1. USFD BZA
USFD BOOKLET

2. USFD BZA

3. USFD BZA

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

5. USFD BZA

6. Frequency of AT Weld Testing
As per correction slip No.1
S.No
Types of Welds
Type of Testing
Testing Schedule 1
Conventional AT Weld
Periodic Tests
Every 40 GMT or 5 Year,
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
USFD BZA

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

8. GMT PARTICULARS OF BZA DIVISION 2014-2015
SECTION
KM FROM-TO
GMT UP
Rail Testing
Weld Testing
GMT DN
Frequency
BZA – KI
46.77
2 Months
2 Years
47.53
GDR-VKT
48.43
38.4
3 Months
3 Years
VKT-BTTR
BTTR-TEL
48.8
37.35
TEL-KCC
KCC-BZA
63.43
1½ Months
46.49
BZA-NDD
53.9
38.72
BZA-NDD UP1/DN1
NDD-SLO
54.26
40.52
SLO-DVD
40.63
29.49
4 Years
SLO-CCT
18.76
4 Months
11.53
9 Months
5 Years
COA-CCT
UP DN
VKT-KAPT
UP DN
5.01
12 Months
9.74
GDR-RU
38.98
31.29
KCC-GNT
17.23
12.97
6 Months
USFD BZA

9. GMT PARTICULARS OF BZA DIVISION 2014-2015
SECTION
KM FROM-TO
GMT SL
Rail Testing
Weld Testing
Frequency
BZA - GDV
13.84
6 Months
5 Years
GDV - BVRM
10.87
9 Months
BVRM - NDD
7.95
12 Months
BVRM - NDD BYEPASS
GDV - MTM
3.62
24 Months
BVRM - NS
5.22
COA - KPLH
VKT-KAPT
14.75
KCC-BZA IIILN
46.49
2 Months
2 Years
TEL-GNT
13.75
SLO-CCT CHORD LINE
11.53
TEL-REPALLE
1.43
NDD - SLO IIILINE
54.26
USFD BZA

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

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

12. Defects in Rail
USFD BZA

13. 0° for central portion of weld
RAIL TESTING
0° for central portion of weld
USFD BZA

14. Area Covered by 70° central Probe
USFD BZA

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

16. 0° for central portion of weld
SKV WELD TESTING
0° for central portion of weld
USFD BZA

17. 70° for head of weld
USFD BZA

18. 70° for flange of weld
USFD BZA

19. 45° for bottom flange center in weld
USFD BZA

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

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

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

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

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

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

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

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

28. AREA NOT COVERED BY USFD IN RAIL TESTING
USFD BZA

29. Thank You
USFD BZA