Informe Ut

TECHNICAL REPORT
Ultrasonic testing in the welds of Upper

Rail Recess one and Upper Rail Recess
two, US and DS
Rev: 01
January 2015
Page 1 of 37
ULTRASONIC TESTING IN THE WELDS

OF REC 3 AND REC 4, US AND DS, AND
REPAIR OF REC 2 DS
January 2015
WDS INGENIERIA, S.A.

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Page 2 of 37
Panama, January 2015

Gentlemen:
Cimolai, S. p. A.
Attention. Eng. Simone Cipolotti.
REF:
Ultrasonic testing in the welds of REC 3 and REC 4, US and

DS, and repair of REC 2 DS.
Cot C201114-017S
Respected Engineer
Attached Technical Report Ultrasonic inspection, by WDS Ingeniera, S.A.,

Testing conducted in welds of Upper Rail Recess 1 and Upper Rail Recess
2, US and DS in the Panama Canal expansion.
This report contains observations and conclusions relating to the service.
Best regards
ENG. Daniel Rivero

ASNT-TC-1A Level II PT, VT, MT.
Level I UT, ECT
AWS Member No 675950
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REPORT CONTENTS
1. OBJECTIVE
2. PROCEDURE
3. INSPECTION DATE, PERSONNEL AND EQUIPMENTS
4. ACCEPTANCE AND REJECT CRITERIA
5. INPECTION RESULTS AND ANALYSIS
6. ANNEXES

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1. OBJECTIVE
Evaluate by ultrasonic testing (UT) welds on the rails of new gates of
Panama Canal
2. PROCEDURE
Testing the head of the rail with a 70 probe (WB70-2E)
Setting up procedure
The signal from the bottom corner of the rail head has to be set on 10
along the base line of the screen. This adjustment requires using the
70 Angle Plate in conjunction with the Range (depth) Control.
1. Line up the blade of the 70 angle plate with the bottom corner
of the head at a rail end and place a vertical mark on the side
of the rail head where the other end of the blade meets the top
of the head.
2. Place the 70 probe on the top of the rail pointing toward the rail
end.
Line up the beam centre of the probe with the mark
determined by the angle plate. Point the probe slightly utwards

toward the corner of the rail head and adjust the signal from the
bottom corner of the head onto 10 along the base line of the
screen. (See Figure 14). This adjustment is made with the Range
(depth) Control. The left hand side of signals should always be
used when setting the position of the signal on the screen.

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Setting up a 70 probe
The screen is now set for finding transverse indicators in the head of the rail.
The screen from 0 to 10 represents the rail from the top to the base of the head.
3. Set the scanning gain by adjusting the Gain Control until the
grass level is 20%, (1/5) screen height as the probe is moved
over the surface of the head. If this gain level does not produce
an indication that reaches 80% screen height then the indication
should be disregarded unless it is established as a defect with
another probe. The Screen is now set for locating Defects
including Transverse Defects and Defective Welds in the head
Scanning for defects with a 70 probe
A. Move the probe in a longitudinal direction along the top of the
rail head.
B. Always scan in both testing directions.
Scanning for Transverse Defects:

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Make a scanning pass in both longitudinal testing directions

along the full length of the rail to be tested slightly favoring the
gauge corner side of the head.
Guidance Notes
Surface horizontal laminations such as occur at wheel burns,
battered crossing noses and squats can often give a similar
display on the screen to a transverse defect. Be careful to avoid
confusing these surface wave reflections with a TD.
Scanning for Weld Defects:
With the probe pointing towards the weld, make three adjacent
longitudinal passes in both testing directions along the head.
Make the passes from at least 150 mm back from the weld
through to just past the weld and cover the full width of the
head. Keep the probe should be parallel with the side of the
head.
4. If a potential defect is present in the head of the rail then a signal
will travel along the screen as the probe is moved. The testing
window for this test is from 0 to 10 along the base line of the
screen. If an indication is present in the testing window then it
should be sized using the Sizing Procedure in Chapter 10 to
determine if a defect is present in the rail.

