AT-WELD-TESTSANJEEV.KUMAR.RATHORE.PWAY.ULTRASONIC.TESTING
This document provides detailed information about AT-WELD ultrasonic testing procedures conducted by Sanjeev Kumar Rathore, a Senior Section Engineer in PWAY/USFD/DHG Division, Ahmedabad Western Railway. The testing involves the periodic examination of complete welds by hand probing using various probes with different frequencies and crystal types. The equipment required, scanning methods, defect classifications, and calibration procedures are described in depth. The images included illustrate the different probes and their applications in testing various weld areas for flaws such as lack of fusion, porosity, blowholes, slag inclusions, and cracks. The document outlines the proper use of acoustic couplant, equipment specifications, and defect classification criteria based on flaw signals obtained during testing.
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AT-WELD-TEST SANJEEV KUMAR RATHORE S.S.E./PWAY/USFD/DHG DIV:AHMEDABAD WESTERN RAILWAY PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 1
AT-WELD ULTRASONIC TESTING PERIODIC TESTING OF COMPLETE WELD BY HAND PROBING OF WELD HEAD/WEB AND BOTTOM.FOLLOWING PROBE ARE USED O 2MHZ-DOUBLE CRYSTAL(18MMDIA)-CIRCULAR 70 2MHZ-SINGLE CRYSTAL(20 MM-CIRCULAROR 20X20 MM(SQUARE) 45 2MHZ-SINGLE CRYSTAL( FOR HALF MOON(20MM CIRCULAROR 20X20MM-SQUARE 45 2MHZ(TWO PAIR) TANDEM PROBE SCANNING FOR LACK OF FUSION A PAIR OF TWO 70 2MHZ SIDE LOOKING FOR FLANFE(HALFMOON) COUPLANT :SOFT GEASE/OIL SHALL BE USED AS COUPLANT AS PER SPECIFICATION GIVEN IN PARA4.1(USFD MANUAL) EQUIPMENT: ANY RDSO APPROVED MODEL OF ULTRASONIC EQUIPMENT FOR AT WELD TESTING AS PER RDSO SPECIFICATION NO. N&C/NDT/129/2005 OR ITS LATEST VERSION ALONG WITH RIG FOR TANDEM 1. 2. 3. 4. 5. PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 2
NORMAL PROBE-1 HEAD-WEB- FOOT -SCNNING PROBE=NORMAL (18MM DIA)(CIRCULAR) FREQUENCY=2MHZ MODE=T-R(DOUBLE CRYSTAL) VELOCITY=5920M/S RANGE=200MM PURPOSE= TO DETECT POROSITY,BLOW HOLE,SLAGE INCLUSION IN HEAD AND UP- TO MIDWEB OF THE AT WELD JOINT CALIBRATION=100MM THICK IIW BLOCK,IST PEAK WIIL BE ON 5DIV IN HORI.SCALE SENSITIVITY=3MM DIA HOLE ON HEAD BELOW 25 MM FROM TOPEAK AT=1.15 DIV FSH=60% CONTI . PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 3
NORMAL PROBE-2 PROCEDURE=PROBE SHALL BE PLACED ON THE HEAD OF THE AT WELD JOINT ENSURING PROPER ACOUSTIC COUPLANT. THE PROBE SHALL BE MOVED ON THE WELD CENTRE TO SCANN THE WELD AREA (X)DEFECT CLASSIFICATION :FOR ANY FLAW SIGNAL OBTAINED BY NORMAL PROBE FROM THE HEAD REGION (A) FLAW SIGNAL 40% AND ABOVE AND UP TO 60% TO BE DECLARED AS DFWO (B) FLAW SIGNAL ABOVE 60% TO BE CLASSIFIED AS DFWR (Y) FOR ANY FLAW SIGNAL OBTAINED BY NORMAL PROBE FROM WEB& FOOT LOCATION (A)FLAW SIGNAL OF HEIGHT MORE THAN20% FROM THE WEB OR FOOT AND UP TO 40% TO BE CLASSIFIED AS DFWO (B)FLAW SIGNAL OF MORE THAN 40% FROM THE WEB OR FOOT TREATED AS DFWR (REMARK:IN HEAD =2.75 DIV&IN WEB =3.9 DIV) BACK ECHO PATTERN= FOR 52/60KG WII SHOW ON 7.8 /8.6 DIV PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 4
