Rail Testing and Weld Inspection Procedures in USFD.BZA Division

USFD BZA USFD BOOKLET

USFD TESTING USFD BZA RAIL TESTING WELD TESTING

Types of Rail testing USFD BZA Winter precaution testing (one round before Oct) NBC+GFC Testing as per GMT > 40 GMT Rail Testing(During Test free Period) Switch portion of Point (Once in a year)

Frequency of Testing for Rails on BG routes Route GMT 5 5 - 8 8 - 12 12 - 16 16 - 24 24 - 40 40 - 60 60 - 80 > 80 Frequency 2 yrs 12 months 9 months 6 months 4 months 3 months 2 months 1.5 months 1 month USFD BZA

Types of Weld Testing USFD BZA Service Welds Testing New Welds Testing After One Year of Initial Testing Initially After Execution Periodic Testing as per GMT Bridge Approaches Every year before October

Frequency of AT Weld Testing As per correction slip No.1 S.N o 1 Types of Welds Type of Testing USFD BZA Testing Schedule Every 40 GMT or 5 Year, Whichever is earlier Immediately after Welding 1 Year As per Schedule given below Conventional AT Weld Periodic Tests 2 SKV Weld Acceptance Test 3 4 First Periodic Test Further Tests Based on Route GMT

Frequency for SKV Weld testing As per correction slip No.1 GMT >45 >30 45 >15 30 0-15 Frequency 2 yrs 3 yrs 4 yrs 5 yrs USFD BZA As per correction slip No.2 Incase of welds on Major Bridges & Bridge approaches(100 m on either side) and in tunnels & on tunnel approaches(100 m on either side) . The minimum frequency shall be once in a year.

GMT PARTICULARS OF BZA DIVISION 2014-2015 Rail Testing Weld Testing Rail Testing Weld Testing GMT UP SECTION KM FROM-TO GMT DN Frequency Frequency Frequency Frequency BZA KI 586.50-569.01 46.77 USFD BZA 2 Months 2 Years 47.53 2 Months 2 Years GDR-VKT 134.300-157.850 48.43 2 Months 2 Years 38.4 3 Months 3 Years VKT-BTTR 157.850-208.250 48.43 2 Months 2 Years 38.4 3 Months 3 Years BTTR-TEL 208.250-397.250 48.8 2 Months 2 Years 37.35 3 Months 3 Years TEL-KCC 397.250-423.710 48.8 2 Months 2 Years 37.35 3 Months 3 Years KCC-BZA 423.710-428.760 63.43 1 Months 2 Years 46.49 2 Months 2 Years BZA-NDD BZA-NDD UP1/DN1 NDD-SLO 428.769-555.780 53.9 2 Months 2 Years 38.72 3 Months 3 Years 428.881-429.642 46.77 2 Months 2 Years 47.53 2 Months 2 Years 555.780-628.330 54.26 2 Months 2 Years 40.52 2 Months 3 Years SLO-DVD 628.330-759.682 40.63 2 Months 3 Years 29.49 3 Months 4 Years SLO-CCT 0.000-12.400 12.400-16.131 - UP 12.400-15.860 - DN 18.76 4 Months 4 Years 11.53 9 Months 5 Years COA-CCT 18.76 4 Months 4 Years 11.53 9 Months 5 Years 94.600-111.130 - UP 94.700-111.130 - DN VKT-KAPT 5.01 12 Months 5 Years 9.74 9 Months 5 Years GDR-RU 0.000-1.470 38.98 3 Months 3 Years 31.29 3 Months 3 Years KCC-GNT 25.360-27.120 17.23 4 Months 4 Years 12.97 6 Months 5 Years

GMT PARTICULARS OF BZA DIVISION 2014-2015 Rail Testing Weld Testing SECTION KM FROM-TO GMT SL Frequency Frequency BZA - GDV 0.00-42.69 USFD BZA 13.84 6 Months 5 Years GDV - BVRM 42.69-108.25 10.87 9 Months 5 Years BVRM - NDD BVRM - NDD BYEPASS GDV - MTM 108.25-154.75 7.95 12 Months 5 Years 108.250-154.750 7.95 12 Months 5 Years 0.00-36.74 3.62 24 Months 5 Years BVRM - NS 0.00-29.48 5.22 12 Months 5 Years COA - KPLH 0.00-44.70 0 24 Months 5 Years VKT-KAPT 0.00-2.710 14.75 6 Months 5 Years KCC-BZA IIILN 0.00-18.59 46.49 2 Months 2 Years TEL-GNT SLO-CCT CHORD LINE TEL-REPALLE 0.00-1.90 13.75 6 Months 5 Years 0.0-1.140 11.53 9 Months 5 Years 0.000-1.748 1.43 24 Months 5 Years NDD - SLO IIILINE 574.927-577.574 54.26 2 Months 2 Years

Probes used in Rail Testing 0 for central portion of Rail 45 only for SEJ 70 for Gauge face, Non-Guage face and Central portion of Rail USFD BZA Probes used in Weld Testing 0 for central portion of weld 45 for bottom flange center in weld (Halfmoon crack) 70 for head and flange of weld