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Additional setting up procedure prior to assessing indications

found in the lower part of the head when testing aluminothermic
welds.
Note: Due to head wear, reflected signals from the overflow of the weld metal
underneath the outer base of the head may display on the screen.
These
indications can be misinterpreted as a defect at the 10 end of the screen. A recheck of the position of the corner at the base of the head is therefore essential.
1. Choose a testing direction and line up the blade of the 70 angle

plate, with the corner at the base of the head created by the far
side corner of the weld.
2. Place a vertical mark on the side of the rail head where the other
end of the blade meets the top of the head.
3. Repeat this operation in the opposite testing direction. (See figure
15).
False defect indication from bottom corner of head
4. Place the 70 probe on the top of the rail pointing toward the weld
with the beam centre of the probe in line with the mark determined
by the angle plate.
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5. Move the probe to one side of the head and point the front of the
probe slightly outwards toward the corresponding corner of the
weld.
6. Adjust the signal from the bottom far corner of the weld onto 8
along the base line of the screen. This adjustment is made with the
Range (depth) Control.
7. Repeat this procedure on the opposite adjacent corner of the weld.
Do not readjust the test range again until all 4 corners of the weld
have been displayed on the screen and their position noted.
8. Turn the probe to the opposite testing direction and repeat the
procedure again. The corners on both sides of the weld should have
displayed on the screen on 8 approximately.
9. Choose the best of these corner signals and set the corner signal on
10 along the base line of the screen. This adjustment is made with
the Range (depth) Control. The left hand side of signals should
always be used to set their position on the screen. Three of the 4
corners should display on the screen in approximately the same
place. If there is no consistency then the weld may be defective and
another weld or a rail end with a similar level of head wear should
be found.
The screen is now set for assessing indicators in the head of the weld.
The screen from 0 to 10 represents the rail from the top to the base of
the head (See Figure 16).
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Guidance Notes
1. Take care when using the WB70 probe for testing the head of welds as small shoulders
left on the side of the head after grinding can give spurious indicators. Avoid twisting the
probe off parallel during testing runs.
2. Surface irregularities in newly ground rail may cause difficulties in testing because of
rocking of the probe. (See Figure 17).
Probe rocking
Determining the location (longitudinal alignment/position) of

defects with a 70 probe
Defects found with an angle probe do not generally lie under the probe
but are located in front of the probe. For the removal of defects it is
necessary to determine the longitudinal alignment of the transverse
defect in the head.
1. Move the probe along until the left hand side of the defect signal is
on 5 on the base line of the screen. A signal on 5 using the above
settings is a reflection from halfway down the head from the top of
the rail.
2. Place a mark on the rail in line with the beam centre of the probe.
3. Lift the probe off the rail.

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4. Place the top end of the blade of the 70 angle plate in line with the
mark and draw a line along the blade of the plate downwards toward
the base of the head.
5. Draw a horizontal line half way down from the top of the head
intersecting the line from the plate.
6. The point where the two lines intersect is the longitudinal alignment
of the transverse indication.
Determining the location (depth) of defects with a 70 probe.
For the removal of defects it is often necessary to determine the depth of
the lowest extremity of a transverse defect in the head. This information
is needed for assessing the practicality of using a Wire Feed Repair Weld.
When the setting up procedure in Section C8-2.1 has been used, each
unit along the base line of the screen represents an increment of depth
equal to 1/10th of the height of the head.
For 60kg rail a practical average height is 40mm giving each unit
on the screen a value of 4mm.
For 53kg rail a practical average height is 35mm giving each unit
on the screen a value of 3.5mm.
1. When sizing is carried out on a defect note the position of the signal
on the screen at the lowest extremity of the defect.
2. Multiply the unit number, (base line number) to the left of the
indication by 4mm or 3.5mm according to the head size above to
determine the depth of the lowest extremity of the defect.
Scanning for defects in wire feed welds with a 70 probe
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1. Move the probe in a longitudinal direction along the top of the rail
head scanning for:
a. Transverse defects in the head that were not removed by the
welder, prior to welding, ie Engine Burn Defects or other
Transverse Defects.
b. Transverse indications due to lack of fusion in the wire feed
weld.
2. Probe the repair area plus 100mm each side along the top of the
rail head.
3. Make multiple passes with the probe in each testing direction paying
particular attention to weld depth area (i.e. weld/rail interface).
4. If a transverse indication is of standard TD-S size (40mm probe
movement or more) size the defect with a 70 probe using the sizing
procedure in Section C10-6.
If the probe movement of the defect is less than 40mm, size the defect
with the twin 70 probe (VS70-04E), using the sizing procedure in Chapter
10.
Testing the web and center foot of the rail with a 38 probe (WB35
2E)
Setting up procedure:
1. Place the probe on top of the rail head with the probe centered over
the top of the web.

