ULTRASONIC TESTING OF RAIL

• SANJEEV KUMAR RATHORE

• S.S.E/(PWAY)/USFD/DHG
• DIV:AHMEDABAD
• WESTERN RAILWAY

PRESENTED BY SANJEEV RATHORE S.S.E.

06/18/2023 1
(PWAY)/USFD/DHG
 AREA CVERED BY70°PROBE

PRESENTED BY SANJEEV RATHORE S.S.E.

06/18/2023 2
(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
PRESENTED BY SANJEEV RATHORE S.S.E.
06/18/2023 3
(PWAY)/USFD/DHG
 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

PRESENTED BY SANJEEV RATHORE S.S.E.

06/18/2023 4
(PWAY)/USFD/DHG
 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

7.

PRESENTED BY SANJEEV RATHORE S.S.E.

06/18/2023 5
(PWAY)/USFD/DHG
 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 2MHZ TWO(F+B) TWO(F+B) FOR
EACH RAIL
70 NONFAUG 2MHZ TWO(F+B) TWO(F+B) FOR
FACE EACH RAIL

RIG 2MHZ TW
O

PRESENTED BY SANJEEV RATHORE S.S.E.

06/18/2023 6
(PWAY)/USFD/DHG
 CALIBRATION&SENSITIVITY
SETTING
• 70°CENTRAL PROBE(F&B)
1. PROBE DIA=20X20
2. FREQUENCY=2MHZ
3. MODE=T+R
4. RANGE=165
5. CALIBRATION=ON IIW BLOCK IST PEAK=6.06
6. CALIBRATION CHECKING=ON IIW BLOCK 25M.M. CURVE ,READ
DEPTH= 25M.M.
7. SENSITIVITY=ON SENSITIVITY BLOCK 12 M.M. DIA HOLE
8. F.S.H.=60% HEIGHT
9. REMARK=ADD 10DB GAIN ON SINGLE LINE& D- MARKED RAIL ON
DOUBLE/MULTIPLE LINE
PRESENTED BY SANJEEV RATHORE S.S.E.
06/18/2023 7
(PWAY)/USFD/DHG
 CLASSIFICATION OF RAIL DEFECT
(70°-CENTRAL) -1
• IN TUNNEL &APP., ON • OTHER THAN LOCATION
MAJOR • H> 50%,V> 60%=IMR
BRIDGES,APPROACHES( • H> 50%,60%>V>
100MM) IN THE
20%=OBS
VICINITY OF HOLES
NEAR THE WELD • 50%>H> 30%,V>
• X..H>30%
20%=OBS
• V> 20%
• 30%≤H≤100%, V<20%
=IMR
=O
• 30%≤H≤100%
• V<20% =O
PRESENTED BY SANJEEV RATHORE S.S.E.
06/18/2023 8
(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

PRESENTED BY SANJEEV RATHORE S.S.E.

06/18/2023 9
(PWAY)/USFD/DHG
 WELD DEFECTS(AT+FB)
PROBE USED NATURE OF DEFECT CLASSIFICATION

70°CENTRAL ANY TRANSVERSE DEFECT IN THE H ≥30%,V≥30%

PROBE RAIL HEAD AT THE FOLLOWING =IMRW
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
ANY TRANSEVERSE DEFECT IN THE H≥50%,V≥50%
RAIL AT TRACK LOCATION OTHER =IMRW
THAN (A) H≥50%,60%>V≥20%
=OBSW
50%>H≥30%,V≥30%
=OBSW

PRESENTED BY SANJEEV RATHORE S.S.E.

06/18/2023 10
(PWAY)/USFD/DHG
 70° GFC&NGC(F&B)
1. PROBE DIA=20X20
2. FREQUENCY=2MHZ
3. MODE=T+R
4. VELOCITY=3230M/S
5. RANGE=165
6. CALIBRATION=ON IIW BLOCK IST PEAK=6.06
7. CALIBRATION CHECKING=ON IIW BLOCK 25M.M. CURVE
SHOW DEPTH=25M.M.
8. SENSITIVITY=ON SENSITIVITY BLOCK ,SET 5MM DIA HOLE
9. FSH=60% FULL SCEEN HEIGHT

PRESENTED BY SANJEEV RATHORE S.S.E.

06/18/2023 11
(PWAY)/USFD/DHG
 CLASSIFICATION OF RAIL DEFECTS
70°GF/NGF
• IN TUNNEL&APP.,ON • OTHER LOCATION
MAJOR • H≥30%,V≥60%=IMR
BRIDGE&APPROACHES(100
• H≥30%,60%>V≥20%=OBS
MM) VICINITY OF
HOLESNEAR THE WELD • 30%>H≥15%,V≥20%=OBS
• H> 15%,V> 20%=IMR • H≥15%,V<20%=O
• H> 15%,V<20%=O

PRESENTED BY SANJEEV RATHORE S.S.E.

