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Title: Draft BS EN 16729-1 Railway applications - NDT on rails in track -

Part 1: Requirements for ultrasonic inspection and evaluation principles

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Introduction
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EUROPEAN STANDARD DRAFT
NORME EUROPÉENNE prEN 16729-1
EUROPÄISCHE NORM
May 2014

ICS 93.100

English Version

Railway applications - Infrastructure - NDT on rails in track - Part

1: Requirements for ultrasonic inspection and evaluation
principles

Applications ferroviaires - Infrastructure - Essais non Bahnanwendungen - ZfP an Schienen im Gleis - Teil 1:
destructifs sur les rails de voie - Partie 1: Exigences pour Anforderungen für Ultraschall-Untersuchungen und
les principes d'évaluation et d'inspection par ultrasons Bewertungsgrundlagen

This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee CEN/TC 256.

If this draft becomes a European Standard, CEN members are bound to comply with the CEN/CENELEC Internal Regulations which
stipulate the conditions for giving this European Standard the status of a national standard without any alteration.

This draft European Standard was established by CEN in three official versions (English, French, German). A version in any other language
made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management
Centre has the same status as the official versions.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,
Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United
Kingdom.

Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are aware and to
provide supporting documentation.

Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without notice and
shall not be referred to as a European Standard.

EUROPEAN COMMITTEE FOR STANDARDIZATION

COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG

CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels

© 2014 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 16729-1:2014 E
worldwide for CEN national Members.
prEN 16729-1:2014 (E)

Contents Page

Foreword ..............................................................................................................................................................3
Introduction .........................................................................................................................................................4
1 Scope ......................................................................................................................................................5
2 Normative references ............................................................................................................................5
3 Terms and definitions ...........................................................................................................................5
4 Basics .....................................................................................................................................................7
4.1 General ....................................................................................................................................................7
4.2 Principle of ultrasonic testing in track ................................................................................................7
4.3 Ultrasonic testing speed and defect detection ...................................................................................7
4.4 Simulation of internal reflectors in reference rails .............................................................................8
5 Detection of reference reflectors ...................................................................................................... 10
6 Control of defect positioning accuracy ............................................................................................ 12
Annex A (normative) Simulated reflectors in reference rails ...................................................................... 13
Annex B (informative) Simulated reflectors in reference rails..................................................................... 33
Annex C (informative) Ultrasonic test areas in rails tested with test vehicles or trolleys ........................ 37

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 prEN 16729-1:2014 (E)

Foreword

This document (prEN 16729-1:2014) has been prepared by Technical Committee CEN/TC 256 “Railway
applications”, the secretariat of which is held by DIN.

This document is currently submitted to the CEN Enquiry.

This document has been prepared under a mandate given to CENELEC by the European Commission and
the European Free Trade Association, and supports essential requirements of EU Directive(s).

This series of European Standards EN 16729 “Railway applications – Infrastructure – NDT on rails in track”
consists of:

— Part 1: Requirements for ultrasonic inspection and evaluation principles

— Part 2: Requirements for describing and identifying internal and surface rail defects

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prEN 16729-1:2014 (E)

Introduction

This standard represents the actual state of the art of automatic ultrasonic testing of rails in track applied by
European railway companies.

This standard applies only to rail profiles meeting the requirements of EN 13674-1.

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 prEN 16729-1:2014 (E)

1 Scope

This European Standard applies to testing of rails installed in track for detecting internal rail defects.

This part of the European Standard applies to testing equipment fitted to dedicated test vehicles or trolleys.
This standard does not define the requirements for vehicle acceptance. This standard is not concerned with
production testing of rails in a production plant.

The standard specifies the requirements for testing principles and systems in order to produce comparable
results in respect of location, type and size of rail defects. This standard is not aiming to give any guidelines
for managing the result of ultrasonic rail testing.