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2. Move the probe along the rail in a longitudinal direction. Set the
left side of the reflected rolling signal from the base of the rail on
10 along the base line of the screen. (See Figure 18). This
adjustment is made with the Range (depth) Control.
Setting up a 38 probe
The screen is now set for finding transverse and diagonal indicators in the web and center foot
of the rail.
The screen from 0 to 10 represents the rail from the top to the base of the foot. (See
Figure 19
Setting rail height

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3. Set the scanning gain by adjusting the Gain Control until the grass
level is 20%, (1/5th) screen height as the probe is moved over the
surface of the head.
If this gain level does not produce an indication that reaches 80% screen
height then the indication should be disregarded unless it is established
as a defect with another probe.
The Screen is now set for locating defects including Bolthole Defects,
Defective Welds in the web and transverse indicators in the center foot of
the rail.
Scanning for defects with a 38 probe

1. Move the probe in a longitudinal direction along the top of the rail
head.
2. Always scan in both testing directions.
Scanning for Bolthole Defects

Make a scanning pass in both longitudinal testing directions along the full
rail length in the bolthole areas with the probe centered over the top of
the web.
Test slowly and obtain a signal from each bolthole.

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signals will occur on the screen in addition to the signals from the
boltholes.
If a bolthole fails to display a signal on the screen, the reason must be
determined.
Scanning for Weld Defects

With the probe pointing towards the weld make two (2) longitudinal
scanning passes in both testing directions with the probe kept centered
over the web. Make the passes from at least 150mm back from the weld
through to just past the weld. Keep the probe parallel with the side of the
rail.
If a potential defect is present in the web, center foot or a bolthole then
a signal will travel along the screen as the probe is moved. The testing
window for this test is from 0 to 10 along the base line of the screen.
If an indication is present in the testing window then it should be sized
using the Sizing Procedure in Section C10-7 to determine if a defect is
present in the rail.

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Guidance Notes
1. Horizontal defects are often located with a 38 probe. Size these indications
with a 0 probe using the Sizing Procedure in Chapter 10.
2. Indications found with a 38 probe between 0 & 2 along the base line of the
screen indicate a potential defect in the head. Size these indications with a
70 probe using the Sizing Procedure in Chapter 10 to determine if a head
defect is present and to determine the size of the defect.
3. When testing with a 38 probe a couple of signals are often obtained on the
base line of the screen between 4 and 2 as the beam from the probe passes
through the top fillet area. These signals should be ignored unless they are a
continuation of a signal that has started from lower down in the rail or they
continue past 2 up into the head area of the rail.
Signals from bottom corner of rail head
Testing the foot of an aluminothermic weld with a twin 70 probe

(VS70-04E)
1. The flaw detector is now set up to read the distance in front of the
probe of any indication on the screen. Each major unit on the screen
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represents a distance of 10mm. eg. When the left hand side of a

signal is at 4 on the base line of the screen then the reflector is
located 40mm from the front of the probe.
2. This measurement can be used to confirm the relevance of an
indication. eg. If a signal appears on 4 on the base line of screen,
measure 40mm from the front of the probe. If this measurement
indicates the opposite side of the weld then the indication is
confirmed as a non-defect reflector from the far corner of the weld.
If the 40mm measurement falls within the relevant range for the
alignment of the fusion plane then the indication is a potential defect and
should be sized (see steps below).
The relevant range for the alignment of the fusion plane is from the
transverse near edge of the external weld metal to the transverse center
of the weld.
Scanning for defects with a twin 70 probe
1. Ensure that the four foot (flange) surfaces adjacent to the weld are
properly cleaned to enable good coupling of the probe to the rail.
Maintaining water saturation of the surface is also essential for this
test.
2. Set the scanning gain. Place the probe on the flange of the rail
adjacent to the weld to be tested and while moving the probe adjust
the grass level to 20% (1/5th) screen height in the primary part

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of the testing window ie (3 to 5 on the base of the screen) with the