06/18/2023 12
(PWAY)/USFD/DHG
 WELD DEFECTS(AT+FB)
PROBE NATURE OF DEFECT CLASSIFICATION
USED
70°GF/NGF
PROBE
ANY TRANSVERSE DEFECT IN THE
RAIL HEAD ON GF/NGF AT THE
H ≥15%,V≥20%
FOLLOWING LOCATION =IMRW
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
ANY TRANSEVERSE DEFECT IN H≥30%,V≥60%
THE RAILHEADONGF/NGF SIDE =IMRW
AT TRACK LOCATION OTHER H≥30%,20%≤V<60%
THAN (A) =OBSW
15%≤H≥30%,V≥20%
=OBSW

PRESENTED BY SANJEEV RATHORE S.S.E.

06/18/2023 13
(PWAY)/USFD/DHG
 SENSITIVITY SETTING BLOCK
TOP-VIEW

PRESENTED BY SANJEEV RATHORE S.S.E.

06/18/2023 14
(PWAY)/USFD/DHG
 SENSITIVITY SETTING BLOCK
SIDE VIEW

PRESENTED BY SANJEEV RATHORE S.S.E.

06/18/2023 15
(PWAY)/USFD/DHG
 SENSITIVITY SETTING BLOCK
(END VIEV)

PRESENTED BY SANJEEV RATHORE S.S.E.

06/18/2023 16
(PWAY)/USFD/DHG
 ACTION TO BE TAKEN AFTER DETECTION OF DEFECTS
CLASSIFICAT PAINTING ON ACTION TO BE TAKEN INTERIM ACTION
ION BOTH FACES OF
WEB
IMR/ THREE CROSS THE DEFECTIVE PORTION SHOULD BE
REPLACED BY A SOUND TESTED RAIL PIECE
SSE/JE/USFD SHALL
IMPOSE SPEED
IMRW WITH RED OF NOT LESS THAN 5.5M LENGTH( IN CASE RESTRICTINOF 30KMPH
PAINT OF FISH PLATED TRACK)&4M LENGTH ( IN IMMEDIATELY T AND TO
CASE OF WELDED TRACK) WITHIN 3DAYS OF BE CONTINUED TILL
DETECTION 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/ ONE CROSS RAIL/ WELD TO BE PROVIDED WITH SSE/JE/PWAY/ USFD TO

ADVICE SECTIONAL
OBSW WITH RED CLAMPED JOGGLED FISHPLATE WIHIN
3 DAYS.SSEE/JE/PWAY/USFD TO JE/PWAY FOR PROVIDING
PAINT JOGGLED FISHPLATE
SPECIALLY RECORD THE OBSERVATION WITHIN 24HRS.
OF THE LOCATION IN HIS REGISTER & KEYMAN WATCH DURING
CHECK IN NEXT TESTING ROUND DAILY THAT LOCATION TILL
IT IS JOGGLED

PRESENTED BY SANJEEV RATHORE S.S.E.

06/18/2023 17
(PWAY)/USFD/DHG
 FREQUENCY OF TESTING
(ALL MAIN LINE B.G.&M.G.)
ROUTE ROUTE HAVING GMT TESTING FREQUENCY(ONCE IN)
ALL MG <2.5 5YEARS
ROUTE 2.5-5.0 3YEARS
>5 2YEARS
ALL BG ≤5 2YEARS
ROUTE >5≤8 12 MONTH
ROUTES >8≤12 9MONTH
(Rail Head >12≤16 6MONTH
Centre And >16≤24 4MONTH
Gauge Face
>24≤40 3MONTH
Corner
Testing >40≤60 2MONTH
>60≤80 1 -1/2MONTH
>80 1MONTH

PRESENTED BY SANJEEV RATHORE S.S.E.

06/18/2023 18
(PWAY)/USFD/DHG
 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

PRESENTED BY SANJEEV RATHORE S.S.E.

06/18/2023 19
(PWAY)/USFD/DHG
 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
• 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

PRESENTED BY SANJEEV RATHORE S.S.E.

06/18/2023 20
(PWAY)/USFD/DHG
 CALIBRATION BLOCK
IIW(VI)

PRESENTED BY SANJEEV RATHORE S.S.E.

06/18/2023 21
(PWAY)/USFD/DHG