SANJEEV KUMAR RATHORE SSEPWAYUSFDDHG Divahmedabad WESTERN RAILWAY 18092017 PRESENTED BY SANJEEV RATHORE SSEPWAYUSFDDHG 1 AREA CVERED BY70PROBE 18092017 PRESENTED BY SANJEEV RATHORE SSEPWAYUSFDDHG ID: 699852
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ULTRASONIC TESTING OF RAIL
SANJEEV KUMAR RATHORE
S.S.E/(PWAY)/USFD/DHG
Div:ahmedabad
WESTERN RAILWAY
18/09/2017
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
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AREA CVERED BY70°PROBE
18/09/2017
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
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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 USEDPROCUREMENT OF USFD EQUIPMENTS SHOULD BE DONE ONLY FROM THE RDSO APPROVED SOURCES18/09/2017PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG3Slide4
SINGLE RAIL TESTER
SINGLE RAIL TESTER IS CAPABLE OF TESTING ONLY ONE OF THE RAILS AT A T IME AND IS PROVIDED WITH SEVEN PROBE
O°,70°CENTRAL FORWARD(CF),70°CENTRAL BACKWARD(CB),
70 °GAUGE FACE FORWARD (GF),70°GAUGE FACE BACKWARD(GB) 70°NONGAUGE FACE FORWARD(NGF), AND 70°NON-GAUGE FACE BACKWARD(NGB
)THE NORMAL PROBE IS DETECTING HORIZONTAL DEFECTS IN THE RAIL HEAD,WEB AND FOOT70°PROBE IS FOR DETECTING TRANSVERSE DEFECT IN HEADTHE SIGNAL RECEIVED FROM THE DEFECTS BY ANY OF THE ABOVE PROBE IS INDICATED ON THE SCREEN,IN ORDER TO FIND OUT THE ORIGIN OF DETECTION18/09/2017PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
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DOUBLE RAIL TESTER
THE DOUBLE RAIL TESTER IS CAPABLE OF TESTING BOTH RAILS AT A TIME. FOR EACH RAIL, SEVEN PROBES HAVE BEEN PROVIDED
0°;70°CENTRAL FORWARD(CF) ,70°CENTRAL BACKWARD(CB),
70 °GAUGE FACE FORWARD (GF), 70°GAUGE FACE BACKWARD(GB) 70°NONGAUGE FACE FORWARD(NGF), AND 70°NON-GAUGE FACE BACKWARD(NGB
)THE NORMAL PROBE IS DETECTING HORIZONTAL DEFECTS IN THE RAIL HEAD,WEB AND FOOT70°PROBE IS FOR DETECTING TRANSVERSE DEFECT IN HEADTHE 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
18/09/2017
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
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DETAILS OF FREQUENCY &PROBES
TYPE
FREQUENCY
PROBE
RIGSRTDRTNORMAL 4MHZONEONE FOR EACH RAIL70 CENTRAL2MHZTWO(F+B)TWO(F+B) FOR EACH RAIL70GAUGEFACE2MHZ
TWO(F+B)TWO(F+B) FOR EACH RAIL
70 NONFAUG FACE2MHZ
TWO(F+B)TWO(F+B) FOR EACH RAIL
RIG
2MHZ
TWO
18/09/2017
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
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CALIBRATION&SENSITIVITY SETTING
70°CENTRAL PROBE(F&B)
PROBE DIA=20X20FREQUENCY=2MHZ
MODE=T+R
RANGE=165CALIBRATION=ON IIW BLOCK IST PEAK=6.06CALIBRATION CHECKING=ON IIW BLOCK 25M.M. CURVE ,READ DEPTH= 25M.M.SENSITIVITY=ON SENSITIVITY BLOCK 12 M.M. DIA HOLEF.S.H.=60% HEIGHTREMARK=ADD 10DB GAIN ON SINGLE LINE& D- MARKED RAIL ON DOUBLE/MULTIPLE LINE18/09/2017PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG7Slide8
CLASSIFICATION OF RAIL DEFECT
(70°-CENTRAL) -1
IN TUNNEL &APP., ON MAJOR BRIDGES,APPROACHES(100MM) IN THE VICINITY OF HOLES NEAR THE WELDX..H>
30% V
> 20% =IMR 30%≤H≤100%V<20% =OOTHER THAN LOCATIONH> 50%,V> 60%=IMR H> 50%,60%>V> 20%=OBS 50%>H> 30%,V> 20%=OBS30%≤H≤100%, V<20% =O
18/09/2017
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
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CLASSIFFICATION OF RAIL DEFECTS(70°-CENTRAL)
S/L-D MARKED-RAILS(10DB)-2
VUL. LOCATION0%≤H≤100%,20%≤V≤100%=IMR
OTHER LOCATION50%≤H≤100%,20%≤V≤100%=IMR
0%≤H<50%,20%≤V≤100%=OBS18/09/2017PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG9Slide10
WELD DEFECTS(AT+FB)
PROBE USED
NATURE OF DEFECT
CLASSIFICATION
70°CENTRAL PROBE
ANY TRANSVERSE DEFECT IN THE RAIL HEAD AT THE FOLLOWING 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
H ≥30%,V≥30%
