Rail Testing and Weld Testing Frequency Guidelines
Discover the detailed guidelines for rail testing and weld testing frequencies, including different types of testing, schedules, and frequencies as per GMT regulations. Learn about the specific testing frequencies for various rail sections within the BZA Division for the years 2015-16. Stay informed about the importance of regular testing to ensure the safety and integrity of railway infrastructure.
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Presentation Transcript
USFD VIJAYAWADA DIVISION
USFD RAIL TESTING WELD TESTING
Types of Rail Testing NBC+GFC Testing as per GMT Winter precaution testing (one round before Oct) > 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 1 yr 9 months 6 months 4 months 3 months 2 months 1.5 months 1 month
Types of Weld Testing New Welds Testing Service 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.3 Type of Testing Testing Schedule Every 40 GMT or 5 Years, whichever is earlier Immediately after Welding 1 Year S.No Type of Weld Conventional AT Weld 1 Periodic Tests 2 Acceptance Test 3 First Periodic Test Further Tests Based on Route GMT Major Bridges & Approaches SKV Weld As per Schedule given below 4 1 Year 5
Frequency for SKV Weld testing As per correction slip No.3 GMT >80 >60 80 >45 60 >30 45 >15 30 0-15 Frequency 1 year 1.5 years 2 years 3 years 4 years 5 years 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 2015-16 Rail Testing Weld TestingGMT DN Frequency 3 Years Rail Testing Weld Testing KM FROM-TO GMT UP SECTION Frequency 2 Months Frequency 2 Months Frequency 2 Years BZA KI 586.50-569.01 42.58 47.85 GDR-VKT 134.300-157.850 2 Months 2 Years 3 Months 3 Years 45.93 37.89 VKT-BTTR 157.850-208.250 2 Months 2 Years 3 Months 3 Years 45.93 37.89 BTTR-TEL 208.250-397.250 2 Months 2 Years 3 Months 3 Years 48.5 34.54 TEL-KCC 397.250-423.710 2 Months 2 Years 3 Months 3 Years 48.5 34.54 KCC-BZA 423.710-428.760 1 Months 1.5 Years 2 Months 2 Years 67.72 47.52 BZA-NDD 428.769-555.780 53.9 2 Months 2 Years 39.5 3 Months 3 Years BZA-NDD UP1/DN1 428.881-429.642 53.9 2 Months 2 Years 39.5 3 Months 3 Years NDD-SLO 555.780-628.330 54.84 2 Months 2 Years 41.7 2 Months 3 Years SLO-DVD 628.330-759.682 44.12 2 Months 3 Years 39.92 3 Months 3 Years SLO-CCT 0.000-12.400 17.16 4 Months 4 Years 10.3 9 Months 5 Years 12.400-16.131 - UP 12.400-15.860 - DN COA-CCT 17.16 4 Months 4 Years 10.3 9 Months 5 Years 94.600-111.130 - UP 94.700-111.130 - DN VKT-KAPT 12 Months 5 Years 4 Months 4 Years 7.73 17.15 GDR-RU 0.000-1.470 3 Months 3 Years 3 Months 4 Years 32.29 28.56 KCC-GNT 25.360-27.120 4 Months 4 Years 6 Months 4 Years 21.20 15.18
Probes used in Rail Testing 0 For central portion of Rail 45 For SEJ & Scabs and Wheel burns (with Test Rig) 70 For Gauge face, Non-Guage face and Central portion of Rail Probes used in Weld Testing 0 Up to central portion of weld 45 For bottom flange center in weld (Halfmoon crack) 70 For head and flange of weld 45 Rig (For New Welds) 70 Side Looking Probes.