HEAD SCANNING-1 (70 PROBEE) 1. 2. 3. 4. 5. 6. 7. PROBE=70 DIA=20MMDIA OR 20X20MM(SQUARE) FREQUENCY=2MHZ MODE=SINGLE CRYSTAL(T+R) VELOCITY=3230M/S RANGE=165MM PURPOSE=DETECT LACK OF FUSION,POROSITY,BLOW HOLES SLAG INCLUSION, CRACKS IN HEAD OF AT WELD CALIBRATION=PUT PROBE ON IIW BLOCK ON 100MM THICK & FIND IST PEAK(MAX.HEIGHT) AT 6.06 DIV &SP=100MM CALIBRATION CHECKING=PUT PROBE 25MM ARC CURVATURE & FIND IST PEAK AT 1.51 DIV CONTI . 8. 9. PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 5
HEAD-SCANNING-2 (70 PROBE) 9 . SENSITIVITY=PLACE THE PROBE ON THE RAIL HEAD DIRECTING THE THE BEAM TOWARDS 3-MM DIA DRILL HOLE IN THE HEAD OF THE STANDARD AT WELD TEST PIECE.MOVE THE PROBE IN LONGITUDINALDIRECTION ON THE RAIL SO THAT REFLECTION FROM THE HOLE IS OBTAINED .NOW SET THE HEIFGHT OF THE REFLECTED SIGNAL TO 60% OF FSH 10. TEST PROCEDURE:PLACE THE PROBE ON THE RAIL HEAD ON ONE SIDE FROM180MM FAR FROM AT WELD CENTRE & MOVE ON THREE ZONES TOWARD THE WELD CENTRE IN ZIG-ZAG MANNER.THIS EXERCISE SHALL BE CARRIED OUT FROM BOTH SIDES OF THE WELD 11.DEFECT CLASSIFICATION: (A) A WELDED JOINT SHOWING MOVING SIGNAL OF 40% OR MORE AND UP TO 60% OF FSH SHALL BE CLASSIFIED AS DFWO (B) A WELD JOINT SHOWING MOVING SIGNAL OF MORE THAN 60% OF FSH TO BE CLASSIFIED AS DFWR (REMARK :5 TO 3 DIV =3.6 DIV ON 60%) PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 6
FOOT-SCANNING-1 (70 PROBE) PURPOSE=TO DETECT OF LACK OF FUSION,POROSITY, BLOW HOLE,SLAGE INCLUSION IN FLANGE OF AT WELD 1. PROBE =70 2. DIA = 20MM OR 20X20MM (SQUARE) 3. FREQUENCY=2MHZ 4. MODE=SINGLE CRYSTAL 5. VELOCITY=3230M/S 6. RANGE=165MM 7. CALIBRATION=PUT PROBE ON IIW BLOCK IN THE THICK OF 100MM CURVE & GET IST PEAK(MAX. HEIGHT) ON 6.06&SP=100MM 8. CALIBRATION CHECKING=PUT PROBE ON IIW BLOCK IN FROM OF 25MM CURVE & GET IST PEAK ON 1.51 DIV 9. SENSITIVITY SETTING= PUT PROBE PN MIDDLE OF FLANGE 180 MM FAR FROM THE WELD CENTRE & MOVE THE PROBE TOWARDS THE 3MM DIA HOLE DRILLED IN THE MIDDLE OF FLANGE OF AT WELD .MANIPULATE OF GAIN & GET 60%FSH (APPRX. 4.2 DIV) PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 7
FOOT SCANNIG-2 (70 PROBE) 10.TEST PPROCEDURE=PROBE SHALL BE PLACED ON THE FLANGE AT A SUITABLE POSITION (180MM) FAR FROM WELD CNTRE)MOVE THE PROBE TOWARDS THE 3MM DIA HOLE IN FLANG IN ZIG-ZAG MANNER THIS PROCEDURE WILL REPEAT IN THREE TIMES IN THREE ZONE OF FLANGE (UPEER,MIDDLE& LOWER) DEFECT CLASSIFICATION (a)A WELDED JOINT SHOWING FLAW ECHO OF 40%VERTICAL HEIGHT OR MORE AND UPTO 60% IS TO BE DECLARED AS DFWO (b) A WELDED JOINT SHOWING FLAW ECHO OF MORE THAN 60% VERTICAL HEIGHT IS DECLARED AS DFWR REMRK = A BUNCH OF MOVING SIGNALLESS THAN 40% & MOER THAN 10% SHALL ALSO BE DECLARED DFWR PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 8
