Usfd - New Indian Railway

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
MANUAL FOR ULTRASONIC TESTING OF

RAILS AND WELDS
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Revised 2012
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Research Designs & Standards Organisation, Lucknow-226011
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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
MANUAL FOR ULTRASONIC TESTING

OF RAILS AND WELDS
Revised 2012
Including up to CS-No.-4
RESEARCH DESIGNS AND STANDARDS ORGANISATION

LUCKNOW – 226 011
Disclaimer: This Compilation is for educational reference only.

For details refer original correction slips.
i
ii
PREAMBLE
Ultrasonic testing of rails was introduced over Indian Railways during early 60s. From a
humble beginning, this technique has graduated itself to an extent that today it is one of the most
powerful tools of preventive maintenance of the permanent way. During the last 40 years of its
existence, a large number of testing procedures, specifications, guidelines and criteria have been
issued from time to time based on the experience gained. In the meantime, the scope of testing
has been extended to Alumino Thermic (AT), Flash Butt (FB), Gas Pressure (GP) welded joint,
SEJs and Points and Crossings.
The advent of fracture mechanics concept coupled with state of the art steel making
technology has thrown open a new dimension in the periodicity of ultrasonic examination. The
rate of crack propagation and fracture toughness characteristics of rails can be experimentally
found which determine the critical crack size.
Based on the above knowledge and experience, it was considered necessary to assimilate
the entire information on ultrasonic examination of rails and present in the form of a manual so
as to guide the ultrasonic personnel in testing, interpretation and decision-making. Accordingly,
the first edition of the USFD Manual was prepared and issued during 1998. Subsequently, a
revision was issued in 2006 in view of the experience gained in the field of USFD testing and
maintenance practices. In the recent part, USFD tesing machines having state of the art digital
technology have been introduced on Indian Railways and since use of digital USFD testing
machine has been made mandatory on Indian Railways, the USFD Manual also required to be
updated so incorporate the sensitivity setting procedure for digital USFD tesing machines and
other modifications. This revised edition is therefore prepared incorporating all the amendments
and revisions. The provisions made are mandatory for all ultrasonic personnel and supersede all
previous instructions in case they happen to be contradictory to the instructions contained in this
manual. This revised version of the manual incorporates Correction Slip No. 1 to 9 to USFD
Manual (2006).
It is also mentioned here that this manual has been exclusively prepared for manual
ultrasonic examination of rails and welds and does not cover test procedures for self Propelled
Ultrasonic Rail Testing (SPURT) Car.
iii
LIST OF CHAPTERS
S.No. Description Page No.
1. Rail defects and their codification 1
2. Ultrasonic testing of rails at manufacturer’s works 8
3. Ultrasonic rail testing equipment and accessories 9
4. Calibration, Sensitivity setting, Maintenance of machines and functions of 11

probes
5. Procedure to be followed by USFD operators for undertaking ultrasonic 17

testing of rails
6. Need based concept in periodic USFD testing of rails and welds 19
7. Limitations of ultrasonic flaw detection of rails 22
8. Procedure for ultrasonic testing of Alumino-thermic welded joints 24
9. Ultrasonic testing of flash butt and gas pressure welded joints 32
10. Ultrasonic testing of rails required for fabrication of points & crossings 36
11. Ultrasonic testing technique of worn out point and splice rail prior to 38
reconditioning by welding and switch expansion joint
12. Ultrasonic testing of rails by SPURT Car 43
13. Reporting and analysis of Rail/Weld failure 48
iv
LIST OF ANNEXURES
Annexure No. Description Page No.

Annexure I Sketch showing details of standard test piece for ultrasonic testing of 49
symmetrical rail section
Annexure IA Sketch showing details of standard test piece for ultrasonic testing of 50
asymmetrical rail section
Annexure II A Classification of Rail defects for Need Based concept of USFD 51
Annexure II B Classification of Weld defects for Need Based concept of USFD 56
Annexure III Proforma for reporting Rail/ Weld replacement or removal on 59

detection by USFD
Annexure IV Details required for Rail/Weld failure analysis 63
Annexure V Check list of ultrasonic testing of Rails/Welds) 67
Annexure VI Master register for defects detected and Rail fractures 69
Annexure VII Master register for defects detected and Weld fractures 70
Annexure VIII Inspection of rail tester and work of PWI/ (USFD) 71
v
LIST OF FIGURES
Fig no. Description Page no.
Fig. 1 Arrangements of probes for testing of new rails in steel plants 73
Fig. 2A Area covered by Normal (00 )probe 74
Fig. 2B Area covered by 700 probe 75
Fig. 2C Area covered by 700, 2MHz probe (Testing for AT weld flange) 76
Fig. 2D Area covered by700 probes in various Gauge face corner detection equipment 77
Fig. 3 Sensitivity setting block for 700 2 MHz (Centre,gauge face & Non gauge face) probes for testing of rail. 78
Fig. 4 Standard rail with artificial flaws for checking of performance of rai testers. 79
Fig. 5 Rail without flaw (00) probe 80
Fig. 6 Longitudinal horizontal split in head region (type 112, 212, 00 probe) 81
Fig. 7 Longitudinal Horizontal split in head web junction (type 1321-2321, 00 Probe) 82
Fig. 8 Vertical longitudinal split in head (type 113, 213, 00 probe) 83
Fig. 9 Side probing of rail head , without flaw 84
Fig.10 Vertical Longitudinal split in head (00 side probing) 85
Fig.11 Vertical longitudinal split in web (type 133, 233, 00 probe) 86
Fig.12 Side probing of rail web without defect 87
Fig.13 Vertical longitudinal split in the web 00 side probing 88
Fig.14 Segregation (00 probe ) 89
Fig.15 Bolt hole without crack (00 probe ). 90
Fig.16 Bolt hole with crack (type 135, 235, 00 probe ) 91
Fig.17 Transverse defect (type 111, 211, 700 2MHz, forward probe). 92
Fig.18 Transverse defect (type 111, 211, 700 2MHz, backward probe). 93
Fig.19 Undetectable star cracks (00 probe) 94
Fig.20(a) Standard AT welded rail piece with artificial flaws for sensitivity setting of 95
ultrasonic equipment to examine AT welds.
Fig.20(b) Standard AT welded rail piece with artificial flaws for sensitivity setting of 96
ultrasonic equipment to examine 75mm wide gap AT welds.
Fig.21(a) Sketch showing the location of flange of rail for ultrasonic testing with 700, 97
2MHz angle probe.
Fig.21(b) Testing of bottom flange of A.T. welds using 700 and 450 Probes. 98
Fig.22(a) Standard AT welding rail test piece(half moon crack) 99
Fig.22(b) Sensitivity setting using 450 tendem probe. 100
Fig.22(c) AT weld testing using 450 tendem probe. 100
Fig.23 Probe positions for testing of half moon crack with 450 probe. 101
Fig.24(a) Position of 450 angle probes and beam path for various flaw locations when 102
examining the head of G.P & F.B.welds.
Fig.24(b) Position of 700 angle probe and beam path for various flaw locations when 103
examining the web and foot of G.P & F.B.welds
Fig.25 Standard test rail piece for testing before manufacturing of points and crossings. 104
Fig.26 (a) Testing procedure for points and splice rails for 1 in 12 crossing BG 52 Kg. 105
Fig.26 (b) Standard test piece (SEJ stock rail). 106
Fig.26 (c) Beam direction of angle probes for sensitivity setting 107
Fig.27 Detail of probes used for testing of rails and welds. 108
Fig.28 Sensitivity setting/Testing with 450 probe using Test Rig (for locations having scabs/wheel burns.) 109
Fig.29 Sensitivity setting block & ultrasonic scaning of tongue rail of SEJ. (Rail in Plan) 110
Fig.30 Typical signal pattern of bunch of moving signals for AT welds. 111
Fig.31 to 56 Typical rail defects. 112-125
vi
CHAPTER 1
RAIL DEFECTS AND THEIR CODIFICATION
1.0 Rail is the most important and critical component of the permanent way. Most common
cause of rail failure is the fatigue fracture, which is due to imperfections present in the
material or due to crack formation during service. Thus successful performance of rails
is based on their resistance to crack initiation and crack propagation. It is therefore
essential to identify and classify the defects in rails and in turn initiate corrective action.
A brief on nature of defects, their causes and classification is presented below.
1.1 Causes of defects: The origin and development of such cracks is due to:
1.1.1 Material defects originating during the manufacturing process such as clusters of non-
metallic inclusions, hydrogen flakes, rolling marks, guide marks etc. which may be
present in spite of successful non-destructive tests carried out on the rails during quality
assurance examination.
1.1.2 Residual stresses induced during manufacture (cooling, rolling, gas pressing and
straightening).
1.1.3 Defects due to incorrect handling e.g. plastic deformation, scoring, denting, etc.
1.1.4 Defects associated with faulty welding i.e. gas pores, lack of fusion, inclusions, cracks
etc.
1.1.5 Dynamic stresses caused by vertical and lateral loads particularly by vehicles with
wheel flats or when the vehicle runs over poorly maintained rail joints etc.
1.1.6 Excessive thermal stresses due to variation in rail temperature beyond specified limits.
1.2 Defect location: In order to study the fractures in rail systematically, they may be
divided into the following categories based on their location of occurrence in the rail
length:
(a) Defects emanating from the rail end or reaching the end of the rail.
(b) Defects observed within fish-plated zone.
(c) Defects not covered in (a) and (b).
1.2.1 Nature of defects in rails
(a) Horizontal crack in head: These cracks run usually parallel to the rail table at a depth of
10-20 mm and may finally split the material layer. Crushing of the railhead may also be
observed in the vicinity of the crack. Clusters of non-metallic inclusions and abnormal
vertical service stresses are the factors responsible for this defect. USFD can easily
detect such flaws.
1
(b) Vertical-longitudinal split in head: These cracks run parallel to the longitudinal axis of
the rail and are caused by presence of non-metallic inclusions, poor maintenance of joints
and high dynamic stresses. It cannot be easily detected in early stages by USFD due to
their unfavourable orientation.
(c) Horizontal crack at head web junction: Such flaws may lead to rail head separation.
Contributory causes are wheel flats, bad fish-plated joint, inclusions and high residual
stresses. USFD is sensitive to such defects and can easily detect them.
(d) Horizontal crack at web-foot junction: Such cracks develop both towards head and foot.
They are caused by high vertical and lateral dynamic loads, scoring and high residual
stresses. USFD can easily detect these flaws.
(e) Vertical longitudinal splitting of the web: It is primarily due to heavy accumulation of
non-metallic inclusions and wheel flats. USFD conducted from rail top can detect it only
if the defect is severe and in an advanced stage. Vertical longitudinal defects of minor
nature are not amenable to USFD examination conducted from rail top. Probing from
railhead sides can detect such defects for which hand probing may be essential.
(f) Bolt hole crack: Such cracks often run diagonally and may run towards head or the foot.
They result from inadequately maintained joints and unchamfered fish boltholes and
stress concentration. USFD can easily detect these cracks. Normal probes provide
indication as diminished back wall echo.
(g) Transverse fracture without apparent origin: These fractures occur suddenly, especially
during winter and may emanate from microscopic flaws (embedded or on surface) and
are generally very difficult to detect by USFD. These minute flaws manifest suddenly
under severe service conditions or when the fracture toughness values are comparatively
low.
(h) Transverse fatigue crack in head: They resemble a kidney in shape in the railhead and
USFD is ideally suited for detecting them. They are generally inclined at the angle of
18o-23o and originate at a depth of 15-20 mm below the running surface. Mainly
hydrogen accumulation and non-metallic inclusions cause this defect. These cracks are
easily detected by 70o probe.
When such defects are nearly vertical, they can be detected using additional gain of 10db.
Defects lying below scabs/wheel burns can be detected by 45o side probing of rail head.
(i) Horizontal crack at top and bottom fillet radius: These cracks are caused by
accumulation of non-metallic inclusions and high residual stresses introduced at the time
of rail straightening. These are difficult to be detected by USFD.
(j) Vertical – longitudinal crack in foot: Such cracks develop from sharp chamfers on the
bottom surface of the rail foot. Cracks occurring in this way are the points of origin of
transverse cracks in the foot.
2
(k) Transverse cracks in rail foot: Due to localised overheating during FB welding,
structural changes in the bottom surface of the rail material takes place which result in a
minor crack. These cracks under the tensile loading give rise to brittle fracture. Such
defects are not detectable by USFD. Transverse cracks originated from AT welds in the
rail foot grow as half moon and are detectable by 45o probe.
1.2.2 Nature of defects in welds: Joining rails by improper welding may introduce a variety of
defects on the joints as well as in the heat affected zone (HAZ) e.g. lack of fusion, cracks,
porosity, slag inclusion, structural variation, etc. The quality of weld depends to a large
extent on the careful execution of the welding operation. USFD testing done by manual
rail tester suffers from following deficiencies:
(i) Full cross section of weld is not covered by normal USFD examination using manual
tester thereby leaving areas in head and foot, which may have flaws.
(ii) Micro structural variations in the weldment cause attenuation of ultrasonic energy.
Therefore, a separate testing procedure for welds has been developed which is elaborated
in Chapters 8 and 9.
1.2.2.1 Defects in Flash Butt Welds:
(a) Transverse cracks: The origin of these cracks is the imperfection in the weldment such as
lack of fusion, inclusions, etc. Fracture usually occurs from these imperfections, which
may be in railhead, web or foot. During the course of its propagation USFD testing is
extremely effective.
(b) Horizontal cracks: These cracks develop in the web and propagate both in head and foot.
The principal cause is large tensile residual stresses acting in the vertical direction.
1.2.2.2 Defects in Alumino-Thermic (AT) Welds:
(a) Transverse crack in head and foot: It is caused by inclusions entrapped during
welding, which leads to crack initiation on the foot and its growth in the web region
causing fracture. Such cracks can be detected by USFD.
(b) Horizontal cracks in web: These cracks occur in AT welds in which the ends having
bolt holes have not been removed. The presence of holes result in unfavorable stress
distribution caused due to non-uniform cooling. USFD can easily detect such flaws.
1.3 Codification of rail and weld defects: Information regarding the type and nature of rail
failures and their service conditions is primarily obtained through personnel responsible
for maintenance of permanent way and it is of utmost importance that they are familiar
with the various types and nature of rail defects and their possible causes to enable them
to report the rail failures accurately. With this objective in view, it is necessary to devise
a suitable coding system for reporting rail failures.
1.3.1 UIC has adopted an Alphanumeric system of codification of rail failures: In view of
its international status and the facility afforded for computerized statistical data
analysis, this system has been adopted by Indian Railways for reporting rail failures.
3
The code for reporting rail failures consists of two parts viz first – Alphabetic,
consisting of three code letters and second numeric, consisting of three or four digits.
1.3.1.1 First part of the code – Alphabetic

(a) First code letter indicates the type of rail:
O indicates Plain rail

X indicates Point & crossing rail
(b) Second code letter which follows the first code letter, indicates the reasons for withdraw
of rail. Thus,
F indicates Fractured rail
C indicates Cracked rail
D indicates Defective rail other than F&C
(c) Third code letter which follows the second code letter, indicates probable cause of failure
or rail. Thus:
R indicates Cause inherent in rail (attributable to faults in the steel
making stage and / or its rolling into rails).
S indicates Fault of rolling stock
C indicates Excessive corrosion
J indicates Badly maintained joint
M indicates Other maintenance conditions (Defects which develop due
To ineffective maintenance or delayed renewal of rails).
D indicates Derailment
W indicates Associated with welding defects (through or adjacent
Within 100 mm of a welded joint)
O indicates Other causes
1.3.1.2 Second part of the code – Numeric: This part of the code consisting of three or four
digits indicates the location of the failure in the rail as well as its characteristics :
(a) The first digit indicates the location of rail failure (head, web or foot)
(b) The second digit indicates:

(i) The position in the rail section from which failure has started except where failure is
associated with welding.
(ii) In case of welding, the second digit indicates the type of welding.
(c) The third digit is interpreted in relation to the first two digits of the code viz :
(i) If failure is due to internal defect (first digit 4 or second digit 1, 3 or 5), it shows the
direction of the crack or fracture.
(ii) If failure is due to surface defect (second digit 2 or 5), it indicates the nature of
defect.
(iii) If failure is by damage (first digit 3), it indicates the cause of the damage (details
have been given in succeeding pages)
(d) The fourth digit gives further details.
4
1.3.1.3 The summary of codification of rail and weld failures is given as under:
(a) First Part – Alphabetic codes
1st letter 2nd letter 3rd letter

Type of rail Reason for withdrawal Probable cause of failure
O-Plain rail F-Fractured R-Inherent in rail
X-Points & C-Cracked S-Fault of rolling stock
Crossings rail D-Defect other than F&C C-Excessive corrosion
J-Badly maintained joint
M-Other maintenance
conditions
D-Derailment (failure
developed later)
W-Associated with welding
O-Other causes
(b) Second Part – Numeric codes
1st digit 2nd digit 3rd digit 4th digit

Location & Origin/Type i) For internal defects in Further details
characteristics Of welding welding shows direction:
if 2nd digit 1,3,5.
1.Within 0- Unknown 1. Transverse 1. At rail seat

fishplate limit 1.within head 2. Horizontal 2. Not at rail seat
3. Vertical longitudinal 1. Top fillet
2. Bottom fillet
3. Not at fillet radius
2.Other 2. Surface of 5. Diagonal at hole
location rail head 8. Diagonal not at hole
3. In web
5. In foot ii) For surface defects
it shows nature of
defects if second
digit 2,3,5.
0. Corrugation 1. Short pitch
2. Long corner
1. Shallow surface defect 1.Running surface
2. Breaking out 2.Guage corner
3. Crushing continuous 1. Isolated
4. Battering local 2 .Repeated
5. Wheel burns
9. Lap, seam, roll mark
5
1st digit 2nd digit 3rd digit 4th digit
Location & Origin/Type i) For internal defects Further details
characteristics Of welding welding shows direction:
if 2nd digit 1,3,5.
3.Damage 0 1 Brushing or arcing

done 2 Incorrect machining
drilling or flame cutting
4.Associated Type of Direction of fracture

with welding welding
1. Flash butt 1. Transverse
2. Thermit 2. Horizontal
3. Electric arc 5. Diagonal at hole
joint
4. Oxy-acyty- 8. Diagonal not at hole
lene joint
7. Building up
8. Traction
bond
5.Corrosion 0 0
1.3.1.4 On the basis of the system of classification described in para 1.3.1.2, a list of the failure
code group to be followed is given as under, along with the meaning of the codes.
Within fish-plate Elsewhere on rail Description

limits
(1) (2) (3)
100 200 Transverse breakage without apparent origin
(i.e. sudden fracture)
111 211 Internal flaw in head, transverse breakage.
112 212 Internal flaw in head, horizontal crack.
113 213 Internal flaw in head, vertical longitudinal split.
1211 2211 Head, surface, shallow surface defect (flaking)
1212 2212 Head, surface, shallow surface defect (line).
1221 2221 Head, surface, breaking out running surface
(scabbing)
1222 2222 Head, surface, breaking out, gauge corner (shelling)
123 223 Head, surface crushing or battering
124 224 Head, surface local batter
- 2251 Head, surface, wheel burn isolated
- 2252 Head surface, wheel burn repeated
1321 2321 Web, horizontal cracks, at top fillet radius
1322 2322 Web, horizontal crack, at bottom fillet radius
1323 2323 Web, horizontal crack, not at fillet radius
133 233 Web, vertical longitudinal splitting (pipe)
135 235 Web, cracks at hole
- 238 Web, diagonal cracks not at hole.
6
Within fish-plate Elsewhere on rail Description
limits
(1) (2) (3)
139 239 Web, lap.
1511 2511 Foot, transverse break at rail seat.
1512 2512 Foot transverse break starting away from rail seat.
153 253 Foot vertical longitudinal split (halfmoon crack)
301 - Damage to rail by brushing or arcing.
302 - Damage to rail by bad machining, drilling or flame
cutting
411 - Welding,flashbutt joint, transverse crack
421 Welding, thermit joint, transverse crack
422 - Welding, thermit joint, horizontal crack.
431 - Welding, electric arc joint, transverse crack
441 - Welding oxyacetylene joint transverse crack.
471 - Welding, building up transverse cracking of head
across the built up portion.
472 - Welding, building up, built up part breaks away.
481 - Welding, traction bond welding crack, at weld
500 - Corrosion.
1.4 Typical rail/weld failure photographs with their codes are given in Figs. 31 to 56.
7
CHAPTER 2
ULTRASONIC TESTING OF RAILS AT MANUFACTURERS’ WORKS
The defects in rails may be due to manufacturing deficiencies, defects arising during
service or defects generated due to a combination of manufacturing defects and service
conditions. The most important source of defects is the manufacturing deficiencies during steel
making, rolling and subsequent processing.
2.1 Testing methods in Steel Plants : Testing in the Steel Plant is carried out with the help of
an on-line ultrasonic testing equipment having multiple probes covering entire cross-section of
the rail. A typical arrangement of probes is shown in Fig.1.
All these probes are 0o (Normal probes) of frequency varying between 2.5 – 4.0 MHz.
They detect defects oriented perpendicular to the direction of the beam.
2.2 Criteria for acceptance : The criteria of acceptance is as per clause 10 of IRS :T-12-2009
or latest (IRS Specification for flat bottom rails). These are reproduced below:
“10 Freedom from defects
10.1 The rails shall be free from all detrimental defects such as cracks of all kinds, flaws,
piping or lack of metal, etc. having an unfavourable effect on the behaviour of the rail in service.
10.2 The absence of harmful internal defects shall be ensured by the continuous on-line
ultrasonic examination. This examination shall be carried out for all rails under the
responsibility of the manufacturer to the satisfaction of the inspecting agency.
10..3 The manufacturer in his offer shall furnish the detailed method of on-line ultrasonic
testing of rails to be followed by him. The limits of permissible defects for ultrasonic testing of
rails shall be as follows and the standard test piece shall be as shown in Annexure-I &
Annexure-IA.
Head : 1.5 mm dia through hole
Web : 2.0 mm dia through hole
Web & Foot junction : 2.0 mm dia through hole
Foot : 0.5 mm deep, 12.5 mm long and 1.0 mm wide notch

