PRESENTATION

ON
INFORMATION REGARDING
USFD TESTING
 BRIEF HISTORY OF USFD TESTING
• Indian Railway started USFD testing of rails in early 60s –having a
rich experience of about 60 years

• First USFD manual issued during 1998 and subsequent revisions in

2006, 2012 and 2022.

• We have been introducing various changes as per the needs (A

Scan-B Scan, 7 Channel-9 Channels) in present scenario of
increase in axle loads.
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 PRESENT SET UP
•There are 9 Teams are working in Jhansi Division under ADEN/Track JHANSI, in
which 18 departmental USFD trained PWI (Two in each team) are deployed.

•Apart from above 17 departmental USFD Trained SSE/JEs are working in

maintenance, time to time these USFD PWIs are deployed with outsourcing USFD
teams apart from their maintenance duties.

•Details of USFD machines available in JHS Division are as under:-

Sr Make Type of Machine No. of Year
. Machine
1 PARAS DRT(A-Scan) 9
7 Probes
2 Modsonic DRT(B-Scan) 1
7 Probes
3 PARAS WT 10
4 Modsonic WT 3

•Proposal of 10 Nos new Digital Ultrasonic SRT machines with 9 Probes (At
HQ) & 10 Nos new Digital Ultrasonic DRT machines with 9 Probes is in under
process.
 Scope of USFD testing

•Total Scope of USFD work in Jhansi Division – 10084 Eqkm,

out of which division achieved 8609 Eqkm (Till 31.01.2023).

•Out of which Departmental teams has done – 5189 Eqkm

(60%), and 3420 Eqkm (40%) done by outsourcing teams.
DEVELOPMENT OF FLAWS IN RAILS

• Development of flaws in rails is inevitable.

• Two main reasons are the inherent defects and fatigue

of rails due to passage of traffic.

• Stresses on Rail are increasing day by day due to

which mechanical properties of rail steel are being
exceeded with passage of wheels.

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 DEFECTS IN RAILS

• SURFACE DEFECTS

• INTERNAL DEFECTS

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 VARIOUS PLANES FOR DEFECT
LOCATION
LONGITUDINAL PLANE

HORIZONTAL
PLANE

TRANSVERSE PLANE

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 CRACK IN HEAD
CRACK IN HEAD
WEB JUNCTION

CRACK IN WEB

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Transverse defect
9
Gauge face corner defect

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Longitudinal Vertical defect

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Star Crack or Bolt Hole Crack

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 TYPES OF USFD MACHINES
Sr. No. Machine name make

1 DRT Double rail tester

2 SRT Single rail tester PARAS, MODSONIC
3 WT Weld tester

Type of TESTING
1. Rail Testing
2. Weld Testing
3. SEJ Testing
4. Turnout Testing
5. Loop Lines Rail Testing
 Ultrasonic Rail Testing Equipment
and accessories
• Procurement of USFD equipments should be done
only from the RDSO approved sources (as per latest
list)

• Maintenance spares should also be procured along

with machine from original equipment manufacturer

• Total life of USFD machine is eight years

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 Single Rail Tester

• Capable of Testing only one rail at a time

• Provided with 7 probes i.e. normal/ 0° (4 MHz), 70°(F) (2

MHz), 70°(B) (2MHz), 70°(GF/F) (2 MHz), 70 ° (GF/B)
(2MHz), 70°(NGF/F) (2 MHz) and 70 ° (NGF/B) (2MHz)

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 Double Rail Tester

• Capable of testing both the rails at a time.

• Probes are same as for SRT.

• Also provided with a threshold arrangement, LED display and

audio alarm .

• Due to frequent misalignment of probes on the fish plated joints

and limitations of detection of bolt hole cracks, it is desirable to
deploy on LWR/CWR sections
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 USFD TESTING AND THEIR PROBES
Type of Probes Scanned area Type of defect
testing
RT 0 degree , 4MHz, d/c Head, web, foot Horizontal
70 degree, 2MHz, s/c Head (gauge, center, non Transverse
gauge)
37 degree, 2 MHz, s/c Web Bolt hole star crack
WT 0 degree, 2 MHz, d/c Head and up to mid web Horizontal, below hole,
pin hole, slag inclusion
70 degree, 2MHz, s/c Head & flange Transverse, below hole,
pin hole, slag inclusion
45 degree, 2MHz, s/c Web & foot web junction Vertical/
Lack of fusion
SEJ 70 degree, 2MHz, s/c Head Transverse
45 degree, 2MHz, s/c Bottom of foot at changing Vertical/
section of S/Rail Lack of fusion
Turn out 0 degree , 4MHz,d/c Head, web, foot Horizontal
70 degree, 2MHz, s/c Head Transverse
Loop Line 0 degree , 4MHz,d/c Head, web, foot Horizontal
70 degree, 2MHz, s/c Head transverse
 INSPECTION AND MAINTENANCE
SCHEDULE OF ULTRASONIC MACHINE
Sr .No. Work to be carried out Schedule

