1. ULTRASONIC TESTING OF RAIL
SANJEEV KUMAR RATHORE
S.S.E/(PWAY)/USFD/DHG
Div:ahmedabad
WESTERN RAILWAY
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

2. PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
AREA CVERED BY70°PROBE
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

3. PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
SRT&DRT
ON INDIAN RAILWAY ,FLAW DTECTION BY ULTRASONICS IS CARRIED OUT WITH THE HELP OF TWO DIFFERENT TYPES OF EQUIPMENTS VIZ SINGLE RAIL TESTER AND DOUBLE RAIL TESTER, SRT IS UTILISED ON INDIAN RAILWAY FOR 40 YEARS & DRT IS RECENT ORIGIN TEN YEARS BACK. IN ADDDITIONAL HAND TESTERS OF SOME DESIGNS ARE ALSO BEING USED
PROCUREMENT OF USFD EQUIPMENTS SHOULD BE DONE ONLY FROM THE RDSO APPROVED SOURCES
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

4. PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
SINGLE RAIL TESTER
SINGLE RAIL TESTER IS CAPABLE OF TESTING ONLY ONE OF THE RAILS AT A T IME AND IS PROVIDED WITH SEVEN PROBE
O°,70°CENTRAL FORWARD(CF),70°CENTRAL BACKWARD(CB),
70 °GAUGE FACE FORWARD (GF),70°GAUGE FACE BACKWARD(GB) 70°NONGAUGE FACE FORWARD(NGF), AND 70°NON-GAUGE FACE BACKWARD(NGB)
THE NORMAL PROBE IS DETECTING HORIZONTAL DEFECTS IN THE RAIL HEAD,WEB AND FOOT
70°PROBE IS FOR DETECTING TRANSVERSE DEFECT IN HEAD
THE SIGNAL RECEIVED FROM THE DEFECTS BY ANY OF THE ABOVE PROBE IS INDICATED ON THE SCREEN,IN ORDER TO FIND OUT THE ORIGIN OF DETECTION
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

5. PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
DOUBLE RAIL TESTER
THE DOUBLE RAIL TESTER IS CAPABLE OF TESTING BOTH RAILS AT A TIME. FOR EACH RAIL, SEVEN PROBES HAVE BEEN PROVIDED
0°;70°CENTRAL FORWARD(CF) ,70°CENTRAL BACKWARD(CB),
70 °GAUGE FACE FORWARD (GF), 70°GAUGE FACE BACKWARD(GB) 70°NONGAUGE FACE FORWARD(NGF), AND 70°NON-GAUGE FACE BACKWARD(NGB)
THE NORMAL PROBE IS DETECTING HORIZONTAL DEFECTS IN THE RAIL HEAD,WEB AND FOOT
70°PROBE IS FOR DETECTING TRANSVERSE DEFECT IN HEAD
THE SIGNAL RECEIVED FROM THE DEFECTS BY ANY OF THE ABOVE PROBE IS INDICATED ON THE SCREEN,IN ORDER TO FIND OUT THE ORIGIN OF DETECTION
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

6. DETAILS OF FREQUENCY &PROBES
TYPE
FREQUENCY
PROBE
RIG
SRT
DRT
NORMAL
4MHZ
ONE
ONE FOR EACH RAIL
70 CENTRAL
2MHZ
TWO(F+B)
TWO(F+B) FOR EACH RAIL
70GAUGEFACE
70 NONFAUG FACE
TWO
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

7. CALIBRATION&SENSITIVITY SETTING
70°CENTRAL PROBE(F&B)
PROBE DIA=20X20
FREQUENCY=2MHZ
MODE=T+R
RANGE=165
CALIBRATION=ON IIW BLOCK IST PEAK=6.06
CALIBRATION CHECKING=ON IIW BLOCK 25M.M. CURVE ,READ DEPTH= 25M.M.
SENSITIVITY=ON SENSITIVITY BLOCK 12 M.M. DIA HOLE
F.S.H.=60% HEIGHT
REMARK=ADD 10DB GAIN ON SINGLE LINE& D- MARKED RAIL ON DOUBLE/MULTIPLE LINE
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