(Inclined at 20o with vertical axis)”
2.3 In case initial testing of rails has not been done in the rail manufacturing plant, the rails
shall be tested either at Flash Butt Welding Plant or at site. In no case rail should be laid in track
without USFD testing.
8
CHAPTER 3
ULTRASONIC RAIL TESTING EQUIPMENT AND ACCESSORIES
3.0 Ultrasonic testing of rails is a specialized activity and the inspectors carrying out the
ultrasonic testing of rails shall be trained by RDSO, in the techniques of USFD testing.
Each Zonal Railway shall create adequate no. of Ex-cadre post of inspectors to ensure that
entire track length in their jurisdiction is ultrasonically tested at the laid down periodicity.
When ultrasonic testing of rails and welds is outsourced to a service providing agency,
compliance to provisions of latest version of Indian Railway Standard Specification for
Ultrasonic Testing of Rails (Provisional) with correction slips issued up to date shall be
ensured.
3.1 On Indian Railways, flaw detection by ultrasonics is carried out with the help of two
different types of equipments viz. Single rail tester and double rail tester. The single rail
tester has been utilised on Indian Railways for over 40 years and the double rail tester is of
a relatively recent origin (developed Ten years back). In addition hand testers of some
designs are also being used. Current list of RDSO approved sources for ultrasonic
rail/weld testers with their respective models, is contained in latest version of ‘Masters list
of approved venders’ circulated bi- annually by Quality Assurance (Mechanical)
Directorate of RDSO. Procurement of USFD equipments should be done only from the
RDSO approved sources.
3.1.1 Total Life of USFD machine is approximately 8 years.
3.1.2 Maintenance spares be procured along with the machine and should be as per para 4.4
pertaining to maintenance spares.
3.2 Single rail tester : Single rail tester is capable of testing only one of the rails at a time
and is provided with seven probes i.e. 0o , 70o Center Forward (C F), 70o Center Backward
(C B), 70o Gauge Face Forward (GF), 70o Gauge Face Backward (GB), 70o Non-gauge
face Forward (NGF) and 70o Non-gauge Face Backward (NGB). The normal probe (0o) is
utilised for the purpose of detecting horizontal defects situated in head, web or foot. The
70o probe has been specifically provided for detecting defects in the rail head, the most
typical of which is the transverse fissure or kidney fracture. The approximate coverage of
the rail section with the help of the above arrangement is indicated in Fig.2A & 2D.
However, this coverage area does not indicate that detect ability of same size of transverse
defect whose nuclei lies within this area at different places will be displayed in same
manner. It will depend upon the size, orientation and depth of the defect.
The signal received from the defects by any of the above probes is indicated on the screen.
In order to find out the origin of detection i.e. which probe has picked up the defect,
provision for displaying the individual probe operation along with audio alarm/LED
display has been made in the equipment.
3.3 Double Rail tester:
3.3.1 The double rail tester is capable of testing both the rails at a time. For each rail, seven
probes have been provided for the present i.e. 0o, 70o Center Forward (C F), 70o Center
Backward (C B), 70o Gauge Face Forward (G F), 70o Gauge Face Backward (G B), 70o
Non-gauge face Forward (NGF) and 70o Non-gauge Face Backward (NGB).
9
The signal received from the defects by any of the probes is indicated on the screen. In
order to find out the origin of detection i.e. which probe has picked up the defect,
provision for displaying the individual probe operation along with audio alarm/LED
display has been made in the equipment.
3.3.2 The normal probe is provided for detection of horizontal defects and 70o probes have been
provided for transverse defects in the head. For detection of bolt hole defects, the
equipment works on the principle of backwall drop, which in the event of a bolt hole
crack shows reduction in echo-amplitude of the backwall. It is also supported by separate
audio alarm with distinctly different tone and LED display.
3.3.3 The introduction of double rail tester has been specifically made for enhancing the
productivity of testing and as well as improving the quality and accuracy of flaw
detection. Due to pre-calibrated arrangement, frequent setting of the equipment is not
considered necessary.
3.3.4 Due to frequent misalignment of probes on the fishplated joints and limitations of
detection of bolt hole cracks having unfavourable orientation and size, it is desirable to
deploy double rail testers on LWR/CWR sections.
It is desirable to deploy only the ‘single rail tester’ ultrasonic testing machine for testing
of sections other than LWR/CWR.
3.4 Specification of rail testers
3.4.1 The single and double rail testers shall be procured to RDSO specification. The
responsibility of inspection for these equipment rests with Director General, RDSO.
3.5 Types of probes: Following types of probes other than mentioned in para 3.2 and
3.3 are also in use. Details of probes and their uses are given at Fig. 27.
450 , 2MHz probe For testing Gas Pressure, Flashbutt Welded rail joints
and half Moon Defect in AT Welds below web foot
junction and SEJ.
Tandem Scanning ( 2 Nos. of 450 probes in a rig) for
detection of lack of fusion in AT welded rail joints.
70o, 2MHz probe20mm circular Flange & Head testing of AT welds
(or 20mm x 20mm square crystal)
700,2MHz Side looking probe Half Moon defect in AT welds below web foot
(SLP) junction.
3.6 Test rig for wheel burnt/scabbed rails:

For detection of transverse flaws in rail head when rail top surface is having wheel
burns/scabs, a test rig with two 450 probes sending beam inward shall be used as shown in
Fig. 28. The distance between probe index marks in the rig shall be adjustable and kept as
134mm and 145mm for 52Kg and 60Kg rails respectively while testing. For other rail
sections this distance can be computed by multiplying rail head width at 20mm from rail
top by 2.
3.7 Tandem rig for AT weld testing :
For detection of vertically oriented defects in AT welds like lack of fusion, a tandem test rig
with two 45o probes shall be used as shown in Fig. 22 (b) and (c).
10
CHAPTER-4
CALIBRATION, SENSITIVITY SETTING, MAINTENANCE OF MACHINES AND

FUNCTIONS OF PROBES
4.1 Rail testing by ultrasonic method shall be carried out by RDSO approved single rail testing
trolley or double rail testing trolley and rig for 45o probes. Details of frequency and number
of each type of probes are as under:
Type Frequency No. of probes

Single Rail Tester Double Rail Tester Rig
Normal/0o 4MHz One One for each rail -

70o (Center) 2MHz Two(F+B) Two(F+B) for each -
rail.
70o(Gauge Face) 2MHz Two(F+B) Two(F+B) for each -
rail
70o(Non-gauge Face) 2MHz Two(F+B) Two(F+B) for each -
rail
45o (Rig testing) 2MHz - - Two
Water is used as couplant while testing with Single Rail Testers/Double Rail Testers. This is
supplied through a water container attached with the trolley. Soft grease to RDSO
Specification No.WD-17-MISC.-92 or WD-24 Misc.-2004/ any thick oil of high viscosity
grade (having viscosity grade of 150 cst or more) is to be used as couplant while undertaking
hand probing of AT welds and deploying 45o probes with test rig for testing rail at scabbed/
wheel burnt locations. The list of approved vendors for soft grease to above mentioned
specification is issued by Quality Assurance (Mechanical) Directorate of RDSO bi-annually.
The same is available on website of RDSO www.rdso.indianrailways.gov.in.
4.1.1 The procedure laid down for ultrasonic testing of rails is broadly divided in the
following steps:
a) Visual inspection of Equipments and accessories
b) Calibration of equipment
c) Sensitivity setting of the equipment and probes
d) Checking of the equipment characteristics
e) Testing and interpretation
a) Visual inspection of Equipments and accessories - Daily check
Ultrasonic equipment is to be inspected daily before start of work as per para 5.1.1.
b) Calibration of Digital USFD: The range calibration in digital SRT/DRT with

multiplexure/ multichannel unit is to be undertaken as follows :
I Calibration for 300 / 200 mm longitudinal wave using 0˚ Double Crystal probe
i. Connect the 0˚ / 4 MHz Double Crystal probe to requisite channel given in multiplexure
or in the unit itself.
11
ii. Select Mode T-R i.e. Double Crystal/ Multichannel mode in Rail Tester having
multiplexure. For multichannel unit, select the calibration set which is required to
calibrate.
iii. Feed the required range i.e 300 mm for rail tester having multiplexure/ 200 mm for
multichannel rail tester.
iv. Put 0˚ Double Crystal probe on IIW (V1) Block after applying couplant at 100 mm
width side.
v. Set Delay and Probe Zero ( in unit having multiplexure ) as per operational manual.
vi. Set first reflected peak at 3.3 div ( if range is selected 300 mm ) or at 5.0 ( if range is
selected 200 mm ) using delay key provided in multiplexure or DELAY parameter
provided in multichannel unit. Place Gate over it . Press measure 0 ( in unit having
multiplexure ) and read the beam path, depth shall be 100 mm.
vii. Second reflected peak will appear at 6.7 & third peak at 10.0 ( if range is selected 300
mm ) or second peak at 10.0 ( if range is selected 200 mm ) .
viii. If last peak is not at 10.0, velocity may be adjusted to set the last peak at 10.0 ( if
velocity control available) or by delay key on multiplexure.
ix. The equipment is calibrated for 300 /200 mm Longitudinal wave for 0˚ Double Crystal
probe.
x. To verify the calibration put probe on top of rail head, the back peak position will be at
5.2 for 52 Kg. rail & at 5.7 for 60 Kg. rail ( if range is selected 300 mm ) or at 7.8 for
52 Kg. rail & at 8.6 for 60 Kg. rail ( if range is selected 200 mm ).
II 165 mm Direct Shear wave calibration for 70˚ / 2 MHz single Crystal Probe
i. Connect the 70˚ / 2 MHz Single Crystal probe to requisite channel given in
multiplexure or in the multichannel unit itself.
ii. Select Mode T-R i.e. Double Crystal mode for rail tester having multiplexure. For
multichannel equipment, select the calibration set and channel required to calibrate.
iii. Feed range 300 mm for rail tester having multiplexure or 165 mm SW for
multichannel unit.
iv. Set Delay and Probe Zero ( in unit having multiplexure ) as per operational manual
v. Put 70˚/2 MHz Single Crystal probe on IIW (V1) Block after applying couplant and
direct the beam towards 100 mm curvature.
vi. Move the probe slightly to and fro to get maximize signal.
vii. Adjust the peak at 6.0 using delay key provided in multiplexure or DELAY parameter
provided in multichannel unit.
viii. Place the gate over this peak, press measure 70 ( in unit having multiplexure ) and read
the beam path it shall be 100 mm.
ix. To verify the calibration, Direct the probe towards 25 mm curvature and maximize the
peak.
x. Put the gate on this peak, the beam path shall be 25 mm.
xi. The equipment is calibrated for 165 mm shear wave.
c) Sensitivity setting of the equipment and probes– Check once every 3 days
The sensitivity of the USFD equipment shall be set up once every 3 days with the help of
standard rail pieces as mentioned below:
Sensitivity (gain) setting: For the sensitivity setting of ultrasonic equipment and the
probes, the following sequence is to be maintained:
12
(i) Place the testing trolley on the standard rail piece having artificial flaws as shown
in Fig. 3 for need based criteria. Check the alignment of probes to make sure that
700 Central probe & 00 probe travel centrally in line with the axis of the rail head
& web. 700 GF & 700 NGF probes shall be aligned towards GF & NGF
respectively at appropriate positions.
(ii) Set the acoustic barrier of the normal probe at right angle to the longitudinal
direction of rail.
(iii) Open the water nozzle and regulate water flow on the probes at an optimum
speed.
(iv) While testing on single line section and ‘D’ marked rails on double / multiple line
section, additional gain of 10db is to be employed.
d) Checking of equipment characteristics– Monthly check
The characteristics of the equipment shall be checked at least once in a month according
to IS:12666 – 88.
The following characteristics shall be checked –
i) Linearity of time base of flaw detector
ii) Linearity of Amplification of flaw detector
iii) Penetrative power
iv) Resolving power
v) Probe Index
vi) Beam angle
In a month all parameters shall be checked with 00/2-2.5 MHz single crystal probe, as per
IS:12666-88 or its latest version.
e) Testing and Interpretation : After sensitivity setting, actual testing of rails is
to be carried out and interpreted for follow up actions.
4.1.2 Checking the function and sensitivity of probes
(a) Normal Probe:
The back wall echo will be adjusted by gain control of USFD tester to 100% of full
screen height and the same shall be taken as reference echo.
(b) Angle probe 70o (Center forward & Center backward):
The equipment shall be able to detect 12 mm dia. hole for need based criteria in the head
portion of the standard rail as shown in Fig. 3 by both forward and backward probes. The
amplitude of the flaw shall be set to 3 div. i.e. 60% of screen height. This adjustment shall be
done by individual potentiometer provided in the junction box.
While testing on single line and ‘D’ marked rails on double/multiple line section,
additional gain of 10dB is to be employed.
Rail defects be classified in accordance with Annexure-IIA, Item 3 (IMR/OBS).
However, when defect signal is exhibited at a weld while testing with increased gain of 10dB,
the classification of defect in accordance with Annexure-IIB, item 2 (IMRW/OBSW) shall be
done based on signal pattern obtained after reducing the gain by 10dB. Thus, increased gain of
10dB for single line and ‘D’ marked rails on double/multiple line shall not be employed for
classification of defect in weld head.
13
(c) Gauge Face and Non-gauge Face Corner probe 70o (Forward and backward):
The trolley is moved on the standard test piece having 5mm Flat Bottom Hole (FBH) made
by use of suitable machine (e.g. Electric Discharge Machine) ensuring truly flat surface on
bottom of the hole as shown in Fig. 3. The beam of 70o forward gauge face and non-gauge
face corner probe is directed to 5mm FBH in rail head. Signals from rail end surface and
5mm FBH will appear on the screen. Move the trolley forward and backward very slowly to
get the maximum signal amplitude from the 5mm FBH and adjust the gain to get 60% of full
height. Same procedure shall be adopted for 700 backward gauge face and non-gauge face
corner probe also.
(d) 45o probe (for locations having scabs/wheel burns):
Machine shall be calibrated for 165 mm range for shear wave in the same manner as per
procedure given at para no. 4.1.1 b) II on the rail of same sectional weight under test. The
test rig shall be placed at 20 mm below rail table on the side of rail head. The transmitter and
receiver probe in the test rig shall be in opposite direction and shall be apart twice the rail
head width. Peak obtained in receiver probe shall be adjusted to full scale height by gain
setting. Testing of rails shall be done by keeping index mark of probe 20mm below rail
table. Testing frequency and classification of defects shall be as per provisions of Para
6.6.1.1 and 6.3 respectively. Note: For 52Kg and 60Kg rails the peak of received signal
shall appear at approximately 95mm (shear wave) and approximately 103mm (shear wave)
respectively.
Note : Procedure to be followed for adjustment in sensitivity setting on account of

variation in rail temperature:
Following procedure shall be used for adjustments in sensitivity setting of Ultrasonic

Rail tester on account of variation in rail temperature before starting the testing of rails.
(a) Switch on the Ultrasonic rail tester and keep the equipment for two minutes for thermal
acclimatization of the component of the equipment before starting the adjustment in
sensitivity setting operation.
(b) In the Morning at 8.00hrs.
(i) Normal Probe: Set the sensitivity of the equipment as per Para 4.1.2(a) and note
the gain required to setup the amplitude of the signal to 60% of full screen height.
(ii) Angle probe 70 degree (Forward and Backward): Set the sensitivity of the
equipment as per Para 4.1.2(b) and note the gain required to set up the amplitude of
the signal to 60% of full screen height.
(iii)Angle Probe 37 degree (Forward & Backward): Set the sensitivity of the
equipment as per Para 4.1.2(c) and note the gain required to set up the amplitude of
the signal to 60% of full screen height.
(iv) Note the rail temperature.
14
(c) After setting the sensitivity of the probes, the ultrasonic rail tester shall be retained on the
standard rail test piece in ON condition and the signal amplitude of individual probe set
as per above procedure, shall be checked on hourly basis. If the drop in the signal is
observed then the drop shall be compensated by applying extra gain with use of gain
control (dB). The height of signal amplitude is maintained to 60% of full screen height.
Note the change in rail temperature from rail temperature at 8.00 Hrs. and corresponding
extra gain used.
(d) Actual Testing: During actual testing on the track, the gain set by the above procedure
shall be maintained depending upon the time and rail temperature during testing. Any
variation in the signal amplitude shall be compensated by giving measured extra gain
(dB) as per step (c) above to carry out ultrasonic testing.
(e) Periodicity of setting the sensitivity: The above procedure for sensitivity calibration
against temperature variation shall be carried out at least once in a month. The
adjustments in sensitivity setting of ultrasonic equipment in respect of gain (dB) shall be
employed accordingly.
4.2 Machine Maintenance- Repairs and Half yearly Schedule
Maintenance: The manufacturer shall guarantee the satisfactory performance of the entire rail
tester system for a period of one year from the date of commissioning of the equipment by the
supplier.
For proper maintenance after expiry of the guarantee period, railway should make proper
arrangements for half yearly repairs of electronic and mechanical parts either under AMC with
the manufacturer of the equipment or may develop suitable departmental facilities.
Each Zonal railway should create centralised depots for carrying out mechanical repairs and
checking the Characteristics of the equipment etc., at least, once in a month.
4.3 Sectional AEN should spent at least few hours (min. two hours) each month during his
routine trolley inspection with USFD team and cross check the working including accuracy/
sitting/calibration of USFD machines. In addition, the SE and SSE (in-charge) should also
associate themselves occasionally.
4.3.1 The officer having technical control over the SE/JE (USFD) shall exercise regular
checks as per Annexure-VIII of USFD Manual once in between two successive half
yearly maintenance schedule carried out in the maintenance depots.
4.4 Spares: The recommended spares for normal maintenance of the equipment are given
below:
Sl. No. Item Number

1. 00 , 4MHz Double crystal probe 8 Nos.
2 00 2MHz Double crystal probe 4 Nos.
3 700 (F&B) Probe 2 MHz Single crystal 8Nos.
4 450 2 MHz Single crystal probe 2 Nos.
5 700 2MHz Single Crystal Probe 6 Nos.
15
6 700 2 MHz single crystal probe SLP 2 Nos.
7 Connecting Cable (Flaw Detector. with junction box) 6 Nos.
8 BNC connector 6 Nos.
9 00 2/ 2.5 MHz Single Crystal Probe 2 No.
10 Battery charger 1 no.
11 IIW Block (as per IS: 4904) 2 per depot
12 60x50x50 mm steel block ( as per steel grade 45C8 to
1 No.
IS:1875-1992)
13 Fuse 12 Nos.
14 Step gauge 1 No.
Besides the above, the “spare” shall also include probe holder, probe shoes, wheel drum and
wheel tyre. The procurement of spares for a machine shall be done from Original Equipment
Manufacturer (OEMs) of that machine only, in order to ensure compatibility of spares with the
machine and to achieve consistent and assured quality of testing. However, mechanical spares
of trolley, standard items such as, battery, battery charger etc. can be procured from open market
also. Spare batteries shall be arranged as and when expecting back up time of battery becomes
low.
4.5 Defects detectable by different probes
a) 0o / Normal probe
i) Horizontal split in head due to presence of seams (type 212)
ii) Horizontal split in head-web and web foot junction due to presence of rolling seams
(type 2321, 2322)
iii) Vertical longitudinal split in rail head and web due to presence of internal seams and
pipes (type 213, 233)
iv) Bolt hole crack (type 135, 235)
v) Segregation in head and web junction
vi) Flakes (type 1211, 2211)
vii) Web-lap (type 239)
b) 700 angle probe

i) Transverse fissure (type 211) due to presence of mostly shatter cracks and some time
due heavy inclusions.
ii) Transverse cracks originating from surface defects like scab (type 1221, 2221)
iii) Wheel burns (type 2251, 2252)
iv) Shelling cracks (type 1222, 2222)
c) 45o angle probe

i)Transverse cracks lying below scabs/ wheel burns”
Typical indications received for various types of defects are indicated in Fig. 5 to 18.
(For 52 Kg. rail section, 300mm. depth range, longitudinal wave calibration).
16
CHAPTER 5
PROCEDURE TO BE FOLLOWED BY USFD OPERATORS FOR

UNDERTAKING ULTRASONIC TESTING OF RAILS.
5.1 USFD operators must adhere to the following instructions:
5.1.1 Before testing
(i) Check the battery condition before start of work .Only fully charged battery is to be used
during testing.
(ii) Check proper functioning of all controls of electronic unit i.e. depth range, gain, reject
etc.
(iii) Check proper functioning of trolley and probes.
(iv) Check junction box, water outlet, probe cable contact and ensure smooth movement of
trolley wheels.
(v) Maintain proper gap between probing face and probe shoe (0.2 mm). Check with the
help of a feeler gauge.
(vi) Check probe alignment by keeping the rail tester on the rail.
(vii) Calibrate the instrument weekly as per procedure given in para 4.1.1(b).
(viii) Set the equipment for proper sensitivity as per para 4.1.1(c).
5.1.2 During testing
(i) Conduct test as per procedure mentioned in Chapter 6.

