S.E.
Railway
No. TC/RFD/Policy/General Office of Pr. Chief Engineer
11, Garden Reach Road
Kolkata-43
CE’s Circular No. 253
Sub- USFD Testing of Rails and Welds.
It has come to notice that even though sufficient number of USFD testing
machines (SRT & DRT) and trained USFD operators are available in the Divisions,
testing of welds are not being undertaken at the prescribed frequency stipulated in USFD
Manual. The USFD operators are being deputed to test the old welds and also new welds
and invariably due to lack of maintenance of proper weld testing records and work load
calculations, the testing of welds are not being done at the laid down frequency.
Moreover, new welds are also not getting tested immediately after.
2. Therefore, it has been decided that the Divisions shall form three separate testing
groups (with USFD machines and operators) to carryout USFD testing of Rails, old welds
and new welds respectively. This would avoid any confusion regarding work load
calculations as the separate groups could conduct testing of rail or old welds or new
welds as scheduled and maintain proper records of the test done.
2.1 Thus the three groups shall test as follows: -
Group To Test Type of Type of probe to be used Periodicity
Tester to
be used
1 Running Double 1 2x0º 4MHz 18mm Ø Test Free Rails rolled Rails rolled
Rail Rail (OR 18mmx18mm Period before in OR after
(Annexu Tester square) Double Crystal April’99 April’99
re-I)
If initial test 15% of 25% of the
done in the stipulated life stipulated life
Steel Plant
If no test at NIL NIL
Plant is done
Subsequent After Passage of 8 GMT subject to
2 2x70º 2MHz(F&B) Tests* maximum interval of one year as per
20mm Ø (OR table below.
20mmx20mm square) Up to 8 GMT 12 months
Single Crystal >8<12 9 months
>12<16 6 months
>16<24 4 months
>24<40 3 months
>40 2 months
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2 Activity -1
Bolt Single 1 0º 4MHz 18mm Ø After Passage of 8 GMT subject to
Holes of Rail Double Crystal maximum interval of one year as per
all types Tester table below.
(Annexu Up to 8 GMT 12 months
re-II) 2 70º 2MHz (F&B)20mm >8<12 9 months
Ø (OR 20mmx20mm >12<16 6 months
square) Single Crystal >16<24 4 months
3 37º 2MHz (F&B) 20mm >24<40 3 months
Ø (OR 20mm x 20mm >40 2 months
square) Single Crystal.
Activity -2
New Single 1 0º 2MHz 18mm Ø Just after execution of weld.
Welds Rail Double Crystal ( For
(Annexu Tester head & web)
re-III) 2 70º 2MHz 20mm Ø (OR
20mmx20mm square)
Single Crystal. (For Head
& Foot)
3 Old Single 1 0º 2MHz 18mm Ø SKV
Welds Rail Double Crystal ( For 1st 1 year of service life
(Annexu Tester head & web) 2nd 120 GMT after 1st
re-IV) 2 70º 2MHz 20mm Ø (OR Periodic Test
20mmx20mm square) 3rd 120 GMT after 2nd
Single Crystal (For Head Periodic Test
& Foot) Subsequent Nil
3 45º 2MHz 20mm Ø (OR Conventional
20mmx20mm square) 1st 1 year of service life
Single Crystal (for half Subsequent After 40 GMT after 1st
moon defect) Periodic Test
OR
70º 2MHz 8mmx8mm
square Single Crystal (for
half moon defect)
* Henceforth the rail testing for all routes with traffic density of 20GMT or more should
be done alternatively for normal testing and by shifting of the 70º, 2MHz(F&B) probe for
detection of gauge face corner defects at the prescribed frequency.
2.2 On the above basis, the Divisions should make a complete review & calculate the
workload as well as requirement of various types of machines as well as that of operators.
Apart from regular USFD operators, there is a pool of PWIs who are already trained in
USFD operation. Also there is good number of machines available. All these should be
kept in view. The above analysis should be submitted to HQ by the Divisions by
25.05.05. Along with this, further requirement of machines/operators should be spelt out.
2.3 Divisions should send vetted indents for procurement of 2MHz, double crystal
(18mm circular) normal probe for AT weld testing as per correction slip No.15 of USFD
Manual. Other required probes are available with XEN/TT/SNY, which may be collected
by the Divisions.
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2.4 One area that creates ambiguity most of the time in the field is marking of the
location of flaw. This ambiguity not only creates problem in taking post flaw detection
action but also makes it impossible for the division to fix up responsibility in case of a
fracture of rail/weld, which has been tested good recently. To eliminate the ambiguity the
following convention is to be followed:
(i) Uniquely number all welds/joints:- Each weld whether FB or AT must be
numbered uniquely. Welds/joints in each mast length will have to be
numbered like ATL1, ATL2, ATL3……….and so on for AT welds on left
rail facing the direction of increasing kilometers. Similarly, like ATR1,
ATR2, ATR3……….and so on for AT welds on right rail facing the
direction of increasing kilometer. For FB weld it will be like FBL1,
FBL2….. OR FBR1, FBR2….. and for joints JL1, JL2…. OR JR1,
JR2….. as the case may be. On the turnout side and crossovers the joints
/welds are to be serially numbered. The numbering is to be done outside
flange keeping clear the length about half the length of the Joggle Fish
Plate.
(ii) For rails the marking at the location of the defect will have to be done with
respect to the adjacent welds and joints giving the length from lower
numbered joint/weld. For example, IMR at 7.5m from ATL2 between
ATL2 & ATL3.
(iii) The location of the defect will give both TP number as well as the location
with respect to weld/joint number.
The numbering of the welds is to be done by 31.05.05 and thereafter the USFD
PWIs will refer the location of defect in terms of TP & weld numbers only.
Enclo: Annexure-I , II , III , IV & V.
(K.Gangopadhyay)
Chief Track Engineer
No.TC/RFD/Policy/General Dated : .05.2005
Copy to :-
1. Secy. to GM for kind information of GM/GRC.
2. Secy. to PCE for kind information of Pr.CE/GRC.
3. AM/CE, Railway Board.
4. CBE, CPDE & CE/TR for information and necessary action please.
5. All Dy.HODs at Hd.Qr./GRC.
6. Sr.DEN (Co-ord)s/S.E.Rly. ADA, CKP, KGP & RNC alongwith 15 copies
each for distribution amongst officers and USFD operators.
7. Principal, Zonal Training Centre, Sini.
8. OS (G-II)/PCE’s office/GRC to keep one copy in CE’s circular file.
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