8. CLASSIFICATION OF RAIL DEFECT (70°-CENTRAL) -1
IN TUNNEL &APP., ON MAJOR BRIDGES,APPROACHES(100MM) IN THE VICINITY OF HOLES NEAR THE WELD
X..H>30%
V> 20% =IMR
30%≤H≤100%
V<20% =O
OTHER THAN LOCATION
H> 50%,V> 60%=IMR
H> 50%,60%>V> 20%=OBS
50%>H> 30%,V> 20%=OBS
30%≤H≤100%, V<20% =O
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

9. PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
CLASSIFFICATION OF RAIL DEFECTS(70°-CENTRAL) S/L-D MARKED-RAILS(10DB)-2
VUL. LOCATION
0%≤H≤100%,20%≤V≤100%=IMR
OTHER LOCATION
50%≤H≤100%,20%≤V≤100%=IMR
0%≤H<50%,20%≤V≤100%=OBS
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

10. PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
WELD DEFECTS(AT+FB)
PROBE USED
NATURE OF DEFECT
CLASSIFICATION
70°CENTRAL PROBE
ANY TRANSVERSE DEFECT IN THE RAIL HEAD AT THE FOLLOWING LOCATION
1.IN TUNNEL &APP (100M)
2.ON BRIDGE APPROACHES(100MM)
3. IN THE VICINITY OF HOLES NEAR THE WELD (50MM FOR OLD WELD AND 75MM FOR NEW AT WELDFROM THE CENTRE OF WELD ON EITHER SIDE
H ≥30%,V≥30%
=IMRW
ANY TRANSEVERSE DEFECT IN THE RAIL AT TRACK LOCATION OTHER THAN (A)
H≥50%,V≥50%
H≥50%,60%>V≥20%
=OBSW
50%>H≥30%,V≥30%
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

11. PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
70° GFC&NGC(F&B)
PROBE DIA=20X20
FREQUENCY=2MHZ
MODE=T+R
VELOCITY=3230M/S
RANGE=165
CALIBRATION=ON IIW BLOCK IST PEAK=6.06
CALIBRATION CHECKING=ON IIW BLOCK 25M.M. CURVE SHOW DEPTH=25M.M.
SENSITIVITY=ON SENSITIVITY BLOCK ,SET 5MM DIA HOLE
FSH=60% FULL SCEEN HEIGHT
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

12. CLASSIFICATION OF RAIL DEFECTS 70°GF/NGF
IN TUNNEL&APP.,ON MAJOR BRIDGE&APPROACHES(100MM) VICINITY OF HOLESNEAR THE WELD
H> 15%,V> 20%=IMR
H> 15%,V<20%=O
OTHER LOCATION
H≥30%,V≥60%=IMR
H≥30%,60%>V≥20%=OBS
30%>H≥15%,V≥20%=OBS
H≥15%,V<20%=O
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

13. PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
WELD DEFECTS(AT+FB)
PROBE USED
NATURE OF DEFECT
CLASSIFICATION
70°GF/NGF
PROBE
ANY TRANSVERSE DEFECT IN THE RAIL HEAD ON GF/NGF AT THE FOLLOWING LOCATION
1.IN TUNNEL &APP (100M)
2.ON BRIDGE APPROACHES(100MM)
3. IN THE VICINITY OF HOLES NEAR THE WELD (50MM FOR OLD WELD AND 75MM FOR NEW AT WELDFROM THE CENTRE OF WELD ON EITHER SIDE
H ≥15%,V≥20%
=IMRW
ANY TRANSEVERSE DEFECT IN THE RAILHEADONGF/NGF SIDE AT TRACK LOCATION OTHER THAN (A)
H≥30%,V≥60%
H≥30%,20%≤V<60%
=OBSW
15%≤H≥30%,V≥20%
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

