The audit found issues with the reliability, accuracy, and standard procedures of rail/weld testing in the zone. Machine maintenance and calibration were inconsistent or not properly documented. Operators lacked proficiency in some inspection techniques and machine characteristic checks. The audit recommends improving training, implementing internal audits, maintaining standard test pieces and records, and ensuring supervisors conduct regular checks to enhance the reliability, accuracy, and standardization of testing practices.

1. Technical Audit of System
and Practice of Rail/Weld
Testing by USFD

2.  A three day technical audit was recently
conducted in a zone.
 The audit was conducted by a team of
Track Directorate and M&C Directorate of
RDSO (5 members) and Faculties of IRICEN
(4 members).
 Three sets of USFD operator along with
machine and registers were audited in detail.
 Discussed with other operators andADENs in
parallel sessions.

3.  Important features
of any testing
system are
 Reliability
 Accuracy
 Standard
Procedure
System
Reliable
AccurateStandard

4.  Any testing system
comprises of
 Man
 Machine
 Method
Method
M/c
Man

5.  Railway Board circulated a check list vide
No.CT/USFD, Dt.28-10-2014.
 Data Survey- Sample data of two block
section fromTMS was taken for study.
 Details
 Length- 17 km
 Rail section- 52 kg, Roll year- 2003
 Route-B, Annual GMT- 22,Total GMT- 200
 Total reported defects- 34 DFWO, 63 OBS + OBS(W)

6.  Thus defective rail and weld were identified
 Observation
 Few entries in the selected data were earlier
shown as OBS/OBS(w) but on later date
shown as GR/GW.
 Once reported as GW earlier history is
erased.
 Similar to weld defect history rail defect
history is also needed.

7.  Information on USFD machine in use e.g.
M/c maintenance log book, probe
replacement, M/c characteristics, setting for
temperature variation etc. are also needed in
TMS.
 While rail testing if OBS(w) is found and the
same is tested for weld and found to be
DFW(O) then two entries are created inTMS.
This may be shown together and counted as
one defect.

8.  As per Chapter 4 of USFD Manual, the
machine shall be
Maintenance Schedule
Visually inspected Daily
Calibration of M/c Once in a week
Sensitivity setting of M/c Once in 3 days
Checking of the equipment
characteristics
Once in a month
Sensitivity calibration against
temperature variation
Once in a month

9.  Details of M/c
 Three rail tester M/c were examined.
 Make- M/s Paras Electronics (711D)
 Type- Digital DRT, RDSO approved.
 Two weld tester M/c were examined.
 Make- M/s E E C (DS322AT),
 Type- Digital, RDSO approved.

10.  Observation
 DRT
• Charging- Not adequate. Charged up to 60%.
• Electronic units- Good.
• Trolley- Good.
• Probe and Shoe- Satisfactory-2, Not good-1.
• Alignment cum Lifting Syst.- Satisfactory.
• Audio Alarm- Sounding.

11.  Observation
 WeldTester
• Charging-Adequate.
• Electronic units- Good.
• Audio Alarm- Sounding.

12.  Accessories- All but the following were
available, (however, availability of spares could
not be verified)-
 IIW block- Not calibrated.
 Stepped Gauge- Not available.
 Supply of Spares- (as informed by supervisors)
 Probe- Supply is good.
 Battery- Supply is good.
 Maintenance Practice- Contractual, OK.

13.  Calibration blocks
 0º normal probe- 60x50x50 mm steel block
 Angular probe- IIW block, as per IS:4904.
 Observation
 Blocks were available but without validation
certification.Validation may be got done from
Engine Development unit of RDSO.
 It was apparent that they were not in use.
However, operators were proficient in doing
calibration.

14.  Rail
 Rail test piece was available and operators
were proficient in ensuring M/c sensitivity.
 Weld
 Weld test piece was available but not
confirming to Para 8.4.1 and Fig. 20(a).
 However, operators were able to ensure
M/c sensitivity but with difficulty and
unreasonable gain.

15.  Following seven M/c characteristics are to be
checked as per IS: 12666 - 1988
 For M/c- (i) Linearity of time base ± 1.25%, (ii)
Linearity of amplification ± 3%, (iii) Resolution, (iv)
Maximum penetration power
 For Probe- (v) Probe index ± 1 mm, (vi) Probe
angle ± 1º, (vii) Dead zone- single crystal < 7 mm,
double crystal < 3 mm.
Note: Tolerances for railway are shown here and
are more stringent than IS.

16.  Observations
 IIW block was the major concern as stated supra.
 The record keeping was sketchy, without specific
values.
 A few operators were able to check all the
characteristics while others were unable to do all the
checks. Some of them were even unable to explain
the procedure orally.
 It is recommended to conduct hands-on workshop to
refresh and sharpen this skill.
 It is recommended that the incharge USFD, PWI shall
relieve other operators for a day, for checking M/c
Characteristics etc. and incharge USFD, PWI shall do
test checking of work done by other operators.

17.  This is necessary to compensate for loss in
signal strength due to rise in temperature
during day.
 It needs temperature gauging and
adjustment of gain.
 Observation
 This checking is not being given due
importance and records were not being
maintained religiously by majority of the
operators.

18.  All the operators were proficient in picking
and identifying the rail flaws.
 Some of the operators were finding
difficulties in hand probing including tandem
rig.
 The soft grease couplent was more viscous
and resisting free movement of hand probe.
 Data feeding for savingA-scan is only being
done for IMR defects.

19.  Reason for not maintaining A-scan appears to
be casual approach under the disguise of time
constraint.
 Time taken:- 7-8 min. for first time.
Subsequent entries:- 2-3 min.
 However, machine key board need to be
more user friendly.
 It is recommended to conduct hands-on
workshop to refresh and enhance proficiency.

20.  Introduce a system of
Internal Audit based
on the checklist given
by Railway Board.
 Internal Audit-Within
the zone, Divisional in-
charge of USFD team
of one Division shall do
technical audit of other
Division’sTeam.

21.  Conduct Focused
Workshop of short
duration (2-3 days) to
tackle one or two
issues.
 Give emphasis on
learning by Hands-on
to sharpen the skill.
 Conduct Refresher
Courses frequently.

22.  Arrange StandardTest
Pieces as per relevant IS
codes and RDSO manuals.
 Give emphasis on Regular
Validation to improve
Accuracy.
 Follow Prescribed Manual
Method to improve
Reliability.
 Timely check of M/c on
nominated days for
Accuracy (one operator to
be relieved by Incharge).
 Test Check by incharge on
nominated days .
Standard
Test Piece-
Accuracy
Regular
Validation-
Accuracy
Prescribed
Manual
Method-
Reliability
Timely
Check of
M/c-
Accuracy
Check by
Incharge -
Reliability

23.  All data related to USFD
M/c (e.g. log book,
various checking) may
be maintain in TMS.
 TMS may also capture
A-scan related to all
defects and archive it.
 User may able to do
Analysis of growth
patterns w.r.t. other
related parameters.