(ii) Maintain proper alignment of all probes during testing, otherwise false echoes may
appear.
(iii) Ensure adequate supply of water for coupling.
(iv) Check proper functioning of 70o probes by touching the probe bottom with fingers.
Noise pattern should appears on the screen.
(v) Look out for back wall echo corresponding to normal probe throught testing.
(vi) Lift the machine at crossings/change of rail table height at joints to protect the probes.
(vii) Mark the locations found defective as per classification.
5.1.3 After testing
(i) Maintain proper record of testing, observations, echo pattern and echo amplitude
of defects in the register in the following format. The details should be supplemented
with A-scan recorded during testing.
17
Section S. Loca- Roll- Rail/we Defect Defect Nature Echo Classification Remar
Line… No. tion ing ld No.& position indicated of echo amplitude/ ks
Km from (Km) mark LH/RH (head/ by (00/700 (shift/fi Travel
Km to…. web/foot) /450Probe) xed) Previ Prese Previo Present
Dateof ous nt us
testing…
(ii) Charge the battery after every day’s work.
IMPORTANT
YOUR ULTRASONIC TESTER IS A DELICATE ELECTRONIC EQUIPMENT. TAKE

ALL POSSIBLE CARE DURING HANDLING, TRANSPORTATION AND STORAGE
TO AVIOD IMPACT, DAMAGE, ETC. LUBRICATE MECHANICAL PARTS
PERIODICALLY AND CHARGE BATTERY REGULARLY.
18
CHAPTER 6
NEED BASED CONCEPT IN PERIODIC USFD TESTING

OF RAILS AND WELDS
6.1 Introduction: Safety against failures of rails in track depends upon the inspection
frequency and the permissible defect size, other factors like rail metallurgy and loading
conditions remaining same. To extract maximum service life out of the rails while ensuring
safety, the inspection frequency has to be increased so that the rails are allowed to remain in
track for longest possible period. At the same time, frequent watch over increasing incidence of
defects is necessary. However, very high frequency of inspection as a general measure is not
always practicable as cost of inspection becomes prohibitive.
The optimum cost of maintaining rails in track can, therefore be achieved if the
inspection frequency is made dependent on the incidence of the defects. In such a concept of
need based inspection, on sections where the number of defects detected is low, the inspection
frequency is also kept low whereas on sections where the number of detected defects is high the
inspection frequency also gets increased. The advantages of such a concept are obvious because
the inspection resources are not unnecessarily frittered away on sections where the condition of
rail is sound and its performance in track does not warrant frequent inspection.
Introduction of Need Based Concept of USFD has necessitated changes in the areas of
classification of defects, frequency of inspection, detection equipment, organization, etc. In the
following paragraphs these aspects are discussed.
6.2 Basis of change in criteria for defect classification: The inspection frequency and
condemning defect sizes are related parameters. If the inspection frequency is high, the
condemning defect size can be suitably increased. Increase in condemning defect size also
enhances the reliability of inspection, as chances of non-detection for smaller size defects are
high. In the existing criteria which was evolved more than 25 years back, the condemning
defects size, especially for OBS defects was kept very small. Now with 25 years of experience
behind us in the area of USFD testing of rails and also the findings of studies in crack
propagation mechanism conducted at RDSO, a more rational condemning defects size has now
been specified. As a result, in the revised criteria to be used for need based USFD inspection,
only IMR and OBS categories exist. The effect of this revision is to rationalise and suitably raise
the condemning defect size in view of the higher frequency specified for inspection.
6.3 Classification of rail defects: Defects detected during through USFD testing of rail
shall be classified as per Annexure-II A. However visible defects on rails/ welds shall not be
clarified by USFD personal and the same shall be recorded & brought to notice of sectional PWI
for further remedial action.
6.3.1 Any defect or defect at any location which is detected by two or more probes and are
considered to be classified at OBS/OBSW based on peak pattern of indivisual probe , should be
classified as IMR/IMRW and action shall be taken accordingly as per para 6.4
6.3.2 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 as per para 6.4.
19
6.4 Action to be taken after Detection of defects: Following action shall be taken in
respect of defective rails & welds:
S. Classifi- Painting on Action to be taken Interim action

No. cation both faces of
web
1. IMR Three cross The flawed portion should be SE/JE(P.Way)/USFD shall impose
IMRW with red paint replaced by a sound tested rail speed restriction of 30 Kmph or stricter
piece of not less than 5.5m immediately and to be continued till
length (in case of fish plated flawed rail/weld is replaced.
track) & 4m (in case of welded He should communicate to sectional
track) within 3 days of SE/JE(P.Way) about the flaw location
detection. who shall ensure that clamped joggled
fish plate is provided within 24 hrs.
2. OBS One cross with Rail/weld to be provided SE/JE(P. Way)/USFD to advise

OBSW red paint with clamped joggled fish sectional SE/JE(P. Way) within 24 hrs
about the flaw location.
plate within 3 days. Keyman to watch during daily
SE/JE(P. Way)/USFD to patrolling till it is joggled fish plated.
specifically record the
observations of the location
in his register in
subsequent rounds of
testing.
6.5 AT/FB/GP weld defect classification
6.5.1 Defects detected by 00/ 4 MHz double crystal probe & 700/ 2 MHz single crystal probe
during through rail testing for defects detected in AT/FB/GP welds shall be classified as per
Annexure-II B.
6.6 Frequency of testing of rails and welds: In view of the revised criteria of defect mentioned
in Para 6.2,the testing frequency of 8 GMT has been prescribed. Based on the same, testing
schedule of rails/welds as laid clown in Para 6.6. l. l shall be followed.
6.6.1 After the initial USFD testing of rails in rail manufacturing plant, the subsequent USFD
testing needs to be carried out at reduced frequency until the rail have undergone 15% of the ..
service life in GMT as given below (para 302(i) (d) of IRPWM):
For rails rolled in April 1999 and later, the reduced frequency shall be 25% instead of 15%.
Gauge Rail Section Assessed GMT Assessed GMT
service life for T.12 service life for T-12
72 UTS rails 90 UTS rails
B.G. 60Kg 550 800
52Kg 350 525
90 R 250 375
M.G. 75 R 150 -
60 R 125 -
20
Rail testing during reduced frequency testing period is to be done using all probes (as
given in para 4.1) as is being done during normal testing frequency period on passage of every 40
GMT traffic or Eight (08) years, whichever is earlier.
Whenever, rails are not tested in rail manufacturing plant, the reduced frequency testing
period shall not be applicable and the rail testing shall be done immediately after its laying in field
and thereafter at the periodicity given in table under para 6.6.1.1 • (CS-No. 4)
6.6.1.1 Frequency of testing for all Main line BG (rail head center and gauge face /
non-gauge face corner) and Main line MG routes is given as under: For other sections
Chief Engineer of the Railway may adopt a frequency at his discretion.
Route Routes having GMT Testing frequency
Once in
All MG routes < 2.5 5 years
2.5 – 5.0 3 years
>5 2 years
All BG routes (rail head <5 2 years

center and gauge face
corner / non-gauge face
corner testing)
>5 <8 12 months
> 8 < 12 9 months
> 12 < 16 6 months
> 16 < 24 4 months
> 24 < 40 3 months
> 40 < 60 2 months
>60< 80 1½ months
>80 1 month
Digital double Rail Tester is to be used for testing of ‘D’ marked rails at reduced interval
to be decided by Chief Track Engineer of Zonal Railway.
6.7 Equipment: RDSO approved rail testing equipment shall be employed for conducting
ultrasonic examination. Both single as well as double rail testing equipments are suitable for this
purpose.
6.8 Check list of Ultrasonic Testing of Rail/Welds:
A check list for the officials inspecting the quality of work being done by the Inspectors
carrying out Ultrasonic Testing of Rails/Welds is placed at Annexure – V.
21
'Additional Policy Instructions 011 Ultrnsonic testing of mils & welds, to be read iu couj unctiu u
with Manual for lJHrasouic testing of rails & welds (Rcvised-2012)'
' I. Frequency of testing of rails and AT welds has been prescribed in Para 6.6 and 8.15.2 respectively of
Manual for Ultrasonic testing of rails & welds (Revised-2012). As a trial preventive measure to reduce
the number of rail failures during reduced testing frequency period and v,1 eL\ failures i!l initial period,
Ultrasonic testing of rails and welds shall be done at frequency prescribed below. This will be valid for a
period of two years, i.e. upto 31.08.2020.
l. 1 Frequency of USFD for all BG and MG routes shall be as under in place of table given in Para 6.o.1.1
of Manual. For other sections, Chief Engineer of the Railway may adopt a frequency at his discretion.
A B C D
Route Route having USFD Testing Frequency during USFD Testing Frequency
GMT the "Reduced frequency testing (Other than during reduced
Period" (As defined in Para frequency testing period) once
6.6.1 ), once in 111
AIIMG < 2.5 8years 5 years

routes 2.5 - 5.0 4vears 3 years
>5 3years 2 years
All BG �5 4 years 2 years
routes >5 <8 30 Months 12 months
> 8 < 12 20 Months 9 moi1ths
>l 2:Sl6 15 Months 6 months
> 16 < 24 10 Months 4 monthr;
> 24 < 40 6 Months 3 month$
> 40 < 60 4 Months 2 monthi;
> 60 < 80 3 Months 1 ½_months
> 80 2 Months 1 month
--··
--
'
CHAPTER – 7
LIMITATIONS OF ULTRASONIC FLAW DETECTION OF RAILS
7.0 Every scientific method/technique/equipment functions on certain principles and its

applicability depends upon fulfillment of preconditions necessary to be satisfied. It accordingly
implies that USFD examination is based on certain guiding principles and its flaw detection
success depends upon thorough understanding of the governing factors.
Thus, the limitations being mentioned are not per-se the deficiency of the USFD
technique rather in the existing arrangement under field conditions the equipment utilised
incorporates facility only for specified defects. This aspect may be kept in view and the
technique is to be pursued accordingly.
Limitations in respect of rail examination considering the various arrangements presently
available have been elaborated below. It may also be mentioned here that limitations with regard
to AT welding i.e. defects in web foot junction half moon cracks, vertical defects in web portion
etc. are no longer limitations of the USFD equipments since in the newly developed equipment
special probes have been provided for detection of these defects.
7.1 (i) To detect the defect efficiently, ultrasonic beam is to be directed towards the flaw
perpendicularly, otherwise, the reflected beam may not be received by the receiver
crystal, resulting in absence/reduction in amplitude of flaw signal in the CRT. Cracks
normally have facets and hence even under misorientation provide reflecting surfaces
leading to flaw indication.
(ii) For detection of defects in rails, probes having incidence angle 0o, 70 o (F), 70 o (B) have
been provided in the USFD trolley. The angles have been choosen in a manner so as to
detect defects which are generally observed during service and have been the cause of rail
fractures.
The section of rail which is scanned by each type of probe has been indicated in Fig.
2A, 2B, 2C and 2D.
For detection of defects originating from Gauge Face and Non-gauge Face Corner, a
dedicated test set-up has been developed. This set-up includes three 70 o probes covering
approx. the full width of the rail head and a set of two 45 o probes. The area scanned by
this arrangement is shown in Fig.2D. A defect located at 5mm from the corner is
detectable using this equipment
All commonly observed defects in rails are detectable by the above arrangement. In the
event of gross mis-orientation of defect at times it may not be amenable for detection,
however such situations are rare.
(iii) Severe pipe in the rail may give indication of flaw echo by 0 o probe, But in case of
hairline or fine central shrinkage (pipe), negligible drop occurring in bottom signal may
remain unnoticed by the USFD operator. (Ref Fig. 8 & 11 )
(iv) For detection of bolt hole cracks, 37 o probes are ideal. This is because the cracks
emanating from bolt holes are generally oblique and propagate in the zig-zag manner.
However, the present SRT/DRT machines have not been provided with 37 o probes due to
limitation of number of channels and detection of bolt hole cracks is accomplished by
normal probe. These cracks are detectable by 0 o probe since they obstruct the path of
sound waves and lead to drop/loss of back wall echo.
22
If the cracks are so located that they are unable to be scanned by 0o probes due to
smaller size or orientation, such cracks may not be detected in initial stages of their
development.”
(v) If sensitivity of the machine is poor or battery gets discharged the operator may miss the
flaw signal. Hence, it is essential to ensure full charging of the battery.
(vi) The ultrasonic probes used in the rail testers have a frequency of 4MHz (longitudinal
wave) and 2MHz (transverse waves). Therefore, cracks lesser than 0.8mm size cannot
be detected by the present arrangement.
The sizes and frequency of the probes employed in the single rail tester/double rail tester
are as under.
S.No. Probe type Size of Crystal Shape of Frequency

crystal
1 0o (Double crystal) 18mm Circular 4MHz
or
18mm x 18mm Square
o
2 70 (Single crystal) 20mm Circular 2MHz
or
20mm x 20mm Square
(vii) 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.
When ever such defects are encountered, loss of back wall echo or an alarm signal is
obtained. This indicates that defects if any below these patches may remain undetected.
Under such circumstances hand probing may be done.
7.2 Testing of SEJs, points and crossings
Due to specific shape on some portion of these components, it is difficult to achieve
proper space for acoustic coupling for testing. Therefore testing of these components is
to be undertaken as per procedure laid down in chapter 10 & 11.
7.3 Testing on sharp curves, gradients, slack gauge etc.
The USFD trolley has been designed to operate under normal conditions of gauge. 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. This is indicated by loss of backwall
echo or also by alarm provided in DRTs for backwall drop. Wherever it is not possible to
ensure proper acoustic coupling due to these reasons, testing by hand probing or by
single rail tester may be resorted to. Acoustic coupling needs to be ensured under all
circumstances to detect the flaws.
7.4 Testing with test rig comprising of 450 probes is effective when the sides of rail head are
nearly vertical. In case of badly worn faces of rail head the quality of result may not be
appropriate.”
23
CHAPTER 8
PROCEDURE FOR ULTRASONIC TESTING OF ALUMINO- THERMIC WELDED
RAIL JOINTS
8.1 Scope:
Following types of testing for Alumino Thermic (AT) welds have been prescribed.
These are:
a) Testing of weld head/web, which gets covered during through periodic rail
testing by SRT/DRT as per Para 6.6. The frequency of testing in this case is
as per Para 6.6.1.1. As per this testing defects detected in weld heads are
classified as ‘IMRW’ and ‘OBSW’ vide Annexure II B. The action to be
taken for such defective welds is as per Para 6.4.
b) Periodic testing of complete weld by hand probing of weld head/web and
bottom flange, using 00 2MHz, 700 2 MHz, 45o 2 MHz probe (AT weld foot
scanning for half moon shaped defect) and 700 2 MHz SL probes. The
frequency of testing in this case is as per Para 8.15.1. As per this testing
defects detected in welds are classified as ‘DFWO/ DFWR’. The action to be
taken for such defective welds is as per Para 8.14.
c) Besides this, welds are also tested after their execution using 00 2MHz, 700
2MHz, 45o 2 MHz probe (AT weld foot scanning for clustered defect/ micro
porosities in web foot region) and 45o 2 MHz (Tandem probe scanning for
lack of fusion). This test is termed as Initial Acceptance Test. As per this
testing, defects detected in welds are classified as ‘DFWO/ DFWR’. The
action to be taken for such defective welds is as per Para 8.10.”
This Chapter covers the requirement of complete ultrasonic testing of Alumino-
thermic welded rail joints by hand probing immediately after execution of the
weld described at c) above and for periodic examination of complete weld
described at b) above only.
8.2 Apparatus required:
8.2.1 Equipment: Any RDSO approved model of ultrasonic equipment for Alumino-
thermic welded rail joints as per RDSO specification No. M&C/NDT/129/2005 or
its latest version along with rig for tandem testing.
8.2.2 Probes: The following probes having Lead zincronate- titanate crystal shall be
used for Ultrasonic testing of Alumino-thermic joints.
a) Normal ( 0° ) 2 MHz, 18 mm. φ Double crystal.
b) 45°/ 2 MHz, 20mm.dia. or 20mm.x20 mm.( square ) crystal size, Single
crystal –2 no.
c) 70°/2 MHz, 20mm.dia. or 20mm.x20 mm. ( square )crystal size, Single crystal
- 1 no.
o
d) A pair of two 70°/2 MHz probes inclined at 20 side looking with respect to
usual beam path. Side looking angle of both probes shall be in opposite
direction to each other
.8.2.3 Cables: Co-axial cable for each probe shall be used .The length shall not be
more than 2.0 metre.
8.2.4 Couplant: soft grease/oil shall be used as couplant as per specification given in
para 4.1.
24
8.3 General Condition: After execution of AT weld, welded zone shall be dressed
properly to facilitate placement of probes and to avoid incidence of spurious
signal on the screen. The top of rail head surface shall be dressed to obtain
reasonably flat and smoo th surface. The flange of the weld up to a distance of
200 mm. on either side of the weld collar shall be thoroughly cleaned with a wire
brush to ensure freedom from dust, dirt, surface unevenness etc.
8.3.1 Visual Examination : All the welded joints shall be cleaned and examined
carefully to detect any visible defects like cracks, blow holes. Any joint which
shows any visible defect shall be declared defective.
8.4 Sensitivity setting procedure:
8.4.1 Standard test rail: The sensitivity of the ultrasonic equipment shall be set with
the help of a standard AT welded rail piece of 600 mm (300 mm rail each side of
joint ) length having a simulated flaw at standard locations as shown in Fig.20 (a).
The standared AT welded rail piece shall be preferably of same AT welding
technique & welding agency which are to be tested in field to avoid confusion of
signals from weld profile.
8.5 0°°/2 MHz, Double crystal Normal Probe:

This scanning is used to detect Porosity, Blow hole, Slag inclusion in head
and up-to mid web of the AT welded joint.
8.5.1 Calibration: Following procedure shall be adopted for calibration of 00 2 MHz double
crystal probe
i. Select range 300 mm with range control key.
ii. Select Mode T-R i.e. Double Crystal mode.
iii. Set Delay 0.
iv. Set Probe Zero 0.
v. Feed longitudinal wave velocity (5920 m/s) / Press measure 0 key.
vi. Feed angle 00.
vii. Connect 0˚ Double Crystal probe and put it on IIW (V1) Block after applying couplant
at 100 mm width side.
viii. Set first reflected peak at 3.3 div. using probe zero. Place Gate over it and read the
beam path, depth shall be 100 mm.
ix. Second reflected peak will appear at 6.7 & third peak at 10.0.
x. If last peak is not at 10.0, velocity may be adjusted to set the last peak at 10.0 ( if
velocity control available).
xi. The equipment is calibrated for 300 /200 mm Longitudinal wave for 0˚ Double Crystal
probe.
xii. To verify the calibration, put probe on top of rail head, the back peak position will be at
5.2 for 52 Kg. rail & at 5.7 for 60 Kg. rail.
8.5.2 Sensitivity setting: Place 0°normal probe on test rail. The reflection from 3
mm.dia. hole in head of standard AT welded rail test piece shall be set to 60% of
full screen height by suitable manipulation of gain control.
8.5. 3 Test Procedure: The probe shall be placed on the head of the AT welded joint
ensuring proper acoustic coupling. The probe shall be moved on the weld centre
to scan the weld area.
25
8.5.4 Defect classification:
a) For any flaw signal obtained by normal probe from the head region,
i) Flaw signal 40% and above and up to 60% to be declared as DFWO.
ii) Flaw signal above 60% to be classified as DFWR.
b) For any flaw signal obtained by normal probe from web or foot location,
i) Flaw signal of height more than 20% from the web or foot and up to 40% to be
classified as DFWO.
ii)Flaw signal of height more than 40% from the web or foot or more to be
classified as DFWR.
8.6 70°°/ 2 MHz (Head scanning):
This scanning is used to detect lack of fusion, porosity, blow hole, slag
inclusion, cracks in head of AT welded joint.
8.6.1 Calibration: Following procedure shall be adopted for calibration of 700 2 MHz single
crystal probe:
i. Select range 165 mm with range control key.
ii. Select Mode T+R i.e. Single Crystal mode.
iii.Set Delay 0.
iv. Set Probe Zero 0.
v. Feed Shear wave velocity (3230 m/s) / Press measure 70 key.
vi. Feed angle 700.
vii. Connect 70˚/2MHz Single Crystal probe and put it on IIW (V1) Block after applying
couplant and direct the beam towards 100 mm curvature.
viii. Move the probe slightly to and fro to get maximize signal.
ix. Using probe zero set this peak at 6.0 or by using gate read beam path 100 mm.
x. To verify the calibration, Direct the probe towards 25 mm curvature and maximize the
peak.
xi. Put the gate on this peak, the beam path shall be 25 mm.
xii. The equipment is calibrated for 165 mm shear wave.
8.6.2 Sensitivity setting: Connect the 70°°/ 2 MHz by means of coaxial cables and
select (T+R) mode. Place the probe on the railhead directing the beam towards 3-
mm. dia.-drilled hole in the head of the standard AT welded test piece. Move the
probe in longitudinal direction on the rail so that reflection from the hole is
obtained. Now set the height of the reflected signal to 60% of full screen height
by suitable manipulation of the gain control . This gain shall be used for testing.
8.6.3 Test procedure: Place the probe on the rail head on one side of the AT welded
reinforcement and move toward the weld in zig-zag manner. This exercise shall
be repeated 2-3 times. The same shall be carried out from both sides of the weld.
8.6.4 Defect classification: i) A welded joint showing moving signal of 40% or more
and up to 60% of FSH shall be classified as DFWO.
ii) A welded joint showing moving signal of more than 60% of full screen height
to be classified as DFWR.
A bunch of moving signals lmore than 10% shall also be considered as
defective weld & to be declared as DFWR. (Fig. no.30).
8.7 450 / 2MHz probe:
8.7.1 450 / 2MHz probe (AT weld foot scanning):
This scan is used to inspect the clustered defects/ micro porosities and half moon
shaped defect at the bottom of weld foot. (Fig. 22 (a))
26
8.7.1.1 Range calibration: Following procedure shall be adopted for calibration of 450 2 MHz
single crystal probe
i. Feed range 275 mm with range control key.
ii. Select Mode T+R i.e. Single Crystal mode
iii. Set Delay 0
iv. Set Probe Zero 0
v. Feed Shear wave velocity ( 3230 m/s)
vi. Feed angle 45˚
vii. Connect 45˚/2 MHz Single Crystal probe and put it on IIW (V1) Block after applying
couplant and direct the beam towards 100 mm curvature.
viii. Move the probe slightly to and fro to get maximize signal.
ix. Using probe zero set this peak at 3.6 or by using gate read beam path 100mm.
x. To verify the calibration, Direct the probe towards 25 mm curvature and maximize
the peak.
xi. Put the gate on this peak, the beam path shall be 25 mm.
xii. The equipment is calibrated for 275 mm shear wave.
8.7.1.2 Sensitivity setting: Place 450 /2MHz probe on the rail head surface at a distance
equal to height of rail from the centre of the AT weld.{Fig. 22 (a)}. Select T+R
single crystal mode. Move the probe 20mm either side of this position (probe index
marking) to pick up half-moon crack in the central region of weld reinforcement as
shown in Fig 23. This exercise shall be carried out two- three times from each side
of the weld and signal from simulated flaw should appear at a distance of
approximately 400mm for 52 kg rail. This distance will vary with respect to rail
section height. The signal so obtained shall be adjusted to 60% of full screen height
by manipulating the gain control.
8.7.1.3 Test Procedure: The probe (450/2MHz probe /single crystal) shall be placed on the
rail head at a distance equal to height of the rail from the centre of AT weld (Probe
index marking) under test with same sensitivity as per para 8.7.1.2. This testing
technique will scan the bottom of the weld in the central zone. The probe shall be
moved 20 mm on either side of the probe index marking. The scanning shall also be
repeated from other side of weld with beam directing towards the foot region of the
weld.
8.7.1.4 Defect classification: Any flaw signal obtained by this probe of 20% height or more
shall be classified as defective AT welded joint (DFWR).
8.7.2 450/ 2MHz single crystal probe (Tandem probe scanning):
The tandem probe rig scan on the rail table by 450 probe is used to detect any
vertically oriented defect such as lack of fusion ,located at head -web junction ,
complete web & up to web-foot junction area.
8.7.2.1 Range calibration: The equipment shall be set for a depth range of 275 mm as
per Para 8.7.1.1. The equipment shall be set in T/R (Double Crystal mode) by
selector switch.
8.7.2.2. Sensitivity setting:Place the tandem rig on the railhead and attach 450 probes
such that the beam direction is as shown in Fig. 22 (b). Adjust the height of
reflected beam received by receiver probe ( Rx ) to 100% of full screen height.
Increase the gain further by 10 dB. This gain shall be used for normal testing of
AT weld by this set up.
27
8.7.2.3 Test procedure: Place the tandem rig on the rail head under test as shown in
Fig. 22 (c). The datum line of the rig shall be in line with centre line of weld. Test
the weld with sensitivity setting as mentioned in para 8.7.2.2. This exercise shall
also be repeated from other side of the weld.
8.7.2.4 Defect classification:
Any flaw signal of 40% of full screen height or more shall be classified as
DFWR.
8.8 70o/2MHz Side Looking (SL) probe:

This procedure shall be used for the detection of half moon shaped transverse
defect with a pair of 700 side looking probes using transmitter-receiver method.
8.8.1 Range calibration: The equipment shall be set for a depth range of 165 mm shear
wave.
8.8.2 Sensitivity setting: Set Range - 165 mm, Velocity- 3230 m/sec, Mode- Double
crystal and Angle – 70o. Connect cables of side looking probes to transmitter &
receiver socket in such a way that direction of side looking crystal face is inward
i.e. towards simulated half moon shaped defect. Place the 700 side looking ( Tx
and Rx) probes on the upper zone of the flange at a distance of 85 mm on either
side of flange {Fig. 22 (a)}. Move the probes slowly in slight zigzag manner
towards the weld upto a distance of 20 mm from weld collar. Set the signal
obtained from simulated half moon defect to 60% of full screen height with the
help of gain control switch. This gain setting will be utilized during testing of the
weld.
8.8.3 Test procedure: Place the transmitter and receiver 70o side looking probes at
positions as mentioned in Para 8.8.2. Move the probes slowly in zigzag manner
towards the weld. The position of transmitter and reciever probes from a defect
signal may vary depending upon the location of half moon defect. This exercise
shall also be done from other side of the weld.
8.8.4 Defect Classification: The defect signal of 20% full screen height or more is to
be classified as DFWR.
8.9 Flange testing by 70°°/2 MHz, 20 mm x 20 mm single crystal probe:

This scanning is done for detecting lack of fusion, porosity, blow hole, slag
inclusion in flange of AT weld.
8.9.1 Range calibration: The equipment shall be set for a depth range of 165 mm shear
wave.
8.9.2 Sensitivity setting:
70°/2MHz, single crystal probe shall be connected to the socket available in the
ultrasonic equipment. The selector switch shall be set to single crystal mode.
Move the probe towards the 3mm. dia hole drilled in the middle of flange of the
AT weld Fig. 20(a) and manipulate gain control to obtain a maximum signal
height 60% full screen height on the screen.
8.9.3 Test Procedure:
70° probe shall be placed on the flange at a suitable distance (180mm.)
corresponding to position ‘L’in Fig. 21(a) such that ultrasonic waves are directed
towards the weld. The probe shall thereafter be moved slowly in a zig-zag manner
towards the weld. Similar testing shall be carried out from ‘C’ and ‘U’ region as
shown in Fig. 21(a).
28
8.9.4 Defect classification:
i) A welded joint showing flaw echo of 40% vertical height or more and upto 60%
is to be declared as DFWO.
ii) A welded joint showing flaw echo of more than 60% vertical height is to be
declared as DFWR.
8.10 Initial USFD testing of AT welds and subsequent testing within the guarantee
period of contract
A thermit welding done in situ shall be joggled fish plated with two clamps
and supported on wooden blocks of 300 -450 mm length untill tested as good
by USFD.
8.10.1
The defective joints (DFWO or DFWR) based on the criteria mentioned in
preceding paras and para 8.12.3 shall not be allowed to remain in service for
initial USFD testing of AT welds and subsequent testing within the guarantee
period of contract and these joints shall be cropped, re-welded 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.
8.11 Periodic testing of welds in service
8.11.1 The periodic testing of welds using 00 2MHz, 700 2MHz, 450 2MHz and 700
2MHz SL probes shall be done as per para 8.15.1.
8.12 Procedure for initial and periodic Ultrasonic Examination of 75mm gap
AT welded Joints
8.12.1 Standard Test Sample – The sensitivity of ultrasonic equipment shall be set with
respect to AT weld standard test sample of 1.5 m length having a simulated flaw
at standard location as shown at Fig.20 (b).
8.12.2 Sensitivity setting: The signal from the simulated flaw of 3mm dia. hole in the
head shall be set to 60% of full screen height with 00, 2 MHz and 700, 2 MHz
probes for detection of discontinuities in the rail head. For Flange testing a signal
from a saw cut of 30mm in the weld metal in the flange 15mm away from the
edge of the weld collar as per Fig. 20(b) shall be set to 60% of full screen height
using 700 2 MHz probe.
8.12.3 Defect Classification:
a) Head - With 00 & 700 probes, rejection criteria will be same as for 25mm gap AT
weld joint. ( Para 8.5.4 and Para 8.6.4)
b) Flange- With 700 2MHz/ probe, Any moving signal of height more than 20% of
the full screen height shall be treated as defective weld (DFWR)
8.13 Defects detected by 00 2MHz , 700 2 MHz, 450 2 MHz and 70o/2MHz SL probes
with RDSO approved customized AT weld tester/existing machine shall be
classified in accordance with provisions contained in Para 8.15.1.
8.14 Action to be taken after detection of defects in AT welds: Action to be taken for
defects in AT welds shall be same as at para 6.4. In addition, following shall also
be applicable for welds classified as defective (DFWO/DFWR) in Initial
acceptance test & periodic testing of A.T welds using hand probing.
29
Classification
Painting on both Action to be taken
faces of weld
(In Head)
(i) In case of DFWO weld, following action will be taken :
Defective weld In case of
‘DFWO/DFWR DFWO, one a) SSE/JE (P.Way)/USFD shall impose speed restriction of 30 kmph or stricter
immediately and communicate to sectional SSE/JE about the flaw location, who
’ with circle with red shall ensure the following :
0
0 / 2MHz, paint. b) Protection of defective weld by joggled fish plates using minimum two
tight clamps immediately with a speed restriction of 30 kmph. Speed restriction
700 / 2MHz, In case of can be relaxed to normal after protection of DFWO weld by joggled fish plates
450/ 2 MHz or DFWR, two with 2 far end tight bolts (one on each side) with champhering of holes, within 3
700 2MHz cross with red days. The joint is to be kept under observation.
(ii) In case of DFWR following action will be taken:
SL probe, paint. a) SSE/JE (P.Way) USFD shall impose speed restriction of 30kmph or
450/ 2 MHz stricter immediately and communicate to sectional SSE/JE about the flaw
Tandem Rig location who shall ensure the following:-
b) Protection of DFWR weld by joggled fish plates using minimum two
tight clamps immediately. SR of 30 Kmph can be relaxed to normal after
providing joggled fish plates with two far end tight bolts one on each side with
champhering of holes. The DFWR weld shall be replaced within three months of
detection.
Adequate traffic block should be granted for removal of DFWR welds.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.
(iii) J11 case of defective weld (OFWO/DFWR) on mEtj or bridges & bridge
approaches ( 100 Metres either side) and in Tunnels & on Tunnels approaches
(100 Met. either side,) foliwing action will be taken
a) SE/JE(P.Way)/USFD shall impose speed restriction of 30 Kmph or stricter
immediately and to be continued till defectiv e weld is replaced. He should
communicate to sectional SE/JE (P.Way) about the flaw location who shall
ensure the following :
b) Protection of defectiv e weld using clamped joggled fish plate witlii11 24
hrs.
c) The defective weld shall berepluc.:ed within 3 days of detection.
Note: DFWR and DFWO found in "Initial Acceptance Test" shall be removed from track as per para 8.10.l .
8.15 Frequency of testing of welded joints
8.15.1 Frequency of Testing of welded joints for through periodic rail testing by SRT/DRT using 0 &
70° probes shall be as per 6.6.1.1.
8.15.2 Testing of AT welded joints by hand probing shal.l comprise of testi1ig by probes with sensitivity setting and calibration
. .
as per referances indicated against them in the Table below
S.No Probes Calibration Sensitivity Setting Acceptance
as per as per Criteria
0
1. 0 2 MHz Para 8.5.1 Para 8.5.2, Fig As per Para 8.5.4
20(a)
2. 0
70 2MHz Para 8.6.1, Para 8.6.2, 8.9.2, As per Para 8.6.4
8.9.1 Fig 20(a) & 8.9.4
3. Para 8.8.1 Para 8.8.2, Fig 22 As per Para 8.8.4
700 2MHz (a)
SL
4. 45o 2 MHz Para 8.7.1 Para 8.7.1.2 , Fig As per Para
(AT weld 22 (a) & 23 8.7.1.4
5. 45o 2 MHz As per As per Para 8.7.2.2 As per Para

single crystal Para 8.7.2.4
probe 8.7.2.1
30
The frequency of testing of AT welds with above listed probes by hand probing shall be as under:
S No Type of Welds Type of Testing Testing Schedule
1 Conventional Periodic Tests Every 40 GMT or 5 Years
AT Weld whichever is earlier
2 Acceptance Test Immediately after welding
3 First Periodic Test 1 year
SKV Weld Routes having GMT Frequency
4 Further tests based on route > 80 1 year
5 GMT >60 < 80 1 1/2 years
6 > 45 < 60 2 years
7 > 30 < 45 3 years
8 > 15< 30 4 years
9 0-15 5 years
In case of welds on major bridges & bridge approaches (100 m Either side) and in tunnels & on
tunnel approaches (100m either side), the minimum frequency of testing shall be once in a year.
Due to unusually high weld failure or other abnormal development in some sections, Chief
Engineer may order testing of welds early, as per need.
The testing interval of USFD testing of defective AT welds shoulc be reduced by 50% of normal
testing interval of AT welds as provided in para 8.15.1 to avoid fractures of defective welds.
(CS-No. 4)
8.16 Through Weld Renewal should be planned after the welds have carried 50% of the
stipulated GMT of rails. Among the various sections, due for Through Weld Renewal (TWR)
as per this criteria, Chief Track Engineer will decide inter se priority based on
incidences of defect detection and weld failures.
Note : Guidelines for the Operators:
a) The correctness of angles and index marking of the probe shall be ascertained before
testing. Only probes meeting the specified values shall be used during testing.
b) Mere appearance of moving signal during flange testing of weld shall not be the
criterion for rejection of a joint. These signals may come from the geometry of the
flange weld reinforcement. Therefore, while declaring a joint defective in flange
testing, operator shall ensure that signals are flaw signals and not the signals coming
due to geometrical configuration of the weld. Following method shall be adopted for
taking decision in this regard:
(i) Horizontal distance of flaw shown on screen of the equipment shall be observed.
(ii) Measure the actual distance from probe index to confirm if the flaw signal is
coming from the weld collar/reinforcement or from the weldment.(Fig.21b)
(iii) The defect signal observed at the collar from one end of testing shall be
confirmed from other end also. If defect is confirmed from both ends the weld must
be marked as defective.
c) Oil or grease shall be used for proper acoustic coupling instead of water for AT
weld testing. Operator shall use the same couplant during testing and setting the
sensitivity.
d) More than one DFWO defect in one weld shall be classified as DFWR.
31
'Additional Policy Instructions 011 Ultrnsonic testing of mils & welds, to be read iu couj unctiu u
with Manual for lJHrasouic testing of rails & welds (Rcvised-2012)'
' I. Frequency of testing of rails and AT welds has been prescribed in Para 6.6 and 8.15.2 respectively of
Manual for Ultrasonic testing of rails & welds (Revised-2012). As a trial preventive measure to reduce
the number of rail failures during reduced testing frequency period and v,1 eL\ failures i!l initial period,
Ultrasonic testing of rails and welds shall be done at frequency prescribed below. This will be valid for a
period of two years, i.e. upto 31.08.2020.
1.2 Frequency of USFD testing during reduced frequency testing period is broadly based on the
criteria of:-
(a) Passage of every 20 GMT traffic during reduced frequency tes1ing period; or
(b) Eight (08) years, whichever is earlier
2. Frequency of testing of AT welds by hand probing with probes listed in Para 8.15.2 of Manual
G shall be as under:
SNo Type of Welds Type of TestinC! Testing Schedule
I Conventional Periodic Tests Every 40 GMT or 5 years
AT weld whichever is earlier
2 Acceptance Test Immediately after welding
3 First Periodic Test 20 GMT or I year whichever is
SKV Weld earlier
Further tests based on route Routes having GMT Frequency
4 GMT > 80 1 years
5 >60::: 80 1 ½y1ars
--··
6 >45::: 60 2 ye:o,rs
--
7 >30:::45 3 years
8 > 15 <30 ' 4 YC8J'$
9 0-15 5 years
CHAPTER 9
ULTRASONIC TESTING OF FLASH BUTT AND GAS PRESSURE WELDED JOINTS
9.1 Scope: This procedure covers the ultrasonic testing technique of flash butt and gas
pressure welded rail joints by using pulse-echo, A-scan examination method of detecting
weld discontinuities.
9.1.1 This practice utilises only shear wave probe having 450 & 700 refracted angle in steel, 450
probes to test head and 700 probe to test web and foot of the welded joints.
9.1.2 Significance: It is essential that evaluation be performed properly by trained and

qualified personnel.
9.2 Code of procedure
9.2.1 Equipment and accessories
(i) Any RDSO approved model of ultrasonic equipment for Alumino-thermic welded rail
joints as per RDSO specification No. M&C/NDT/129/2005 or its latest version.
(ii) Two single crystal 450 2 MHz probes, one single crystal 700 2 MHz probe.
(iii) 00 4 MHz double crystal probe (00 2 MHz single crystal probes, shall be used to check
equipment characteristics.)
(iv) Battery with specific voltage suitable for the USFD to be used.
(v) Battery charger
(vi) Voltmeter
(vii) Standard rail piece of 2.5 m length having standard simulated defects at standard
locations (Fig. 4).
(viii) Calibration block 60 X 50 X 50 mm of steel grade 45C8 to IS : 1875 – 1992.
(ix) Steel measuring tape.
(x) IIW-VI or V2 block
9.3 Pre-requisite
(i) Coupling condition/surface preparation: The protruding upset metal around welded
joint shall be removed by any suitable mechanical means in such a way that the
remaining protruded metal does not produce sharp corner and the finished surface of the
protruded metal if any left should merge smoothly into the surfaces of the adjacent base
metal. The scanning surfaces must be free from weld spatter, scale, dirt, rust and extreme
roughness on each side of the weld for a distance equal to 200 mm.
32
Couplant: The couplant should wet the surfaces for the probes and the scanning surfaces
and eliminate any air space between the two. Depending upon availability and feasibility
of the testing, oil or grease can be used as couplant.
(ii) Calibrate the depth range of ultrasonic flaw detector with the help of 60 X 50 X 50 mm
steel block of steel to grade 45C8 to IS : 1875 – 92 .
9.4 Calibration and sensitivity setting
(i) Calibrate the digital ultrasonic weld tester for 165 mm shear wave as per procedure given
at para no. 8.6.1 and after calibration switch over to T/R double crystal mode.
(ii) Connect the 45o probes, one to transmitter connector and the other to receiver connector.
Place the 45o probes on standard rail piece as shown in Fig. 24 (a). Move the probes
forward and backward alternately and set the gain to achieve 60% height of full screen
from a 5 mm dia drill hole drilled in head.
(iii) Remove the 45o probes and connect 70o probe (Turn the probe selector T+R i.e. single
crystal mode). Place the probe at approximately 100mm from the 5 mm dia hole on the
web as shown in Fig. 24(b). Move the probe to and fro from 5 mm dia hole and set the
gain to achieve 60% height of full screen and this gain level shall be reference gain for
testing of web and flange of the joints.
(iv) The equipment is now calibrated for depth range of 16.5 mm per main scale division (for
machine having 10 main divisions on horizontal scale) to shear wave and gain of the
UFD is set separately for conducting the test using 45o and 70o probes.
9.5 Examination of flash butt/gas pressure welded rail joints in depot (Initial testing):
Examination of flash butt welded joints is performed separately for the rail head, web and
flange. In case of scanning of weld at rail head, two single crystal 45o angle probes of 2.0
MHz shall be used, one of which shall act as transmitter and the other as receiver. A 70o
single crystal angle probe of 2 MHz frequency shall be employed for examining the
welds at web and flange. All the above probes have index marks on their housing to
denote the point at which the central beam emerges.
9.5.1 Testing of weld at rail head: After calibration has been done, the two 45o angle probes
shall be connected to the unit by means of two probes cables one acting as transmitter
and other as receiver. The probe selector switch shall be operated in T/R mode in which
one works as Transmitter and the other as receiver.
Oil or grease as per specification given at para no 4.1 shall be applied as couplant along
the right and left hand side faces of the rail head, up to 100 mm from the joint on both
sides of the weld.
33
9.5.1.1 Two 45o angle probes shall be placed and moved along the two side faces of the rail head
in the longitudinal direction of the rail. Slight twisting movements, with the beam
directed towards the weld, shall be imparted mutually to the probes as shown in the Fig.
24 (a). In order to examine the entire width of rail head as well as the height, maximum
mutual displacement at start shall be equal to width of top of rail head. If, for example,
the left hand probe is at maximum width displacement away from the weld the right hand
probe shall be directly over the weld and vice-versa. The probe shall then be advanced
from the weld as shown in the Fig. 24 (a). The movement shall be continued until the
probes are in reversed positions with respect to the beginning of the test. This operation
shall be repeated 3-4 times and at the end of each traverse slight horizontal twisting
movements shall be given to the probes. Probing may be continued from the other side of
the joint also to take care of defects unfavorably oriented to the search beam applied from
the other side.
9.5.1.2 Detection of defects: The common flash butt welding defects are lack of fusion and
oxide inclusions. They are generally transversally oriented. If the rail head is free from
defects, no flaw signal will appear on the screen. If there are flaws, the beam will be
reflected at the discontinuities and picked up by the receiver probe. For a particular rail
section, the flaw signal shall always appear at a fixed graduation on the horizontal scale.
The location of the flaw can be determined by the position of the probes. Invariably the
flaw will be on that side of the rail head, which is nearer to the weld. If both the probes
are at equal distance from the weld, the flaw will be in the center of the rail head as
shown in Fig. 24 (a). An indication of the flaw size can be made from the amplitude of
the flaw signal and the extent of the transverse of the probes.
Any welded joint when tested with gain setting specified showing flaw signal shall be
considered defective.
9.6 Testing of weld at rail web and flange
9.6.1 Setting of sensitivity: To examine the web and flange locations of flash butt welded rail
joints the gain level of flaw detector’s setting shall be changed and set as per para
9.4(iii) and probe selector switch shall be turned to single crystal operation i.e. in T + R
mode.
9.6.2 Couplant: Oil or grease as per specification given at para no 4.1 shall be applied as
couplant along the right and left hand side surfaces of the rail web and foot up to 100
mm and 180mm. respectively away from the joint on both sides of the weld.
9.6.3 Testing procedure: The probe shall be positioned 100 mm away from the weld in web
region and transversed in a zigzag manner towards the weld. The probing should be done
on the web so as to cover the entire width as shown in Fig 24 (b). Testing of the flange
should be done as per the procedure described in Para 8.9.3 (Fig. 21 (a)).
9.6.4 Detection of defects: To detect flaws in the web, the probe must be twisted slightly
in the direction of the web. No flaw signal will appear on the screen if the rail flange
and web are sound. If there are discontinuities in the weld, moving flaw signals will
appear on the screen. When the flaw signal is at its maximum height, the distance of
the probe from the weld joint shall be measured, to determine the location of the flaw.
Any welded joint when tested with normal gain setting showing any moving signal
shall be considered as defective.
34
9.7 Periodic Testing
9.7.1 Frequency of testing with 00 & 700 probe: Same as for rails and shall be carried out
along with rail testing.
9.7.2 Frequency of testing with 700 hand probing for web and flange: Normally there is no
need for hand testing after first testing of welds. Additional hand probing be carried out
as per para 9.8.
9.8 For Flash Butt Welds: 450 and 700, 2 MHz hand probing for web and flange:
In case of flash butt welds normally there is no need for hand testing (with 450 and 700
probes), however, Chief Engineer may order hand probing with these probes in case
failure rates are high in his opinion.
35
CHAPTER 10
ULTRASONIC TESTING OF RAILS REQUIRED FOR

