'.

JOB REQUIREMENTS

2.0 The pouring tube is assembled with pressure Pouring Tank cover. The molten
metal rises through the pouring Tube into the mould by means of controlled
2.1 pressure (Max. of 35 PSI) pouring technique.

3.0

3.1

3.2 The Pouring tube will be required for the manufacture of cast steel wheels to the
following composition.
 Carbon 0.47%to 0. 77%
Manganese 0.60%to 0.80%
Phosphorus 0.03%Max.
Sulphur 0.03%Max.
Silicon 0.15%to 0.40%Min.
Molybdenum 0.07%to 0.15%
Vanadium 0.10%to 0.16%

3.3 EASE OF GRINDING

The tube, after assembly is required to be ground off flush with the surrounding
parting ring using a hand held grinder. It should be easy to grind with hand
grinder. Grinding wheel specification to IS 551 (37C 16R--4B- LS) to its latest
revision.

3.4 In its service the Pouring tube is required to withstand slag attack ( slag basicity
is around 1.75 to 3.2 generally) and action of ladle insulation compound of
the following composition:

Carbon 40 to 60%
SiO2 40 to 50%
Al203 10%Max.
Fe203 5%Max.
CaO 5%Max.

3.5 The Pouring tube should also withstand repeated up and down movements in the
molten metal which are done as a part of the process for preventing localised
solidification of the metal inside the tube.

3.6 Occasionally the tube is also required to be fitted with steel cone at the bottom to
facilitate piercing of the slag layer.

3.0 MANUFACTURE

4.1 CHARECTERISTICS OF RAW MATERIALS USED:

Supplier will provide details of the grade, source, specification and acceptance
criteria of important raw materials used for manufacturing of pouring tube to
satisfy the job requirement mentioned above

4.2 MANUFACTURING FACILITIES REQUIRED:

The manufacturer shall document details about in-process production parameter
 (sieve analysis of materials, green BO, green strength, temperature & duration of
baking) during manufacturing, which shall be offered for verification of RWF's
representative on demand during capacity/capability assessment or inspection.

4.3 TESTING FACILITIES

The manufacturer shall have all the facilities to test the properties of pouring
tube ceramic specified in this specification.

4.4 QUALITY ASSURANCE PLAN (QAP)

The manufacturer shall submit their Quality Assurance Plan (QAP), which will
be followed in the manufacturing of pouring tube ceramic to satisfy the
technical requirement as required under this specification.

TECHNICAL DATA

5.0 MATERIAL & MANUFACTURING PROCESS

5.1 Fired Ceramic Tube manufactured through extrusion process only.

SIZE FOR CERAMIC POURING TUBE

5.2

Outer dia. : 6 3/8" ± 1/8" (162mm ± 3mm)

Inner dia. : 3 1/2" HJ'/ -1/8" (89mm + Omm/_3mm)
Length : 84" + 112"1 -0" (2133.6mm +12.7mm/ -0mm)
(NOTE: Equivalent metric dimensions are acceptable.)

5.3 DISTORTION

5.3.1 Warpage should not exceed 1/2" (12.7mm) in its entire length. Concentricity
should be within 3/32"(2.4mm) i.e. the difference between the max. wall thickness
and the min. wall thickness should not exceed 3/16" (4.8mm).

5.4 PROPERTIES

5.4.1 Permeability (measured perpendicular to axis). Typical values expected are

0.0050 cm. gm. sec. The tenderers should furnish supporting certificates. The
surface and structure of the tube should be such that when the glaze is applied
(as described in paragraph Nos. 6.2 & 6.3), the tube should be airtight and
should present a glazy uniform surface.
5.5 STRUCTURE

5.5.1 There should be no loose particles or surface imperfections visible to the naked
eye which may get washed off from the tube and get included in the metal during
pouring. Broken pieces of used tubes can be collected by the tenderers for their
guidance.

5.6 THERMAL SHOCK RESISTANCE TEST

° °
5.6.1 A 6" (152.4mm) long section of pouring tube is pre-heated to 1800 F (982 C),
removed from the heating furnace and placed on a sand bed. Steel at about
° °
2900 F(1553 C) as poured into the tube and it is air-cooled. There should be no
thermal cracks or spalling on pouring of the metal.

5.7 The nominal chemical composition and other properties of pouring tube are
given below.

5.7.1 COMPOSITION FOR POURING TUBE

(When tested as per IS 12107:1987 Part 2, 3 & 6 or equivalent ASTM Standard)

AbO3% :66
SiO2% : 30
Fe2O3% :1

5.7.2. PHYSICAL PROPERTIES FOR POURING TUBE

(When tested as per IS 1528:2012 Part 15 or equivalent ASTM Standard)

App. Porosity % : 25
B.D. (gram/cc) : 2.2
Specific gravity : 2.9

5.7.3 X-RAY FINDINGS

MIU I IIf
Major 1. Cristobalite
Minor 2. L-Quartz
3. L-Alumina

6.0 OPERATIONAL PARAMETERS & REQUIREMENT OF CERAMIC TUBE

6.1 Ceramic tube is cut to the exact size by using diamond circular saw.
6.2 Tube is fixed on the Holding casting using Air setting cement and allowed to dry
in air. Subsequently Flame drying is done for not less than 2 hours with 30 lbs
(13.62 kg) weight on top to prevent swelling.