1. Visual inspection of machine and accessories Daily

2. Sensitivity setting of equipment 3 days

3. Calibration of equipment Weekly

4. Characteristics checking Monthly

5. Sensitivity setting based on temperature variation Monthly

6. Repairs and maintenance of electronics and mechanical Half yearly

parts
RAIL TESTING FREQUENCY AND WORKING SEQUENCE
1. Rail testing – manufacturing plant
2. Reduced frequency period
25% of stipulated GMT (rolled after April 1999)
15% of stipulated GMT (rolled before April 1999)
3. Testing frequency in reduced frequency period - on passes of every 40 GMT or 8 years
whichever is earlier
4. (a) Rail Testing Frequency (normal rail testing frequency criteria-8 GMT & higher frequency
corresponding to 6 GMT of traffic is given as under)

Route GMT Testing frequency Cc+8+2t Route’s Frequency For 52

Once in Kg (90 UTS) & Temperature Zone III
& IV – Once in
B.G. <5 2 Year 18 Months
>5 < 8 12 Months 9 Months
>8 < 12 9 Months 6 ½ Months
>12 < 16 6 Months 4 ½ Months
>16 < 24 4 Months 3 Months
>24 < 40 3 Months 2 ½ Months
>40 < 60 2 Months 1 ½ Months
>60 < 80 1.5 Months 1 Months
>80 1 Month 20 days
 FREQUENCY OF AT WELD TESTING

Sr. Types of welds Type of testing Testing schedule

No.
1 SKV Weld Acceptance test Immediately after welding / within a
month (as per IRPWM-2020)
2 First periodic test 20 GMT or one year whichever is earlier

Subsequent test Routes having GMT frequency

(based on route GMT)
3 0 - 15 5 years
4 >15 ≤ 30 4 years
5 >30 ≤ 45 3 years
6 >45 ≤ 60 2 years
7 >60 ≤ 80 1.5years
8 >80 1 year
FREQUENCY OF SEJ ,TURNOUT & LOOP LINES

Items Frequency once in a Reference

SEJ As same as rail frequency USFD MANUAL

TURN OUT As same as rail frequency USFD manual

Zone -1 & 2 of tongue rail as

TONGUE same as rail frequency
RAIL Zone-3 shall be examined
visually
LOOP LINE A route - 1 year L.No.- 219-W/USFD/1/
Other route - 2 years Corresp./NCR/pt –x/dt
23.06.22
 USFD Test Check of ADEN
1. As per IRPWM PARA 103.8 Sectional AEN should spend at least few hours
(min 2 hours) each month during his routine trolley inspection with USFD
team and cross check the work incl accuracy, setting, calibration of machine
etc.

2. For Outsourced work Test Check of 5% by ADENs should be carried out.

 Calibration of Equipment

Probes :- 0o
Calibration :- USFD tester is to be calibrated for 300 mm/200mm
depth range (long wave) with II W (VI) Block on 100 mm
side.
(i) Adjust surface echo at ‘Zero’ using ‘Shift/Delay’ control.
(ii) Adjust Range by ‘H-shift/Delay’ and range’ control
simultaneously to get signals at 3.3/6.7/10 for 300mm
range and 5/10 for 200 range.

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 Calibration of Equipment
Probes :- 70o(F), 70o(B), 70o GF(F), 70o GF(B).

Calibration :- USFD tester is to be calibrated for 300 mm

depth range (long wave)/165mm Shear wave with II
W (VI) Block on 100 mm side.

(i) Adjust surface echo at ‘Zero’ using ‘Shift/Delay’

control.

(ii) Adjust Range by ‘H-shift/Delay’ and range’ control

simultaneously to get signals at 6.0 on 100 mm
curvature.
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Sensitivity setting

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DEFECT CLASSIFICATION AND MARKING
Particular Defect Marking with Location of
red paint marking
Defects IMR XXX Both faces of web
founds
during Rail IMRW XXX Both faces of web
Testing
OBS X Both faces of web

OBSW X Both faces of web

Defects DFWO O Both faces of head

founds
during DFWR XX Both faces of head
Weld
Testing
 ACTION
TAKEN OF RAIL DEFECT
Sr Classification painting on both Action taken Interim action
no faces of web with
red paint