SENSITIVITY SETTING NORMAL,HEAD &FLANG PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 9
SIDE LOOKING PROBE-1 (70 PROBE) PURPOSE= TO DETECT OF HALFMOON SHAPED TRANSEVERSE DEFECT WITH A PAIR OF 70 SIDE LOOKING PROBE USING TRANSMITTER RECEIVER METHOD PROBE DIA=20MM OR 20X20MM(SQUARE ) FREQUENCY=2MHZ MODE =T-R(DOUBLE CRYSTAL RANGE=165 VELOCITY=3230MM CLIBRATION= SAME AS 70 PROBE CALIBRATION CHECKING =SAME AS GIVEN ABOVE OF 70 PROBE(SELECT T OR R &CONNECT IT IN MACHINE WITH SINGLE MODE) SENSITIVITY SETTING=CONNECT THE 70 SIDE LOOKING PROBE TO TRANSMITTER & RECEIVER PLACE THE 70 SIDE LOOKING PROBE (TX&TR) ON THE UPPER ZONE OF THE FLANGE AT A DISTANCE OF 85MM ON EITHER SIDE OF FLANGE . ,,,CONT . PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 10
SIDE LOOKING PROBE-2 (70 PROBE) MOVE BOTH PROBE SLOWLY IN ZIG-ZAG MANNER TOWARDS THE WELD UPTO A DISTANCE OF 20MM FROM WELD COLLAR. SET THE SIGNAL OBTAINED FROM HALFMOON DEFCT TO 60% OF FULL SREEN HEIGHT TEST-PROCEDURE PLACE THE TX &TR 70 SIDE LOOKING PROBES AT POSITION AS MENTIONED GIVEN FIGURE & MOVE THE ROBE SLOWLY IN ZIG-ZAG MANNER TOWARDS THE WELD THE POSITION OF TX & TR PROBES FROM A DEFECT SIGNAL MAY VARY DEPENDING UPON THE LOCATION OF HALFMOON DEFECT THIS EXEECISE SHALL ALSO BE DONE FROM OTHER SIDE OF WELD DEFECT CLASSIFICATION: THE DEFECT SIGNAL OF 20% FULL SREEN HEIGHT OR MORE IS TOBE CLASSIFIED AS DFWR PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 11
SENSITIVITY SETTING SIDE LOOKING ARTIFICIAL FLAW POSITION OF S/L PROBE PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 12
45PROBE -1 AT WELD FOOT SCANNING a) PURPOSE=TO INPECT THE CLUSTERED DEFECT/MICRO POROSITY AND HALFMOON SHAPED DEFECT AT BOTTOM OF WELD FOOT PROBE DIA=20X20MM FREQUENCY=2MHZ MODE =T+R(SINGLE CRYSTAL) VELOCITY=3230M/S RANGE 275MM CALIBRATION=PUT THE PROBE ON IIW BLOCK OF THICK 100MM SET MAX. PEAK HEIGHT ON DEPTH 100MM & SET IST PEAK(MAX. HEIGHT) ON 3.6 ON HOIZONTAL SCALE & GET IIND PEAK ON 7.27 DIV ON HORIZONTAL SCALE. CALIBRATION CHECKING= PUT PROBE ON IIW BLOCK ON 25 MM CURVE SIDE & GET MAX PEAK ON DEPTH 25MM (HORIZONTAL SCALE =.90 DIV) ..CONT b) c) d) e) f) g) h) PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 13
45PROBE-2 AT WELD FOOT SCANNIG SENSITIVITY SETTING PLACE THE 45 PROBE ON THE RAIL HEAD SURFACE AT A DISTANCE EQUAL TO HEIGHT OF RAI LFROM THE CENTRE OF THE AT WELD MOVE THE PROBE 20MM EITHER SIDE OF PROBE INDEX MARKING TO PICK UP HALF MOON CRACK IN THE CENTRAL REGION OF WELD FOOT THIS EXECISE SHALL BE CARRIED OUT TWO THREE TIMES FROM EACH SIDE OF THE WELD AND SIGNAL FROM SIMULATED FLAW SHOULD APPEAR AT DISTANCE OF APPROXIMATELY 400MM FOR 52KG RAIL .THIS DITANCE WILL VARY WITH RESPECT TO RAIL SECTION HEIGHT T GET SIGNAL JUST 60% FULL SCEEN HEIGHT .CONT . PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 14