14. SENSITIVITY SETTING BLOCK TOP-VIEW
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

15. SENSITIVITY SETTING BLOCK SIDE VIEW
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

16. SENSITIVITY SETTING BLOCK (END VIEV)
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

17. PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
ACTION TO BE TAKEN AFTER DETECTION OF DEFECTS
CLASSIFICATION
PAINTING ON BOTH FACES OF WEB
ACTION TO BE TAKEN
INTERIM ACTION
IMR/IMRW
THREE CROSS WITH RED PAINT
THE DEFECTIVE PORTION SHOULD BE REPLACED BY A SOUND TESTED RAIL PIECE OF NOT LESS THAN 5.5M LENGTH( IN CASE OF FISH PLATED TRACK)&4M LENGTH ( IN CASE OF WELDED TRACK) WITHIN 3DAYS OF DETECTION
SSE/JE/USFD SHALL IMPOSE SPEED RESTRICTINOF 30KMPH IMMEDIATELY T AND TO BE CONTINUED TILL FLAWEDRAIL/WELD IS REPLACED. HE SHOULD COMMUNICATE TO SECTIONAL JE/PWAY ABOUT THE FLAW LOCATION WHO SHALL ENSURE THAT CLAMPED JOGGLED FISHPLATEIS PROVIDEDWIHIN 24HRS
OBS/OBSW
ONE CROSS WITH RED PAINT
RAIL/ WELD TO BE PROVIDED WITH CLAMPED JOGGLED FISHPLATE WIHIN 3 DAYS.SSEE/JE/PWAY/USFD TO SPECIALLY RECORD THE OBSERVATION OF THE LOCATION IN HIS REGISTER & CHECK IN NEXT TESTING ROUND
SSE/JE/PWAY/ USFD TO ADVICE SECTIONAL JE/PWAY FOR PROVIDING JOGGLED FISHPLATE WITHIN 24HRS.
KEYMAN WATCH DURING DAILY THAT LOCATION TILL IT IS JOGGLED
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

18. FREQUENCY OF TESTING (ALL MAIN LINE B.G.&M.G.)
ROUTE
ROUTE HAVING GMT
TESTING FREQUENCY(ONCE IN)
ALL MG ROUTE
<2.5
5YEARS
3YEARS
>5
2YEARS
ALL BG ROUTE ROUTES (Rail Head Centre And Gauge Face Corner Testing ≤5
>5≤8
12 MONTH
>8≤12
9MONTH
>12≤16
6MONTH
>16≤24
4MONTH
>24≤40
3MONTH
>40≤60
2MONTH
>60≤80
1 -1/2MONTH
>80
1MONTH
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

19. TH.&GFC TESTING OF RAIL (SOME IMPORTANT FACTS)
1.VISUAL INSPECTION OF EQUIPMENT AND ACCESSORIES-DAILY CHECK
2.CALIBRATION OF EQUIPMENT= ONCE A WEEK
3.SENSITIVITY SETTING OF THE EQUIPMENT AND PROBE= ONCE EVERY 3DAYS(CS-3) 4.CHECKING OF EQUIPMENT CHARACTERISTICS=MONTHLY CHECK
5.TESTING ON SINGLE LINE SECTION AND “D” MARKED RAILS ON DOUBLE /MULTIPLE LINE SECTION. ADITIONAL 10DB GAIN IN 70° CENTRAL PROBE IS TO BE EMPLOYED.
6.. ADITIONAL OF 10DB GAIN IS NOT TO BE EMPLOED FOR CLASSIFICATION OF DEFECT IN WELD HEAD.
7.DEFECT AT ANY LOCATION WHICH IS DETECTED BY TWO OR MORE PROBE AND ARE CONSIDERED TO BE CLASSIFIED AS OBS/OBSW BASE ON PEAK PATTERN OF INDIVVSUAL PROBE SHOULD BE CLASSIFIED IMR /IMRW-CS-3
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

20. TH.&GFC TESTING OF RAIL (SOME IMPORTANT FACTS)
7. IN CASE OF TWO OR MORE OBS/OBSW DEFECT ARE LOCATED WITHIN A DISTANCE OF 4.0 MTRE FROM EACH OTHER . SUCH OBS/OBSW DEFECTS SHALL BE CLASSIFIED AS IMR/IMRW-CS-3 8.SENSITIVITY SETTING BLOCK SHOULD BE LENGTH OF 1.5 MTRE-CS-3
9..ANY SWEEPING SIGNAL ON HORIZONTAL BASE LINE THAT DOES NOT EXTEND BEYOND2.5 DIVISION FROM THE LEFT EDGE OF THE SCREEN SHALL BE RECORDED AS GAUGE CORNER CRACKING (GCC) AND NOT OBS
CODE DESCRIPTION
TRANVERSE FLAW IN HEAD
TRANSVERSE CRACK IN FLUSH BUTT JOINT
HORIZONTAL CRACK IN FLUSH BUTT JOINT
TRANSVERSE CRACK IN I AT WELD
HORIZONTAL CRACK IN AT WELD
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG

21. CALIBRATION BLOCK IIW(VI)
11/9/2018
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG