Non-Destructive Testing and Inspection of Rails at JSPL – Ensuring Safety and Reliability

Safety and reliability of a railway system primarily depend on the soundness of critical components and their freedom from defects. This paper presents an efficient inspection method for rails during manufacturing at Jindal Steel and Power Ltd., India, aiming to mitigate failures from manufacturing defects. The study introduces an on-line laser-based straightness measurement system, on-line eddy current testing, and on-line ultrasonic testing. The laser-based system utilizes a unique mathematical algorithm to compute the rail's true horizontal and vertical shape based on measurement data. The on-line eddy current testing identifies typical manufacturing defects with specialized probes, while the on-line ultrasonic testing detects internal imperfections such as laminar defects, inclusions, and tension cracks in the railhead, web, and base. Results indicate that the implementation of these technologies has led to significant advancements in the inspection and reliability of rails, ultimately contributing to improved operational safety and quality in rail transport. Continuous investment in technology and research ensures that high-performance rails are delivered to meet contemporary demands.