Gain Control.
3. Point the probe toward the weld to be tested.
4. Use a long testing sweep to make several longitudinal passes from
80mm back through to 20 mm from the transverse edge of the
weld. Cover the full width of the flange with the testing passes.
Keep the probe parallel with the edge.
5. Repeat this procedure on all four of the flange surfaces adjacent to
the weld.
6. If an indication is obtained on the screen it is necessary to
determine its relevance before sizing is carried out. The following
criteria must be met.
The indication must appear within the appropriate testing

window. When the probe is moved back and forth a significant
signal must travel across the base line of the screen for at least
one major unit between 3 and 7 to qualify for sizing.
The signal on the screen indicates the distance from the front of
the probe to the reflector in the weld. This distance must be
measured with a rule. The measured distance must put the
reflector within the near half of the weld for the indication to
qualify for sizing.
The primary part of the test window for this test is from 3 to 4
along the base line. All indications travelling from 3 to 4 must be
sized.

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7. If the indication complies with the criteria in Step 6, both (i) and (ii)
or part (iii), then the defect should be sized.
Guidance Notes
The strongest reflections from lack of fusion often occur between 4 and 3 along the base
line of the display. Special attention should be given to this part of the testing window. It
is, however, essential to disregard indications which display between 3 and 0 along the
base line of the screen as these are typically due to surface wave reflectors from the weld
and are not a defect indication.
2. Make sure you test right to the edge of the rail foot. A slight overlap of the edge of the foot
is OK
3. Special care is needed to detect defects extending from the edge of the web outwards
underneath the bottom fillet radius. Signals in this area are lost because the probe cannot
sit on the radius. If any indication displays strongly on the screen in the testing window as
displayed in Figure 24 but drops due to the probe lifting off on the radius, the weld should
be classified as a DW-M Foot unless the sideways probe movement has already qualified
the defect as a DW-L.
1.
defect under bottom fillet radius

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Testing the full rail with a twin 0 probe (SEB-2 0)

Setting up procedure for twin 0 probe (SEB-2 0)
1. Place the probe on the top of the rail with both the sending and
receiving probe aspects directly over the web.
2. Locate the back wall echo from the base of the foot and set the
signal on 9.5 on the base line of the screen with the Range (Depth)
Control.
Setting up a twin 0 probe
3. Adjust the Gain Control until the Grass is 20% (1/5) screen height.
4. Set the probe Zero with the Pulse Delay Control The Screen is now
set for locating Horizontal and Longitudinal Vertical defects in the
head and web of the rail. The screen from 0 to 10 represents the
rail from the top to the base of the foot.
Scanning for defects with a twin 0 probe

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Move the probe in a longitudinal direction along the rail keeping the probe
centered over the web.
Scanning for horizontal defects
Horizontal defects will be indicated by a reflected signal between 0 and
9.5 on the base line of the screen.
This type of defect displays on the screen as a strong signal. The position
of the signal along the base line of the screen is determined by the depth
of the defect and determines its defect name.
Eg.
HSH 0 to 2, HWS 2 to 3, HSW 4 to 7, FWS 7 to 8.
Horizontal Splits in Head and Web

Note: Horizontal defects close to the top of the rail will have several repeat signals.
The first signal indicates the depth of the defect.
Scanning for vertical defects
This type of defect does not display a reflected signal from the defect on the screen.

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The presence of a Vertical Split is indicated by a drop in the back wall echo. The strong
signal from the base of the rail drops below the top of the screen or drops completely.
If this occurs a 0 probe such as a K4NF should be placed on the field side vertical face
of the head to check for a Vertical Split Head and on the side of the web to check for a
Vertical Split Web.
Vertical Splits in Head and Web

Variations from the standard signal presentation on the flaw detector screen should be
investigated as a potential defect.
These potential defects should be located and sized with the most appropriate probe to
determine whether they qualify as a defect. Only Horizontal defects should be sized using
a twin 0. Vertical splits should be sized with a miniature 0 probe.

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Guidance Notes
1. It is always essential to determine the reason for a drop in the signal height of
the back wall echo (base of rail signal). See Section C8-6.2 'Back Wall Echo'
for reasons other than defects that cause the back wall echo to drop in height.
2. If a loss of signal height occurs, then a second test must be conducted to
establish the presence of a vertical split in the head or web. This is carried out
by testing from the side of the head for a VSH and from the side of the web for
a VSW. A miniature 0 probe is used for this purpose. See separate setting up
and testing instructions for this procedure in Section C8-7.
3. The lower end of a VSH often turns horizontal and breaks out underneath the
head in the top fillet area. When this occurs a similar signal to a HWS is
displayed on the screen between 2 and 3. When any HWS signal indicates
on the screen, always carry out a side of head test for a VSH.
4. Follow up testing stick indicators with hand testing If a section of rail has loss
of back wall echo when testing with the stick, retest the suspect length with a
hand probe, as it is easier to manipulate a hand probe and therefore maximize
the back wall echo. If a back wall signal exceeding the top of the screen can
be obtained with the twin 0 hand probe then the rail is satisfactory.
5. This probe is essential for finding Gassing in an aluminothermic weld. A 38
probe will often give a very poor indication from gassing.
Scanning for gassing defects

