Kolkata, Aug 25: Eastern Railway’s Sealdah Division has stepped up track safety by deploying 20 Ultrasonic Flaw Detection (USFD) machines to examine rails and welds across its 1,375-km track network. The technology is aimed at identifying hidden defects before they develop into serious cracks or rail fractures that could disrupt train services or threaten passenger safety.
USFD is a non-destructive inspection method that uses ultrasonic waves to detect internal flaws that may not be visible during a routine physical examination. Early identification allows railway engineers to take preventive action, including repairs or replacement of defective sections, before the problem becomes critical. Eastern Railway has previously described USFD testing as an important part of regular rail and weld inspections in the Sealdah Division.
The Sealdah network includes 761.24 km of 60-kg rails and 613.76 km of 52-kg rails. Of the 20 machines currently deployed, 10 are being used for rail inspection and the remaining 10 for checking welds. A dedicated team of operators and inspectors carries out the testing and follows up on defects identified during the process.
The inspection system has also been connected with the Track Management System (TMS). Digital B-Scan reports generated during inspections are uploaded to the system for monitoring and review. Divisional supervisors conduct an additional check of the data, creating another layer of verification and helping reduce the possibility of defects being overlooked.
Inspection schedules are adjusted according to traffic levels and the type of rail. Sections carrying heavier traffic are inspected more frequently, while less-used routes follow longer inspection cycles. Welds also undergo initial testing followed by periodic checks. This approach allows railway authorities to focus greater attention on sections where track stress and operational demand are higher.
The initiative is particularly important for passengers because Sealdah is one of Eastern Railway’s busiest divisions, handling an estimated 1.5–1.8 million passengers a day. Its network supports extensive suburban services as well as long-distance trains, making the condition of the tracks crucial for both safety and reliable train movement.
The focus on preventive inspection also comes at a time when railway authorities are placing greater emphasis on eliminating avoidable risks across busy networks. The objective of the USFD programme is not simply to find visible damage, but to detect problems before they become visible and potentially dangerous.
By combining ultrasonic testing, trained personnel and digital monitoring, Sealdah Division is building a more proactive track-maintenance system. For passengers, the benefit is straightforward: better track monitoring, earlier repairs and an additional layer of protection against failures that could affect safe train operations.