=IMRW
ANY TRANSEVERSE DEFECT
IN
THE
RAIL AT TRACK LOCATION OTHER THAN (A)
H≥50%,V≥50%
=IMRW
H≥50%,60%>V≥20%
=OBSW
50%>H≥30%,V≥30%
=OBSW
18/09/2017
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
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70° GFC&NGC(F&B)
PROBE DIA=20X20
FREQUENCY=2MHZ
MODE=T+R
VELOCITY=3230M/SRANGE=165CALIBRATION=ON IIW BLOCK IST PEAK=6.06CALIBRATION CHECKING=ON IIW BLOCK 25M.M. CURVE SHOW DEPTH=25M.M.SENSITIVITY=ON SENSITIVITY BLOCK ,SET 5MM DIA HOLEFSH=60% FULL SCEEN HEIGHT18/09/2017PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG11Slide12
CLASSIFICATION OF RAIL DEFECTS
70°GF/NGF
IN TUNNEL&APP.,ON MAJOR BRIDGE&APPROACHES(100MM) VICINITY OF HOLESNEAR THE WELD H
> 15%,V>
20%=IMRH> 15%,V<20%=OOTHER LOCATIONH≥30%,V≥60%=IMRH≥30%,60%>V≥20%=OBS30%>H≥15%,V≥20%=OBSH≥15%,V<20%=O18/09/2017PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG12Slide13
WELD DEFECTS(AT+FB
)
PROBE USED
NATURE OF DEFECTCLASSIFICATION
70°GF/NGF
PROBE
ANY TRANSVERSE DEFECT IN THE RAIL HEAD ON GF/NGF AT THE FOLLOWING 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
H ≥15%,V≥20%
=IMRW
ANY TRANSEVERSE DEFECT
IN
THE
RAILHEADONGF/NGF SIDE AT TRACK LOCATION OTHER THAN (A)
H≥30%,V≥60%
=IMRW
H≥30%,20%≤V<60%
=OBSW
15%≤H≥30%,V≥20%
=OBSW
18/09/2017
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
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SENSITIVITY SETTING BLOCK
TOP-VIEW
18/09/2017PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
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SENSITIVITY SETTING BLOCK
SIDE VIEW
18/09/2017
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
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SENSITIVITY SETTING BLOCK
(END VIEV)
18/09/2017
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
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18/09/2017
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
ACTION TO BE TAKEN AFTER DETECTION OF DEFECTS
CLASSIFICATIONPAINTING ON BOTH FACES OF WEB
ACTION TO BE TAKEN
INTERIM ACTION
IMR/IMRW
THREE CROSS WITH RED PAINT
THE DEFECTIVE PORTION SHOULD BE REPLACED
BY A SOUND TESTED RAIL PIECE OF NOT LESS THAN 5.5M LENGTH
( IN CASE OF FISH PLATED TRACK)&
4M LENGTH ( IN CASE OF
WELDED TRACK) WITHIN 3DAYS OF DETECTION
SSE/JE/USFD SHALL IMPOSE SPEED
RESTRICTINOF 30KMPH IMMEDIATEL
Y 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 24HRS
OBS/OBSW
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
SSE/JE/PWAY/ USFD TO ADVICE SECTIONAL JE/PWAY FOR PROVIDING JOGGLED FISHPLATE
WITHIN 24HRS
.
KEYMAN WATCH DURING DAILY THAT LOCATION TILL IT IS JOGGLED
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FREQUENCY OF TESTING
(ALL MAIN LINE B.G.&M.G.)
ROUTE
ROUTE HAVING GMT
TESTING FREQUENCY(ONCE IN)ALL MG ROUTE<2.55YEARS2.5-5.03YEARS>52YEARSALL BG ROUTE ROUTES (Rail Head Centre And Gauge Face Corner Testing≤52YEARS>5≤812 MONTH
>8≤129MONTH
>12≤16
6MONTH
>16≤24
4MONTH
>24≤40
3MONTH
>40≤60
2MONTH
>60≤80
1
-1/2MONTH
>80
1MONTH
18/09/2017
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
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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 CHECK5.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-318/09/2017PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG19Slide20
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 OBSCODE DESCRIPTION211 TRANVERSE FLAW IN HEAD411 TRANSVERSE CRACK IN FLUSH BUTT JOINT412 HORIZONTAL CRACK IN FLUSH BUTT JOINT421 TRANSVERSE CRACK IN I AT WELD422 HORIZONTAL CRACK IN AT WELD18/09/2017PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG20Slide21
CALIBRATION BLOCK
IIW(VI)
18/09/2017
PRESENTED BY SANJEEV RATHORE S.S.E.(PWAY)/USFD/DHG
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