6. Use the SEB 0 probe with the gain slightly higher than usual and look for
complete loss of back wall echo from the base of the weld continuing
throughout the width of the weld. Return the grass to normal scanning gain
and check for any horizontal cracks associated with the weld.
7. Confirming Gassing Defects with a 0 Probe. If indications that are similar
to gassing i.e. multiple simultaneous signals are found in a weld with the 70
or 38 probes but there is no complete loss of backwall echo with the 0 probe,
disregard the indications. Make sure however that the indication is like a typical
gassing display and not a lack of fusion indication.
Setting up SEB0 for testing depth of horizontal Indicators

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1. Place probe on field side of unworn rail head

2. Set reflected signal from opposite side of the head (back wall echo)
on 7 on the base line of screen. (Head width is 70mm)
Signal from opposite side of head
3. Place probe on outer extremity of foot with probe overhanging the

edge of the foot
4. Set reflection from base of foot on 1 on base line of screen (the
extremity of the foot is 10mm thick at the edge).
Signal from edge of foot
5. Repeat Steps 2 and 4 until both signals are set in correct position.

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6. Note: Screen is now set to read depth of horizontal indicators in

mm.
7. Place probe on top of head and size indicators for both depth and
length.
Measuring depth and length of indications
Scanning for wire feed weld defects with a twin 0 probe

Move the probe in a longitudinal direction along the rail keeping the probe
centered over the web.
Test the repair area plus 100mm each side, paying particular attention to
weld depth area (i.e. weld/rail interface).
Horizontal defects in a wire feed weld will appear between 0 and 2 on the
base line of the screen (the head area of the rail) when using a '0 probe'.
Variations from the standard signal presentation on the flaw detector
screen should be investigated using the Sizing Procedure in Chapter 10 to
determine whether they qualify as a defect.
Back Wall Echo (BWE)

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When testing from the top of the head on standard rail which is not
defective, there should be a strong back wall echo from the base of the
rail set between 9 & 10 on the screen. Loss of this back wall echo can
indicate the presence of a defect.
Other rail features can however affect this signal.
Loss of back wall echo when the rail is not defective can be the result of:
1. When a railhead is worn so that the probe is tilted toward the field
side top fillet.
This will result in a loss of back wall but stronger echos from the
top fillet and base of the head. These signals typically display on 2
and 3 on the base line of the screen.
2. When testing the nose of a crossing or curve worn rail where the
center of the head is no longer over the center of the web due to
machining or head wear. This prevents the beam getting to the base
of the rail.
3. Surface damage to the head including sub-surface laminations or
grooving of the head due to wear, particularly on the nose or wing
rail of a crossing.
4. Probe surface not making proper contact with the surface of the rail.
eg. grease, poor probe surface, insufficient coupling (water). These
problems should be corrected.
Other, less common, faults in rail can cause loss of Back Wall Echo.
These include:
Loss of back wall echo from the base of the foot with an
twin 0 probe can also be caused by loss of section in the
Inspected by:
Eng. Cuicas Wisthon
+507 6662 4768 / +507 68604245
Report by:
Eng. Cuicas Wisthon
Ciudad de Panam
TECHNICAL REPORT
two, US and DS
Rev: 01
January 2015
web due to corrosion.
Page 26 of 37
This usually occurs in tunnels or
other damp areas and is rare in other locations. If the

corrosion reduces the internal width of the web then it can
stop the beam from reaching the base of the foot. Major
corrosion can be seen by visual examination and may
warrant removal of the rail. Corrosion is also the most
common cause of Foot/Web Separation (FWS)
Another occasional cause for this signal loss can be

lamination just beneath the top surface of the head. This
sub-surface lamination can be due to shelling or lamination
from engine burns or where squats are occurring. Shallow
indications due to the above will display at the zero end of
the screen.
Using a miniature 0 probe for locating VSH defects