2 Normative references

The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.

prEN 16729-2, Railway applications – Infrastructure – NDT on rails in track – Part 2: Requirements for
describing and identifying internal and surface rail defects

EN 1330-4, Non-destructive testing – Terminology – Part 4: Terms used in ultrasonic testing

EN 13674-1, Railway applications – Track – Rail – Part 1 Vignole railway rails 46 kg/m and above

3 Terms and definitions

For the purposes of this document, the following terms and definitions apply.

3.1
ultrasound
in test systems according to this standard ultrasound at a frequency range of 2 MHz to 5 MHz is used

3.2
parts of the rail
parts of the rail are defined in Figure 1

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prEN 16729-1:2014 (E)

Key
A = rail head
B = rail web
C = rail food
D = rail head surface
E = gauge corner area
F = rail head side area
G = rail head fillet radius area
H = rail web area
I = rail food fillet radius area
J = rail food area
1 = Field side
2 = Gauge corner side

Figure 1 — Parts of the rail

3.3
indication
signal shown on the display of an ultrasonic instrument or system as a result of received ultrasonic energy.
Evidence obtained by non-destructive testing

3.4
Flat Bottomed Hole (FBH)
FBH shall be machined using a twist drill at the appropriate diameter followed by a slot drill hole of the same
diameter to the required depth to generate the flat end of the hole. Accuracy in diameter and depth shall be
within 0,1 mm. Accuracy in angle shall be within 0,1°

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 prEN 16729-1:2014 (E)

3.5
Side Drilled Hole (SDH)
SDH shall be machined using a twist drill at the appropriate diameter. Accuracy in diameter shall be within
0,1 mm. Accuracy in angle shall be within 0,1°

3.6
Electrical Discharge Machined (EDM) notch
EDM notch shall be machined to the desired shape and orientation with an accuracy of 0,1 mm. Accuracy in
angle shall be within 0,1°

3.7
Pulse Repetition Frequency (PRF)
number of ultrasonic transmission pulses generated per unit of time (Hz or kHz)

3.8
simulated reflector
artificial feature designed to represent a real defect of a known size, orientation and position

3.9
functional reflector
artificial feature designed to dynamically test an ultrasonic system at normal operation speed

3.10
ultrasonic sensor (probe)
electro-acoustical device, usually incorporating one or more transducers intended for transmission and/or
reception of the ultrasonic waves

3.11
ultrasonic reference reflectors
collection of known target reflectors manufactured into rail located at a suitable location, used to determine the
capability of an ultrasonic test system to detect internal rail reflectors in an in-service track

4 Basics

4.1 General

In order to verify the performance of the automatic ultrasonic systems for rail testing there shall be defined
reference reflectors in a test track. These reference reflectors shall be recorded and reported at the normal
operational speed of the test vehicle/system.

The reference rail shall be constructed from new rail to provide the correct head profile and running surface
condition. Rails with corrosion on the running surface shall be cleaned to allow the transmission of ultrasound
prior to any testing, for example using a powered steel wire brush.

4.2 Principle of ultrasonic testing in track

Ultrasound transmitted into rail will reflect from the rail surfaces of the steel. Fractures and defects within the
rail, as well as the boundary of the rail will act as rail surfaces, and therefore reflect the ultrasound. By
receiving, recording and interpreting the returned ultrasonic signals, it is possible to detect discontinuities
within rail installed in track before they present an unacceptable risk to the integrity and strength of the rail.

4.3 Ultrasonic testing speed and defect detection

Practical ultrasonic beams have a width which is determined by the size of the transducer and the frequency.
All defects have a finite size, so there is an interaction between the ultrasonic beam and the defect. As the
beam sweeps across the defect as the train travels along the track ultrasound will be reflected from the defect
and will be detected by the transducer. All modern ultrasonic systems use a threshold level in a gate and the

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prEN 16729-1:2014 (E)

system will record a response when the reflection is above the threshold level. By controlling the gain in the
ultrasonic system and the gate threshold level the number of responses for a given size of reflector can be
defined.

A defect can be sized by setting the system parameters so that a known number of responses are received
from a known sized reflector. The relationship of the number of responses and the size of the defect is known.
This applies to all the defects in Annex A.

The required minimum sampling frequency depends on the beam width, the critical defect size and the
number of responses required for an indication to be recorded and reported.

