achievements during the year 2016-17 1.1 track …...cleaning machine model frm-85f, manufactured by...

Achievements during the year 2016-17

1.1 Track Recording Cars

1.1.1 Track Monitoring

At present four TRCs are available with this directorate. The recording of track geometry is done as per stipulations of IRPWM para No. 606. Track Machines Directorate monitors the health of the Indian Railways track through Track Recording cars and send the track defect reports to concerned zonal railways so that the track can be maintained timely.

At present total liability of track recording on Indian Railway as per IRPWM comes out to be approx. 1,95,000 track kms. In the current year, total 85112 km has been recorded with 04 operational TRCs.

1.1.2 Reinforcement of Track Recording Cars As per recommendations of “High Level Task Force on Safety Regarding

system and process to improve the safety performance on Indian Railways” submitted to MR, all TRCs should be re-equipped with modern systems and Laser based sensors for effective measurements and recording of track parameters.

At present RDSO is running four Track Recording Cars (TRCs), out of which two are LASER Contactless Sensor Based and two are Contact Sensor Based. Procurement and commissioning of 05 additional TRCs is under process and at the end of December-2019 total of 09 TRCs will be operational. The estimated date of commission of additional TRCs are furnished in the table below:

Type of TRC Present

position Additional TRCs

Estimated date of commissioning

Total nos. of TRCs at the end of 2019

Contact based Non-Laser TRC

02 01 Feb 2017 3

LASER based modern TRCs

02 01 April’ 2018 3

LASER based, integrated TRCs equipped with video cameras for track component scanning, rear window video recording & mapping of MMD envelop and vehicle parameters

NIL 03 01-Oct.’2018, 02-Dec.’2018, 03-March’2019

3

The 03 additional integrated TRCs will have facilities for measurement of track geometry parameters including curvature, rail wear parameters, identification of defects in track components i.e. sleeper & fastening and rails through video recording, rear window video recording of track feature, identification of any obstacle in maximum moving dimension envelop of IR track and acceleration measurement at axle box and pivot of car body the specification for these track monitoring system has been finalized and sent to Board for approval. TMM Directorate is having staff to operate and maintain only 05 TRCs. Thus the operation and maintenance of additional 04 TRCs is required to be managed through contract. Out of additional 04 TRCs contract for 01 TRCs is under finalization. Detail estimate for 01 TRC included in WP of 2015-16 is vetted & sanction and specification are under approval with Board, remaining 02 TRCs has been included in RSP 2016-17.

These additional 04 TRCs will require a total nos. of 8 special LHB coaches with 200 kmph speed potential, 4 coaches for TRC and 4 nos. coaches for staff. A regular chasing with RCF/Kapurthala is required for getting these

special type of coaches manufactured before supply of TRC systems. Vetting and sanction of detail estimate of 02 TRCs included in RSP 2017-18 needs to be expedited.

1.2 Large Track Machines

1.2.1 Specification of Track machines

Due to more traffic density & less availability of block, in order to enhance the output of track machines, specification of following machines have been revised and approved by Railway Board for better output

i) Ballast Regulating Machine (BRM)

ii) Ballast Cleaning Machine (BCM) iii) Multipurpose Tamping Machine 1.2.2 Maintenance Schedule Manual of Track Machines issued to railways

To ensure proper maintenance of Track Machines, RDSO has issued Maintenance schedule of following machines to railways: i) High Output Tamping Machine (CSM 09-32) ii) Ballast Regulating Machine (BRM-METEX) iii) Ballast Regulating Machine (BRM-USP-2000SWS) iv) Ballast regulating machine (GMAC,Model-SPZ-210 k)

1.2.3 Revision of Maintenance Schedule Manual of Track Machines issued to

Railways

To ensure proper maintenance of Track Machines, RDSO has revised the Maintenance schedule of following machines to railways:

i) Revision-1 of Plasser make Worksite Tamping Machine ii) Revision-1 of Tamping Express Machine.(09-3x)

1.2.4 Critical Spare Parts

For maintenance of any machine, timely availability of spare parts and consumables play an important role. To keep the machine in sound condition, list of Critical Spare Parts of following machines have been prepared and issued to Railways:

i) Ballast Regulating Machine (BRM-METEX) ii) Ballast Regulating Machine (Kershaw) iii) Ballast Regulating Machine (BRM-USP-2000SWS) iv) UNIMAT-Split Head-MFI v) Shoulder Ballast Cleaning Machine (FRM-85F) vi) Work Site Tamper VPR-02 M

1.2.5 Inspection Check List

To avoid failure of On-Track Machines in block section, inspection check list of following machines have been prepared and issued to Zonal Railways:- i) Ballast Regulating Machine (BRM-METEX) ii) Ballast Regulating Machine (BRM-GMEC, Model-SPZ-210K)