1.
Use the appropriate miniature 0 probe. (4NF/MB4F).
2.
Place the probe on the vertical face of the head on the field side of
a new rail.
3.
Set the left-hand side of the transmission signal on Zero along the
base line of the screen and

the left-hand side of the signal from the opposite side of the head (back
wall echo) on 10. If

Inspected by:
Eng. Cuicas Wisthon
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Report by:
Eng. Cuicas Wisthon
Ciudad de Panam
TECHNICAL REPORT
two, US and DS
Rev: 01
January 2015
Page 27 of 37
preferred, the back wall echo can be set on 5 and the repeat of the back
wall echo on 10. Set
the Gain initially to 58db.
Scanning for VSH defects
1.
Conduct two (2) Lengthwise Testing Passes along the Vertical Face
of the Head on the Field

Side of the rail ensuring that the grass is at 1/5 th screen height for both
passes. Adjust the Gain when required to maintain this level of grass.
Pass 1 is conducted adjacent to the base of the head to check for inclusion
bands (IB's).
Keep the edge of the probe in line with the bottom comer of the rail head.
Pass 2 is conducted adjacent to the top of the head to check for a potential
VSH. Keep the
edge of the probe in line with the top corner of the rail head.
2.
To qualify as a valid indication the reflection must appear as a
continuous signal on the screen between '1' and the back wall echo signal
on the base line and be of full screen height.
If however the testing surface is poor due to rough texture or irregular
angles then an indication of only 70% screen height is required.
3.
If a valid indication is present in the testing window then it should
be sized using the Sizing

Procedure in Section C10-10 to determine if a defect is present in the rail.

Inspected by:
Eng. Cuicas Wisthon
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Report by:
Eng. Cuicas Wisthon
Ciudad de Panam
TECHNICAL REPORT
two, US and DS
Rev: 01
January 2015
Page 28 of 37
If an indication of full screen height is found on both the top and bottom
passes at the same location in the head, then the top indication only
should be sized.
2.
DATE
OF
INSPECTION,
PERSONNEL
AND
EQUIPMENT
Inspection of the unions was held betwen January 26th and January 29th,
2015 in Cocol, Panama The staff was involved for inspection:
- Eng Cuicas Wisthon, ASNT-TC-1A Level II: VT, PT, MT, and UT.
EQUIPMENT USED:
- Ultrasound Equipment Olympus EPOCH LTX.
- Calibration block IIW Type 1.
- Digital Camera.
- Coupling Gel.
- Tape Measure.
4.
CRITERIA FOR ACCEPTANCE OR REJECTION:

Evaluation, acceptance and rejection took place following from TMC
224 RAIL DEFECTS AND TESTING and AWS D15.2/D15.2M:2013

RECOMMENDED PRACTICES FOR THE WELDING OF RAILS AND RELATED
RAIL COMPONENTS FOR USE BY RAIL VEHICLES.

Inspected by:
Eng. Cuicas Wisthon
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Report by:
Eng. Cuicas Wisthon
Ciudad de Panam
TECHNICAL REPORT
two, US and DS
Rev: 01
5.
January 2015
Page 29 of 37
INSPECTION RESULTS, ANALYSIS AND RECOMMENDATIONS

During the ultrasound inspection of the welds belonging to rail of
the gates relevant discontinuities were detected, relevant discontinuities

in the rail were detected as well.

Inspected by:
Eng. Cuicas Wisthon
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Report by:
Eng. Cuicas Wisthon
Ciudad de Panam
TECHNICAL REPORT
two, US and DS
Rev: 01
January 2015
Page 30 of 37
INSPECTION REPORT ULTRASONIC FLAW

DETECTOR
Project: Rail Welding Inspection
Client: Cimolai
Area:
Datum:
Report N: 01
SPECIFICATIONS MATERIAL UNDER TEST

