Modern non-destructive testing tools and technologies

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Modern non-destructive testing tools and technologies

In September 2001, the second International Specialized Exhibition of Devices and Equipment for Industrial Non-destructive Testing "Flaw Detection-2001" was held in St. Petersburg. Within the framework of the exhibition, a scientific and practical seminar "Modern means and technologies of non-destructive testing on the railways of the world" was organized at the initiative of the Ministry of Internal Affairs of Russia, St. Petersburg State University of Railways, SUE Oktyabrskaya Railway, SUE Research Institute of Bridges and Flaw Detection.

The seminar was organized in three main areas:

About stationary and mobile computerized complexes, microprocessor-based removable and portable flaw detectors for non-destructive testing (NC) of rails;

@ computerized complexes and microprocessor portable flaw detectors for assembly of wheelsets, parts and assemblies of rolling stock during their manufacture and repair;

6 systems and organization of NC of railway transport equipment, including methodological aspects of training, retraining, certification and certification of NC specialists.

The seminar was held at the St. Petersburg State University of Railway Transport. The participants were welcomed by the Rector of PSUPSa, Professor V.I. Kovalev, who noted that the seminar was being held in accordance with the instructions of the First Deputy Minister of Railways A.S. Misharin. 250 specialists from 44 cities of Russia, Belarus, Ukraine, Moldova, as well as Germany were delegated to it.

The main task of the participants was a deep and objective analysis of the effectiveness of existing NC systems and the development of recommendations for dramatically improving the reliability of NC while reducing the cost of control and the number of operators, taking into account the upcoming reform of the federal railway transport of Russia. V.I. Kovalev noted that if great strides have been made in the field of NC in the track and wagon farms, then in the locomotive Unfortunately, the work on the introduction of NC tools is just beginning to unfold in the economy. There is no unified personnel training system.

The chief engineer of the Oktyabrskaya Road, V.A. Gapanovich, familiarized the seminar participants with the implementation of NC tools on the road. In particular, he noted that 1,272 people are employed in non—destructive testing on the road, and only 5% (63 people) are specialists with higher education. Therefore, the training of personnel in the field of NC is particularly important. There are 1,384 flaw detection devices in operation on the road, of which 816 are ultrasonic, 318 are magnetic powder, 146 are eddy current and 96 are ferrosonde. 563 flaw detectors are used in the track's facilities, 573 in wagons and 186 in locomotives.

In the locomotive industry in 2000, 208 thousand parts were checked with NC facilities, 7 thousand of them were rejected. V.A. Gapanovich noted the need for NC automation in order to minimize the influence of the human factor. A promising direction is the introduction of methods for controlling wheelsets and couplings on the train.

The report "Analysis of the effectiveness of non-destructive testing systems in railway transport and tasks to improve it" was delivered by the Head of the Department of Technical Policy of the Ministry of Internal Affairs of Russia Z.S. Nagovitsyn. He noted that currently

The time is especially important in the light of reforming railway transport and improving traffic safety to expand the use of NC. There are over 11,000 technical means of flaw detection in operation on railways, based on ultrasonic (60%), magnetic (30%) and eddy current (10%) methods. Annually, more than 30 million critical parts of rolling stock are checked and approximately 400 thousand parts are withdrawn from service due to dangerous defects.

NC methods used in manufacturing plants do not provide complete detection of dangerous metallurgical defects. Modern domestic flaw detection equipment is not inferior in functionality, and in some cases surpasses its global counterparts, however, a significant proportion of them are morally and physically outdated and require replacement. The NC tools used provide only manual or mechanized control, so its reliability largely depends on the human factor. Of the total number of rail breaks in 2000, up to 12% were due to defects undetected by flaw detectors.

The speaker noted that it is necessary to automate the NC process, to introduce NC systems more widely on the train, and to use complex non-disassembly technologies when conducting NC using the ultrasonic method.

Next, B.C. Nagovitsin focused on the training of personnel in the field of NK. Currently, such control is carried out by more than 13 thousand specialists, but their average skill level is low, mainly of the IV — V category.