FABRICATION OF POINTS AND CROSSINGS
10.1 New rails without bolt holes and suitable for laying in track are used for the fabrication of
points and crossings. These rails, therefore, do not have any chance of fish bolt hole
cracking or any progressive type of defects. The defects like pipe, seam, lap, inclusions,
segregation can only be expected in these rails. Therefore, in the procedure for ultrasonic
testing of these rails only normal probe (0o) is required. Probing shall be carried out from
top of the rail head, side of the rail head and side of the web. The use of angle probe has
not been included as transverse progressive crack of fish bolt hole cracks are not
expected. This testing will be undertaken besides visual examination of rails for freedom
from any surface defects.
10.2 Scope: This chapter stipulates the ultrasonic testing technique of new rails required for
fabrication of points and crossings by hand probing using ultrasonic flaw defector and lays
down the acceptance standard.
10.3 Accessories
10.3.1 Probes: One single crystal normal probe 20/25 mm dia, 2/2.5 MHz frequency for
checking the efficiency of the ultrasonic flaw detector. One double crystal normal
probe of 4 MHz frequency, 18mm dia (overall), stainless steel casing and with
perspex insert having a path length equal to 50 mm of steel required for testing of rails.
Both the probes shall meet the requirement of the tests stipulated in equipment
specification.
10.3.2 Battery: The battery shall be a rechargeable, plug-in type (preferably Ni-Cd type)
6V/12V suitable for working about eight hours continuous operation per charge.
10.3.3 Battery charger: The battery charger shall be suitable for charging the battery
provided with the flaw detector.
10.3.4 Co-axial cable: Two meter co-axial cable fitted with BNC connector for connection
with single crystal probe.
10.3.5 Calibration block: 60x50x50mm block of steel to grade 45C8 of IS:1875 – 1992.
10.3.6 Standard test rail: The rail piece shall be 250/300 mm in length preferably of the same
section used for the manufacture of crossings, having 1.5 mm dia and 2.0 mm dia flat bottom
holes drilled along the central axis of the head, web and foot locations as indicated in Fig. 25.
10.3.7 Checking the sensitivity of the probe: The double crystal normal probe shall be able to
detect 1.5 mm, 2.0 mm and 2.0 mm dia flat bottom holes in the rail head, web and foot
respectively of the standard test rail. The amplitude of the peaks shall be set at 60% height.
36
10.4 Testing procedure
10.4.1 Surface preparation: The probing faces of the rail shall be cleaned with hard wire
brush to make it free from dirt, etc. for achieving acoustic coupling.
10.4.2 Checking the equipment: Check the correct functioning of the flaw detector or probe
and adjust the sensitivity of the unit with standard test rail as in para 10.3.7
10.4.3 Calibration: Calibrate the unit for 300mm range for testing the rail while probing from
top of the rail and for 100mm range while testing from the side head and web.
10.4.4 Testing: After calibration of the unit the rails shall be tested manually using double
crystal normal probe 4.0 MHz frequency with water/oil as couplant. The rails shall
be tested by probing from the rail head top, rail head side and web. Typical
oscillogram pattern for various probe positions are given for guidance as indicated
below:
(i) Probing from the rail table: Oscillogram pattern for sound rail will be as given at Fig.5.
The pattern obtained on the defective rails will be as in Fig.14 for segregation, Fig.11
for vertical longitudinal split in web.
(ii) Side probing from rail head: Oscillogram pattern for sound rail shall be as given at
Fig.9.
The pattern obtained on defective rails will be as given in Fig.10 for vertical split in head.
(iii) Side probing from web: Oscillogram pattern for sound rail shall be as given in Fig.12.
The pattern obtained on defective rails will be as given in Fig.13 for vertical split in
web.
10.5 Acceptance standards: Any flaw peak appearing on the cathode ray tube of
amplitude higher than 60% of the full screen height shall indicate a defective rail and
such rails shall not be used for fabrication of points and crossings.
10.6 Guidelines for USFD testing of toungue rail of point & crossing in service
10.6.1 For purpose of USFD testing of tongue rails of points and crossings, the tongue rail can be
demarcated in three zones as under:
a)Zone-1: Where full width of rail head is available. This zone shall be covered in normal rail
testing.
b)Zone-2: Region where scanning by 700 probe is easily feasible i.e.upto width of rail head of
points and crossings, where 700 probe of 20 mm crystal size can be suitably placed over it.
c)Zone-3: Rest portion of tongue rail of points and crossing.
37
10.5
10.6.2 The USFD testing of tongue rails of points and crossings shall be done as given below.
The sensitivity setting for the probes shall remain same as used for through periodic rail testing.
a. Zone-1: This part of tongue rail of points & 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 hinder the movement of trolley up to full
width of rail head part , lower dia. of guide roller shall be used.
b. Zone-2: This part of tongue rail shall be tested manually using 700 / 2 Mhz single crystal
probe having crystal size 20 mm dia. or 20 x20 mm square crystal.
c. Zone-3: This part of the tongue rail shall be examined visually.
10.6.3 Classification of defects: The defect classification shall be made as per provisions given
in Item 1(A), 2(A),3(A) and 4(A) of Annexure -II-A of 'Manual of 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 of
Ultrasonic testing of rails & welds(Revised 2012)'shall be applicable.
10.6.4 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.
CHAPTER 11
ULTRASONIC TESTING TECHNIQUE OF WORN OUT POINT AND SPLICE RAILS

PRIOR TO RECONDITIONING BY WELDING AND SWITCH EXPANSION JOINT
11.1 The worn out points and crossings are taken to the Reconditioning Depot for reclamation
of the same by suitably depositing hard facing electrode over the worn out areas to
enhance the service life and also for effecting savings thereby. As per extant practice, the
worn out areas of the wing rails and point and splice are ground for removing loose
metals and oxides over the surface before undertaking welding. Freedom from any
fatigue crack over the surface to be built-up is also ensured by MPI/DPI before
reclamation. As the nose portion of the crossing consisting of the point and splice is
subjected to heavy impact and dynamic stresses during service, it is felt necessary to
check them ultrasonically to ensure their freedom from any internal flaw prior to
reconditioning, so that the defective points and splices can be rejected for ensuring safety
in the train operation.
11.2 Scope: This testing procedure stipulates the ultrasonic testing techniques of worn out point
and splice rails which need reclamation. Zone I of the crossing shall be tested utilising
probes fitted in USFD trolley and zone II and III shall be tested by hand probing with 0o
and 70o probes wherever necessary for detection of internal flaws {Fig. 26 (a)}. The
testing is required to be carried out in dismantled condition in the welding depot. It also
suggests to subject some vulnerable locations to MPI/DPI to ensure freedom from
surface/sub-surface defects.
11.3 Personnel qualification: It is essential that evaluation be performed by properly trained

and qualified testing personnel.
11.4 Equipment and accessories
11.4.1 Equipment: Pulse-echo type ultrasonic flaw detector approved by RDSO.
11.4.2 Accessories
(i) Probes: The rail test trolley shall have following probes made of PZT, barium titanate or
similar type of piezo electric crystals:
(ii)
(a) Double crystal 4 MHz, 18mm(crystal dia) 0o probe-1 No. fitted in trolley.
(b) Single crystal 2 MHz, 20mm(crystal dia)70o probe- 2 No. fitted in trolley.
(c) Single crystal 2 MHz, 20mm(crystal dia) 70o probe -1 No. for hand probing.
(iii) Battery with specific voltage suitable for the USFD to be used.
(iv) Battery charger
(v) Voltmeter.
(vi) Standard rail piece of 2.5m length having standard simulated defects at standard locations
(Fig.4)
(vii) Calibration block 60 x 50 x 50 mm of steel grade 45C8 to IS: 1875 – 1992.
(viii) Steel measuring tape.
(ix) IIW-VI or V2 Block
(x) Co-axial cable-2.5m length fitted with BNC connector for connection with single crystal
probe.
38
11.4.3 Pre-requisites
(i) Battery power: Before undertaking testing, check the power of the battery to ensure that it
is fully charged.
(ii) Check the correct functioning of the ultrasonic flaw detector on IIW block as per IS:
12666- 1988.
(iii) The couplant should wet the surfaces of the probes and the scanning surfaces properly.
Depending upon the availability and feasibility of the testing – water, oil or grease can be
used as couplant.
(iv) Calibrate the depth range of USFD with help of calibration block for 300mm depth range
(longitudinal wave) with the help of 0o double crystal 4 MHz probe. The equipment is
thus calibrated for depth range of 60/30mm per main scale division for longitudinal wave
for equipment having 5/10 main scale div. on horizontal scale.
11.5 Checking the sensitivity
11.5.1 0o and 70o probes fitted with the rail tester trolley shall be able to detect 5mm dia flat
bottom hole at the foot/5mm dia through hole at web-foot junction and 5mm dia through
hole at head respectively of the standard 2.5m long test rail. (See Fig.4) and set gain of
the USFD so that the flaw signal amplitude is adjusted to 60% of the vertical screen
height.
11.5.2 During hand probing by 70o single crystal 2 MHz probe it should be connected with the
equipment by a coaxial cable. Turn the probe selector switch to single crystal operation
and set the gain of the USFD with 5mm dia drilled hole in the head of the standard rail by
side probing. The flaw signal amplitude shall be similarly adjusted to 60% of the vertical
screen height.
11.6 Testing procedure {Ref.Fig. 26 (a)}: The points and splices of different turnouts shall be
divided into three zones, viz.
Zone –I : To be tested by the rail tester trolley according to accessibility utilising 0o

(Towards and 70o probes.
the heel
of the
crossing)
Zone-II: To be tested by 0o and 70o probes provided in the rail tester trolley by
(Middle hand probing from the rail head top surface.
of the
crossing)
Zone–III: To be tested by the 70o 2 MHz single crystal probe by hand probing at
(Toward the head portion from both the sides of the head. The web and flange
the nose location of zone III shall be tested by the same probe.
of the
crossing)
Besides the above, the bolt hole locations at the web shall be thoroughly examined visually
and magnetic particle/dye penetrate inspection shall be conducted to ensure freedom from
cracks since ultrasonic testing of the bolt hole crack on the web is not feasible.
39
11.7 Acceptance standard
Zone I, II &III: Any point or splice when tested with gain setting as specified in
para11.5.2, showing any moving signal shall be considered as
defective.
11.8 PROCEDURE FOR ULTRASONIC TESTING OF SWITCH EXPANSION JOINT
11.8.1 A number of SEJs have been found to fail in service due to fatigue cracks generated
from the bottom of the rail and also from rail head endangering safety. It was therefore
considered essential to develop a procedure for detection and classification of defects in
SEJs. Details of the procedure are described below.
11.8.2 Scope:This procedure stipulates the ultrasonic testing technique of new SEJs as well as
those in service and lays down the acceptable standard with regard to defects
noticed. In view of the design of the SEJs, testing is to be accomplished by hand
probing.
11.8.3. Accessories:
11.8.3.1 Probes: The following probes shall be used for ultrasonic examination of SEJs
(i) 0oNormal probe, 18mm dia./2MHz, Double crystal for time scale
calibration.
(ii) 45o/2MHz, 20x20mm PZT crystal, Single crystal for locating flaws in
middle of web-flange area.
(iii) 70o/2MHz, 20x20mm PZT crystal, Single crystal for locating flaws in
nose of the SEJ.
(iv) A 60mmx50mm x 50mm rectangular block of steel to grade 45C8 of IS-
1875-1992.
11.8.3.2 Couplant: Water/soft grease/thick oil shall be used as couplant.
11.8.3.3 Cables: Co-axial cable for each probe shall be used. The length shall not exceed 2
meters.
11.8.3.4 Standard test piece: A 1000mm long rail piece having nose of SEJ stock shall be
used for preparation of standard test piece. One simulated flaw of 3mm x
5mm shall be made in the bottom of flange as shown in Fig. 26(b) at
location A. This simulated flaw shall be used for sensitivity setting of 45o
angle probe. Another 5mm. Dia. through hole shall be made in the rail head
at location B, 25mm. below the top of the rail surface and away from nose
portion (as shown in Fig. 26(b) for sensitivity setting of 70o angle probe.
11.8.4 Range calibration: The time scale shall be calibrated for 500mm longitudinal
wave for setting depth range for 45o angle probe and 300mm longitudinal
wave for 70oangle probe with the help of 0o (normal) probe. Rectangular
block of 60 mm x50 mm x 50 mm steel to 45C8,IS-1875-1992 shall be used.
40
11.8.5 Sensitivity setting
11.8.5.1 The depth range shall be set for 500mm longitudinal wave using normal probe.
There after 45o /2MHz single crystal probe shall be placed on the rail head at a
distance of 160mm (for 52 Kg.)/ 175mm (For 60 Kg.) approximately from the
junction of flange as shown in Fig. 26(c). The probe shall be placed so as to direct
the beam towards the simulated flaw as shown in Fig. 26(c). The probe shall be
moved towards the saw cut in zig-zag manner so as to get maximum reflection
from saw cut.
The height of this reflected signal shall be adjusted to 40% of full screen height
with the use of gain control knob. This gain setting shall be utilized during
examination of SEJ using 45o angle probe while maintaining the movement
towards the nose of SEJ.
11.8.5.1.1 Any flaw peak of amplitude higher than 20% of full screen height shall be
classified as IMR. The SEJ should be adequately protected till it is replaced.
11.8.5.2 70o angle single crystal probe: The depth range shall be set to 300mm
longitudinal wave with the help of normal probe. Thereafter 70o/2MHz single
crystal probe shall be placed on the rail head at a distance of approximately
70mm from 5mm dia hole so as to direct the beam towards the hole. The
reflection from 5mm dia. hole shall be adjusted to 60% of full screen height with
use of gain control. This gain setting shall be utilized during testing of SEJ while
testing with 70o angle probe with probe movement towards SEJ.
11.8.5.2.1 Any flaw peak of amplitude higher than 20% of full screen height shall be
classified as IMR. The SEJ should be adequately protected till it is replaced.
11.8.6 Testing frequency : Same as that for normal track as stipulated in the need based
concept.
Note: The probe positions indicated are for 52kg rail section. For other rail
sections, the distance may be suitably modified.
11.9 Procedure for ultrasonic Testing of tongue rail of SEJ
11.9.1 Scope :
An ultrasonic test procedure has been prepared for detecting defects in tongue rail at
location where sharp change in one of the flange portion has been designed. Study
reveals that even a small fatigue of 4 -5 mm width in this location caused failure of
tongue rail. USFD procedure has been designed to detect defects smaller than above
mentioned width. Physical verification at site of track reveals that ultrasonic testing
of vulnerable location of tongue rail of SEJ is not feasible under in situ condition
because this portion remains inside the bracket over it. For conducting ultrasonic
testing bracket has to be removed for getting access to scanning area.
41
11.9.2 Apparatus required:
a. Equipment: Any RDSO approved model of ultrasonic equipment for Alumino-

thermic welded rail joints as per RDSO specification No. M&C/NDT/129/2005 or
its latest version.
b. Probes: 70˚/ 2 MHz, 20 mm dia. or 20 x 20 mm square crystal size Single Crystal

probe.
c. Couplant: Soft grease or thick oil shall be used as couplant.
11.9.3. General Condition: Prior to conducting testing, the bracket over the sharp
curvature in the flange portion of tongue rail of SEJ shall be removed. Cleaning of
flange with kerosene shall be done to remove dirt oil or grease over it. Flange shall
be smooth and free from pittings otherwise paper grinding shall be carried out for
smoothening the surface.
11.9.4 Sensitivity setting procedure:
11.9.4.1 Standard test piece: The sensitivity of the ultrasonic equipment shall be set with
the help of Standard Tongue rail of SEJ test piece containing a 5 mm saw cut at
sharp curved location of flange as shown in Fig. 29.
11.9.4.2 Range Calibration: The equipment shall be set for a depth range of 165 mm S-
Wave. Connect the 70˚/ 2 MHz probe with ultrasonic equipment and select T + R
(Single Crystal) mode by selector switch.
11.9.4.3 Sensitivity Setting: Place the 70˚/ 2 MHz probe at a distance of approx. 110 mm.
far from saw cut on the upper zone of flange of tongue rail with beam directing
towards the saw cut. Move the probe in slight zigzag manner towards cut direction.
The reflection from 5 mm cut shall be maximized and shall be set to 60% full
screen height by suitable adjustment of gain control.
11.9.4.4 Test Procedure: The 70˚probe shall be placed on the upper zone of flange at a
distance of approx.110 mm far from sharp curve portion with beam directing
towards curve portion. Move the probe in slight zigzag manner up to curve portion.
This scanning shall be carried out 2-3 times.
11.9.5 Defect Classification: Any flaw signal obtained by 70˚probe of 20% vertical height
of screen or more shall be treated as defective tongue rail of SEJ.
11.9.6 For testing the head of tongue rail of SEJ, procedure laid down at para 11.8.5.2 &
11.8.5.2.1 shall be followed by hand probing.
11.9.7 Testing frequency: Frequency of USFD testing of tongue rail of SEJ shall be once
in a year.
--------------
42
CHAPTER 12
ULTRASONIC TESTING OF RAILS BY SPURT CAR
12.1 Introduction
12.1.1 Continuous testing of rails by manual flaw detectors is strenuous and demands
continuous concentration on CRT screen, also the speed achievable is only 2/6 track km
in a day. An equipment which can shortlist likely defective spots quickly can improve the
effectiveness of the testing.
12.1.2 Self Propelled Ultrasonic Rail Testing (SPURT) Car has been procured for this purpose
and is in operation since May’88 over Indian Railways. This car tests both the rails while
traveling up to 30 km/h. Most of the testing operations have been automated in this car.
12.2 Description of SPURT Car
12.2.1 SPURT Car has water supply system with a capacity of 4000 litres guiding system for
probe beam positioning and air system for lifting and lowering of probe. Probes used are
of the following types:
Probes Defect type
0o (Normal) Horizontal flaws
70o Central Vertical transverse flaw

