ER’s Sealdah Division deploys USFD machines for track safety
Kolkata: The Sealdah Division of Eastern Railway (ER) has strengthened passenger safety and train operations by introducing Ultrasonic Flaw Detection (USFD) machines.
This modern, non‑destructive testing technique enables engineers to detect hidden internal defects or flaws in rails and welds before they develop into dangerous fractures that can derail trains.
Track fractures are common in the region during winter due to temperature variations. While physical examination can detect visible fractures, hidden flaws often remain undetected until they become major cracks. Such fractures can cause derailments, leading to casualties or service disruptions.
“To ensure every inch of its 1,375 track km – comprising 761.24 km of 60 kg rails and 613.76 km of 52 kg ones – remains safe, the Sealdah Division is using 20 specialised USFD machines. While 10 are dedicated to rail testing, the remaining test welds to check for flaws,” a senior ER official said.
A dedicated team of operators and inspectors work daily with these machines to detect flaws early so preventive repairs can be made. To eliminate human error and enhance efficiency, track inspection is fully integrated with the Track Management System (TMS) software. The TMS automatically tracks testing schedules based on annual traffic (Gross Million Tonnes) and rail specifications, issuing reminders and alerts so no section is missed.
“Immediately after testing, operators upload digital B‑Scan reports directly from the field into the TMS for real‑time monitoring. All reports are securely archived for up to three months, ensuring transparency and easy review,” the official said.
There is a two‑layer safety verification for accuracy. Divisional supervisors re‑check uploaded B‑Scan data to detect subtle defects missed by field operators. Testing frequencies are calibrated according to track usage and rail type. High‑traffic routes undergo more frequent testing – ranging from once every two years for light‑traffic routes to every 20 days on heavily loaded routes carrying over 80 Gross Million Tonnes annually. Every weld undergoes immediate initial testing, followed by structured periodic checks.
Rajeev Saxena, Divisional Railway Manager, Sealdah, said passenger safety is the top priority. “By combining the expertise of our field operators with USFD machines and smart digital monitoring like TMS and B‑Scan analysis, Sealdah Division ensures robust track health and reliable train services every single day,” he said.
The Sealdah Division is one of the busiest in Indian Railways, handling nearly 1.5–1.8 million passengers daily. Apart from suburban services linking Kolkata to northern and southern districts of West Bengal, it runs trains such as the Rajdhani and Duronto, and also connects Kolkata to north Bengal with services including the heritage Darjeeling Mail.