In conclusion of his report, B.C. Nagovitsyn proposed the following measures to improve the effectiveness of non-destructive testing in railway transport:

- review regulatory documents containing technical requirements for the serviceability and safety of rails, assemblies and parts of rolling stock during manufacture and repair;

- to create modern tools and technological processes for automated control of rails and critical parts of rolling stock, ensuring increased reliability and reducing the cost of control during repairs. In particular, it is necessary to develop automated systems and integrated non-disassembly NC technologies that provide increased sensitivity and noise immunity, automatic documentation, decryption and storage of results. To introduce portable flaw detection indicators for express inspection of parts and components of rolling stock at VET and repair facilities;

v provide roads with NC specialists of various skill levels. In particular, to develop uniform requirements for training, advanced training, and voluntary certification of personnel in the field of NC in railway transport. To prepare and submit to the Ministry of Labor of the Russian Federation proposals for supplementing the "Unified Tariff and Qualification Directory of jobs and professions of workers" with regard to the requirements for the qualification of flaw detectors, taking into account the introduction of modern means and technologies of the Tax Code. To develop requirements for road (regional) training centers for the training of specialists in the field of ovide roads with NC specialists of various skill levels. In particular, to develop uniform requirements for training, advanced training, and voluntary certification of personnel in the field of NC in railway transport. To prepare and submit to the Ministry of Labor of the Russian Federation proposals for supplementing the "Unified Tariff and Qualification Directory of jobs and professions of workers" with regard to the requirements for the qualification of flaw detectors, taking into account the introduction of modern means and technologies of the Tax Code. To develop requirements for road (regional) training centers for the training of specialists in the field of NC. To organize the retrofitting of the educational and methodological base for personnel training, taking into account the introduction of new NC tools and technologies;

- to develop and put into effect the requirements for quality systems in the field of NC of railway transport organizations in accordance with the international standards ISO 9000 series version 2000;

- to establish that the accreditation of NC laboratories at manufacturers of technical equipment according to RD 32.151—2000 is a prerequisite for the order for their supply for the needs of railway transport.

The report "Modern trends in trThe report "Modern trends in traffic safety and the development of non-destructive testing" was delivered by the Head of the Department of Radio Engineering of PSUPSA A.E. Kraskovsky. He stopped at a brief historical background on train safety. I compared the data on accidents at the beginning of the 20th century with the current level. For example, at that time there were about 4-5 thousand crashes and accidents per year (marriages were not included in the classification). Currently, there are also about 5,000 traffic safety violations, but now rail transport carries out significantly larger volumes of traffic. Therefore, if we calculate per unit of work (100,000 train kilometers), then the level of traffic safety is 200 times higher at the beginning of the 21st century than it was 100 years ago!

The speaker further noted that although traffic volumes are increasing, total investments in rolling stock and track have decreased, real operating costs are not increasing.

Analyzing the current level of traffic safety, A.E. Kraskovsky said that the number of marriages in the first half of 2001 decreased by 10% compared to the same period in 2000alyzing the current level of traffic safety, A.E. Kraskovsky said that the number of marriages in the first half of 2001 decreased by 10% compared to the same period in 2000 (3812/3454). The number of crashes in 8 months of 2001 was 6, and in the whole of 2000—5, 3/3 people died, respectively, 86/51 cars of locomotives were broken.

2/0. Full break in movement 81/75 h. Gatherings at the beginning of September 2001 were 72 (in 2000 — 44), i.e. an increase of more than 1.6 times. Moreover, the ratio changes in the direction of increase.

A significant decrease in investment in the industry and the containment of the growth of operating costs, which include the maintenance of a traffic safety system, are the root causes of the decline in traffic safety. The speaker noted that the department has developed a formula for calculating the level of traffic safety, according to which, based on the volume of traffic and the actual cost of ensuring traffic safety, the expected level of traffic safety can be predicted. It is possible to identify material factors affecting traffic safety: long-term investments and operating costs.

In the report of the Director of the Center for Non-Destructive Testing (branch of the Research IIt is possible to identify material factors affecting traffic safety: long-term investments and operating costs.

In the report of the Director of the Center for Non-Destructive Testing (branch of the nstitute of Bridges of the Ministry of Internal Affairs of Russia) G.Ya. Dymkin, the main attention was paid to improving the system of ultrasonic inspe

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