(forward and backward)
70o side wise Vertical transverse flaw
35o (forward and backward) Star cracks
550 Vertical longitudinal flaws.
12.2.2 As SPURT car tests at higher speed, observation for flaws can not be done
manually. Identification of defect is done electronically according to laid down
logics. Also it has computer for tabulating, printing and storage of data.
12.2.3 Comparative characteristics of manual USFD tester and SPURT car are tabulated below:
SPURT car USFD manual machine

Real time recording of defects. No automatic recording of defect.
Analysed by computer hence less strenuous. Testing requires sustained and intense
Concentration.Testing is objective. Testing depends on the interpretation by operator.
43
SPURT car USFD manual machine
Testing of 80-120 track km per day. Testing of 2 to 6 track km per day.
Only ultrasonic information is available Ultrasonic information is supplemented by

and severity classification is dependent visual information also. So severity
on visual information. So classification classification is done.
is not possible.
Repetition of test at a spot is difficult due Repetition of test at a spot can be conveniently to
speed and path constraint done
To take advantage of both machines, the method used by Railways having SPURT
car is to use both as complementary to each other. SPURT car short lists the likely
defective spots and manual equipment is used to check only these locations. During
this check the severity classification is done.
12.3 Locations not tested by SPURT Car
12.3.1 Fishplated joint causes damage to SPURT car probes and also efficacy of testing reduces
depending upon condition of joints, therefore only LWR/CWR lengths are normally
tested by SPURT car. Also probes are lifted on points and crossings, SEJ’s and buffer
rails and these remain untested. At locations fitted with ground rail lubricators, probes are
also lifted and hence testing is not done at such locations.
12.3.2 Testing of rail with surface defects like wheel burn and scab is also to be done
manually.
12.3.3 The real time out put as well as final defect report contains the information about
stretches not tested by SPURT car.
12.4 Role of Railways
12.4.1 From the time of drawing a programme by RDSO for testing of rails by SPURT car
until the testing work gets completed, action in Railways is required at three levels.
(i) Headquarter
(ii) Devision and
(iii) USFD and sectional SE/JE(P. Way)
12.4.2 Headquarter
12.4.2.1 Programme of testing will be drawn by RDSO in consultation with CTE of a Railway.
For this, information about LWR stretches, frequency of testing, rail sections will be
made available by USFD cell of the Railway to RDSO for drawing the programme of
testing.
44
12.4.2.2 On receipt of the programme from RDSO, Engg. headquarter is to get the
confirmation of path and deputation of crew by operating branch. It is to be ensured
that proper messages are transmitted by operating branch to all concerned. Reference
is also to be made to Rly. Board’s letter No. 90/Track III/TK/72 dated 9.7.90 in this
regards. Relevant extracts are reproduced below:
The monitoring special shall be accompanied by following officers from the

railway and division:
All routes Any officer from the track modernization cell preferably dealing with rail
testing and SE/JE(P.Way)/USFD of the section.
Division Sectional DEN/AEN
One nominated Sr.DEN/DEN at the divisional headquarter shall ensure that there is
proper liaison in the control office to ensure suitable path for the monitoring special.
Any other special requirement as indicated by RDSO should also be taken care of. The
confirmation of the programme is also to be conveyed back to RDSO.
12.4.2.3 Headquarter is also to ensure through divisions for any other assistance requested by
RDSO for successful and effective testing by SPURT car. Clear instructions are to be
issued to division that sectional AENs/DENs should accompany SPURT car and
movement should be watched by Sr.DENs with proper intercommunication.
12.4.2.4 For follow up testing within reasonable time of 10-15 days after the SPURT car run,
additional USFD machines are to be sent to the section. The distribution of machines
and operators is to be programmed at this stage by USFD cell of headquarter. Also
push trolley are to be provided to USFD operators so that average progress of about 8
km follow up testing is achieved.
12.4.3 Division
12.4.3.1 Though the programme of running is confirmed initially by COM, yet the real day-to-
day control is at divisional level and divisions role is most critical in effective
utilization of SPURT car.
12.4.3.2 On receipt of testing programme from headquarter, Sr.DEN will study the same along
with COM confirmation and actual train paths available. Slight modifications in
timing, keeping the constraints that (i) the testing can start earliest 8 o’clock (ii) spread
of working should not be much and (iii) testing to be done in day light, is possible.
Keeping all these in view, testing path is to be planned in consultation with operating
branch and the path schedule is to be drawn and get confirmed by operating branch.
RDSO official in charge of SPURT car is to be informed about the change, in advance.
12.4.3.3 At the time of testing, sectional AENs, SE/JE(P. Way) and SE/JE(P. Way)/USFD are to
accompany the test special. During the run, AEN will liase with control, Sr.DEN and
Sr.DOM regarding path. It should be ensured that movement is through main line only
to avoid any length untested.
12.4.3.4 At the end of the run SPURT car is to stabled in proper siding. It may also require
fuelling and watering arrangements as required for SPURT car, for fuelling, watering,
shunting and placement, are all to be arranged by AEN.
45
12.4.3.5 AEN is also to ensure that SE/JE(P. Way) USFD knows clearly about the follow up
testing to be done. In case knowledge is lacking, RDSO official will coach the SE/JE(P.
Way) about the procedure to be followed by him for follow up testing.
12.4.4 SE/JE(P. Way) /USFD
12.4.4.1 During testing
(a) SE/JE(P.Way) will accompany testing run of SPURT car. He will supply the
information regarding the section of rails, GMT and left and right rail convention
followed in the section.
(b) SE/JE(P.Way) will carry results of last USFD testing with him for prima facie
checking of results reported by SPURT car.
(c) After the testing run SE/JE(P. Way) /USFD will collect the testing output for real
time, final defect computer out put and statement of the untested stretches for follow
up work.
12.4.4.2 Follow up testing
(a) SE/JE(P. Way) /USFD are required to carry out follow up testing on the locations,
indicated in final defect report, which gives the location of the defect in kilometer ,
defect type, and its size. Also the location is paint marked and thus gets identified. The
paint marks will be more than the defects contained in final defect report, the excess
being caused by definite noise edited later by SPURT car operator. For the sequencing,
real time report can be used as in this report number of defects will equal number of
paint marks. Ground features like bridges, L-xing, etc. are also reported in output for
use as reference in locating a defect.
(b) After locating a spot, the SE/JE(P.Way) will carry out testing for a length of 2 m i.e. 1
m on either side of the spot and classify the defect, if any, according to the criteria laid
down.There is a possibility that the spurt car may have been calibrated on
conventional threshold values of defect size in rail while the Need Based concept of
USFD testing of rails based on a different defect size in rail has already been
introduced in the section being tested. In such a situation the follow up testing should
be done with the Need Based concept of USFD testing only.
(c) Occasionally spots reported defective by SPURT car in its final defect report may be
found with no defect during follow up testing. Over reporting can occur for following
reason.
(i) Electronic or mechanical disturbance caused due to sudden dynamics or intrusion of

foreign objects.
(ii) Physical features like fishplated joints or extra holes being interpreted as flaw.
46
12.5 Routes tested by SPURT car
12.5.1 SPURT car conducts tests twice a year on the routes given below:
(i) New Delhi - Howrah

(ii) New Delhi - Mumbai Central
(iii) Mathura Jn - Chennai
12.5.2 LWR/CWR track only on the above routes are tested by SPURT car. Fishplated/SWR
track is not tested by SPURT car and will require testing by Railways.
12.6 The stretches left untested by SPURT car should be tested by manual USFD testing
using Need based criteria.
47
CHAPTER 13
REPORTING AND ANALYSIS OF RAIL/WELD FAILURES
13.1 After each fracture FAILURE REPORT shall be prepared as per proforma given in
Annexure –III and Annexure- IV by SE/JE(P. Way) and Divisions respectively.
13.1.1 All the fractured rail/weld pieces of 150mm length on each side of fractured face,
except those attributable to known extraneous causes such as fractures resulting from
accidents, series of fractures resulting from passage of flat wheels, etc., shall be sent to
Chemist and Metallurgist for detailed investigation in the following cases:
a) Rail failure within 5 years of primary renewal/Spate of premature rail

failures.
b) Weld failure within one year of execution.
c) Repetitive rail fractures of same rolling mark.
13.1.2 The Chemist & Metallurgist should submit consolidated investigation report to
Headquarters and Director/M&C/RDSO for making out a management information
report based on investigation carried out on the above rail failures. The annual briefs
made out by RDSO on the analysis of rail fracture must cover these details. Director
(M&C) may call for specific samples from Chemist & Metallurgist for confirmation of
their findings.
13.1.3 In the following instances, the samples of rail/weld shall be forwarded to

Director/M&C/RDSO.
(a) Rail/ weld samples involved in accident/derailment

(b) Rail samples of imported origin failed in service within guarantee
period.
13.2 All the failure reports and defects detected are required to be compiled in the form of
Annexure VI & VII at divisional level. Each weld failure shall be analysed by
sectional Sr. DEN/DEN, to ascertain whether the failure is sudden, due to impact or
inherent defects such as lack of fusion, micro porosities, formation of fin etc. The data
including causes, nature and frequency of defects shall be analysed and managerial
decisions required for preventive/ corrective action shall be taken promptly.
48
\
1 2 3 4 5 6 7 8 9 10 11 12
X=18.0 mm FOR 60 Kg/M. RAIL
X
X=23.0 mm FOR 52 Kg/M. RAIL
A B B C C D D D E E F F
LENGTH 12.5
X
SECTION - G.G.
(REFERENCE SECTION- F.F.)
A B B C C D D D E E INCLINED NOTCH 20°

F F
WITH VERTICAL
12.5 mm LONG
1.0 mm WIDTH
MINIMUM DEPTH
HEAD
CL OF RAIL C OF RAIL C 0.25 mm AT 20° ANGLE
L L OF RAIL
49
CL OF WEB L OF WEB C OF WEB
L
1. ALL DIMENSIONS ARE IN MILLIMETRES.

SECTION - A.A. SECTION - B.B. SECTION - C.C. 2. FBH DENOTES FLAT BOTTOM HOLE.
3. DIMENSIONS ARE NOT TO SCALE.
4. HOLES AT LOCATIONS 1, 3, 4, 10 ARE KEPT
CL OF RAIL
CL OF RAIL FOR ALIGNMENT/ SETTING PURPOSE ONLY.
CL OF RAIL
5. SENSITIVITY LEVEL SHALL BE WITH REFERENCE HOLES/
NOTCHES AT LOCATIONS 2, 5, 6, 7, 8, 9, 11, 12
BRAND SIDE i.e. TOP HEAD Ø 1.5 THROUGH HOLE ------------------- 1 NO.
1 9 M IN .
L SIDE HEAD Ø 1.5 FBH ------------------------------ 1 NO.
CL OF CL OF WEB
WEB Ø 2.0 FBH ----------------------------------- 3 NO.
Ø 2.0 FBH WEB
FOOT WEB JUNCTION: Ø 2.0 THROUGH HOLE ------------ 1 NO.
AT 3 PLACES G. G.
LEFT FOOT-12.5mm LONG , 1.0mm WIDE
RECTANGULAR NOTCH INCLINED 20° WITH VERTICAL
SECTION - D.D. SECTION - E.E. SECTION - F.F. AXIS ( SHORT EDGE 0.5 mm). ------------------ 1No.
RIGHT FOOT - 12.5mm LONG, 1.0mm WIDE RECTANGULAR
NOTCH INCLINED 2O° WITH VERTICAL AXIS
ANNEXURE- I
Para 2.2
A B
F
C OF RAIL
50
1. ALL DIMENSIONS ARE IN MILLIMETRES.
2. FBH DENOTES FLAT BOTTOM HOLE.
3. DIMENSIONS ARE NOT TO SCALE.
4. HOLES AT LOCATIONS A, A1, B1, B3, B4, B5 ,B6, B7, C1, D3 &
E1 ARE
L KEPT FOR ALIGNMENT/ SETTING PURPOSE ONLY.
5. SENSITIVITY LEVEL SHALL BE WITH REFERENCE HOLES/
NOTCHES AT LOCATIONS B, B2, C, D, D1, D2, E, F, F1
i.e. TOP HEAD Ø 1.5 THROUGH HOLE ----------- 1 NO.
SIDE HEAD Ø 1.5 FBH ------------------------------- 1 NO.EACH SIDE
WEB Ø 2.0 FBH ---------------------------------------- 3 NO.
FOOT WEB JUNCTION: Ø 2.0 THROUGH HOLE ------------ 1 NO.
6. LEFT FOOT-Ø2.0 THROUGH HOLE (LENGTH MIN 20MM)
AT THE CENTRE OF SIDE OF FOOT (AT ONE SIDE)-------1 NO.
RIGHT FOOT-Ø2.0 THROUGH HOLE (LENGTH MIN 20MM)
AT THE CENTRE OF SIDE OF FOOT
(AT OPP NOT IN SAME LINE ALONG THE LENGTHSIDE) SIDE)-----1
NO.
7. IT IS ESSENTIAL THAT THE BOTTOM OF ALL BLIND HOLES ARE
DRILLED FLAT FOR FB HOLES.
8. SPECIFIED HOLE TOLERANCE
1.5 MM HOLE : 1.5 TO 1.55 MM
2.0 MM HOLE : 2.0 TO 2.06 MM
5.0 MM HOLE : 5.0 TO 5.08 MM
( ALL OTHER TOLERENCES OF THE ABOVE HOLES SHALL BE IN
ACCORDANCE WITH ASTM E 428).
9. NOT TO SCALE
Para 2.2
ANNEXURE- IA
Annexure II A
(Para 6.3)
CLASSIFICATION OF RAIL/WELD DEFECTS FOR

NEED BASED CONCEPT OF USFD
Note : “Any sweeping signal on horizontal baseline that does not extend beyond 2.5 divisions
from the left edge of the screen or vice versa shall be recorded as Gauge Corner
Cracking (GCC) and not as OBS”.
For Rail Defects
S. Probe used Nature of defect Oscillogram pattern Classification
No
1. Normal A) Within fishplated area - No back echo before or after
probe 4MHz (i) Any horizontal defect in appearance of bolt hole echo
(sensitivity head web or foot of with IMR
set with length equal to distance Flaw echo with or without
respect to between rail end and multiples
100% back first bolt hole and OR
wall signal connected with the rail Drop in back echo before or
height from head. after appearance of bolt hole
rail bottom) echo with flaw echo with or
without multiple
(ii) Any horizontal defect No back echo between bolt IMR

connecting both bolt hole echo. Flaw echo with or
holes without multiples.
(iii) Any defect originating No back echo before or after IMR
from bolt holes and appearance of bolt hole echo
progressing at an angle with or without flaw echo
towards head-web
junction or web-foot
junction.
B) Outside fish plated area -
a) Any horizontal defect No back echo with flaw echo IMR
progressing at an angle in (shifting/without shifting) for
vertical plane in the rail at the any horizontal length
following locations in the track: OR
i) In tunnel & on tunnel No back echo and no flaw
approaches(100 m either side) echo
ii) On major bridges & bridge
approaches(100m either side)
iii) In the vicinity of holes near the
weld (50 mm for old AT weld and
75mm for new AT weld from the
centre of weld on either side of weld)
b)Any horizontal defect No back echo with flaw echo IMR

(shifting/without shifting) for
horizontal length > 20mm
progressing at an angle in No back echo with or without
vertical plane in the rail at track shifting flaw echo for OBS
locations other than (a) above. horizontal length< 20 mm
51
C) Vertical longitudinal split In case of partial/complete IMR
(piping) loss of back echo, side
probing shall be carried out
with 0o probe, if any flaw
echo with/ without multiples
is observed (in any length)
2. 70o 2MHz A) Any transverse defect in the
Centre rail head at the following
Probe locations in the track
(Sensitivity i) In tunnel & on tunnel
Flaw Peak Height (V) in %

set with approaches (100 m either side)
IMR
12mm dia. ii) On major bridges & (H / 30;V / 20)
Standard bridge approaches (100m either
hole in rail side)
(H<30;0<V<100)
Non Reportable
head 25mm iii) In the vicinity of holes
from rail near the weld (50 mm for old
top) AT weld and 75mm for new
For non ‘D’ AT weld from the centre of
Non Reportable* #
marked rails weld on either side of weld) (30[ H[ 100;V<20)
on
double/mult EXTENT of movement of flaw echo on horiz. scale (H) in %
iple line
sections
B) Any transverse defect in the
IMR
rail head at track locations other (H / 50;V / 60)
than A) above
(50>H/ 30;V/ 20)

(H<30;0<V<100)
Non Reportable
OBS
OBS*
(H / 50;60>V / 20)
Non Reportable* #
(30 [ H [ 100;V<20)
EXTENT of movement of flaw echo on horiz. scale (H) in %

* Details to be forwarded to RDSO quarterly in format at para 5.1.3
# To be marked as 'O' on web of rail
52
3. 70o 2MHz A) Any transverse defect in the
(Centre) rail head at the following
Probe locations in the track
(sensitivity i) In tunnel & on tunnel
set with approaches (100 m either side)

IMR
12mm dia. ii) On major bridges & (0[ H[ 100;
Standard bridge approaches (100m either 20[ V[ 100)
hole at rail side)
head 25mm iii) In the vicinity of holes
from rail top near the weld (50 mm for old
and with AT weld and 75mm for new
additional AT weld from the centre of Non
gain of weld on either side of weld) Reportable
10dB (0[ H[ 100; V<20)
thereon). EXTENT of movement of flaw echo on horiz. scale(H) in %

For all
single line
sections and
‘D’ marked
rails on B) Any transverse defect in the
double rail head at track locations other
OBS IMR
/multiple than A) above (0[ H<50; (50[ H[ 100;
line sections 20[ V[ 100) 20[ V[ 100)
Non
Reportable
(0[ H[ 100; V<20)
EXTENT of movement of flaw echo on horiz. scale(H) in %
53
4. 700 probes A) Any transverse defect in the
Gauge Face rail head on gauge face side/
& Non- Non-gauge Face at the
gauge Face following locations in the track IMR

(H/ 15;V / 20)
side i) In tunnel & on tunnel
(Sensitivity approaches (100 m either side)
Non Reportable
(H<15;V/ 20)
set on 5mm ii) On major bridges &
FBH) bridge approaches (100m either
side)
iii) In the vicinity of holes
near the weld (50 mm for old
Non
AT weld and 75mm for new Reportable Non Reportable* #
AT weld from the centre of (H<15; V<20) (H/ 15;V<20)
weld on either side of weld) EXTENT of movement of flaw echo on horiz. scale (H) in %
B) Any transverse defect in the

IMR
rail head on gauge face/ Non-

(H / 30;V / 60)
gauge Face side at track
(15[ H<30;V/ 20)

locations other than A) above
Non Reportable
(H<15;V/ 20)
OBS*
OBS
(H/ 30;20[ V<60)
Non
Reportable
(H<15
Non Reportable* #
V<20) (H / 15;V<20)

54
SNo Probe Used Nature of Defect Oscillogram Pattern Classification
0
5. 45 probes A) Any transverse Loss of signal height IMR
mounted in defect in the rail head, equal to or more than
test rig with scabs/wheel burn 20% of full scale height.
(sensitivity on top surface, at the
set to 100% following locations in
with respect the track
to reflection i) In tunnel & on tunnel
signal approaches (100 m
received either side)
from ii)On major bridges &
opposite bridge approaches
face of rail (100m either side)
head) iii) In the vicinity
of holes near the weld
(50 mm for old AT
weld and 75mm for
new AT weld from the
centre of weld on
either side of weld)
B) Any transverse
Loss of signal height IMR
defect in the rail head
equal to or more than
with scabs/wheel burn
80% of full scale height.
on top surface at track
locations other than A)
above.
Loss of signal height OBS
equal to or more than
20% but less than 80%
of full scale height
55
Annexure II B
(Para 6.5.1)
Weld defects(AT+FBW)
S.No. Probe used Nature of defect Oscillogram pattern Classification
1. Normal probe A) Any horizontal defect No back echo with IMRW
4MHz progressing at an angle in flaw echo (shifting or
(sensitivity set vertical plane in the rail without shifting)
with respect to at the following locations
100% back wall in the track:
signal height i). In tunnel & on tunnel
from rail approaches (100 m either
bottom) side)
ii). On major bridges &
bridge approaches(100m
either side)
iii) In the vicinity of
holes near the weld (50
mm for old AT weld and
75mm for new AT weld
from the centre of weld
on either side of weld)
B) Any horizontal defect No back echo with OBSW
progressing transversely flaw echo (shifting or
in the rail at track without shifting)
locations other than A)
above
56
2. 70o 2MHz A) Any transverse defect
Centre probe in the rail head at the
(Sensitivity set following locations in the

with 12mm dia. track IMRW
Standard hole at i) In tunnel & on tunnel (H / 30;V / 20)
rail head 25mm approaches (100 m either
from rail top) side)
(H<30;0<V<100)
ii) On major bridges
Non Reportable
& bridge approaches
(100m either side)
iii) In the vicinity of
Non Reportable* #
holes near the weld (50 (30 [ H [ 100;V<20)
mm for old AT weld and
75mm for new AT weld EXTENT of movement of flaw echo on horiz. scale (H) in %