DEFECTS DETECTABLE BY VARIOUS PROBES HORIZONTAL FLAWS - 0o PROBE TRANSVERSE FLAWS - 70o PROBE BOLT HOLE FLAWS (Horizontal) - 0o PROBE GFC & NGFC FLAWS - 70o PROBE
RAIL TESTING 0 for central portion of weld 0 4 Mhz Freq. Probe 0 4 Mhz Freq. Probe Rail Weld
Area Covered by Guage Face Corner probe Area Covered by Guage Face & Non Guage face Corner probe
SKV WELD TESTING 0 for central portion of weld 0 2 Mhz Freq. Probe
DEFECT CLASSIFICATION IN SINGLE/DOUBLE RAIL TESTING (RAILS) Non-Reportable Reportable IMR / +++ Mark on either side of Web Classification /Mark Location of defect OBS / + BTV / Mark on either side of Web Horizonta l 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% Probe used Horizontal Vertical Horizontal Vertical Vertical Within Fish plated Area - - - 0 No Back Echo with or without shifting flaw echo for any horizontal length < 20mm Outside Fishplated Area - - Normal track Vulnerable Locations Normal track Vulnerable Locations < 30% < 20% 30% to 50% 20% to 60% 60% 70 Central < 30% < 20% - - 30% 20% < 15% > 20% 15% to 30% 20% to 60% 30% 60% 70 Guage Face & Non- Guage Face - - - - 15% > 20% 15% to 30% Normal track < 15% > 20% 20% to 60% 30% 60% 70 Guage Face & Non- Guage Face Vulnerable Locations - - - - 15% > 20%
DEFECT CLASSIFICATION IN SINGLE/DOUBLE RAIL TESTING (WELDS) Non-Reportable Reportable Classification /Mark OBSW / + IMRW / +++ BTV / Mark on either side of Web Mark on either side of Web Location of defect Probe used Horizontal Vertical Horizontal Vertical Horizontal Vertical Vulnerable Locations No Back Echo with or without shifting flaw echo - - - - 0 No Back Echo with or without shifting flaw echo Normal track - - - - 30% to 50% Normal track < 30% < 20% 20% to 60% 50% 60% 70 Central Vulnerable Locations < 30% < 20% - - 30% 20% 15% to 30% Normal track < 15% > 20% 20% to 60% 30% 60% 70 Guage Face & Non- Guage Face Vulnerable Locations - - - - 15% > 20%
DEFECT CLASSIFICATION IN SKV WELD TESTING Reportable Reportable Classification/Mark DFW (O) / O Mark on either side of Head 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%
Rail Testing: Action to be Taken IMR/ IMRW: SR 30 kmph to be imposed immediately by USFD PWI. It should be clamped with joggled fish plate with in 24 Hrs 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.
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 to Sectional SSE/JE. 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. 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 100 kmph for passenger train should be imposed.
Action to be taken-Contd. as per correction slip No.3 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: 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 2 to 3 mm deep layer from Rail Table in Double crystal Probe and a 6 to 7 mm in single crystal probe can not be tested as it falls in the dead zone of the probe . 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. 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.
CS No.3 to USFD Manual Imp points. Defect at any location which is detected by two or more probes and are considered to be classified as OBS/OBSW based on peak pattern of individual probe, should be classified as IMR/IMRW and action shall be taken accordingly as per Para 6.4. In case two or more OBS/OBSW defects are located within a distance of 4.0 metre from each other, such OBS/OBSW defects shall be classified as IMR/IMRW and action shall be taken accordingly. Sensitivity setting of equipment and probes shall be done every 3 days.
CS No.3 Guidelines for Testing of Tongue Rails For purpose of USFD testing of tongue rails of points and crossings, the tongue rail can be demarcated in three zones as under: Zone-I : This part of tongue rail of point & crossings where full width of rail head is available, shall be covered in normal rail testing using double rail tester. In some of the switches in which guide roller of double rail tester binder the movement of trolley up to full width of rail head part, lower dia of guide roller shall be used. Zone-2 : This part of tongue rail shall be tested manually using 70 /2 MHz , Single crystal probe having crystal size 20 dia. or 20x20 mm square crystal. Zone -3 : This part of the tongue rail shall be examined visually. Classification of defects : The defect classification shall be made as per provisions given in item l(A), 2(A) , 3 (A) and 4(A) of Annexure-II-A of 'Manual for Ultrasonic testing of rails & welds, (Revised-2012) . However, in zone-2 provisions given in item 2(A) and 3 (A) of Annexure-II-A of Manual for U1trasonic testing of rails & welds, (Revised-2012)' shall be applicable. Action to be taken after detection of defects: SE/JE (P.Way)/USFD shall impose speed restriction of 30 Kmph or stricter immediately and to be continued till flawed tongue rail is replaced which should be done within 3 days of detection.