1.2.6 Revision of Inspection Check List

To avoid failure of On-Track Machines in block section, inspection check list of following machines have been revised and issued to Zonal Railways:- i) Revision-1 of Plasser make Worksite Tamping Machine

1.2.7 Speed Certificates

i) Speed certificate for conducting detailed oscillation trial and EBD trial

have been issued for following Track Machines:

a) Point & Crossing Tamping Machine (UNIMAT, Model-08-475-4S, T-Code: PCTM/08-475-4S)

b) Multi Purpose Tamping Machine (Model UNIMAT Spilt Head MFI, T-Code: CMTUSHP)

ii) Provisional speed certificate of UNIMAT-08-475-4S has been prepared and issued.

iii) Amendment No. 2 to speed certificate for conducting detailed oscillation trial of Dynamic Track Stabilizer (DGS-62N) has been issued.

iv) Amendment No. 1 to provisional speed certificate of Shoulder Ballast Cleaning Machine Model FRM-85F, manufactured by M/s Plasser India, has been issued vide letter no. TM/HM/11/12/FRM-85F dated 03.02.2017

v) Transportation Code of following Track Machines has been allotted by Railway Board:

a) Tamping, Lining and Levelling Machine 08-32 DUOMATIC manufactured by M/s Plasser India.

b) Lifting Lining, Levelling and Tamping Machine 08-32C DUOMATIC manufactured by M/s Plasser India.

c) 4-Wheeler self propelled Utility Track Vehicle with mobile crane supplied by M/s Phooltas Tampers Pvt. Ltd. Patna.

d) Ballast Cleaning Machine Model RM80-92U manufactured by M/s Plasser India.

e) High Output Tamping Machine 09-3X (axle load 18.5 t) manufactured by M/s Plasser India.

1.2.8 Guidelines for monitoring of quality of Hydraulic Oil issued to Zonal Railways.

1.2.9 Indian Railway Track Machine Manual (IRTMM-2000)

The IRTMM-2000 has been revised by the committee of SAG officers nominated by Railway Board and the draft revised IRTMM has been sent to Railway Bard for approval.

1.2.10 Codal Life of Track Machines

The codal life of track machines has been reviewed by a committee of SAG officers nominated by Railway Board and the recommendation of the committee has been approved by the Railway Board.

1.2.11 Indigenization of drawing & specification of Track Machines Spares

Indigenization of drawing & specification of twenty spares of different on track machines issued by RDSO.

1.3 Small Track Machines 1.3.1 Development of new machine

1) Prototype testing of Light Weight Rail Drilling Machine (LWRDM)

developed by M/s Kelvin Enterprises (India), New Delhi completed. STMC recommendation sent to Railway Board vide letter no. TM/SM/Track dated 27/28.03.2017

2) On the basis of revised specification trial testing of Machine (ERC Inserter & Extractor) offered by M/s SVJ Corporation Kolkata completed. STMC recommendation sent to Railway Board vide letter no. TM/SM/Track dated 27/28.03.2017.

1.3.2 Multi sourcing of vendors

In connection with multi sourcing of vendors Prototype testing of Magnetic Base Type Rail Thermometer developed by M/s Kelvin Enterprises, India, New Delhi completed. STMC recommendation sent to Railway Board vide letter no. TM/SM/Track dated 27/28.03.2017.

1.3.3 Revision/up-gradation of specifications Specification of Continuous Rail Thermometer has been revised and approved by Board vide letter no. 2009/Track-III/TK/12 dated 18.05.2016. Subsequently amendment 03 of Approved list of Manufacturers/ suppliers of Small Track Machines and P-Way measuring tools dated 01.10.2015, valid upto 31.12.2017, issued vide letter no. TM/SM/Track dated 01.06.2016.

Testing of upgraded Continuous Rail Thermometer (CRT), developed by M/s votive Marketing Pvt. Ltd., Lucknow as per revised specification has been approved and communicated to all concerned. Functional specification of ERC Inserter and Extractor revised and approved by EDTM.

1.3.4 Others

On the basis of complaint received from Western Railway M/s Lakshmi Industrial Corporation, Meerut, kept under suspension in approved list for supply of Abrasive Rail Cutter. Information communicated to all concerned vide letter no. TM/SM/Track dated 31.08.2016.

Meeting of Standing Committee on Small Track Machines held on 20.03.2017 & 21.03.2017. Minutes sent to Railway Board vide letter no. TM/SM/Track dated 27/28.03.2017 for approval.

1.4 Track Lab

Track Laboratory is having well qualified research and technical staff with static and dynamic testing facilities of track components. Track components can be tested on hard as well as ballasted deck under simulated dynamic loading condition as occurring in the field by actual rolling wheel axle set.