IMRW
B) Any transverse defect (H / 50;V / 60)

in the rail
(50>H/ 30;V/ 20)

at track locations other
than A) above
(H<30;0<V<100)
OBSW
Non Reportable
OBSW*
(H / 50;60>V / 20)
Non Reportable* #
(30 [ H [ 100;V<20)

57
3. 700 probes A) Any transverse defect
Gauge Face & in the rail head on gauge
Non-gauge Face face/ Non-gauge Face
IMRW

side Probe side at the following (H/ 15;V/ 20)
(Sensitivity set locations in the track
Non Reportable
on 5mm FBH) i) In tunnel & on tunnel
(H<15;V/ 20)
approaches (100 m either
side)
ii) On major bridges
& bridge approaches
(100m either side) Non
Reportable
iii) In the vicinity of (H<15;
Non Reportable* #
(H/ 15;V<20)
V<20)
holes near the weld (50
mm for old AT weld and EXTENT of movement of flaw echo on horiz. scale(H) in %
75mm for new AT weld

B) Any transverse defect IMRW

in the rail head on gauge (H/ 30;V/ 60)
(15[ H<30;V/ 20)

face/ Non-gauge Face
Non Reportable
(H<15;V/ 20)
side at track locations
other than A) above
OBSW
OBSW*
(H/ 30;20[ V<60)
Non
Reportable
(H<15
Non Reportable* #
V<20) (H/ 15;V<20)
EXTENT of movement of flaw echo on horiz. scale(H) in %

58
ANNEXURE-III
(Para 13.1)
(To be prepared and submitted by PWIs)
PROFORMA FOR REPORTING RAIL/ WELD REPLACEMENT OR REMOVAL

ON DETECTION BY USFD
1. SE/JE(P.WAY) : (STATION CODE)
2. BLOCK SECTION : (Station code - Station code)
3. LINE :
a) UP/DN/Single : Upline-1, Down Line-2, Single Line-3
b) BG/MG /NG/Others : BG-1, MG-2, NG-3 & others-4
c) Rail No./ Weld No. : One digits ( within TP )
d) Right hand/ Left hand : RH-1, LH-2
4. GMT (TOTAL) : 0-50, 51-100,101-150,151- 200, 201-250, 251- 300, 301-350 ,

(for released rails add 1 2 3 4 5 6 7
previous traffic carried) 351- 400, 401-450, 451-500 > 500
8 9 10 11
5. KM & TP : ( 8 digits - 4 for Km / 2 for TP-2 for TP )
6. STRAIGHT/CURVE : Straight-0, Curve-(indicate degree of curvature

in one digit)
7. INNER/ OUTER RAIL : Inner – 1, Outer - 2

IN CASE OF CURVE
8. (a) TYPE OF FAILURE : FRACTURE-1, REMOVAL AFTER

DETECTION-2
(b) Date of fracture/removal 6 digits ( dd/ mm/ yy )
(c) Gap at the time of fracture 2 digits (mm)
9. RAIL/WELD : RAIL-1, AT WELD-2 (Fracture within 100mm

of weld to e considered as weld failure) FB
Weld-3, Gas Pressure Weld-4
10. SECTION OF RAIL : 60kg-1, 52kg-2, 90R-3, 75R-4, 60R-5, 50R-6
11. TYPE OF RAIL : 72 UTS-1, 90 UTS-2, Head Hardened-3
12. ROLLING MARK OF RAIL :
13. HOT STAMPING :

NUMBER/ CAST NUMBER
59
14. MONTH & YEAR OF : Two digits for month & two digits for year : suffix P
ORIGINAL/ SECONDARY Two digits for month & two digits for year : suffix S
LAYING
15. TOTAL NUMBER OF : Two digits

YEARS IN SERVICE
16. MONTH AND YEAR : Two digits for month & two digits for year
OF WELDING
17. (a) TYPE OF SLEEPER : PRC-1, ST-2, CST-3,WOODEN-4, OTHERS-5

(b) TYPE OF FITTINGS Elastic Fastening-1, Conventional-2
(c) SLEEPER DENSITY 1660-1, 1540-2, less than 1540-3
(numbers per Km)
18 BALLAST CUSHION : Three digits
( in mm)
19. IN CASE OF AT WELD : TPP-1, ITC-2, HTI-3, SAGAR-4, OBEROI-5

Raybon – 6, Morwel – 7, Deptt.- 8, Indiana – 9,
Others - 10
20. TYPE OF AT WELDING : Conventional–1,SKV-2,75mm GAP-3,

Combination Joint-4
21 LAST USFD CLASSIFICATION: Good-1, IMR-2, IMRW-3, OBS-4, OBSW-5,

DFWO-6, DFWR-7
22. FLAW DETECTED/

UNDETECTED :
a) IN CASE OF RAIL : Rail with detected flaw–1, Flaw undetected by USFD–

2
FRACTURE
b) IN CASE OF WELD : Weld with detected flaw–3,Flaw undetected
FRACTURE by USFD– 4
23. CAUSE OF FRACTURE
a) In Case of Rail : Inherent manufacturing defect –1, Corrosion –2, Bad

fracture maintenance-3, Fault of the rolling stock-4, Sudden-5, Due to
wheel burn/ scabbs-6, other causes-7
b) In Case of Weld : Poor quality of welds-1, Corrosion-2, Bad

maintenance-3, fracture Fault of the rolling stock-4,
Sudden–5, Any other causes–6
24. FRACTURE : Four digits

CODIFICATION
60
25. ORIGIN OF DEFECT AS : Head-1, Web-2, Foot-3, No origin-4
DETECTED BY USFD
26. AVOIDABLE/ : Avoidable-1, Unavoidable -2

UNAVOIDABLE
27. TYPE OF USFD FOR : Need based – 1, Conventional-2

RAIL AND WELD
28. MONTH & YEAR OF

LAST USFD
(a) FOR RAIL (including weld) : Two digits each for month and year
(00 +700 Probe)
(b) Flange testing of weld : Two digits each for month and year
(700 2 MHz Probe)
29. FOR WELDS IF NOT TESTED, : YES-1, NO-2

WHETHER FISH
PLATED BY JOGGLED FISH
PLATE WITH TWO TIGHT
CLAMPS
30. IN CASE OF WELD FRACTURE : YES-1, NO-2

WHETHER BOLT HOLES
AVAILABLE
31. IN CASE OF CWR/LWR
a) Date of last distressing : Two digits each for date, month & year
b) distressing temperature : Two digits
32. IN CASE OF SWR/FP
a) Date of last gap survey : Two digits each for date, month & year
b) Date of rectification : Two digits each for date, month & year
33. IN CASE OF CRACK

ORIGINATING FROM
BOLT HOLE
a) Date of oiling/greasing : Two digits each for date, month & year
b) Were the bolts tight : Yes-Y, No-N
c) Were the bolt holes chamfered : Yes-Y, No-N
d) In case of elongation, size of : (Two digits in mm)
bolt hole
e) Sleeper spacing : Normal-1, Joint sleeper spacing-2
34. IN CASE OF FAILURE OF AT : Yes-Y, No-N

WELDS WITHIN 2 YEARS
61
35. IN CASE OF FAILURE OF FBW
a) Name of welding plant : Station code

b) Panel No. : (Three digits)
c) Joint No. : (Two digits)
36.LOCATION OF FRACTURE : Fish plated Zone(Bolt hole area)- 1, Mid rail-2

(For rail fracture) SEJ-l ,Glued Joint-4, Point &Crossing-5
62
ANNEXURE-IV
(Para 13.1)
DETAILS REQUIRED FOR RAIL/WELD FAILURE ANALYSIS

(Only for guidance for generating data at Division’s level )
1. RAILWAY ZONE : (CR-01, ER-02, NR-03, NER-04, NFR-05,

SR-06, SCR- 07, SER-08, WR- 09,ECR-
10,ECoR-11,NCR-12, NWR-13,SECR-14,
SWR-15, WCR-16)
2. DIVISION : As per code
3. SE/JE(P. WAY) : (Station code)
4. SECTION (NAME OF LINE OR BRANCH) : (Station code)
5. BLOCK SECTION : (Station code-Station code)
6. DATE OF FRACTURE/REMOVAL : Two digits each for date, month and year
7. TIME OF DETECTION : 4 Digits( 2 for hours/2 for minutes)
8. ROUTE CLASSIFICATION : (A, B, C, D, DS, ES, E, Q, R1,R2,R3, S)
9. LENGTH OF BLOCK SECTION (in KM) : (Two digits)
10. MAX. PERMISSIBLE SPEED : (Three digits)
11. MAX. PERMISSIBLE AXLE LOAD : 20.32T-1, 22.1T-2, 22.86T-3, above

22.86T-4, MG-5
12 GMT(ANNUAL) : 0-5, 5-10, 10-15, 15-20, 20-25, 25-30, 30-35, 35-40, > 40
1 2 3 4 5 6 7 8 9
13. CWR/LWR/SWR/FISH PLATED : CWR-1, LWR-2,SWR-3,FISH PLATED-4
14. LINE :
(a) Up/down/single : Upline-1, Down line-2, single line-3
(b) BG/MG/NG/Others : BG-1, MG-2, NG-3, Others-4
15. RAIL NUMBER/ WELD NUMBER IN TP : (two digits)
16. RAIL – RIGHT HAND OR LEFT HAND : RH-1, LH-2
17 GMT(TOTAL) : 0-50, 51-100,101-150,151- 200, 201-250, 251- 300, 301-350 , 351- 400, 401-450,
(for released rails 1 2 3 4 5 6 7 8 9
add previous 451-500, > 500
traffic carried) 10 11
18. KM & TP : (8 digits-4 for Km/2 for TP-2 for TP)
63
19. STRAIGHT/CURVE : Straight-0 Curve-(indicate degree of
curvature in one digit)
20. INNER/OUTER RAIL IN CASE OF CURVE : Inner-I, Outer-2
21 a) TYPE OF FAILURE : Fracture-1, Removal After Detection-2

b) Date of Fracture/Removal : 6 digits(dd/mm/yy)
c) Gap at the time of fracture : 2 digits (mm)
22. RAIL/WELD : RAIL-1, AT Weld-2, FB Weld-3,

(Fracture within 100mm of weld to be Gas Pressure Weld-4,
considered as weld failure)
23 . SECTION OF RAIL : 60kg-1, 52kg-2, 90R-3, 75R-4, 60R-5, 50R-6
24. TYPE OF RAIL : 72 UTS-1, 90 UTS-2, Head Hardened-3
25. ROLLING MARK OF RAIL :
26. HOT STAMPING NUMBER/CAST NUMBER :
27. MONTH & YEAR OF ORIGINAL : Two digits for month and two digits for year:
Suffix P
SECONDARY LAYING/WELDING : Two digits for month and two digits for year:
Suffix S
28. TOTAL NUMBER OF YEARS IN SERVICE : Two digits
29. SLEEPER TYPE : PRC-1, ST-2, CST-3, WOODEN-4,

OTHERS-5
30. FITTING TYPE : Elastic fastening-1, conventional-2
31. SLEEPER DENSITY(numbers per Km) : 1660-1, 1540-2, less than 1540-3
32. BALLAST CUSHION (in mm) : Three digits
33. TYPE OF AT WELD : Conventional-1, SKV-2, 75mm gap-3,

Combination Joint-4
34. IN CASE OF AT WELD : TPP-1, ITC-2, HTI-3, SAGAR-4, OBEROI - 5

Raybon -6, Morwel-7, Deptt. – 8,Indiana–9,
Others-10
35. LAST USFD CLASSIFICATION : Good-1, IMR-2, IMRW-3, OBS-4, OBSW-5,

DFWO-6, DFWR-7
64
36. FLAW DETECTED/UNDETECTED
a) IN CASE OF RAIL FRACTURE :Rail with detected flaw – 1, Flaw undetected

by USFD – 2
b) IN CASE OF WELD FRACTURE : Weld with detected flaw – 3, Flaw undetected

by USFD– 4
37. CAUSE OF FRACTURE
a) IN CASE OF RAIL FRACTURE : Inherent manufacturing defect –1, Corrosion –2,

Bad maintenance-3, Fault of the rolling stock-4,
Sudden-5, Due to wheel burn/ scabs -6, other
cause-7
b) IN CASE OF WELD FRACTURE : Poor quality of welds-1, Corrosion-2, Bad
maintenance-3, Fault of the rolling stock-4,
Sudden-5, any other cause-6
38. FRACTURE CODIFICATION : Four digits
39.Origin of defect as detected by USFD : Head-1, Web-2, Foot-3, No origin-4
40. AVOIDABLE/UNAVOIDABLE : Avoidable-1, Unavoidable -2
41. TYPE OF USFD FOR RAIL AND WELD: Need based – 1, Conventional-2
42. MONTH & YEAR FOR LAST USFD :

(a) FOR RAIL (including weld) (00 +700 Probe) :Two digits each for month and year
(b) Flange testing of weld (700 Probe) :Two digits each for month and year
43. FOR WELDS IF NOT TESTED, WHETHER : YES-1, NO-2

FISH PLATED BY JOGGLED FISH PLATE WITH
TWO TIGHT CLAMPS
44. IN CASE OF WELD FRACTURE : YES-1, NO-2

WHETHER BOLT HOLES AVAILABLE
45 IN CASE OF CWR/LWR
a) Date of last destressing : Two digits each for date, month and year
b) Destressing temperature : Two digits
46. IN CASE OF SWR/FP

a) Date of last gap survey : Two digits each for date, month and year
b) Date of rectification : Two digits each for date, month and year
47. WHETHER FAILURE OF AT WELDS : YES-Y, NO-N

WITHIN 2 YEARS
65
48. IN CASE OF CRACK ORIGINATING FROM :
BOLT HOLE
a) Date of oiling/greasing : Two digits each for date, month and year
b) Were the bolts tight : Yes-Y, No-N
c) Were the bolt holes chamfered : Yes-Y, No-N
d) In case of elongation, size of bolt hole : (two digits in mm)
e) Sleeper spacing : Normal-1, joint sleeper spacing-2
49. IN CASE OF FAILURE OF FBW
(a) Name of welding plant : Station code

(b) Panel No. : (three digits)
(c) Joint No. : (Two digits)
50. LOCATION OF FRACTURE : Fish plated zone (Bolt hole area)-1,

(For Rail Fracture) Mid rail-2, SEJ-3, Glued Joint-4,
Points & Crossings-5
66
ANNEXURE –V
(Para 6.8)
CHECK LIST OF ULTRASONIC TESTING OF RAIL/WELDS
DIVISION------------------------SECTION----------------------------- LINE: UP/DN/SINGLE

ROUTE----------------Km. FROM-----------------TO-----------------DATE---------------------
1. Name of the operators then trained by RDSO Last refresher course done
i) ------------------------------------- --------------------------------- --------------------------------
ii) -------------------------------------- --------------------------------- -------------------------------
2. Method of Testing : Conventional/Need Based

3. Rail section &Brand Mark : …………………………………………………….
4. Annual GMT : …………………………………………………….
5. Whether within service life : …………………………………………………….
6. Frequency : …………………………………………………….
7. Date of last Testing : …………………………………………………….
8. Reason for overdue if overdue : …………………………………………………….
9. Type of USFD M/C : …………………………………………………….
10.Model,Manufacturing Year & M/C no. : …………………………………………………….
11.Visual condition of electronic unit :Very Good/Good/Satisfactory/Not satisfactory
12.Visual condition of trolley :Very Good/Good/Satisfactory/Not satisfactory
13.Date of calibration of M/C : (to be filled up from M/C register)
14.Date of sensitivity setting of M/C : (to be filled up from M/C register)
15.Date of checking of characteristics : (to be filled up from M/C register)
16.Fuction of Controls : …………………………………………………….
17.Alignment of probes & lifting system : …………………………………………………….
(with respect to the center line)
18.Watering arrangement of probes : …………………………………………………….
19. Date of change of last probes : …………………………………………………….
with probe details
20.Condition of probes:
Types of probe Right hand side Left hand side 70o 2 45o 2 70o 2
MHz MHz MHz
(Flange (8mm x
testing) 8mm)
Description 0o 70oF 70oB 0o 70oF 70oB (Flange (Flange
testing) testing)
Working/Not
working
Condition of shoes
21. i) Watering condition of Battery : …………………………………………………….

ii) Year of procurement of battery : …………………………………………………….
22.Condition of Audio Alarm : Sounding/ Not Sounding
23.Checking spares with the M/C : Available/ Not available
67
24. Testing knowledge of SE/JE (P.WAY)
i) Criteria for marking defects and : …………………………………………………….
calibration and sensitivity setting of M/C
ii) Criteria for periodicity of USFD testing : …………………………………………………….
25.Date of Test check by : (i) AEN

(ii) Sr. DEN/DEN
26.Test check of Last days work : Date of testing

a) Rail testing :Test checked from Km……to Km………
Classification of defects confirmed : Yes/No
for all markings(IMR/REM/OBS)
If No, No. of markings not confirmed : ………………………………...Nos.
Whether any defect found extra (missed : Yes/No
during regular testing)
If Yes, No. of such defects and classification: ………………………………………… Nos.
b) WELD testing :No. of Welds test checked……………….Nos.
Type of welds :SKV/Conventional AT/FB
Whether testing results confirmed for all : Yes/No
If No, No. of the welds differing detected results: ………………………. Nos.
27. General Observation :

(i) …………………………………………
(ii) ……………………………………………
(iii) …………………………………………………….
(iv) ……………………………………………………
Signature
Name of Inspecting official……………..
Designation …………….Date …………….
68
ANNEXURE –VI
(Para -13.2)
MASTER REGISTER FOR DEFECTS DETECTED AND RAIL FRACTURES
S. Date Km Ref. Code Defects in rail Defects in Rail fractures other than Rail Remarks
No To other than rail originating from bolt hole fractur
FR originating originating es
no. from bolt hole from Bolt origina
hole ting
from
bolt
hole
IMR OBS Rail Flaw Sudd Any
with un- en other
detect detec fract causes
-ed ted by ures (04)
flaw USFD (03)
(01) (02)
69
ANNEXURE – VII
(Para - 13.2)
MASTER REGISTER FOR DEFECTS DETECTED AND WELD FRACTURES
S. A.T. weld defects A.T. weld fractures FBW Remarks

No. Weld Flaw Sudden Any fractures
Ref. To FR
with undetect fractures other

Code
Date
Km.
DFWO
DFWR
OBSW
IMRW
no.
detected ed by (07) Cause

flaw USFD s (08)
(05) (06)
Note: Entries in column 05 and 06 above shall clearly indicate type of defect such as lack of
fusion, porosities, formation of fin etc
70
ANNEXURE-VIII
(Para 4.3.1)
INSPECTION OF RAIL TESTER AND WORK OF PWI (USFD)
Name of SE/JE (P.WAY)/USFD, Grade & HQ.
Trained by RDSO during.
Last course attended at RDSO…
MACHINE INSPECTED BY SHRI ……………………

DATE OF INSPECTION……………………………….
1. MACHINE
i) Make and Sr. No. of the machine

a) SRT(ECIL/VIBRONICS/EEC/Paras/Others) …
b) DRT(EEC/PARAS/Others)
ii) Month & Year of procurement of machine
iii) Function of controls.
(On/Off, Gain, H. Shift, Depth,
Energy & Reject etc.)
iv) Brightness of the machine.

(Base line and flaw peaks)
v) Working of the junction box.

(All terminals)
vi) Condition of the probe cables

(Connected cables and BNC’s).
vii) Condition of probes-00,

70oF & B and 7002 MHz,
4502MHz, 7002 MHz SLP
(with respect to wear & sensitivity)
viii) Alignment of probes & lifting system.

(With respect of centre line.)
ix) Condition of shoes of probes (Un-even wear).

Provision of 0.2mm gap.
x) Watering arrangements.
(Proper and adequate supply
to different probes).
xi) Checking spares with machine
(Wheels-2, Normal probe – 1
71
700 F & B-1, 7002 MHz-1, 45o2MHz - 2 &700 2 MHz SLP – 1, probe shoe,
probe holder, battery)
xii) Working condition of Batteries. (Voltage
and Specific Gravity) & charging system
xiii) Year of procurement of Battery.
xiv) Condition of Trolley Wheels.
xv) Tools with machine.
xvi) General up-keep of machine

and trolley
2. CALIBRATION & SENSITIVITY SETTING OF MACHINE:
i) Availability of IIW Block, multimeter, Standard rail piece

with artificial flaws and Steel block.
ii) Checking of operating characteristics by

IIW Block last done.
iii) Sensitivity setting of machine

last done and gain level employed.
iv) Checking of calibration and sensitivity

setting of machine.
3.QUALITY OF TESTING: Sec.-------To------LINE(Single/UP/DN.)