Thickness
Diameter shaft Pre TT Post TT
N/A
N/A
N/A
Welding Procedure:
Welding Type
Surface condition Temperature
Code / applied standard:
N/A
Environment
EQUIPMENT USED
Brand: Olympus
Serial: SD010312
Model: EPOCH LTC
Transducer: Sonatest
Dimensions: 0.250 "
Frecuency: 2.25 MHz
Pattern calibration : ASME SECC V, ART 4
Pattern Reference: N / A
Others:
TECHNICAL PARAMETERS AND INSPECTION
Technique: Defectology
Range: 150 mm
Reference level: 45 dB
DAC calibration beam path: N / A
Reference Reflector:
Scanning Level (dB):
Incident angle: 0 , 45 and 70
Beam exit: Normal and Tilt
Coupling: Methylcellulose
Delay
Probe delay
Velocity
PCS
DSS
0,0 s
6,0 s
3280 m/s and 5800 m/s
N/A
N/A
Defects determination
%DAC
Result
Defect
Weld
Stamping
Sector
Ubicac.
Length
Depth height 45 60 70 type Acept Reject
REC3-DS1
X
REC3-DS2
X
REC3-DS3
X
REC3-US1
N/A
Internal
Weld
10mm
7mm
X
REC3-US2
X
REC3-US3
X
Equipment presentation/line:
Weld sketch: N/A
COMMENTS: Relevant discontinuities in REC3-US1 were detected, corresponding to the first weld Upper Rail Recess 3 US listed in the
direction from the building machine to the Canal, is rejected by the presence defects along all the subsurface of the weld with 10mm
of Depth and 7mm of height.
MADE BY
REVIEWED BY
APPROVED BY
COMPANY
SIGNATURE
NAME
ENG. Wisthon Cuicas
Eng. Wisthon Cuicas
Eng. Wisthon Cuicas
DATE
01-30-2015
01-30-2015
01-30-2015
Equipment
N/A
N/A

Inspected by:
Eng. Cuicas Wisthon
+507 6662 4768 / +507 68604245
Report by:
Eng. Cuicas Wisthon
Ciudad de Panam
TECHNICAL REPORT
two, US and DS
Rev: 01
January 2015
Page 31 of 37
INSPECTION REPORT ULTRASONIC FLAW

DETECTOR
Client: Cimolai
Welding Procedure:
Area:
Datum:
Equipment
N/A
N/A
Brand: Olympus
Delay
0,0 s
Weld
Stamping
REC4-DS1
REC4-DS2
REC4-DS3
REC4-US1
REC4-US2
REC4-US3
N/A
Report N: 01

Thickness
N/A
N/A
N/A
Welding Type
N/A
Environment
EQUIPMENT USED
Serial: SD010312
Model: EPOCH LTC
Dimensions: 0.250 "
Frecuency: 2.25 MHz
Others:
Range: 150 mm
Probe delay
Velocity
PCS
DSS
6,0 s
3280 m/s and 5800 m/s
N/A
N/A
%DAC
Result
Defect
Sector
Ubicac.
Length
Depth height 45 60 70 type Acept Reject
X
X
X
X
X
Internal Interphase
43, 37 and
48mm
8mm
4mm
Weld sketch: N/A
Lineal
COMMENTS: Relevant discontinuities in REC4-US3 were detected, corresponding to the third weld Upper Rail Recess 4 US listed in the
direction from the building machine to the Canal, is rejected by the presence of porosity with length of 37, 48 and 43 millimeters
COMPANY
SIGNATURE
NAME
DATE
MADE BY
REVIEWED BY
APPROVED BY
Eng. Wisthon Cuicas

01-30-2015
Eng. Wisthon Cuicas

01-30-2015
Eng. Wisthon Cuicas

11-30-2015

Inspected by:
Eng. Cuicas Wisthon
+507 6662 4768 / +507 68604245
Report by:
Eng. Cuicas Wisthon
Ciudad de Panam
TECHNICAL REPORT
two, US and DS
Rev: 01
January 2015
Page 32 of 37
REINSPECTION REPORT ULTRASONIC FLAW

DETECTOR
Client: Cimolai
Welding Procedure:
Area:
Datum:
Equipment
N/A
N/A
Brand: Olympus
Delay
0,0 s
Weld
Stamping
REC2-US2
Report N: 01

Thickness
N/A
N/A
N/A
Welding Type
N/A
Environment
EQUIPMENT USED
Serial: SD010312
Model: EPOCH LTC
Dimensions: 0.250 "
Frecuency: 2.25 MHz
Others:
Range: 150 mm
Probe delay
Velocity
PCS
DSS
6,0 s
3280 m/s and 5800 m/s
N/A
N/A
%DAC
Result
Defect
Sector
Ubicac.
Length
Lepth height 45 60 70 type Acept Reject
X
Weld sketch: N/A
COMMENTS: No significant discontinuities were detected during the inspection.
COMPANY
SIGNATURE
NAME
DATE
MADE BY
REVIEWED BY
APPROVED BY
ENG. Wisthon Cuicas