Facilities available:

Static and dynamic testing of track components

Fatigue testing of track components on RAIL TRACK PANEL FATIGUE TESTING EQUIPMENT

Fatigue testing of track components on Hydraulic Pulsator

Measurement of toe load of elastic fastenings

Evaluation of stress at critical locations for track components

Calibration of helical springs for mechanical toe load measuring device

Verification of calibration of load cell for electronic toe load measuring device

Calibration of OMS in association with Research Directorate of RDSO

Creep resistance test

Important works done in the Track Lab in year 2016-17

1.4.1 Fatigue testing of 60 kg (90 uts) A.T. Welded Rail Joint (grounded at bottom of rail foot)

Track Design Directorate vide note No. CT/Welding/Policy dated 04.04.2016,

provided a test scheme for fatigue testing of 60 kg (90 UTS) A.T. Welded

Rail Joint.

Test Scheme:

According to scheme, three weld samples, made with one meter long new

rail pieces, having overall length of 2.0 m have been prepared at Thermit

portion plant, Lucknow and send to Track Laboratory. Weld geometry of two

samples out of three have been ground on foot, to the level of rail & one has

been left intact. Each sample has to be placed on test frame as shown in fig.

1 having span of 1.5m & is to be subjected to dynamic loading for stress

range of tensile 20 kg/sq.mm to compressive 4 kg/sq. mm (these are the

stress on the bottom of rail foot). As per instruction of EDTM one more weld

sample having grounded on foot, to the level of rail has been tested as

sample no. 4.

Loading Parameters:

Downward lodging Upward loading Frequency

219.351 KN 43.879 KN 9 Hz

Figure showing the actual test setup:

1500mm

150m

mm

2000 mm

Testing of sample No. 1 (Job No.: TL/16-4001)

This sample is made with one meter long new rail pieces, having overall

length of 2.0 m, weld geometry (collar) of this sample have been ground on

foot, to the level of rail. As Shown in photo graph below:

The sample was mounted of test rig as shown in fig:1 and dynamic loading

was applied as per table given below:


219.351 KN 43.879 KN 9 Hz

The sample Failed after 5,06,137 cycles, & broken right from the middle of

the weld.

TEST ARRANGEMENT (Fig:1)

Weld Broken after 5, 06,137 cycles

Testing of sample No. 2 (Job No.: TL/16-4003):


length of 2.0 m, weld geometry(collar) of this sample has not been grounded

(i.e. normal A.T.welded rail joint) as shown in photograph below:




219.351 KN 43.879 KN 9 Hz

Sample withstood 2.0 million cycles








219.351 KN 43.879 KN 9 Hz

The sample Failed after 9,12,294 cycles, & broken right from the middle of

the weld.

Weld Broken after 9,12,294 cycles


Further EDTM suggested to test one more sample grounded at bottom of rail

foot and accordingly, this Directorate vide note no TM/TL/58 Vol.VI dated

28.10.2016 requested to arrange another sample. The sample was received

in Track Lab vide challan no 02/18/TPP dated 29.11.2016 on date.







219.351 KN 43.879 KN 9 Hz

The sample Failed after 16,23,410 cycles, & broken from the heat zone of

the weld.

Sample broken after 16,23,410 cycles

Conclusion:

SN Sample/Job No. weld geometry of this

sample have been

ground on foot, to the

level of rail

weld geometry of this

sample has not been

grounded (i.e. normal A.T.

welded rail joint)

1 sample No. 1 (Job No.:TL/16-4001)

Broken after 5, 06,137

cycles

NO


Withstood 2.0 million

cycles


Broken after 9,12,294

cycles

NO


Broken after 16,23,410

cycles

NO

1.4.2 Field trial for Development of Automatic rail lining arrangement during unloading of 20 rail panel

Track Lab is developing an automatic Rail unloading system for 20 rail panel. In this connection some field trials for its effective working has been done at different section. After modification, a field trail was again conducted for 52KG, 20 rail panel at Bhojipura – Bijauriya, new construction of line. Another trial for Automatic rail unloading system was conducted for 60 KG, 20 rail panel at Colonel Ganj – Maizapur section. This arrangement was successful tested in different sections.

1.4.3 Effect of non-availability of clean Ballast cushion on Rail Stress

In reference Railway Board letter no.2010/CE-II/TS/3 RDSO (SC) dated 06.02.2017, Railway Board has adviced to determine the adverse effect on Track Modulus and rail stress on account of non-availability of minimum clean ballast cushion due to overdue deep screening. For the above work, the sites have been selected between Unnao-Balamou section. To carry out compressive study of effect of non-availability of minimum clean ballast cushion on track modulus and rail stress, one BFR has been arranged at Makhi Station in Unnao-Balamou section to take reaction of load application on track.

Rail unloading Block Rail unloading Clamp

Arrangement of Rail unloading

To measure Rail Stresses, strain gauging work on 12 mts. 60 Kg rail has been completed. Work is in progress and recording at one location is completed. Loaded BFR:

Strain Gauging in 60 kg Rails:

Some Other Important work done from April 2016 to March 2017:-

SN Description Nos

1 Calibration of Oscillation Monitoring System (OMS) 49

2 Testing of ERC samples of 23 mm diameter for 32.5 axle

load

24

3 Testing of ERC-J samples 40

4 Calibration of Helical Spring 02

5 Composite GRSP 01 new +

10 old

4 Fatigue Testing of 60 kg (90 UTS) A.T. Welded Rail Joint. Report No. TM-202 (Grounded sample – 3 nos.and ungrounded – 1 no.)