4.4 Simulation of internal reflectors in reference rails

Two identical sets of reference reflectors selected from Annex A and Annex B shall be installed in the left and
right rail of a section of track. The length of the reference rails is not defined by this standard. The distance
between the simulated reflectors should be at least one meter for safety reasons.

Due to influences of water and dirt to the ultrasonic responses reference holes and notches shall be plugged
with a synthetic compound.

NOTE The infrastructure manager must carry out a risk assessment to determine if reinforcement of the reference
reflectors is necessary (fishplates or similar) and determine the maintenance regime of the reference rails.

Table 1 — Simulated reflectors in reference rails (normative references)

No. Figure Type Description Dimensions

S/F a [mm]
01 A.1 F Volumetric reflector in rail head A = 7; 10; 20;
D=6
02 A.2 S Central transverse defect (20 degrees) in rail head A = 10–20
D = 5;10
03 A.3 S Gauge transverse defect (20 degrees) in rail head A = 10 – 20
B = 10 – 15
D = 5; 10
04 A.4 S Full width transverse defect (20 degrees) in rail head A = 20
D=3
L=7
05 A.5 S Full width transverse defect (35 degrees) in rail head A = 20
D=3
L=7
06 A.6 S Full width transverse defect (53 degrees) in rail head A = 20
D=3
L=7
07 A.7 F Volumetric reflector gauge side of rail head A = 25
B = 20; 25; 30; 36
D=6–8
08 A.8 F Volumetric reflector field side of rail head A = 25
B = 20; 25; 30; 36
D=6–8
09 A.9 S Horizontal defect in rail head (version 1) A = 20
D = 5; 8; 10
10 A.10 S Horizontal bolt hole crack Dmax = 36

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 prEN 16729-1:2014 (E)

L = 5; 10
11 A.11 S Bolt hole crack position A Dmax = 36
L = 5; 10
12 A.12 S Bolt hole crack position B Dmax = 36
L = 5; 10
13 A.13 S Bolt hole crack position C Dmax = 36
L = 5; 10
14 A.14 S Bolt hole crack position D Dmax = 36
L = 5; 10
15 A.15 F Volumetric reflector at head – web radius D=6
16 A.16 F Volumetric reflector mid – web D=6
17 A.17 F Volumetric reflector at foot – web radius D=6
18 A.18 S Head – web radius transverse defect (35 degrees) D=3
L = 10
19 A.19 S Foot – web radius transverse defect (53 degrees) D=3
L = 10
20 A.20 S Vertical longitudinal defect (version 1) A = 20
H = 10; 15; 20
L = 50 – 100
21 A.21 S Vertical longitudinal defect (version 2) A = 20
D=5
L = 50 – 100
22 A.22 S Change in foot depth C = 5; 10
L = 80
W = 30
23 A.23 S Rail foot crack 5 mm (version 1) C=5
R = 17
24 A.24 S Rail foot crack 10 mm (version 1) C = 10
R = 22
25 A.25 F Multiple repeated feature (version 1) A = 25
D=6
10 holes within
2 000
26 A.26 F Resolution check feature (version 1) A = 25
D=6
L = 8; 9; 11; 13; 16;
21; 26
20
a S = simulated reflector, F = functional reflector

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prEN 16729-1:2014 (E)

Table 2 — Simulated reflectors in reference rails (informative references)

No. Figure Type Description Dimensions

S/F a [mm]
27 B.1 S Simulated gauge corner crack A = 20
B = 20
28 B.2 S Horizontal defect in rail head (version 2) A=5
B = 25
L = 25
29 B.3 S Horizontal head – web crack (mid rail) L=5
30 B.4 S Horizontal head – web crack (rail end) L = 15
31 B.5 S Vertical longitudinal defect (version 3) A = 40
L = 75
32 B.6 S Rail foot crack 5 mm (version 2) C=5
R = 35
33 B.7 S Rail foot crack 10 mm (version 2) C = 10
R = 40
a S = simulated reflector, F = functional reflector

5 Detection of reference reflectors

The reference reflectors listed in Table 1 and Table 2 shall detect with the mandatory probe angles listed in
Table 3.

