Rail integrity management by means of ultrasonic testing

This paper discusses the monitoring of the condition of the OREX ore export line rails in South Africa. Ultrasonic testing is widely used to monitor defect development and growth as well as to plan and manage programs to ensure a high level of rail integrity. An overview of the performance and history of the line is given in terms of rail defect levels and derailments due to rail failures in relation to traffic volumes. Some of the inherent characteristics of the rails are discussed and related to the defect development. From the available data it is clear that the rails are degrading in a ‘wear-out mode’, with increasing defect rates. The use of high technology ultrasonic testing equipment has enhanced the level of knowledge of the condition of the rails tremendously and has led to programs that actually improved the overall condition of the line and eliminated derailments due to rail defects.