04

samples

5 Design & Development of Automatic rail lining arrangement during unloading of 20 rail panel

completed

6 Design & Development of ERC Block Toe load In process

measuring device with indicator capacity 2Ton and Hydraulic Jack with table to pull in/out toe

7 Design & Development of High speed LVDT with inbuilt

DAQ and battery Universal input 32 channel data logger

with inbuilt:

In process

8 Fatigue Testing of ERC MK-V samples In process

1.5 Finalization of Study Reports

During the year, 10 study reports have been finalized and issued. The details of study reports are as under:-

S.N. Report No. Description

1. TM-197 Report on Codal Life of Track Machine & evaluation of quality of out put of Track Machine

2. TM-198 Maintenance Schedule Manual of BRM (Metex)

3. TM-199 Inspection Check List of BRM (Metex)

4. TM-200 Inspection Check List of BRM, GMAC model SPZ-210K

5. TM-201 Specification of Rail Inspection Vehicle (RIV)

6. TM-202 Fatigue testing of 60 Kg (90 UTS) welded rail joint (grounded at bottom of rail foot)

7. TM-203 Maintenance Schedule Manual for BRM (USP2000SWS)

8. TM-204 Inspection Check List of BRM (USP2000SWS)

9. TM-205 Maintenance Schedule Manual of BRM (GMAC model SPZ-210K)

10. TM-206 Functional specification of Abrasive Stone (Rail Grinding Stone)


1.1 Track Monitoring

1.1.1 Track Machines directorate monitors the health of the track on Indian

Railways through Track Recording cars and sends the details to concerned zonal railways so that the track can be attended to timely, thus reducing failures during service.

During the year 2014-15, a total of 1,11,477 track Km have been recorded by track recording car. In the current year, total 136793 km has been recorded.

1.1.2 GPS based acceleration measurement system at axle box level

GPS based system for measurement of acceleration was developed and tested in field. This system is capable of recording vertical and lateral acceleration at axle box level on both left and right side of axle. The system is designed to measure acceleration at both axle box and on the coach floor.

The repeatability of acceleration peaks at same speed was tested in field during trials and found within expected accuracy. Location of acceleration peaks recorded by GPS was verified using tachometer and found within acceptable limit. Further trials for fixing limits of acceleration at axle box level will be conducted by West central Railway as the system has been installed in a ICF coach of WCR.

1.2 Large Track Machines 1.2.1 Specification of Track machines

Due to more traffic density & less availability of block, in order to enhance the output of track machines, specification of following machines have been revised for better output:

i) Multipurpose Tamper (MPT)

ii) Ballast Regulating Machine (BRM) iii) Ballast Cleaning Machine (BCM) 1.2.2 Maintenance Schedule of Track Machines issued to railways

To ensure proper maintenance of Track Machines, RDSO has issued Maintenance schedule of following machines to railways:

v) Worksite Tamper (WST, VPR-02M) vi) Track laying Equipment (PQRS) vii) UNIMAT-Spilt head-MFI

1.2.3 Critical Spare Parts

For maintenance of any machine, timely availability of spare parts and consumables play an important role. To keep the machine in sound condition, list of Critical Spare Parts of following machines have been prepared and issued to railways:

vii) UNIMAT 4S-08-475 ii) Ballast regulating Machine (Kershaw) viii) UNIMAT-Spilt head-MFI ix) BRM-Kersaw

x) VPR-02M

1.2.4 Inspection Check List

To avoid failure of On-Track Machines in block section, inspection check list of following machines have been prepared and issued to Zonal Railways:-

ii) Track Laying Equipment (PQRS) ii) Worksite Tamper (VPR-02M) iii) Ballast Cleaning Machine (BCM-RM 80-92U) iv) UNIMAT-Spilt head-MFI v) BRM-China

1.2.5 IRTMM-2000 Correction Slips

Following correction slips to Track Machine Manual have been prepared & sent to Railway Board for approval

i) Correction slip to chapter 2.4.2 and 2.4.3 – Screen floor sixe of BCM

ii) Correction slip to chapter 3.1.3 – Tamping tool depth iii) Correction slip to chapter 6.3.1 – OEM inspection during POH

1.2.6 Speed Certificates

Provisional speed certificate of following on-track machines have been prepared and issued to Zonal Railways:- i) Tamping Express Model 09-3X(20.0t axle load) (Plasser India) ii) Utility Track Vehicle with mobile crane (Phooltas Patna) iii) Utility Track Vehicle (OEPL Hyderabad) iv) Utility Track Vehicle (BEML Banglore) v) Dynamic Track Stabilizer (BHEL Jhansi) vi) Ballast Regulating Machine Model-USP 2000 SWS (Plasser India) vii) Lifting Lining, Levelling and Tamping Machine Model 08-32C