Where the end of a drill hole is used as a reflector the hole bottom shall be machined flat (FBH – flat bottom
hole).

NOTE The ultrasound probe angles listed in Table 3 are used in most ultrasonic test vehicles or trolleys. The
infrastructure manager shall define which probe angles are to be used. This will be dependent on what defects are to be
detected.

Table 3 — Reference reflectors detected with defined probe angles (1 of 3)

Parallel Squinting
within in the
No. Reflector Centred on the middle of the rail the direction
gauge of gauge
corner corner
35 50 45 65 65 65 – 70
0° *)
−40° −60° −55°T −70° −70°Sat °Sq
Volumetric reflector in rail
01 M O O M M O
head
Central transverse defect
02 M
(20 degrees) in rail head
Gauge transverse defect
03 O M
(20 degrees) in rail head
Full width transverse
04 defect (20 degrees) in rail O O O M M
head

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 prEN 16729-1:2014 (E)

Full width transverse

05 defect (35 degrees) in rail O O M M M
head
Full width transverse
06 defect (53 degrees) in rail O M O
head
Volumetric reflector
07 O O M
gauge side of rail head
Volumetric reflector field
08 O O M
side of rail head
Horizontal defect in rail
09 M
head (version 1)
10 Horizontal bolt hole crack M
11 Bolt hole crack position A O M O O
12 Bolt hole crack position B O M
13 Bolt hole crack position C O M O O
14 Bolt hole crack position D O M
Volumetric reflector at
15 M M O
head – web radius
Volumetric reflector mid –
16 M M
web
Volumetric reflector at
17 O M
foot – web radius
Head – web radius
18 transverse defect (35 O M
degrees)
Foot – web radius
19 transverse defect (53 M
degrees)
Vertical longitudinal
20 O M
defect (version 1)
Vertical longitudinal
21 O M
defect (version 2)
22 Change in foot depth M
Rail foot crack 5 mm
23 M
(version 1)
Rail foot crack 10 mm
24 M
(version 1)
Multiple repeated feature
25 O O O M O
(version 1)
Resolution check feature
26 O O O M O
(version 1)
Simulated gauge corner
27 O M M
crack
Horizontal reflector in rail
28 M
head (version 2)

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prEN 16729-1:2014 (E)

Horizontal head – web

29 M
crack (mid rail)
Horizontal head – web
30 M O
crack (rail end)
Vertical longitudinal
31 M
defect (version 3)
Rail foot crack 5 mm
32 M
(version 2)
Rail foot crack 10 mm
33 M
(version 2)
M = mandatory O = optional
NOTE:
1) Probe angles defined with respect to the vertical plane
2) All angled transducers shall be configured to scan in both directions (forward and backward).
3) Reference reflectors shall be orientated to check transducers scanning in both directions.
*Probe angle transverse to rail length

6 Control of defect positioning accuracy

To determine the distance of the defects accurately bolt holes of a known size and separation shall be tested
in both directions. See Table 4 as an example.

Table 4 — Permitted differences of the defect positioning accuracy

No. of bolt hole Distance to bolt hole 1 [m] Permitted difference [mm]
01 0 reference reflector
02 50 ± 100
03 100 ± 200
04 150 ± 300
05 200 ± 400
06 250 ± 500
07 300 ± 600
08 350 ± 700
09 400 ± 800
10 450 ± 900
11 500 ± 1 000

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 prEN 16729-1:2014 (E)

Annex A
(normative)

Simulated reflectors in reference rails

Key

A = A1, A2, A3 (three drills)

A1 = 7 mm

A2 = 10 mm

A3 = 20 mm

D = 6 mm

Figure A.1 — Volumetric reflector in rail head

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prEN 16729-1:2014 (E)

Key

A = 10 mm to 20 mm

D = D1, D2 (two drills)

