1. USFD

2. TYPES OF MACHINES USED IN RAIL TESTING
SINGLE RAIL TESTER
1.PARAS WITH MULTI-CHANNELS & MULTI-COLOURED SIGNALS
2.MODSONIC WITH MULTIPLEXER

3. TYPES OF MACHINES USED DOUBLE RAIL TESTER PARAS WITH MULTI-CHANNEL
II. EEC WITH MULTIPLEXER

4. TYPES OF MACHINES USED FOR
WELD TESTING
2. EEC
1. PARAS
3. MODSONIC

5. Probes used in Rail Testing
0° For central portion of Rail
45° For SEJ & Scabs and Wheel burns
(with Test Rig)
70° For Gauge face, Non-Gauge face and Central portion of Rail
Probes used in Weld Testing
0° Up to central portion of weld
45° For bottom flange center in weld (Half-moon crack)
70° For head and flange of weld
45° Rig (For New Welds)
70° Side Looking Probes.

6. CALIBRATION TO BE DONE ONCE IN A WEEK [Para 5.1.1(vii)]
SENSITIVITY TO BE DONE ONCE IN 3 DAYS
[Para 4.1.1(c)]

7. What is Calibration
Calibration is the process of configuring an instrument with standard values.

8. Need for Calibration & Sensitivity
Calibration of equipment is done to fix Horizontal and Vertical Scale on the screen.
Sensitivity is setting values in the equipment for obtained signal strength received from known artificial defects.

9. Calibration for 300/200 mm Longitudinal wave using 0° probe
Connect 0° 4 MHz Double crystal probe
Select T-R Mode in Rail tester having Multiplexure, for Multichannel unit select the calibration set.
Feed the required range i.e 300mm for Multiplexure/200 mm for Multichannel unit .
Put 0° 4 MHz Double crystal probe on IIW(VI) block after applying couplant at 100 mm width side.
Set Delay and probe zero as per operational manual.
Set first reflected peak at 3.3 div(for 300mm) or at 5.0(for 200mm) using delay key.
continues…

10. . Place Gate over it and measure beam path, depth shall be 100 mm.
Second reflected peak will appear at 6.7 div & third peak at 10.0 div (for 300mm) or second peak at 10.0(for 200mm).
If last peak is not at 10.0 Div velocity may be adjusted to set the last peak at 10.0 or by adjusting delay key .
The equipment is calibrated for 300/200 mm longitudinal wave for 0° 4 MHz Double crystal probe .
To verify the calibration put probe on top of rail head the back peak position at 5.2 div for 52 kg & 5.7 div for 60 kg (for 300mm) or 7.8 div for 52kg & 8.6 div for 60 kg (for 200mm)

11. RT - 0◦ Calibration Set-up IIW block
Machine Calibrated for 200 mm range
0˚ 4MHz Double crystal probe
SRT-Paras Monitor
1 st peak at 100 mm
2 nd peak at 200 mm
100 mm
IIW Block

12. RT - 70◦ Calibration Set-up IIW block
Machine Calibrated for 165 mm range
IIW(International Institute of Welding) Block

13. What is Sensitivity
Sensitivity is the smallest amount of difference in quantity that will change an instrument's reading. 

14. RT- Sensitivity Piece – Manual Fig

15. RT – Sensitivity Piece
5 mm Ǿ Flat Bottom Hole
12 mm Ǿ Bottom Hole

16. RT - 0° Probe Sensitivity on 52 Kg Rail
Zero Degree Probe 100% of FSH(Full Screen Height)
SRT-Paras Monitor
Back Peak height - 100%
0˚ 4MHz Single crystal probe
Rail Piece

17. RT – 70°Probe Sensitivity on 52 Kg Rail
70° Central - 60 % of FSH(Full Screen Height) From 12mm dia Hole
Peak height at 60%
70˚ 2MHz Single crystal probe
SRT Paras Monitor
Rail Sensitivity Piece
12 mm dia hole

