ULTRASONIC TESTING OF STOCK

AND TONGUE RAIL OF SEJ/ISEJ

.
 Contents

1. Equipment & Accessories used.

2. Standard Rail Piece
3. Testing of stock/tongue rail of SEJ/ISEJ by 45° probe.
4. Testing of stock/tongue rail of SEJ/ISEJ by 70° probe.
5. Testing of stock/tongue rail of SEJ/ISEJ by 0° probe.
6. Testing of flange of stock/tongue rail of SEJ/ISEJ by
70° probe.
7. Testing frequency.


1. Equipment & Probes

a. RDSO approved USFD.

b. 0º - 2 MHz, DC probe, for

calibration

c. 45º -2 MHz, SC probe.

d. 70º- 2 MHz, SC probe.

 2. Standard test Piece
A 1000 mm long rail piece having nose of SEJ/ISEJs
stock.

One simulated flaw of 3mm x 5mm shall be made in

bottom as shown in Fig.26(b) at location A.

Another 5 mm dia. through hole shall be made in the

rail head at location B.

 5 mm saw cut at sharp curved location of flange in a

standard tongue rail of SEJ/ISEJ as shown in Fig.29.
 3.Testing by 45º Single Crystal angle probe
 For detection of defects originated from bolt hole and machined edge at
bottom of stock /tongue rail of SEJ/ISEJ.

 Range Calibration – 500 mm L wave

 Sensitivity setting - 45° Probe on Rail table at a distance equal to rail

height from the defect plane on the bottom as shown in Fig. 26C and
keeping defect signal to 40% of FSH.
3.Testing by 45º Single Crystal angle probe
 Procedure-Probe shall be moved on the head of
stock/tongue rail of SEJ/ISEJ while maintaining the
movement towards the nose of SEJ/ISEJ. Probe shall be
moved towards the nose and away from the nose in entire
machined portion of rail.

Defect Classification – Any flaw signal higher than 20% of

FSH shall be classified as IMR. The defective SEJ/ISEJ
should be adequately protected .
 4.Testing by 70º Single Crystal angle probe
 For detection of transverse defects originating in head of stock/tongue
rail of SEJ/ISEJ.

 Range Calibration – 300 mm L wave

 Sensitivity setting - 70° Probe on Rail head at a distance of approx. 70

mm from 5 mm dia. hole as shown in Fig. 26C and keeping defect signal
to 60% of FSH.
4.Testing by 70º Single Crystal angle probe
 Procedure- 70° Probe shall be placed on the head of
stock/tongue rail of SEJ/ISEJ while maintaining the
movement towards the nose of SEJ/ISEJ. Probe shall be
moved towards the nose and away from the nose in entire
machined portion of stock/tongue rail of SEJ/ISEJ.

Defect Classification – Any flaw signal higher than 20% of

FSH shall be classified as IMR. The defective SEJ/ISEJ
should be adequately protected .
 5.Testing by 0º Double Crystal probe
 Scope - For detection of horizontal defects in head , web and web-foot
junction of stock/tongue rail defects originating in head of stock/tongue
rail of SEJ/ISEJ.

 Range Calibration - 300 mm L wave.

 Sensitivity setting - 0°/2MHz Probe on Rail head to get reflected signal

from back end of the rail and keeping reflected signal to 60% of FSH.

 Procedure- 0°/2MHz Probe shall be moved on the top of the

stock/tongue rail of SEJ/ISEJ to facilitate detection of horizontal defect
in head ,web and flange.

 Classification- Any flaw peak of amplitude higher than 20% of FSH or

partial /complete loss of backwall echo shall be classified as IMR. The
defective SEJ/ISEJ shuld be adequately protected.
 6.Testing of Flange of stock and tongue rail by 70º Single Crystal Angle probe

 Scope - For detection of defects in tongue/stock rail at location where sharp

change in one of the flange portion has been designed.For conducting test
bracket needs to be removed first.

 Range Calibration - 165 mm S wave.

 Sensitivity setting - 70° Probe is placed on the upper zone of flange at a

distance of approx. 110 mm far from 5 mm saw cut on the standard tongue rail
piece and keeping signal from 5 mm deep saw cut to 60% of FSH as shown in
Fig.29.

 Procedure- 70° Probe shall be placed on the upper zone of flange at a distance
of approx.110 mm far from sharp curve portion with beam directing towards curve
portion and also in backward direction of the curved portion

 Classification- Any flaw signal from 70° Probe having amplitude of 20% or
higher shall be treated as IMR. The defective SEJ/ISEJ should be adequately
protected.
 7. Testing Frequency

 Testing frequency of stock and tongue rail of SEJ/ISEJs

(except for flange testing by 70° Probe ) shall be same as
that for normal track.

 Testing frequency of stock and tongue rail of SEJ/ISEJs for

flange by 70° Probe shall be once in a year under traffic
block.
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