D1 = 5 mm

D2 = 10 mm

E = 20°

L = 20 mm

1 =Thermit weld

2 =Plug of rail steel

NOTE This reflector shall be present in forward and reverse directions

Figure A.2 — Central transverse defect (20 degrees) in rail head

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 prEN 16729-1:2014 (E)

Key

A = 10 mm to 20 mm

B = 10 mm to 15 mm

D1 = 5 mm

D2 = 10 mm

E = 20°

L = 20 mm

1 = Thermit weld

2 = Plug of rail steel

NOTE This reflector shall be present in forward and reverse directions

Figure A.3 — Gauge transverse defect (20 degrees) in rail head

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prEN 16729-1:2014 (E)

Key

A = 20 mm

D = 3 mm

E = 20°

L = 7 mm

NOTE This reflector shall be present in forward and reverse directions

Figure A.4 — Full width transverse defect (20 degrees) in rail head

Key

A = 20 mm

D = 3 mm

E = 35°

L = 7 mm

NOTE This reflector shall be present in forward and reverse directions

Figure A.5 — Full width transverse defect (35 degrees) in rail head

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 prEN 16729-1:2014 (E)

Key

A = 20 mm

D = 3 mm

E = 53°

L = 7 mm

NOTE This reflector shall be present in forward and reverse directions

Figure A.6 — Full width transverse defect (53 degrees) in rail head

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prEN 16729-1:2014 (E)

Key

A = 25 mm

B = B1, B2, B3, B4 (four drills)

B1 = 20 mm

B2 = 25 mm

B3 = 30 mm

B4 = 36 mm

D = 6 mm to 8 mm

1 = gauge side of rail

Figure A.7 — Volumetric reflector gauge side of rail head

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 prEN 16729-1:2014 (E)

Key

A = 25 mm

B = B1, B2, B3, B4 (four drills)

B1 = 20 mm

B2 = 25 mm

B3 = 30 mm

B4 = 36 mm

D = 6 mm to 8 mm

1 = field side of rail

Figure A.8 — Volumetric reflector field side of rail head

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prEN 16729-1:2014 (E)

Key

A1 = 20 mm

A2 = 40 mm

D = D1, D2, D3 (three drills)

D1 = 5 mm

D2 = 8 mm

D3 = 10 mm

D4 = 15 mm

Figure A.9 — Horizontal defect in rail head (version 1)

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 prEN 16729-1:2014 (E)

Key

A = depends on rail head

L = L1, L2 (two cuts)

L1 = 5 mm

L2 = 10 mm

D ≤ 36 mm

W ≤ 6 mm

Figure A.10 — Horizontal bolt hole crack

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prEN 16729-1:2014 (E)

Key

A = depends on rail head

L = L1, L2 (two cuts)

L1 = 5 mm

L2 = 10 mm

D ≤ 36 mm

W ≤ 3 mm

1 = rail end

Figure A.11 — Bolt hole crack position A

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 prEN 16729-1:2014 (E)

Key

A = depends on rail head

L = L1, L2 (two cuts)

L1 = 5 mm

L2 = 10 mm

D ≤ 36 mm

W ≤ 3 mm

1 = rail end

Figure A.12 — Bolt hole crack position B

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prEN 16729-1:2014 (E)

Key

A = depends on rail head

L = L1, L2 (two cuts)

L1 = 5 mm

L2 = 10 mm

D ≤ 36 mm

W 3 mm

1 = rail end

Figure A.13 — Bolt hole crack position C

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 prEN 16729-1:2014 (E)

Key

A = depends on rail head

L = L1, L2 (two cuts)

L1 = 5 mm

L2 = 10 mm

D ≤ 36 mm

W ≤ 3 mm

1 = rail end

Figure A.14 — Bolt hole crack position D

Key

A = depends on rail head

D = 6 mm

Figure A.15 — Volumetric reflector at head – Web radius

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prEN 16729-1:2014 (E)

Key

A = depends on rail head (centre line of profile)

D = 6 mm

Figure A.16 — Volumetric reflector mid-web

Key

A = depends on rail head

D = 6 mm

Figure A.17 — Volumetric reflector at foot – Web radius

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 prEN 16729-1:2014 (E)