DUOMATIC (Plasser India) viii) Ballast Regulating Machine Model –PBR 400R (Plasser India) ix) Dynamic Track Stabilizer Model –DSP-C8T (Metex-JSC Moscow) x) Utility Track Vehicle (BHEL Jhansi) xi) Ballast Regulating Machine Model – RPB-01 (Metex-JSC Moscow) xii) Multi Purpose Tramping Machine type UNIMAT-COMPACT/M

(Plasser India) xiii) Rail Grinding Machine (RGI-72) (Loram-USA)

1.3 Small Track Machines

1.3.1 Development of new machines

In connection with development of new machines following work have been done:

i) Portable Rail & Switch grinder:

Specification of machine has been developed & P.O. for procurement of 3 nos. of machines has been placed. Extension of delivery period

has been given upto May, 2016.

ii) Gang Men Warning System:

Based on trial on SC Railway, the specification for Gang Men Warning System has been developed in association with Tele Communication Directorate & EOI has been invited for vendor development. RDSO has proposed for extended trial of above item, which has been approved by Board on five Zonal railways viz Northern, North Eastern, Southern, South Eastern & Western Railways,

iii) Light Weight Rail Drilling Machine:

Its vendor has been developed and approved. Prototype testing of machine developed by another vendor (M/s SVJ Corp. Kolkata) has been completed and approved for putting up the case to STMC.

iv) ERC Inserter & Extractor:

On the basis of trial of machine developed by one vendor (M/s Lakshmi Industrial Corp. Meerut), broad functional requirement is under process of revision.

v) Development of Light Weight Weigh Push Trolley:

One additional vendor has been developed and approved by Board. Prototype testing of machine developed by another vendor (M/s R.N. Engg. Enterprises, Asansol) has been completed and approved for putting up the case to STMC.

1.3.3 Multi sourcing of vendors:

In connection with multi sourcing of vendors, three additional vendors for respective Small Track Machines (Heavy duty Hydraulic Extractor for Jammed ERCs (10t), Hydraulic Rail Tensor (Non-infringing type) 70t capacity, Hydraulic Track Lifting cum Slewing Device (TRALIS) 15t capacity) have been approved. In addition type testing of two Small Track Machines (Portable DC welding Generator & Gang Work site Remote Control Hotter) developed by M/s Himalayan Power Machine Mfg. Co. & M/s. Lakshmi Industrial Corporation respectively have been completed and recommended by STMC to Railway Board for approval. Prototype testing of two machines (Abrasive Rail Cutter & Rail Cutting Wheel Abrasive Disc) developed by vendors (M/s R.N. Engg. Enterprises, Asansol & M/s SVJ Corp. Kolkata respectively) has been completed and approved for putting up the case to STMC.

1.3.4 Up gradation of vendors from Part-II to Part-I :

In connection with up gradation of vendors from Part-II to Part-I, three vendors for respective Small Track Machines (Portable DC Welding Generator, Light Weight Rail Mono cum Road Trolley and Gang Worksite Remote Control Hooter) have been upgraded. Concerned Zonal Railways have been asked to send the performance for upgradation of vendors under Part-II.

1.3.5 Revision/up-gradation of specifications:

Specification of Route Data (File) Preparation System has been revised and approved by Board and informed to all concerned. Revision of specification of Continuous Rail Thermometer is under process.

1.3.6 Discontinuing unused/less used Small Track Machines:

In response to Board’s directive, recommendation for deletion of one less used Small Track machines (Micro Controller based Oscillation Monitoring System) has been approved by Board vide letter no. 2008/Track-III/TK/8 Vol. IV dated 24.09.2015. Approved List has been revised accordingly and circulated to all concerned.

1.3.7 Meeting of Standing Committee on Small Track Machines held on 04.02.2016 & 09.02.2016. Minutes sent to Railway Board for approval.

1.4 Track Laboratory












1.4.1 Fatigue testing of wider pre-stressed concrete sleepers to drawing no. RDSO/T- 8527 (capacity – 25.0t). (Report No. TM-194)

Vide Track Design Directorate note referred above, a test scheme for Static & Dynamic testing of wider sleeper as per Drawing No. RDSO/T-8527 was provided. Testing of sleeper was carried out as per test scheme given by Track Design Directorate.

Test scheme

Before dynamic testing

As per test scheme, “Static load shall be applied at rail seat centre and increased gradually till a fine crack appears at the rail seat bottom for a height of 15 mm (approx) and such cracking load will be recorded.

After creation of the crack, this rail seat was tested for dynamic loading on Rail Track Panel Fatigue Testing Equipment as per the loading parameters mentioned below

Sl.

