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Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
Rdso Presentation Sperry Rail India
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Rdso Presentation Sperry Rail India

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  • 1. Sperry Rail International A Rockwood Company Sperry Rail International A Rockwood Company Ultrasonic Testing of Rail Bob Crocker
  • 2. Sperry Rail International Overview A Rockwood Company • Rail is an engineering structure like many others • Strength and stiffness based on material properties and shape • However, introduce a sharp tipped crack as a stress intensifier and all bets are off • Huge holes have no effect as long as the radius is large
  • 3. Sperry Rail International A Rockwood Company
  • 4. Sperry Rail International A Rockwood Company
  • 5. Sperry Rail International A Rockwood Company Network Rail Infrastructure • Network Rail owns approximately 21,000 miles of track, therefore 42,000 miles of rail • This comprises of approximately 16,000 miles of continuously welded rail (CWR) and 5,000 miles of jointed track, so millions of welds and bolted joints • This includes approximately 35,000 switch and crossing (S&C) units.
  • 6. Sperry Rail International A Rockwood Company The Facts of Life for a Railway • Cracks can occur anywhere at any time • 42000 miles and 35000 S&C to cover • The only way to avoid cracks in railway rails is to stop running trains !
  • 7. Sperry Rail International A Rockwood Company The Facts of Life for an NDT Man • It is a peculiar irony which is often overlooked, even by the NDT community: – We can’t find a crack until it is there • Therefore the task is: – We have to find cracks between point of creation and before they cause the rail to break
  • 8. Sperry Rail International A Rockwood Company Background • Hither Green disaster November 1967 • Section of rail at a bolted joint came away • Caused by cracks growing from bolt holes • Realisation that cracks too small to be detected by visual inspection could cause catastrophic failure • Real NDT arrived
  • 9. Sperry Rail International A Rockwood Company
  • 10. Sperry Rail International A Rockwood Company Transverse Defects Tache Ovales
  • 11. Sperry Rail International A Rockwood Company Squats Squats
  • 12. Sperry Rail International Gauge A Rockwood Company Corner Cracking Direction of Travel
  • 13. Sperry Rail International A Rockwood Company Bolt Hole or “Star” Cracks
  • 14. Sperry Rail International A Rockwood Company Web Defect – Bolt Hole Cracks • Star Cracks
  • 15. Sperry Rail International A Rockwood Company Welds
  • 16. NDT Philosophy Sperry Rail International A Rockwood Company • Objective: – find everything – test it often – pre-emptive crack detection – defect management to replace crisis recovery • How: – comprehensive ultrasonic inspection
  • 17. Sperry Rail International Sperry Rail International A Rockwood Company Who are we ? • The Worlds First Company to Provide the Railways with a Rail Flaw Detection Service • Worlds Largest Rail Inspection Company • Over 65 Years Experience in Rail Flaw Detection • An Expanding Fleet of over 120 vehicles The Only Company Totally Focused to Rail Flaw Detection
  • 18. Sperry Rail International - Sperry Rail International A Rockwood Company We’ve been around awhile
  • 19. Customer Base Sperry Rail International A Rockwood Company • Europe North America – Network Rail (UK) Amtrak – LUL (UK) BNSF – Sweden CSX – Norway Norfolk Southern – Germany Canadian Pacific – Estonia Canadian National – Finland New York Subway – Switzerland – Spain • India • China • Australia
  • 20. Sperry Rail International A Rockwood Company
  • 21. Horizontal Defects Sperry Rail International A Rockwood Company (0 Degree) A B C D E A B C D E
  • 22. Transverse Defects Sperry Rail International Tache Ovales A Rockwood Company (0 and 70 Degree) A B A B A B A B
  • 23. Hole-in-the-Web Defects Sperry Rail International A Rockwood Company (37 Degree) A B C D E A B C D E
  • 24. Sperry Roller Search Unit Sperry Rail International (RSU) A Rockwood Company
  • 25. RSU on Rail Sperry Rail International A Rockwood Company
  • 26. Sperry Rail International RSU Mounting A Rockwood Company
  • 27. Sperry UTU 2 Sperry Rail International A Rockwood Company
  • 28. Sperry 200 Rail Bound Sperry Rail International A Rockwood Company Non Stop Inspection Vehicle
  • 29. Sperry UTU 5 Sperry Rail International A Rockwood Company
  • 30. Sperry Rail International Sperry Land Rover A Rockwood Company
  • 31. Cometi Sperry Rail International A Rockwood Company
  • 32. Service Loco Sperry Rail International A Rockwood Company
  • 33. Sperry Walking Stick Sperry Rail International A Rockwood Company
  • 34. Sperry Rail International A Rockwood Company The Usual Pose
  • 35. Testing in Norway Sperry Rail International A Rockwood Company