1. IMR/ XXX Rail replace within 1. SSE/JE/USFD shall

IMRW 3 days by a sound impose-SR of 30 kmph
tested rail piece. or stricter till flawed
Min 5.5m length (fish rail/weld replaced.
plated track) 2.Communicate to
4m (welded track) sectional PWI
3.Section PWI - JFP
within 24 hrs.
2. OBS/ X 1. JFP with clamp 1.SSE/JE/USFD - advice
OBSW within 3 days. sectional PWI within 24
2. SSE/JE/USFD - hrs about flaw location.
record the observations 2.Key man – watch till
JFP.
Ultrasonic testing of Alumino-thermic
Welded rails joints
Probes used:

a. Normal (0º) 2 MHz, 18 mm Double crystal.

b. 45º/2MHz, 20mm dia. or 20mmx20mm (square) crystal

size, Single crystal – 2 Nos.

c. 70º/2MHz, 20mm dia. or 20mmx20mm (square) crystal

size, Single crystal – 1 No.

d. 70º/2MHz, Side Looking (SL) Probes – 1 Set

 Standard Test Rail piece
The sensitivity of the ultrasonic equipment shall be
set with the help of a standard AT welded rail piece
of 600 mm length having a simulated flaw at
standard locations.
 Initial USFD Testing of AT Welds
• A thermit welding done in situ shall be joggled fish plated with two clamps
and supported on wooden block of 300 – 500 mm length until tested as
good by USFD.

Defect classification:
Initial testing:
Flaw echo ≥ 30% - DFWN
Periodic testing:
Flaw echo  40% and upto 60% - DFWO
Flaw echo > 60% - DFWR
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• The defective joints (DFWN) based on the criteria shall not be allowed to
remain in service and these joints shall be cropped, re­welded and tested
again. The re-welded joints shall be scanned ultrasonically again with the
same set of acceptance criteria to ensure freedom from any harmful
defects.
 ACTION TAKEN ON DEFECTIVE AT WELDS
Classification Painting on both faces Action taken
(in head) with paint
DFWO One circle 1. SSE/JE/USFD - SR of 30 kmph or stricter
2. communicate to sectional PWI
3. PWI (sectional) ensure -
a. JFP immediately with 2 clamp
b. SR relax after two tight far end bolts within 3 days.

DFWR Two cross 1. SSE/JE/USFD - SR of 30 kmph or stricter

2. communicate to sectional PWI about the flaw location,
3. PWI (sectional) ensure -
a. JFP immediately with 2 clamp
b. SR relax after two tight far end bolts
c. Replacement within 3 months otherwise SR -100 kmph
(passenger) & 75 kmph (goods)

1. SSE/JE/USFD -SR 30 kmph or stricter till

DFWO/DFWR replacement.
(on major bridge, 2.and communicate to sectional PWI
tunnel & Bridge 3.PWI (sectional) - ensure
approach 100m a). JFP with clamp within 24 hrs.
either side) b). Replacement within 3 days
SOME IMPORTANT POINTS FOR RAIL &
WELD TESTING
•Two defects(OBS/OBSW) within 4m - treated IMR.
• Track length less than 200m - not treated test free patch.
( Rly board Track/21/2007/0903/7 dated 10.03.15)
• DRT is to be used for testing of ‘D’ marked rails at reduced interval. In Jhansi Division approx
70 Tkm D- Mark Rail is available in VGLB-MKP route for which testing frequency of Rail is 1.5
month.
•Defective AT welds testing - reduce frequency 50% of normal testing of weld.
• At the vulnerable location ( major and important bridges, & tunnels) AT welds testing- min
once in a year.
• More than one DFWO defect in one weld - classify DFWR.
• Soft grease to RDSO specifi.-WD-17-MISC-92 or WD-24 Misc-2004 /any thick oil of high
viscosity grade (150cst or more) to be used at couplant while testing of AT- Welds.

• Water is used at couplant while testing with SRT/DRT.

Limitation of Ultrasonic Flaw
Detection of Rails
• Equipment utilized incorporates facility only for
specified defects.

• To detect the defect efficiently, ultrasonic beam is to

be directed towards the flaw perpendicularly – the
defect may not be oriented favourably for detection

• A 4 mm deep layer from rail table can not be tested

as it falls in the dead zone of the probe

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 Limitation of Ultrasonic Flaw
Detection of Rails
• In case of hairline or fine central shrinkage (pipe),
negligible drop occurring in bottom signal may remain
unnoticed by the USFD operator.

• Bolt hole cracks can be best detected by 37 deg probe,

which is now available on testing machine. At fish plated
joint, if the cracks are not favorably oriented or are of
smaller size, their detection may be difficult in initial stages.

• Similarly, if the cracks are propagating vertically

downwards or upwards, detection is not possible.

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