Test Span

Load Range

Nos. of rail seat to be tested

Frequency of loading

Total nos. of cycles

1.

640mm 2.5t to 21.4t

(24.53 KN to 209.93 KN)

1 8.33 Hz 2.0Million

Crack propagation was measured after completion of every 0.5 million cycles of loading.

After dynamic testing

After completion of 2.0 million cycles the same rail seat was tested under gradually increasing static load till its fracture/failure and corresponding load at its failure was recorded. The other rail seat i.e. untested rail seat of the sleeper was tested under gradually increased static load till the fracture/failure of the sleeper and corresponding value of load was recorded. Testing of three no. sleeper was completed on 26.11.14.and the test report has been sent to Track Design Directorate on 03.12.2014.

640mm span

Sleeper Dynamic Loading actuator

Failure of rail seat

Photograph of Test setups

640mm Test Span Actuator Sleeper

Sleeper No.

First Rail Seat Second Rail Seat Remarks

Initial Crack(T)

Failure Load(T)

Initial Crack(T)

Failure Load(T)

1 28 55 33 55 Completed 2.0 million cycles without fail.



1.4.2 Laboratory measurement of Frame Resistance of cross bracing arrangement for continuation of Long Welded rails on sharp curves and steep gradients (Report No. TM-190)

Track Design Directorate has developed the Cross Bracing Arrangements of sleepers to be put in place for continuation of LWR/CWR on sharp curves

(>50). Accordingly, track Lab conducted a trial for measurement of Lateral Track Frame Resistance with and without bracing to determining the actual contribution of cross bracings.

For above trial, Cross-Bracings were prepared at NR Bridge workshop and 30nos of hole were drilled in 15 sleepers to fit the bracing. 30 nos Dowell were grouted with adhesive Bondcrete. Bracings were fitted on sleepers with the help of plate screws. All the arrangements were made along with 13m rail panel with 60kg rail and PSC sleepers. Complete Rail panel was supported on rollers, with two rollers beneath each sleeper to make the arrangements Friction free. Rail posts were already grouted at both sides of rail panel for taking reaction to apply the load. Strain gauges were also been fixed on Rail to take the measurement of maximum stresses. Maximum stresses in rail should not reach beyond the limit of 46 kg/mm2during the application of load and bending of rail.

Table - A (Sleeper Spacing 60 CM)

5 Meter Span 7 Meter Span

Max Load (tonnes)

Avg Deflection (MM)

EIeq (T/SqM)

Max Load (tonnes)

Avg Deflection (MM)

EIeq (T/SqM)

With Bracing

10 39.05 667 10 67.05 1066

Without Bracing

10 63.65 409 6.4 93.15 491

Table –B (Sleeper Spacing 65 CM) 5 Meter Span 7 Meter Span

Max Load (tonnes)

Avg Deflection (MM)

EIeq (T/SqM)

Max Load (tonnes)

Avg Deflection (MM)

EIeq (T/SqM)

With Bracing

10.4 43.95 616 10.4 71.78 1035

Without Bracing

7.2 56.68 331 6.1 94.65 461

All the data were taken up to max rail stress 46kg/mm2 at rail foot.

It was observed that the EIeq value increased by 117-124% with use of cross-bracing in same span and sleeper spacing. It was also seen that when cross-bracing is used, the lateral deflection is reduced by 24-28% for the given lateral load with same span and sleeper spacing, which indicates the higher rigidity of track frame using cross-bracings as compare to plain track.

Photographs

(1) (2)

(3) (4)

(1) - Drilling in PSC sleeper (2) - Preparation of Track Panel (3) - Fixing of Bracings (4) - Inspection of Trial by Director Track Machine-I and Director Track Design

(5) (6)

(7) (8)

(9)

(5) - Application of load by Hyd Jack and Proving ring (6) - Load applied and track get curved (7) - Astro-med Stress Recorder for stress recording (8) - Deflection measurement by Dial Gauges (9) - Complete setup

1.4.3. Development of Ballast compaction measurement Device:

Board desired to develop a device/small equipment that can be used for measurement of ballast compaction. In this regard, the development of “Ballast compaction measurement instrument” was done at Track Lab by using LVDT (Linear variable differential transformer) and vertical settlement of rail under train/loading was measured. The device consists of one LVDT, mounted on spring loaded arrangement with wire attached to rail foot seat with the help of specially designed clip. The settlement of rail seat is transferred to LVDT which in turn change the voltage in synchronization with settlement. This change in voltage is recorded with analogue recorder. Field trials of this device were conducted in LKO-CNB section.

Fig.-1LVDT mounting arrangement Fig.-2 Specially designed clip fastened

to rail seat Deflection transfer arrangement

Fig.-3 Recorder on which deflection is measured Fig.-4 Wheel passing

over the device

The LVDT used was giving good results when the speed of the train was low but at higher speeds the results obtained were erratic and no reproducibility was observed. Besides using LVDT (Linear variable differential transformer) possibility of using potential meter was also explored because sensitivity of LVDT used was not as high as required. In this concept Linear motion of rail is converted into circular motion and this motion is measured in terms of variable voltage by data acquisition system. Field trials of this device were conducted in LKO-CNB section.