18. RT - 70◦ Sensitivity on 52 Kg Rail - Pic
70° Guage/Non-Guage face - 60% of FSH(Full Screen Height) from 5mm Flash Bottom Hole
End Peak
GFC Peak height at 60%
70˚ 2MHz Single crystal probe
SRT-Paras Monitor
5 mm Flash Bottom Hole
Rail Sensitivity Piece

19. WT-Sensitivity piece – Manual Fig

20. Weld Testing Sensitivity Piece
3mm Dia Hole
3mm Dia Through Hole
3mm Dia Through Hole
Half moon crack

21. Calibration for 165 mm Shear wave using 70°/2 MHz single crystal probe
Connect 70° 2 MHz Single crystal probe
Select T+R Mode in Rail tester having Multiplexure, for Multichannel unit select the calibration set.
Feed the required range i.e 300mm for Multiplexure/165 mm for Multichannel unit .
Set Delay and probe zero as per operational manual.
Place 70° 2 MHz Single crystal probe on IIW(VI) block after applying couplant at 100 mm curvature.
Move the probe slightly to and fro to get maximize signal
Adjust the peak at 6.0 div using delay key.
continues…

22. . Place Gate over it and measure beam path shall be 100 mm.
To verify the calibration Direct the probe towards 25 mm curvature and maximize the peak.
Put the gate on this peak the beam path shall be 25mm.
The equipment is calibrated for 165 mm Shear wave for 70° 2 MHz Single crystal probe .

23. WT – Calibration of 70° Probe

24. WT - Sensitivity of 70° Head
70° Head – 60% of FSH (Full Screen Height)

25. WT - Sensitivity of 70°Flange
70° Flange – 60% of FSH (Full Screen Height)
Upper Zone

26. WT - Sensitivity of 70°Flange
70° Flange – 60% of FSH (Full Screen Height)
Middle Zone

27. WT - Sensitivity of 70°Flange
70° Flange – 60% of FSH (Full Screen Height)
Lower Zone

28. WT-Sensitivity of 70° SL (Side Looking)
70° Side looking – 60% of FSH (Full Screen Height)

29. WT – Calibration of 45° Probe
Beam path= 100 mm at 3.6th Division

30. WT – Calibration of 45° Probe
Beam path= 100 mm at 3.6th Division

31. WT - 45° Sensitivity

32. Part - II
BRIEF OF DIFFERENT TYPES OF TESTING CARRIED OUT AS PER RAILWAY BOARD INSTRUCTIONS

33. Types of USFD Testing
USFD
RAIL TESTING
WELD TESTING

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

35. Frequency of Testing for Rails on BG routes
Route GMT
Frequency
≤ 5
2 years
>5 ≤ 8
1 year
>8≤12
9 months
>12 ≤ 16
6 months
>16 ≤ 24
4 months
>24 ≤ 40
3 months
>40 ≤ 60
2 months
>60 ≤ 80
1.5 months
> 80
1 month

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

37. Frequency of AT Weld Testing
as per correction slip No.3
S.No
Type of Weld
Type of Testing
Testing Schedule 1
Conventional AT Weld
Periodic Tests
Every 40 GMT or 5 Years,
whichever is earlier 2
SKV Weld
Acceptance Test
Immediately after Welding 3
First Periodic Test
1 Year 4
Further Tests Based on Route GMT
As per Schedule given below 5
Major Bridges & Approaches 6
Flashbutt Welds
As per the instructions of CTE

38. Frequency for SKV Weld testing
As per correction slip No.3
GMT
Frequency
>80
1 year
>60≤80
1.5 years
>45≤60
2 years
>30≤45
3 years
>15≤30
4 years
0-15
5 years
Incase of welds on Major Bridges & Bridge approaches(100 m on either side) and in tunnels & on tunnel approaches(100 m on either side), the minimum frequency shall be once in a year.

39. THANQ