45PROBE-3 AT WELD FOOT SCANNING TEST PROCEDURE PLACE THE PROBE ON THE RAIL HEAD AT ADISTANCE EQUAL TO HEIGHT OF THE RAIL FROM THE CENTRE OF AT WELD CENTRE(PROBE INDEX MARKING THIS TESTING TECHNIQUE WILL SCAN THE BOTTOM OF THE WELD IN THE CENTRAL ZONE THE PROBE SHALL BE MOVED 20MM ON EITHER SIDE OF THE PROBE INDEX MARKING THIS SCANNING SHALL ALSO BE REPEATED FROM OTHER SIDE OF WELD WITH BEAM DIRECTING TOWARDS THE FOOT REGION OF THE WELD DEFECT CLASSIFICATION ANY FLAW SIGNAL OBTAINEDED BY THIS PROBE OF 20% HEIGHT OR MORE SHALL BE CLASSIFIED AS DEFECTIVE WELDED JOINT PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 15
DETECTION OF HALFMOON by 45 PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 16
45PROBE-1 TANDEM RIG PURPOSE= TO DETECT ANY VERTICALLY ORIENTED LIKE LACK OF FUSION IN THE RAIL HEAD ,WEB,&FOOT REGION BELOW/ THIS TEST IS TERMED AS INITIAL ACCEPTANCE TEST PROBE=45 (2NO.) PROBE DIA=20X20MM FREQUENCY =2MHZ MODE=T-R(DOUBLE CRYSTAL) CALIBRATION= SAME AS 45 PROBE SENSITIVITY SETTING=PLACE THE TANDOM RIG ON THE RAIL HEAD AND ATTACH 45DEGREE PROBES SUCH THAT THE BEAM DIRECTIONIS AS SHOWN FIG.ADJUST THE HEIGHT OF REFLECTED BEAM RECEIVED BY RECEIVER PROBE(RX) TO 100% OF FULL SCRRN HEIGHT INCREASE THE GAIN FURTHER BY10DB. THIS GAIN SHALL BEUSFD FOR NORMAL TESTING OF AT WELD BY THIS SET UP .CONT.. PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 17
45PROBE =2 TANDEM PROBE PLACE THE TANDEM RIG ON THE RAIL HEAD UNDER TEST AS SHOWN IN FIG. THE DATUM LINE OF THE RIG SHALL BE IN LINE WITH CENTRE LINE OF WELD TEST THE WELD WITH SENSITIVITY SETTING MANNER THIS EXERCISE SHALL ALSO BE REPEATED FROM OTHER SIDE DEFECT CLASSIFICATION ANY FLAW SIGNAL OF 40% OF FULL SCREEN HEIGHT OR MORE SHALL BE CLASSIFIED AS DFWR TEST PROCEDURE PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 18
SENSITIVITY SETTING TANDEM PROBE PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 19
ACTION TAKEN (DFWO)-1 CLASSIFICATION : DFWO SIGNIFICATION: PAINTING ON BOTH FACES OF WELD(IN HEAD)(ONE CIRCLE WITH RED PAINT) ACTION TAKEN: SSE/JE(PWAY)/USFD SHALL IMPOSE SPEED RESTRICTION OF 30KMPH OR SRICTER IMMEDIATELY AND COMMUNICATE TO SECTIONAL SSE/JE ABOUT THE FLAW LOCATION .WHO SHALL ENSURE THE FOLLOWING ,,,,,,,,,,,,, PROTECTION OF DEFECTIVE WELD BY JOGGLED FISH PLATE MINIMUM TWO TIGHT CLAMPED IMMEDIATELY WITH A SPEED RESTRICTION OF 30KMPH .SPEED RESTRICTION CAN BE RELAXED TO NORMAL AFTER PROTECTION OF DFWO WELD BY A JOGGLED FISH PLATES WITH TWQO FAR END TIGHT BOLTS( ONE ON EACH SIDE ) WITH CHAMPHERING OF HOLES..WITHIN 3 DAYS. THE JOIN IS TO BE KEPT UNDER OBSERVATION PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 20