Key

A = depends on rail head

D = 3 mm

E = 35°

L = 10 mm

Figure A.18 — Head – web radius transverse defect (35 degrees)

Key

A = depends on rail head

D = 3 mm

E = 53°

L = 10 mm

Figure A.19 — Foot – web radius transverse defect (53 degrees)

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prEN 16729-1:2014 (E)

Key

A = 20 mm

H = H1, H2, H3 (six drills)

H1 = 10 mm

H2 = 15 mm

H3 = 20 mm

L = L1, L2

L1 = 50 mm

L2 = 100 mm

1 = Thermit weld

Figure A.20 — Vertical longitudinal defect (version 1)

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 prEN 16729-1:2014 (E)

Key

A = 20 mm

D = 5 mm

H = 6 mm (2, 3, 4 drills)

L = L1, L2

L1 = 50 mm

L2 = 100 mm

A = Thermit weld

Figure A.21 — Vertical longitudinal defect (version 2)

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prEN 16729-1:2014 (E)

Key

C1 = 5mm

C2 = 10mm

L = 80mm

W = 30mm

X = view on arrow

Figure A.22 — Change in rail foot depth

Key

C = 5 mm

R = 17 mm

W = 2 mm

Figure A.23 — Rail foot crack 5 mm (version 1)

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 prEN 16729-1:2014 (E)

Key

C = 10 mm

R = 22 mm

W = 2 mm

Figure A.24 — Rail foot crack 10 mm (version 1)

Key

A = 25 mm

D = 6 mm

L = 222 mm between 10 drills

Figure A.25 — Multiple repeated feature (version 1)

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prEN 16729-1:2014 (E)

Key

A = 25 mm

D = 6 mm

L = L1, L2, L3, L4, L5, L6, L7

L1 = 8 mm

L2 = 9 mm

L3 = 11 mm

L4 = 13 mm

L5 = 16 mm

L6 = 21 mm

L7 = 26 mm

Figure A.26 — Resolution check feature (version 1)

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 prEN 16729-1:2014 (E)

Annex B
(informative)

Simulated reflectors in reference rails

Key

A = 20 mm

B = 20 mm

E = 20°

R = 5 mm

W ≤ 3 mm

1 = Gauge side of rail

Figure B.1 — Simulated gauge corner crack

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prEN 16729-1:2014 (E)

Key

A = 5 mm

B = 25 mm

L = 25 mm

W ≤ 3 mm

1 = void filled a weld

2 = field side of rail

Figure B.2 — Horizontal reflector in rail head (version 2)

Key

A = depends on rail profile

L = 5 mm

W ≤ 3 mm

Figure B.3 — Horizontal head – web crack (mid rail)

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 prEN 16729-1:2014 (E)

Key

A = depends on rail profile

L = 15 mm

W ≤ 3 mm

Figure B.4 — Horizontal head – web crack (rail end)

Key

A = 40 mm

L = 75 mm

W = 2 mm

Figure B.5 — Vertical longitudinal defect (version 3)

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prEN 16729-1:2014 (E)

Key

C = 5 mm

R = 35 mm

W = 2 mm

Figure B.6 — Rail foot crack 5 mm (version 2)

Key

C = 10 mm

R = 40 mm

W = 2 mm

Figure B.7 — Rail foot crack 10 mm (version 2)

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 prEN 16729-1:2014 (E)

Annex C
(informative)

Ultrasonic test areas in rails tested with test vehicles or trolleys

Key

A = Non direct tested zone up to12 mm

Figure C.1 — Ultrasonic tested area in rails with the 0° probe

Key

A = Non direct tested zone 3 mm – 8 mm

B = Maximum tested zone with 70° probe

Figure C.2 — Ultrasonic tested area in rails with the centred 70° probe

37
prEN 16729-1:2014 (E)

Key

A = Non direct tested zone 3 – 8 mm

B = Maximum tested zone with 35° probe

Figure C.3 — Ultrasonic tested area in rails with the 35° probe

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