6.3 Complete tube is dipped in glaze material to have a coating on the outer surface
of the tube (Glazing is facilitated by application of vacuum).

6.4 The ceramic tube is subjected to extreme thermal shock in operation. To

° °
minimise this. tube is preheated in an electric oven gradually about 200 F(93 C)
° ° °
per hour upto 1800 F(982 C) to 2000°F(1093 C) and held at this temp. till it is
taken for assembly to pouring cover and pouring operation.

6.5 Pre-heated tube is assembled to the pouring tank cover (See Fig.1) and is
° °
immersed in the liquid metal at about 2950 F(1621 C) during casting of wheels.
Duration of casting is approximately 45 minutes to 1 hour.

6.6 Tube is used second time after an interval of upto 2 1/2 hours during which tube
° °
is kept in holding furnace at about 1800 F(982 C) along with the cover.

6.7 The tube should not bend/crack or get attacked by slag/metal and puncture
during the use.

6.8 The above information is given for manufacture/production purpose.

7.0 The manufacturers shall issue a test certificate for all parameters under clause
No. 5.0.

8.0 SAMPLING NORM AND ACCEPTANCE CRITERIA

Each time a consignment is received a sample shall be drawn as per table and
used. If the material fails with respect to any of the clauses mentioned in 5.0 &
6.0, the entire lot shall be rejected.

SI.No. Quantity Sample Size

01 Upto 200Nos 2Nos

200 &above
02 5Nos
and batches of 500Nos.
 ALT I DESCRIPTION JOB No. I INITIALS
rt\ IJPDATEll �PEln\PECIFICATION RWF/M/SPECN-1/012/1987
� Alt 'o'. CHA!iGED LENGTH ffiOM 82"(2082.8mm) TO
1.w.1 J 84-"( 2133.6mm). 6773 I 1 ,I" -1 11,
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84"�b' •
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2133.6-o mm

1. MATL: AS PER SPECN "POURING TUBE CERAMIC-RWF/M/SPECN-1/012-ALT.'O'

2. WARPAGE SHOULD NOT EXCEED 1/2" (12.7 mm) IN THE ENTIRE LENGTH.
3. CONCENTRICllY SHOULD BE WITHIN 3/32" (2.4 mm)THAT IS THE MAX.
AND MINIMUM THICKNESS SHOULD NOT DIFFER BY
MORE THAN (4.8mm).
4. PHYSICAL PROPERTIES:
PERMEABILllY (MEASURED PERPENDICULAR TO AXIS):
lYPICAL .005 gm. cm. sec. THE SURFACE AND STRUCTURE
OF THE TUBE SHOULD BE SUCH THAT WHEN THE GLAZE IS
APPLIED, THE TUBE WILL BE AIR TIGHT,
STRUCTURE
THERE SHOULD BE NO LOOSE PARTICLES
WHICH CAN BE WASHED OFF THE TUBE IN TO THE METAL.
iii. SHOCK RESISTANCE TEST :
REFDRG. z
�
I

mm) LONG SECTION OF POURING TUBE IS PREHEATED �,'-'f

-
-0
::0 (982'C) REMOVED FROM THE HEATING FURNACE AND
m ON A SAND BED. STEEL AT 2900'F(1593"C) IS POURED
IN TO THE CENTER OF TUBE AND IT IS AIR COOLED, THERE EXTRUDED POURING TUBE
-0

IDm
5o SHOULD BE NO THERMAL CRACKS OR SPALLING.
5. SUPPLY IN EQUIVALENT METRIC DIMENSIONS
IS ACCEPTABLE.
(OROERlNG SIZE) CB 07.07.08
:'I
C, DRG.No.C/M0-12/9
"CXJ
s, -<l� I
JOB No 3970 SHEET OF
:
I�
Ai'?ROVEO

o:i
 AMEDMENT SHEET FOR RECORD

Alt 'n' Alt 'o' Job

Description Sign
Cl. No. CL No No

Pouring tube as per enclosed Drawing

No.C/M0-12/9, Alt.' j '.
2.1 2.1 Changed to
Pouring tube as per enclosed Drawing
No.C/M0-12/9, Alt.'k'.

Removed the reference

3.1 3.1 (See Fig.1 )
as Fig 1 is deleted

Added Clause:

QUALITY ASSURANCE PLAN (QAP)

The manufacturer shall submit their Quality

Assurance Plan, which will be followed in
4.4
the manufacturing of pouring tube ceramic to 6778 r=>t "·
l.)\J,P"_J!?.,.,
satisfy the technical requirement as required
under this specification.

112 12 7
Length: 82" + / -o" (2082.8mm + · mm/ -0mm)

5.2 5.2 Changed to

1 12 7
Length: 84" + /Z'/ -0" (2133.6mm + · mm/ -0mm)

Fig 1 Deleted

Drg No. C/MO-12/9 Alt 'j,

Drg Drg Replaced with
Drg No. C/MO-12/9 Alt k