01-30-2015
Eng. Wisthon Cuicas

01-30-2015
Eng. Wisthon Cuicas

01-30-2015

Inspected by:
Eng. Cuicas Wisthon
+507 6662 4768 / +507 68604245
Report by:
Eng. Cuicas Wisthon
Ciudad de Panam
TECHNICAL REPORT
two, US and DS
Rev: 01
January 2015
Page 33 of 37
6. ANNEXES

Inspected by:
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Report by:
Eng. Cuicas Wisthon
Ciudad de Panam
TECHNICAL REPORT
two, US and DS
Rev: 01
January 2015
Page 34 of 37
PHOTOGRAPHIC RECORD

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Report by:
Eng. Cuicas Wisthon
Ciudad de Panam
TECHNICAL REPORT
two, US and DS
Rev: 01
January 2015
Page 35 of 37

Inspected by:
Eng. Cuicas Wisthon
+507 6662 4768 / +507 68604245
Report by:
Eng. Cuicas Wisthon
Ciudad de Panam
TECHNICAL REPORT
two, US and DS
Rev: 01
January 2015
Page 36 of 37
REFERENTIAL FAULT LOCATION

SCHEME

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Report by:
Eng. Cuicas Wisthon
Ciudad de Panam
TECHNICAL REPORT
two, US and DS
Rev: 01
January 2015
Page 37 of 37

Inspected by:
Eng. Cuicas Wisthon
+507 6662 4768 / +507 68604245
Report by:
Eng. Cuicas Wisthon
Ciudad de Panam

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TECHNICAL REPORT

Ultrasonic testing in the welds of Upper

ULTRASONIC TESTING IN THE WELDS

WDS INGENIERIA, S.A.

Panama, January 2015

Ultrasonic testing in the welds of REC 3 and REC 4, US and

Attached Technical Report Ultrasonic inspection, by WDS Ingeniera, S.A.,

This report contains observations and conclusions relating to the service.

ENG. Daniel Rivero

WDS INGENIERIA, S.A.

Line up the beam centre of the probe with the mark

determined by the angle plate. Point the probe slightly utwards

WDS INGENIERIA, S.A.

Scanning for Transverse Defects:

Make a scanning pass in both longitudinal testing directions

WDS INGENIERIA, S.A.

Additional setting up procedure prior to assessing indications

1. Choose a testing direction and line up the blade of the 70 angle

False defect indication from bottom corner of head

Determining the location (longitudinal alignment/position) of

WDS INGENIERIA, S.A.

WDS INGENIERIA, S.A.

Setting rail height

WDS INGENIERIA, S.A.

Scanning for defects with a 38 probe

Scanning for Bolthole Defects

Test slowly and obtain a signal from each bolthole.

Scanning for Weld Defects

WDS INGENIERIA, S.A.

Signals from bottom corner of rail head

Testing the foot of an aluminothermic weld with a twin 70 probe

represents a distance of 10mm. eg. When the left hand side of a

WDS INGENIERIA, S.A.

of the testing window ie (3 to 5 on the base of the screen) with the

The indication must appear within the appropriate testing

WDS INGENIERIA, S.A.

defect under bottom fillet radius

WDS INGENIERIA, S.A.

Testing the full rail with a twin 0 probe (SEB-2 0)

Setting up a twin 0 probe

Scanning for defects with a twin 0 probe

HSH 0 to 2, HWS 2 to 3, HSW 4 to 7, FWS 7 to 8.

Horizontal Splits in Head and Web

WDS INGENIERIA, S.A.

Vertical Splits in Head and Web

WDS INGENIERIA, S.A.

Scanning for gassing defects

Setting up SEB0 for testing depth of horizontal Indicators

WDS INGENIERIA, S.A.

1. Place probe on field side of unworn rail head

Signal from opposite side of head

3. Place probe on outer extremity of foot with probe overhanging the

Signal from edge of foot

WDS INGENIERIA, S.A.

6. Note: Screen is now set to read depth of horizontal indicators in

Measuring depth and length of indications

Scanning for wire feed weld defects with a twin 0 probe

WDS INGENIERIA, S.A.

web due to corrosion.