Potention meter circular disc Arrangement showing the transfer of deflection.

Data Acquisition for recording the Data

It was observed that the potential meter gave good results in first few trials but it lost its sensitivity when repeated loading and unloading trials were conducted. After every three trials, potential metered needed replacement. Meanwhile, Digital dial gauge were procured which could also be used to measure rail settlement under loading. This digital dial was placed in the bottom of rail seat and when the train moves the maximum displacement of rail gave the amount of ballast compaction. Field trial is in progress. The instrument is giving good results.

Photograph of arrangement of Digital Dial Gauge used for measurement of ballast compaction:

Digital Dial Gauge

1.4.4 Field trial for Study of Behavior of ERC during PQRS and Tie Tamping

operation

During tamping and PQRS operations track is lifted by machine and due to lifting of complete track structure, the Rail fastening clips (ERC) get more stresses and deflection. The behavior of ERCs during the tamping and PQRS operations was studied in field.

Trial Scheme

There was no certain scheme how to study the behavior of ERCs during above machine operations. Track Lab official prepared a scheme to conduct the above trial. Following points were considered in the trial scheme.

A) During PQRS operation:

i) Measurement of gap at the toe of selected ERCs using 0.05 mm filler gauge under lifted condition of rail panel.

ii) Measurement of stresses on selected ERCs (as shown in diagram at Annexure-1) under lifted condition.

iii) Measurement of Toe load of selected ERCs before and after PQRS working.

iv) Measurement of Toe Load of selected ERCs under lifted condition. B) During Tamping operation:

i) Measurement of stresses on selected ERCs (as shown in diagram at Annexure-2) during tamping operation at 50 mm lift.

ii) Measurement of Toe Load of selected ERCs before and after tamping.

iii) Measurement of gap at the toe of selected ERC using 0.05 mm filler gauge under lifted condition of rail track.

All the data were collected on the basis of above scheme at two different trial sites for Tamping and PQRS operations.

Photographs of PQRS Trials

( 1 ) ( 2 )

(3 ) ( 4 )

(1) PQRS Machine at Banga

(2) Toe load measurement before lifting

(3) Toe Load Measurement During Lifting

(4) Stresses Measurement of ERCs

Photographs of Tamping Site

( 1 ) ( 2 )

(3 ) ( 4 )

(1) Toe Load Measuring at Tamping site

(2) Wiring of Instrumented ERCs

(3) Tamping Machine operation at Instrument ERC location

(4) Dummy Box and Instrumented ERCs

After analyzing the results obtained, it was seen that there was no major change in the stresses generated in all the ERCs during Tamping operation and PQRS lifting and there was no noticeable difference in ERCs behavior before and after Tamping operations and PQRS lifting. There was small change in Toe-load which was not considerable. No gap was recorded between ERCs and Sleeper Liners during lifting of both operations.

1.4.5 Non-destructive stress free temperature measurement of CWR by force

application method

As per scheme provided by CTE, C.R. Mumbai, regarding “non-destructive stress free temperature measurement of CWR by force application method-trial of equipment developed by C.R. for determination of stress free temperature by force application method” was completed and test result were sent to Track Design Dte. on 11.03.2016.

1.4.6 Other Important Work Done in Track Laboratory

Ballast resistance trial just after temping at different squeezing time of tamping Machine at BWN-BGNA section has been completed.

Testing of Toe Load using in service 6.2 mm thick Composite Groove Rubber sole pads laid in track for performance evaluation – 30 nos.

Testing of ERC MK-V samples – 24 nos.

Calibration OMS - 47

Testing of J-clips – 08 nos.




11. TM-187 Maintenance Schedule Manual for Levelling, Tamping and Lining Machine WST(VPR-02M)

12. TM-173B Report of the Committee for fixing selection of relevant chord and give their recommendation on Report No. TM-173

13. TM-188 Behavior of ERCs during PQRS & Tie Tamping operations

14. TM-189 GPS based portable system for acceleration measurement at axle box level

15. TM-190 Lab measurement of frame resistance of cross-bracing arrangements

16. TM-191 Draft specification for Switch Rail Grinding Machine

17. TM-192 Draft specification for 8 Stone Rail Grinding Machine

18. TM-193 Draft specification for 24 Stone Rail Grinding Machine

19. TM-194 Fatigue testing of wider prestressed concrete sleepers to Drawing No. RDSO/T-8527 (capacity 25.0t)

20. TM-195 Report on monitoring and evaluation of the working of DGS on Indian Railways

21. TM-196 Maintenance Schedule Manual for UNIMAT spilt head-MFI


1.1 Track Monitoring 1.1.1 Track Machines directorate monitors the health of the track on Indian

Railways through Track Recording cars and sends the details to concerned zonal railways so that the track can be attended to timely, thus reducing failures during service.

