ULTRASONIC TESTING OF RAIL 10252021 PRESENTED BY SANJEEV

ULTRASONIC TESTING OF RAIL 10/25/2021 PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG 1

AREA CVERED BY 70°PROBE 10/25/2021 PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG 2

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 10/25/2021 PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG 3

SINGLE RAIL TESTER 1. SINGLE RAIL TESTER IS CAPABLE OF TESTING ONLY ONE OF THE RAILS AT A T IME AND IS PROVIDED WITH SEVEN PROBE 2. O°, 70°CENTRAL FORWARD(CF), 70°CENTRAL BACKWARD(CB), 3. 70 °GAUGE FACE FORWARD (GF), 70°GAUGE FACE BACKWARD(GB) 70°NONGAUGE FACE FORWARD(NGF), AND 70°NON-GAUGE FACE BACKWARD(NGB) 4. THE NORMAL PROBE IS DETECTING HORIZONTAL DEFECTS IN THE RAIL HEAD, WEB AND FOOT 5. 70°PROBE IS FOR DETECTING TRANSVERSE DEFECT IN HEAD 6. 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 10/25/2021 PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG 4

DOUBLE RAIL TESTER 1. THE DOUBLE RAIL TESTER IS CAPABLE OF TESTING BOTH RAILS AT A TIME. FOR EACH RAIL, SEVEN PROBES HAVE BEEN PROVIDED 2. 0°; 70°CENTRAL FORWARD(CF) , 70°CENTRAL BACKWARD(CB), 3. 70 °GAUGE FACE FORWARD (GF), 70°GAUGE FACE BACKWARD(GB) 70°NONGAUGE FACE FORWARD(NGF), AND 70°NON-GAUGE FACE BACKWARD(NGB) 4. THE NORMAL PROBE IS DETECTING HORIZONTAL DEFECTS IN THE RAIL HEAD, WEB AND FOOT 5. 70°PROBE IS FOR DETECTING TRANSVERSE DEFECT IN HEAD 6. 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 10/25/2021 PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG 5

DETAILS OF FREQUENCY &PROBES TYPE FREQUENCY PROBE RIG SRT DRT NORMAL 4 MHZ ONE FOR EACH RAIL 70 CENTRAL 2 MHZ TWO(F+B) FOR EACH RAIL 70 GAUGEFACE 2 MHZ TWO(F+B) FOR EACH RAIL 70 NONFAUG FACE 2 MHZ TWO(F+B) FOR EACH RAIL RIG 2 MHZ 10/25/2021 TW O PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG 6

CALIBRATION&SENSITIVITY SETTING • 70°CENTRAL PROBE(F&B) 1. 2. 3. 4. 5. 6. 7. 8. 9. PROBE DIA=20 X 20 FREQUENCY=2 MHZ MODE=T+R RANGE=165 CALIBRATION=ON IIW BLOCK IST PEAK=6. 06 CALIBRATION CHECKING=ON IIW BLOCK 25 M. M. CURVE , READ DEPTH= 25 M. M. SENSITIVITY=ON SENSITIVITY BLOCK 12 M. M. DIA HOLE F. S. H. =60% HEIGHT REMARK=ADD 10 DB GAIN ON SINGLE LINE& D- MARKED RAIL ON DOUBLE/MULTIPLE LINE 10/25/2021 PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG 7

CLASSIFICATION OF RAIL DEFECT (70°-CENTRAL) -1 • IN TUNNEL &APP. , ON MAJOR BRIDGES, APPROACHES( 100 MM) IN THE VICINITY OF HOLES NEAR THE WELD • X. . H>30% • V> 20% =IMR • 30%≤H≤ 100% • V<20% =O 10/25/2021 • 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 PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG 8

CLASSIFFICATION OF RAIL DEFECTS(70°-CENTRAL) S/L-D MARKED-RAILS(10 DB)-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 10/25/2021 PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG 9

WELD DEFECTS(AT+FB) PROBE USED NATURE OF DEFECT CLASSIFICATION 70°CENTRAL ANY TRANSVERSE DEFECT IN THE PROBE RAIL HEAD AT THE FOLLOWING LOCATION 1. IN TUNNEL &APP (100 M) 2. ON BRIDGE APPROACHES(100 MM) 3. IN THE VICINITY OF HOLES NEAR THE WELD (50 MM FOR OLD WELD AND 75 MM FOR NEW AT WELDFROM THE CENTRE OF WELD ON EITHER SIDE ANY TRANSEVERSE DEFECT IN THE RAIL AT TRACK LOCATION OTHER THAN (A) H ≥ 30%, V≥ 30% =IMRW 10/25/2021 PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG H≥ 50%, V≥ 50% =IMRW H≥ 50%, 60%>V≥ 20% =OBSW 50%>H≥ 30%, V≥ 30% =OBSW 10