Kms/From--------To----------------------
i) Check of last days/week/month work
(Comparison with last round testing)
by SE/JE (P WAY.)/ (USFD)
ii) Checking of IMR/DFWR of Rails/Welds
4. TESTING KNOWLEDGE OF SE/JE (P WAY):
i) Criteria for marking defects and calibration

and sensitivity setting of machine.
ii) Criteria for periodicity of USFD testing.
(As per criteria laid down by Railway Board.)
iii) Policy and latest instructions of USFD.
Signature of Inspecting Officer
72
FIG. 1: ARRANGEMENT OF PROBES FOR TESTING
OF NEW RAILS IN STEEL PLANTS
73
NEUTRAL AXIS
FIG. 2A: AREA COVERED BY NORMAL ( 0°) PROBE

(FOR A.T. WELD,AREA BELOW NEUTRAL AXIS REMAINS UNTESTED)
74
FIG. 2B: AREA COVERED BY 70° PROBE
75
FIG.2C: AREA COVERED BY 70°, 2 MHz,
(20mm CIRCULAR OR 20mm X 20mm
SQUARE CRYSTAL) PROBE.
(TESTING FOR A.T. WELD FLANGE)
76
AREA COVERED BY 70° PROBES IN EQUIPMENT
WITH GAUGE FACE CORNER, CENTRE AND
FIELD CORNER PROBES
FIG. 2D: AREA COVERED BY 70° PROBES IN

VARIOUS GAUGE FACE CORNER
DEFECT DETECTION EQUIPMENT
77
RAIL HEAD WIDTH
5Ø FBH
15
SLICE FROM RAIL HEAD
300
12Ø THROUGH HOLE

25
20
40
20° 25
90°
78
APPROX. 100
1.5m LONG ALUMINIUM / WOODEN HOUSING FOR TEST PIECE HAVING TOP TABLE
WIDTH EQUAL TO RAIL HEAD WIDTH
1. The slice from rail head for sensitivity setting shall be from rail of same sectional weight which is to be tested (i.e. for testing on 60Kg/52Kg, 90R rails etc. the
sensitivity testing piece shall be from 60Kg, 52Kg, 90R rails respectively).
2. In case of machines having provision of variable shift of gauge face probes following shall be ensured:
a) Maximum shift of probe shall be limited to the extant up to which there is no loss of acoustic coupling depending on rail top profile.
b) The sensitivity setting shall be done at the shift level with which actual testing is to be carried out.
c) The shift of probe shall not be altered during testing without fresh setting at altered shift .
ALL DIMENSIONS ARE IN mm.
FIG. 3 - SENSITIVITY SETTING BLOCK FOR 70 ° 2MHz (CENTRE, DRAWING IS NOT TO SCALE
GAUGE FACE AND NON-GAUGE FACE ) PROBES
N.A.
79
FIG.4: STANDARD RAIL WITH ARTIFICIAL FLAWS FOR

CHECKING OF PERFORMANCE OF RAIL TESTERS
NOTE:- ALL DIMENSIONS ARE IN MILLIMETERS.
b
80
a - SURFACE ECHO.
b - BACK ECHO.
FIG.5: RAIL WITHOUT FLAW (0° PROBE)
b
b1
b2
b3
81
a b4
a - SURFACE ECHO.
b - FLAW ECHO.
b1,b2 . . . MULTIPLE FLAW ECHOES
FIG.6: LONGITUDINAL HORIZONTAL SPLIT IN HEAD REGION

(TYPE 112 &212, 0° PROBE)
b b1
b2
b3
a
82
a - SURFACE ECHO.
b - FLAW ECHO.
b1,b2. . . . MULTIPLE FLAW ECHOES
FIG. 7 LONGITUDINAL HORIZONTAL SPLIT IN HEAD-

WEB JUNCTION (TYPE 1321-2321,0° PROBE)
c
a b
83
a - SURFACE ECHO.
b - FLAW ECHO.
c - SUPPRESSED BACK ECHO
FIG.8: VERTICAL LONGITUDINAL SPLIT IN HEAD (TYPE 113 & 213, 0° PROBE)
b
bi
b2
I k
IHIII 11111111 IIIIIIIIIIIIIIIIIIII
I I I Z
84
SURFACE ECHCi
b BACK E'THC'
bl)2... .MLTLTLE BACK ECHOES
FIG.9: IL'E. FROEING OF RAIL HEAD, WITHOUT ELAW
b
b1
b2
b3
a b4
85
a - SURFACE ECHO
b - FLAW ECHO
b1,b2. . . . MULTIPLE FLAW ECHOES
FIG. 10 : VERTICAL LONGITUDINAL SPLIT IN HEAD (0° SIDE PROBING)
I b
86
H iiiii iiiiiii
a- SURFACE
ECHO
b-FLAW ECHO
c -SUPPRESSED BAC}: ECHO
FIG. 11: VERTICAL LONGITUDINAL SPLIT IN WEB

(TYPE 133 & 233-0° PROBE)
r b2
b4
87
IUUIIIIIILUIIIUIIIUIIIUIIIU IIIU 11111111
1 2 S i i I 1
4-SUFFACE EXHO
b - LACK ECHO
b 1,b2. ... MIJLITPLE E;ACK ECHOES
FIG. 12: SIDE PROBING OF RAIL WEB WIThOUT DEFECT
b
b1
b2
b3
a
88
a - SURFACE ECHO
b - FLAW ECHO
b1,b2 . . . . MULTIPLE FLAW ECHOES
FIG. 13 : VERTICAL LONGITUDINAL SPLIT IN WEB (0°SIDE PROBING)
b
89
a - SURFACE ECHO
b - FLAW ECHO (GRASSY PEAK PATTERN)
FIG. 14 : SEGREGATION (0° PROBE)
MOVEMENT OF PROBE
b
90
a - SURFACE ECHO
b - BOLT HOLE ECHO
FIG. 15 : BOLT HOLE WITHOUT CRACK (0° PROBE)
MOVEMENT OF PROBE
b
b2 b1
a
91
a - SURFACE ECHO
b - BOLT HOLE ECHO
b1& b2 - SHIFTING FLAW ECHOES
FIG. 16: BOLT HOLE WITH CRACK (TYPE 135,235,0° PROBE)
MOVEMENT OF PROBE
b2 b1
92
b - FLAW ECHO AT MAXIMUM AMPLITUDE

b1 - FLAW ECHO STARTS APPEARING FROM HERE
b2 - FLAW ECHO VANISHES HERE.
FIG.17: TRANSVERSE DEFECT (TYPE 111, 211

70°,2 MHz, FORWARD PROBE)
MOVEMENT OF PROBE
b
93
b1 b2
b - FLAW ECHO AT MAXIMUM AMPLITUDE

b1 - FLAW ECHO STARTS APPEARING FROM HERE
b2 - FLAW ECHO VANISHES HERE.
FIG.18: TRANSVERSE DEFECT BY (TYPE 111, 211

70°,2 MHz, BACKWARD PROBE)
94
FIG. 19 : UNDETECTABLE STAR CRACKS ( 0° PROBE )
95
3 mm HOLE AT THE MIDDLE

OF THE FLANGE THROUGH
THE WELD.
FIG. 20(a) : STANDARD A.T. WELDED RAIL PIECE WITH ARTIFICIAL

FLAWS FOR SENSITIVITY SETTING OF ULTRASONIC
EQUIPMENT TO EXAMINE A.T. WELDS
3 Ø HOLE
25
PROBE
30
15
750 750
ELEVATION
96
30
PROBE
15
30 mm DEEP SAW CUT IN WELD COLLAR, 15 mm
AWAY FROM EDGE OF WELD COLLAR
BOTTOM PLAN
FIG. 20(b): STANDARD A.T. WELDED RAIL PIECE WITH ARTIFICIAL
FLAWS FOR SENSITIVITY SETTING OF ULTRASONIC
EQUIPMENT TO EXAMINE 75 MM WIDE GAP A.T. WELDS
U U C
L C L
FIG.21(a): SKETCH SHOWING THE LOCATION

OF FLANGE OF RAIL FOR ULTRASONIC
TESTING WITH 70°, 2 MHz , (20mm
CIRCULAR OR 20mm X 20mm SQUARE
CRYSTAL) ANGLE PROBE
97
A.T.WELD
45°
S
70
°
H
A.T.WELD
S
°
70
H
FIG. 21(b): TESTING OF BOTTOM FLANGE OF A.T.

WELDS USING 70° AND 45° PROBES
98
WELD
PORTION
70° 2 MHz SL
70° 2 MHz SL
PROBE
PROBE
5mm
RAIL BOTTOM
10 mm
WELD PROFILE BOTTOM
ELEVATION
70° 2 MHz SL 70° 2 MHz SL
SECTIONAL ELEVATION AT AA PROBE PROBE
99
T1/R1 T2/R2
R1/T1 R2/T2
5mm
70° 2 MHz side looking 70° 2 MHz SL
(SL) probe placed at upper PROBE
UPTO 2 mm MAXIMUM
10mm DEPENDING ON CUTTING TOOL
zone of rail flange
WELD PROFILE BOTTOM

PLAN showing position of 70° 2 MHz
DETAILS AT C SECTIONAL side looking (SL) probe on rail flange
ELEVATION AT BB
FIG. 22 (a ) : STANDARD A.T. WELDED RAIL TEST PIECE

( HALF MOON CRACK)
Tx
Fusion faces
Fig.22(b): Sensitivity setting using 450 tandem probe
Fig. 22(c) : AT weld testing using 450 tandem probe
100
B F B F
101
FIG. 23: PROBE POSITIONS FOR TESTING OF

HALF MOON CRACK WITH 45° PROBE
250
R T
N.A.
250 250
500
CALIBRATION AND SENSITIVITY SETTING (USING 45° PROBE)

ON STANDARD RAIL PIECE
DETERMINING FLAW
LOCATION HORIZONTAL DETERMINING FLAW LOCATION VERTICAL
FLAW ON FBW/
LEFT HAND GPW
SIDE
(FOR CRACKS IN RAIL HEAD TOP PORTION)
R T
FLAW IN
MIDDLE
(FOR CRACKS IN MIDDLE ZONE OF

RAIL HEAD)
T
R
FLAW ON
RIGHT HAND
SIDE
(FOR CRACKS TOWARDS BOTTOM OF RAIL

HEAD)
FIG.24 (a): POSITION OF 45° ANGLE PROBES AND BEAM PATH

FOR VARIOUS FLAW LOCATIONS WHEN EXAMINING
THE HEAD OF G.P. & F.B. WELDS
NOTE:- ALL DIMENSIONS ARE IN MILLIMETERS. TEST RANGE 165mmSW
102
250
N.A.
5mmØ
250 250
500
CALIBRATION AND SENSITIVITY SETTING (USING 70° PROBE)

ON STANDARD RAIL PIECE
WEB OF
RAIL
WELD : FREE FROM FLAWS, NO FLAW SIGNAL
FLAW AT TOP (PROBE SIDE):FLAW ECHO AT GRADUATION MARK 5.6
FLAW IN MIDDLE: FLAW ECHO AT GRADUATION MARK 4.2
FLAW AT BOTTOM (OPPOSITE SIDE TO PROBE);FLAW ECHO

AT GRADUATION MARK 2.8
FIG.24(b): POSITION OF 70° ANGLE PROBE

& BEAM PATH FOR VARIOUS FLAW
LOCATION WHEN EXAMINING THE
WEB AND FLANGE OF G.P. & F.B. WELDS
NOTE:- ALL DIMENSIONS ARE IN MILLIMETERS. TEST RANGE:165 mm SW
103
FREEDOM FROM DEFECTS: SUCH DEFCTS INCLUDE (AMONG OTHER DETREMENTAL DEFECTS)
CRACK OF ALL KINDS, FLAWS, PIPING OR LACK OF METAL.
THE LIMIT OF PERMISSIBLE DEFECTS

FOR UST OF RAILS SHALL BE AS
FOLLOWS:-
HEAD - 1.5 mm Ø FLAT BOTTOM HOLE.

WEB - 2.0 mm Ø FLAT BOTTOM HOLE
FOOT - 2.0 mm Ø FLAT BOTTOM HOLE
1.5 mm FBH
REJECTION LEVEL
104
ANY SIGNAL EITHER FROM HEAD

WEB OR FOOT HAVING HEIGHT
MORE THAN THE RESPECTIVE
SIGNAL HEIGHTS ( GAIN SETTING
TO 60% OF SCREEN HEIGHT )
WILL BE CONSIDERED AS
DEFECTIVE.
2mmØ FBH
FIG. 25: STANDARD TEST RAIL PIECE FOR TESTING OF RAILS

BEFORE MANUFACTURING OF POINTS & CROSSINGS
PLAN OF POINT RAIL
ZONE-I ZONE-II ZONE-III
105
ZONE-I,II PROBE POSITION ZONE - III PROBE POSITION

PLAN OF SPLICE RAIL
ZONE-I ZONE-II ZONE-III
FIG. 26(a): TESTING PROCEDURE FOR POINT AND SPLICE RAILS FOR
1 IN 12 CROSSING B G 52 Kg
5 Ø THROUGH HOLE AT
DEPTH OF 25 mm IN RAIL HEAD
LOCATION '
B'
LOCATION '
A'
ELEVATION
106
PLAN
FIG. 26(b) : STANDARD TEST PIECE (SEJ STOCK RAIL)
100
160
5
ELEVATION
107
PLAN
FIG. 26(c) : BEAM DIRECTION OF ANGLE PROBES FOR

SENSIVITY SETTING
Sl. PROBE ANGLE BEAM PATH APPLICATION
No.
T R
0° 1. LONGITUDINAL
4MHz HORIZONTAL
1 DEFECTS IN
DOUBLE
CRYSTAL HEAD WEB
AND FOOT
2.STAR CRACK IN WEB
( BOLT HOLE)
T+R T+R
70°
1. TRANSVERSE
FORWARD(F)
AND DEFECTS IN
2
RAIL HEAD
BACK WARD(B)
2MHz
SINGLE CRYSTAL
B F
R 1. TRANSVERSE DEFECTS IN
T+ HEAD PORTIONS OF F.B. AND
45°
2MHz G.P.WELDED JOINT
3 2. HALF MOON DEFECTS IN
SINGLE
CRYSTAL A.T.WELDS BELOW
WEB-FOOT JUNCTION
R
T+
70° 2 MHz, (20mm
4 CIRCULAR OR 1. DEFECTS OF A.T.WELDED
20mm X 20mm JOINTS IN FLANGE LOCATION
SQUARE CRYSTAL)
SINGLE CRYSTAL
R
T+
1. HALF MOON DEFECTS IN

5 70° A.T.WELDED JOINTS IN
2 MHz FLANGE LOCATION
SIDE LOOKING BELOW WEB-FOOT
PROBE (SLP) JUNCTION
20°
FIG. 27 : DETAIL OF PROBES USED FOR

TESTING OF RAIL AND WELDS
108
PROBES TEST RIG
R T
SCAB/ WHEEL 2xd

BURN
PLAN
PROBES
TEST RIG
109
20mm
ELEVATION
FIG. 28 : Sensitivity setting/Testing with 45° probe
using Test Rig (for locations having
scabs/wheel burns)
5 mm SAW CUT
5 mm
Direction
of Probe
110
FIG.29 SENSITIVITY SETTING BLOCK & ULTRASONIC

SCANNING OF TONGUE RAIL OF SEJ (RAIL IN PLAN)
jIIi:I r'
i ' il I II I ii I
ri -c øe
TE
TE
11H
TE
p41
RU SAVE
r --i
ZOOM
CONFIO. SETTING
L L
FIG.30: Typical signal pattern of bunch of moving signals for AT

welds
111
FIG. 31 : 100 OR 200 - TRANSVERSE BREAKAGE WITHOUT APPARENT
ORIGIN
FIG. 32 : 123 OR 223 - HEAD, SURFACE CRUSHING OR BATTERING
112
FIG. 33 : 111 OR 211 - INTERNAL FLAW IN HEAD , TRANSVERSE BREAKAGE
113
FIG. 34 : 112 OR 212 - INTERNAL FLAW IN HEAD , HORIZONTAL CRACK
114
113
213
FIG. 35 : 113 OR 213 - INTERNAL FLAW IN HEAD , VERTICAL

LONGITUDINAL SPLIT
115
FIG. 36 : 1211 OR 2211 - HEAD, SURFACE, SHALLOW SURFACE DEFECT (FLAKING)
FIG. 37 : 1221 OR 2221 - HEAD, SURFACE, BREAKING OUT RUNNING SURFACE

(SCABBING)
FIG. 38 : 1222 OR 2222 - HEAD, SURFACE, BREAKING OUT GAUGE CORNER

(SHELLING)
116
- -r
FIG. 39 : 2251 - HEAD, SURFACE, WHEEL BURN ISOLATED
FIG. 40 : 2252 - HEAD SURFACE, WHEEL BURN REPEATED
FIG. 41 : 153 OR 253 - FOOT VERTICAL LONGITUDINAL SPLIT

(HALF MOON CRACK)
117
FIG. 42 : 1321 OR 2321 - WEB , HORIZONTAL CRACK, AT TOP FILLET RADIUS
118
__________ ' -- -
1322 1322
1322
-u-
2322 2322
FIG. 43 : 1322 OR 2322 - WEB, HORIZONTAL CRACK AT BOTTOM

FILLET RADIUS
119
FIG. 44 : 133 OR 233 - WEB, VERTIVAL LONGITUDINAL SPLITTING (PIPING)
120
FIG. 45 : 135 OR 235 - WEB , CRACKS AT HOLE
FIG. 46 : 124 OR 224 - HEAD, SURFACE LOCAL BATTER
FIG. 47 : 139 OR 239 - WEB, LAP
121
FIG. 48 : 301 - DAMAGE TO RAIL BY BRUSHING OR ARCING
FIG. 49 : 302 -DAMAGE TO RAIL BY BAD MACHINING , DRILLING OR

FLAME CUTTING
122
f
FIG. 50 : 411 - WELDING, FLASH BUTT JOINT, TRANSVERSE CRACK
FIG. 51 : 421 - WELDING, THERMIT JOINT TRANSVERSE CRACK
123
FIG. 52 : 422 - WELDING, THERMIT JOINT HORIZONTAL CRACK
FIG. 53 : 431 - WELDING, ELECTRIC ARC JOINT TRANSVERSE CRACK
FIG. 54 : 471 - WELDING, BUILDING UP TRANSVERSE CRACKING OF

HEAD ACROSS THE BUILT UP PORTION
124
FIG. 55 : 472 - WELDING, BUILDING UP, BUILT UP PART BREAKS AWAY
FIG. 56 : 481 - WELDING, TRACTION BOND WELDING CRACK AT WELD
125

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GOVERNMENT OF INDIA

MANUAL FOR ULTRASONIC TESTING OF

MANUAL FOR ULTRASONIC TESTING

RESEARCH DESIGNS AND STANDARDS ORGANISATION

Disclaimer: This Compilation is for educational reference only.

S.No. Description Page No.

1. Rail defects and their codification 1

2. Ultrasonic testing of rails at manufacturer’s works 8

3. Ultrasonic rail testing equipment and accessories 9

4. Calibration, Sensitivity setting, Maintenance of machines and functions of 11

5. Procedure to be followed by USFD operators for undertaking ultrasonic 17

6. Need based concept in periodic USFD testing of rails and welds 19

7. Limitations of ultrasonic flaw detection of rails 22

8. Procedure for ultrasonic testing of Alumino-thermic welded joints 24

9. Ultrasonic testing of flash butt and gas pressure welded joints 32

12. Ultrasonic testing of rails by SPURT Car 43

13. Reporting and analysis of Rail/Weld failure 48

Annexure No. Description Page No.

Annexure II A Classification of Rail defects for Need Based concept of USFD 51

Annexure II B Classification of Weld defects for Need Based concept of USFD 56

Annexure III Proforma for reporting Rail/ Weld replacement or removal on 59

Annexure IV Details required for Rail/Weld failure analysis 63

Annexure V Check list of ultrasonic testing of Rails/Welds) 67

Annexure VI Master register for defects detected and Rail fractures 69

Annexure VIII Inspection of rail tester and work of PWI/ (USFD) 71

RAIL DEFECTS AND THEIR CODIFICATION

(b) Defects observed within fish-plated zone.

(c) Defects not covered in (a) and (b).

1.2.1 Nature of defects in rails

1.2.2.1 Defects in Flash Butt Welds:

1.2.2.2 Defects in Alumino-Thermic (AT) Welds:

1.3.1.1 First part of the code – Alphabetic

O indicates Plain rail

(b) The second digit indicates:

(a) First Part – Alphabetic codes

1st letter 2nd letter 3rd letter

(b) Second Part – Numeric codes

1st digit 2nd digit 3rd digit 4th digit

1.Within 0- Unknown 1. Transverse 1. At rail seat

3.Damage 0 1 Brushing or arcing

4.Associated Type of Direction of fracture

Within fish-plate Elsewhere on rail Description

ULTRASONIC TESTING OF RAILS AT MANUFACTURERS’ WORKS

“10 Freedom from defects

Head : 1.5 mm dia through hole

Web : 2.0 mm dia through hole

Web & Foot junction : 2.0 mm dia through hole

Foot : 0.5 mm deep, 12.5 mm long and 1.0 mm wide notch

ULTRASONIC RAIL TESTING EQUIPMENT AND ACCESSORIES

3.1.1 Total Life of USFD machine is approximately 8 years.

3.3 Double Rail tester:

3.6 Test rig for wheel burnt/scabbed rails:

CALIBRATION, SENSITIVITY SETTING, MAINTENANCE OF MACHINES AND

Type Frequency No. of probes

Normal/0o 4MHz One One for each rail -

a) Visual inspection of Equipments and accessories - Daily check

b) Calibration of Digital USFD: The range calibration in digital SRT/DRT with

(d) 45o probe (for locations having scabs/wheel burns):