DEFECTS DETECTABLE BY VARIOUS PROBES HORIZONTAL FLAWS - 0o PROBE USFD BZA TRANSVERSE FLAWS - 70o PROBE BOLT HOLE FLAWS (Horizontal) - 0o PROBE GFC & NGFC FLAWS - 70o PROBE

Defects in Rail USFD BZA

RAIL TESTING 0 for central portion of weld USFD BZA

Area Covered by 70 central Probe USFD BZA

Area Covered by Guage Face Corner probe USFD BZA Area Covered by Guage Face & Non Guage face Corner probe

SKV WELD TESTING 0 for central portion of weld USFD BZA

70 for head of weld USFD BZA

70 for flange of weld USFD BZA

45 for bottom flange center in weld USFD BZA

DEFECT CLASSIFICATION IN SINGLE/DOUBLE RAIL TESTING For Rail Defects Non-Reportable Reportable IMR / +++ Mark on either side of Web Classification/ Mark OBS / + Mark on either side of Web BTV / USFD BZA Location of defect Probe used Horizontal Vertical Horizontal Vertical Horizontal Vertical No Back Echo with or without shifting flaw echo / with or without multiple echoes for any horizontal length No Back Echo with or without shifting flaw echo for any horizontal length > 20mm 50% Within Fish plated Area - - - 0 No Back Echo with or without shifting flaw echo for any horizontal length < 20mm Outside Fishplated Area - - 30% to 50% 20% to 60% 60% Normal track Vulnerable Locations Normal track Vulnerable Locations < 30% < 20% 70 Central 30% 20% < 30% < 20% - - 15% to 30% 20% to 60% 30% 60% < 15% > 20% 70 Guage Face & Non- Guage Face 15% > 20% - - - - For Weld Defects Non-Reportable Reportable IMRW / +++ Mark on either side of Web Classification/ Mark OBSW / + Mark on either side of Web BTV / Location of defect Probe used Horizontal Vertical Horizontal Vertical Horizontal Vertical

DEFECT CLASSIFICATION IN SKV WELD TESTING Reportable Reportable Classification/Mark DFW (O) / O Mark on either side of Head USFD BZA DFW(R) / ++ Mark on either side of Head Probe used Location of defect Horizontal Vertical Horizontal Vertical No Back Echo with or without shifting flaw echo 0 Probe Within weld - o 2MHz probe (flange 70 testing for AT welds) Head Any Moving Peak 40% Any Moving Peak >60% o 2MHz probe (flange 70 testing for AT welds) Foot Any Moving Peak 40% Any Moving Peak >60% o / 70 (SIDE 45 LOOKING) 2MHz probe (flange testing for AT welds) Half Moon Any Moving Peak >20% 45 / 2MHz (2 Nos) ((For New AT Welds) Head, Foot, Web - - Any Moving Peak 40%

Action to be Taken Rail Testing: Action to be taken IMR/ IMRW: USFD BZA SR 30 kmph to be imposed immediately by USFD PWI. Should be replaced with in 3 days of detection. OBS/OBSW: USFD PWI should advise sectional PWI with in 24 hours. To be clamped with Joggled fish plates with in 3 days, till such time keyman should watch during his daily patrolling.

Action to be Taken Weld Testing: Action to be taken (i)In case of DFW(O) SR 30 kmph or Stricter to be imposed immediately by USFD PWI & communicate Sectional SSE/JE. USFD BZA With SR 30kmph, immediately to be joggled with minimum two tight clamps and SR can be relaxed to normal after joggled fish plating with 2 far end tight bolts within 3 days. Joint is to be kept under observation.

Action to be Taken-Contd. ii) In case of DFW(R) SR 30 kmph or Stricter to be imposed immediately by USFD PWI & communicate Sectional SSE/JE. USFD BZA SR can be relaxed to normal after joggled fish plating with 2 far end tight bolts. Should be removed within 3 months. In case of Non-removal within three months, a speed restriction of 75 kmph for loaded goods train and 100kmph for passenger train should be imposed.

Action to be taken-Contd. As per correction slip No.2 iii) In case of DFW(O) / DFW(R) on Major Bridges & Approaches(100 m on either side) and in tunnels & on tunnel approaches (100m either side), the following action to be taken: USFD BZA Should Communicate to Sectional SE/JE P.Way about the flaw location. Protection of defective weld using clamped joggled fishplate within 24 Hours. Should be removed within 3 days of detection.

Limitation of Ultrasonic Flaw Detection of Rails A 3 mm deep layer from rail Table can not be tested as it falls in the dead zone of the probe . USFD BZA To detect the defect efficiently, ultrasonic beam is to be directed towards the flaw perpendicularly. At fish plated joint, if the cracks are not favorably oriented detection may not be possible. Similarly, if the cracks are propagating vertically downwards or upwards, detection is not possible. cracks lesser than 0.8mm size cannot be detected

Limitation of Ultrasonic Flaw Detection of Rails - Contd Rails having rust, pitting, hogging, battering of rail end, misalignment of joints, scabs, wheel burns and other surface imperfections restrict proper acoustic coupling between probe and rail table and may not permit detection of flaws. USFD BZA In the event of dimensional variations in the gauge and also at sharp curves it is possible that the probes are not properly contacting the rail surface while testing with Double Rail Tester.

AREA NOT COVERED BY USFD IN RAIL TESTING USFD BZA

USFD BZA Thank You