ACTION TAKEN DFWR-2 CLASSIFICATION :DFWR SIGNIFICATION: TWO CROSS WITH RED PAINT (PAINTING ON BOTH FACES OF WELD IN HEAD) ACTION TAKEN :SSE/JE(PWAY)/USFD SHALL IMPOSE SPEED RESRIVTION OF 30KMPH OR STRICTER IMMEDIATELY AND COMMUNICATE TO SECTIONAL SSE/JE ABOUT THE FLAW LOCATION WHO SHALL ENSURE THE FOLLOWING: PROTECTION OF DFWR WELDBY JOGGLED FISH PLATES USINGMINIMUM TWO TIGHTCLAMPS IMMEDIATELY .SR30KMPH CAN BE RELAXED TO NORMAL AFTER PROVIDING JOGGLED FISHPLATES WITH TWO FAR END TIGHTBOLTS ONE ON EACH SIDE WITH CHAMPHERING OF HOLES.THE DFWR WELD SHALL BE REPLACED WITHIN THREE MONHS OF DETECTION ADEQUATE TRAFFIC BLOCK SHOULD BE GRANTED FOR REMOVAL OF DFWR WELD. IN CASE OF NON REMOVAL WITHIN THREE MONTHS, SR OF 75KMPH FOR LOADED TRAIN AND 100 KMPH FOR PSSENGER TRAIN SHOULD BE IMPOSED PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 21
FREQUENCY OF TESTING AT WELD SR NO. TYPE OF WELD TYPE OF TESTING TESTING SCHEDULED 1. CONVENTIO NAL AT WELD PERIODIC TESTS EVERY 40 GMT 2. ACCEPTANCE TEST IMMEDIATELY AFTER WELDING SKV WELD 3. FIRST PERIODIC TEST AFTER ONE YEAR FURTHER TESTS BASED ON ROUTE GMT ROUTE HAVING GMT FREQUENCY >80 1YEAR >60 80 1 YEAR 4. >45 60 2YEARS 5 >30 45 3YEARS 6 >15 30 4YEARS 7 3/18/2025 0-15 5YEARS PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 22
SOME FACTS ABOUT AT WELD-1 1. CO-AXIAL CABLE FOR EACH PROBE SHALL BE USED. THE LENGTH SHALL NOT BE MORE THAN 2.0METRE 2. COUPLANT IS SHALL BE USED SOFT GREASE & OIL 3. GENERAL CONDITION: THE TOP OF RAIL HEAD SURFACE SHALL BE DRESSED TO OBTAIN REASONABLY FLAT & SMOOTH SURFACE. THE FLANGE OF THE WELD UP TO A DISTANCE OF 200MM ON EITHER SIDE OF THE WELD COLLAR SHALL BE THROUGHLY CLEANED WITH A WIRE BRUSH TO ENSURE FREEDOM FROM DUST, DIRT SURFACE UNEVENNESS 4. BY VISUAL EXAMINATION: ALL THE WELD JOINTS SHALL BE CLEANED AND EXAMINED CAREFULLY TO DETECT ANY VISIBLE DEFECT SHALL BE DECLARED DEFECTIVE PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 23
SOME FACTS ABOUT AT WELD-2 5.A THERMIT WELDING DONE IN SITU SHALL BE JOGGLED FISH PLATED WITH TWO CLAMPED TILL TESTED AS GOOD BY USFD DUE TO UNUSUALLY HIGH WELD FAILURE OR OTHER ABNORMAL DEVELOPEMENT IN SOME SECTIONS CHIEF ENGINEER MAY ORDER TESTING OF WELDS EARLY ,AS PER NEED. 6 THE TESTING INTERVAL OF USFD TESTING OF DEFECTIVE WELDS SHOULD BE REDUCED BY 50% OF NORMAL TESTING INTERVAL OF AT WELDS TO AVOID FRACTURED OF DEFECTIVE WELDS 7.THRPOUGH WELD RENEWAL SHOULD BE PLANNED AFTER THE WELDS HAVE CARRIED 50% OF THE STIPULATED GMT OF RAILS. 8.CHIEF TRACK ENGINEER WILL DECIDE PRORITY BASED ON INCIDENCES OF DEFECT DETECTION AND WELD FAILURE 9..MEASURE THE ACTUAL DISTANCE FROM PROBE INDEX TO CONFIRM IF THE FLAWS SIGNAL IS COMING FROM THE WELD COLLAR/REINFORCEMENT OR FROM THE WELDMENT PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 24
SOME FACTS ABOUT AT WELDS-3 10.OIL OR GREASE SHALL BE USED FOR PROPER ACOUSTIC COUPLING ISTEAD OF WATER 11. MORE THAN ONE DFWO DEFECT IN ONE WELD SHALL BE CLASSIFIED AS DFWR 12. A BUNCH OF MOVING SIGNAL LESS THAN 40% AND MORE THAN 10% IN FLANGE SCANNING SHALL BE CONSIDERED DFWR PRESENTED BY:SANJEEV RATHORE= SSE/PW/USFD/DHG 3/18/2025 25
