Topic 10 4 Vehicular USFD VEHICULAR USFD TESTING

Topic – 10. 4 Vehicular USFD

VEHICULAR USFD TESTING § To improve the quality and progress, vehicular USFD testing has been introduced. Northern railway has started this vehicular USFD testing, which is outsourced to M/S PE/NIA JV having MOU with TVEMA of Russia.

SYSTEM OF VEHICULAR USFD TESTING § USFD probe assembly frame has been fitted with one of the bogie of the RBMV (Rail Borne Maintenance Vehicle). § Some of the features of RBMV mounted USFD system are given below: a) Testing progress 100 -120 kms/day b) Testing speed-40 Kmph c) Two operators per system d) Magnetic probe guidance unite e) 18 channel flaw detection system (9 on each side)

SYSTEM OF VEHICULAR USFD TESTING f) Probe to be used are – 0°, 70°CF/CB, 70° GFF/GFB, 40°CF/CB and 70° NGFF/NGFB g) Video monitoring of track through out testing h) B scan representation along with A scan f) Continuous recording of A-scan and B- scan g) Distance- Amplitude Curve indicate defect characteristics h) Pparameters displayed – Testing speed, time and location i) USFD probe assembly frame have been provided with pre loaded springs and magnets to insure contact with rail top. j) Vehicular USFD testing can overcome most of the limitations of manual testing.

BENCH MARKING (CALIBRATION) PROCESS § Test pieces of 60 Kg rail with artificial flaws was prepared and inserted in the track at Safipur station on Unnao – Balamau section of Northern Railway. § Repetitive testing on calibration track at speed of 30 kmph on this artificial flaws

OPERATION OF RBMV MOUNTED USFD SYSTEM 02: 53 • In vehicular testing, the transducers are provided on a separate testing trolley which is having separate small size wheels. • In non-testing mode, the testing trolley is up and locked, for testing the trolley is lowered on the track. • Some of these vehicles are self propelled while others require a separate power for their operation.

OPERATION OF RBMV MOUNTED USFD SYSTEM • The testing speed may vary from 30 kmph to 80 kmph depending upon the design of the testing car and the condition of the track. • The vehicle is provided with on board computers and all signals captured by the transducers are sent to the computer. 02: 53

OPERATION OF RBMV MOUNTED USFD SYSTEM • Machine will be driven by a competent operator. • The operator sitting in the control unit of the vehicle can see the signals picked up by different probes and ensure proper functioning of the system. 02: 53

OPERATION OF RBMV MOUNTED USFD SYSTEM • Railway will provide Assistant loco Pilot having route learning. • Most of these systems provide 'B' scan as well as 'A' scan image. • 'B' scan image gives the two dimensional view of the defect. • A moving scan of about 200 m length is shown continuously on the screen during the run. 'A' scan image can also be displayed wherever desired by the operator. • Operation of USFD apparatus and analysis of recorded data will be carried by two trained operators.

OPERATION OF RBMV MOUNTED USFD SYSTEM • A software is installed on the car which can analyze the captured data as per the requirements of the client and produce a list of the suspected defects along with their locations. • Sectional SSE/JE will accompany the machine. • After each round of testing suspect list will be generated.

OPERATION OF RBMV MOUNTED USFD SYSTEM • Vehicular testing will be followed by manual verification of suspects. • Adequate no of RDSO certified spot verifiers will deployed to complete the spot verification of suspects and accordingly the defects will be verified and classified. • Such systems are used in most of the railway networks in the world.

CURRENT TENDER IN INDIA § Northern railway entered into contract for vehicular USFD on the following Rajdhani routes: § New Delhi to Deen Dyal Nagar -1600 track Kms § New Delhi to Ratlam § Scope of work - 1500 track Kms - 10 rounds of testing § Value - Rs. 13. 65 Cr.