70° GFC&NGC(F&B) 1. 2. 3. 4. 5. 6. 7. PROBE DIA=20 X 20 FREQUENCY=2 MHZ MODE=T+R VELOCITY=3230 M/S RANGE=165 CALIBRATION=ON IIW BLOCK IST PEAK=6. 06 CALIBRATION CHECKING=ON IIW BLOCK 25 M. M. CURVE SHOW DEPTH=25 M. M. 8. SENSITIVITY=ON SENSITIVITY BLOCK , SET 5 MM DIA HOLE 9. FSH=60% FULL SCEEN HEIGHT 10/25/2021 PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG 11

CLASSIFICATION OF RAIL DEFECTS 70°GF/NGF • IN TUNNEL&APP. , ON MAJOR BRIDGE&APPROACHES(100 MM) VICINITY OF HOLESNEAR THE WELD • H> 15%, V> 20%=IMR • H> 15%, V<20%=O 10/25/2021 • OTHER LOCATION • • H≥ 30%, V≥ 60%=IMR H≥ 30%, 60%>V≥ 20%=OBS 30%>H≥ 15%, V≥ 20%=OBS H≥ 15%, V<20%=O PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG 12

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 (100 M) 2. ON BRIDGE APPROACHES(100 MM) 3. IN THE VICINITY OF HOLES NEAR THE WELD (50 MM FOR OLD WELD AND 75 MM 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) 10/25/2021 PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG H≥ 30%, V≥ 60% =IMRW H≥ 30%, 20%≤V<60% =OBSW 15%≤H≥ 30%, V≥ 20% =OBSW 13

SENSITIVITY SETTING BLOCK TOP-VIEW 10/25/2021 PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG 14

SENSITIVITY SETTING BLOCK SIDE VIEW 10/25/2021 PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG 15

SENSITIVITY SETTING BLOCK (END VIEV) 10/25/2021 PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG 16

ACTION TO BE TAKEN AFTER DETECTION OF DEFECTS CLASSIFICA TION PAINTING ON ACTION TO BE TAKEN BOTH FACES OF WEB DEFECTIVE PORTION SHOULD BE IMR/IMRW THREE CROSS THE REPLACED BY A SOUND TESTED RAIL PIECE WITH RED OF NOT LESS THAN 5. 5 M LENGTH ( IN CASE PAINT OF FISH PLATED TRACK)&4 M LENGTH ( IN INTERIM ACTION OBS/OBS W SSE/JE/PWAY/ USFD TO ADVICE SECTIONAL JE/PWAY FOR PROVIDING JOGGLED FISHPLATE WITHIN 24 HRS. KEYMAN WATCH DURING DAILY THAT LOCATION TILL IT IS JOGGLED CASE OF WELDED TRACK) WITHIN 3 DAYS OF DETECTION 10/25/2021 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 PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG SSE/JE/USFD SHALL IMPOSE SPEED RESTRICTINOF 30 KMPH 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 24 HRS 17

FREQUENCY OF TESTING (ALL MAIN LINE B. G. &M. G. ) ROUTE HAVING GMT TESTING FREQUENCY(ONCE IN) ALL MG ROUTE <2. 5 5 YEARS 2. 5 -5. 0 3 YEARS >5 2 YEARS ALL BG ROUTES (Rail Head Centre And Gauge Face Corner Testing ≤ 5 2 YEARS >5≤ 8 12 MONTH >8≤ 12 9 MONTH >12≤ 16 6 MONTH >16≤ 24 4 MONTH >24≤ 40 3 MONTH >40≤ 60 2 MONTH >60≤ 80 1 -1/2 MONTH >80 1 MONTH 10/25/2021 PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG 18

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 3 DAYS(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 10 DB GAIN IN 70° CENTRAL PROBE IS TO BE EMPLOYED. • 6. . ADITIONAL OF 10 DB 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 10/25/2021 PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG 19

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 BEYOND 2. 5 DIVISION FROM THE LEFT EDGE OF THE SCREEN SHALL BE RECORDED AS GAUGE CORNER CRACKING (GCC) AND NOT OBS • CODE DESCRIPTION • 211 TRANVERSE FLAW IN HEAD • 411 TRANSVERSE CRACK IN FLUSH BUTT JOINT • 412 HORIZONTAL CRACK IN FLUSH BUTT JOINT • 421 TRANSVERSE CRACK IN I AT WELD • 422 HORIZONTAL CRACK IN AT WELD 10/25/2021 PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG 20

CALIBRATION BLOCK IIW(VI) 10/25/2021 PRESENTED BY SANJEEV RATHORE S. S. E. (PWAY)/USFD/DHG 21