  • 36. Testing in Norway Sperry Rail International A Rockwood Company
  • 37. Sperry in India Sperry Rail International A Rockwood Company Organisation - Equipment
  • 38. Sperry Rail International A Rockwood Company Rail Inspection Process • Vehicle runs along a route selected by the railway organisation and gathers data about features (“suspects”) in the rail • The data is analysed according to defined standards • Reports are sent out to staff “on ground” via internet. • They verify “suspects” to confirm them as “defects” using walking sticks to defined standards. • Verification Reports are transmitted back via internet • Verified data used to compile run-on-run analysis
  • 39. Sperry Rail International A Rockwood Company Route Verification • All our data is tagged with a satellite location (GPS) • We take the list of satellite locations recorded at 5 second intervals and superimpose them on a detailed map of the network • This has the intended route marked on it and we can see where we were diverted off route
  • 40. Which Track ? Sperry Rail International A Rockwood Company
  • 41. Route Verification Sperry Rail International A Rockwood Company
  • 42. Sperry Rail International A Rockwood Company Data Analysis • We use 9 probes on each rail • We store the ultrasonic response from every probe every 5mm interval along the rail • We construct a side view of the rail using the ultrasonic data. This is called the B-scan • We can scroll through every test using the stored records. • The analyser is trained to look for characteristic patterns in the data and the process is aided by machine-based algorithms • Most suspects produce a response on more than one of the probes which increases confidence in the data because every probe is independent of every other probe
  • 43. B-scan Analysis Sperry Rail International A Rockwood Company
  • 44. B-scan Presentation Tache Ovale Sperry Rail International A Rockwood Company
  • 45. B-scan Presentation Star Crack Sperry Rail International A Rockwood Company
  • 46. B-scan Presentation Squat Sperry Rail International A Rockwood Company
  • 47. B-scan Presentation Vertical Longitudinal Split Sperry Rail International A Rockwood Company
  • 48. Sperry Rail International A Rockwood Company B-scan Presentation Twin View
  • 49. Verification Sperry Rail International A Rockwood Company •Verification carried out by NR personnel •Staff directed to the site of a suspect using the railway mileage and GPS in the reports •They use a Sperry walking stick and hand-held probes to confirm the suspect as a defect (or not) •Procedures have been established to ensure uniformity of reporting •Often track features give an ultrasonic response but are not a defect. These are entered into the “features” database to create an inventory of track features. •All this information is fed back to the analyser on the next inspection run
  • 50. Defect Database Sperry Rail International A Rockwood Company
  • 51. Sperry Rail International A Rockwood Company B-scan Presentation Twin View
  • 52. Repeated Sperry Rail International A Rockwood Company Objects
  • 53. Analysis – Run-on-Run View Sperry Rail International A Rockwood Company • Gives the user an overview of tests of a section of track over a period of time • Provides a visual indication of the location and severity of suspects and defects • Indicates gaps in testing
  • 54. The Integrated Process Compliant Track Analysis Sperry Rail International A Rockwood Company Start 1. B-Scan Analysis 2. Route Validation Create Base 3. Suspect Reporting Track Map 4. Verification Feedback 5. Verification Validation Pre-Compliance 6. Twin View Analysis Process x3 7. RMO Identification NR / Sperry Min 8. BMO Identification Defect Audit 9. Compliance Rev Meeting 10. NARMO Identification NO 11. BMO / RMO Growth Analysis 3 Audits OK YES Compliant Verification only of new indications or Track Indications that are growing / changing End
  • 55. Data becomes Information The Integrated Approach Sperry Rail International A Rockwood Company to Defect Management Track Insp Freq Rail Test Proc Management Standards Binders Detection Standards Calibration Location Rail Inspection Database Process Reporting / Verification
  • 56. Sperry Rail International Summary A Rockwood Company • Frequent, comprehensive ultrasonic inspection of the whole rail cross-section of plain line, welds and joints. • Population of a Defect Database that turns data into Management Information • Pro-active defect management, rather than reactive crisis recovery
  • 57. Sperry Rail International This is what it is all really about A Rockwood Company Number Of Broken Rails 1000 800 600 Number Of 400 Broken Rails 200 0 1999 2000 2001 2002 2003 2004 Year “The lowest number of broken rails in the UK railway’s history”

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