During the year 2013-14, a total of 85,589 track Km have been recorded by track recording car. In the current year, total 1,11,477 km has been recorded.

1.1.2 Two high speed laser contact less sensor based track recording cars have

been procured for monitoring health of IR track at high speed. This will ensure need based maintenance of track. Both of these have been commissioned and pressed into service. These TRCs are capable of recording rail wear along with track geometry parameters serving at maximum speed of 160 kmph.

1.1.3 Identification of two relevant chords for measurement of track parameters on

the basis of natural frequency of various rolling stocks plying on IR track

In view of operation of mixed traffic on IR track measurement of track parameter on single chord is not feasible, as different wavelength track irregularities affect various rolling stocks having different natural frequencies. Thus there was need to identify two relevant chords for measurement of track parameters affecting vehicle ride on the basis of natural frequencies of rolling stocks plying on IR track so that the transfer function of track parameter measurement remains between 0.8 to 1.0. Chord lengths finally approved by Railway Board are furnished below:-

S.No. Parameter Short Chord/Base Long Chord/Base

1. Unevenness 9.0 m 18 m

2. Alignment 9.0 m 15 m

3. Twist 3.0 m 15 m

These chords are relevant up to a maximum speed of 160 Kmph for various rolling stock having different speed potential considered in the study and plying on IR Track.

1.2 Large Track Machines 1.2.1 Framing of New Specification/Revision of existing Specification of track

machines

Specifications of new On Track Machines, to be procured for use in railways, are framed by RDSO and approved by Railway Board. Revision of existing specification of On Track Machines, being used in railways is also done, based on the field experience and updating of performance. i) Specification of “High Output Tamping cum Stabilizing Machine

capable of 3500 sleepers per hour peak output for B.G. (1676mm)” has been revised and sent to Railway Board for approval.

ii) Global EOI for development of specification of “Formation Rehabilitation Machine” has been invited in order to collect the various type of machines, technologies available globally. A committee comprising of directors of concerned directorates (TMM, GE and Track Directorates) has been constituted to finalize the case.

1.2.2 Maintenance Schedule of Track Machines issued to railways

Maintenance of On-Track Machine is a challenging task. Presently, more than 721 On Track Machines are working over different zonal railways. Maintenance of these machines is being done by zonal railways with the assistance of local trade available, zonal track machine workshops, CPOH / Allahabad & Rainapadu and RDSO/ Lucknow. With experience over the years, the railway engineers have developed adequate expertise in the maintenance of these machines. However, in absence of approved maintenance instructions, different maintenance practices have come into vogue. Therefore, it has become imperative to have a uniform maintenance standard throughout the Indian Railways. Maintenance schedule of following machines have been revised and issued to railways:

i) Rail Grinding Machine ii) BCM RM-80-92U

1.2.3 List of Critical Spare Parts of Track Machines issued to railways

For maintenance of any machine, timely availability of spare parts and consumables play an important role. Thus, to keep the machine in sound condition, first and foremost prerequisite is availability of spares and consumables. As there are thousands of items/spares which are required for maintenance of machines, it is very much required to identify critical spares which are vital and in turn, to ensure availability of such spares well within the scheduled time. For this ‘List of Critical Spare Parts’ for various On Track Machines are prepared. List of Critical Spare Parts of following machines have been prepared and issued to railways: i) Track Laying Machine (TRT) ii) Utility Track Vehicle UTV) iii) Shoulder Ballast cleaning Machine (SBCM)

1.2.4 Audit Inspection of Tamping Machines

As per Railway board’s instruction, audit inspection of following machines has been carried out and the report has been sent to Railway Board: (i) Continuous Action Tamping Machine (CSM 09-32) (ii) Tamping Express (09-3X)

1.2.5 Speed Certificates of Track machines

Speed certificate for every new On Track Machine is issued for inception in Indian Railways. For any revision/correction in the speed certificate, necessary amendments are incorporated. Following amendments have been issued to Railways:

i) Amendment no.1 to speed certificate for conducting detailed

oscillation trials and EBD trials of BG Rail Borne Maintenance Vehicle

(RBMV) manufactured by M/s Phooltas Harsco Rail Solutions Pvt.

Ltd., Patna has been issued to GM/N. Railway vide letter no.

TM/HM/11/7/RBMV dated 03.11.14

ii) Amendment no.2 regarding CRS sanction for running of RGM model RGM-72 has been issued to railways vide letter no. TM/HM/11/23/RGM dated 02.12.14

iii) Proposal for allotment of Transportation Code for following machines have been sent to Board: a) Letter no. MC/TW dated 02.01.2015 for DTS Model DSP-C8T

b) Letter no. MC/TW dated 05.01.2015 for BRM Model PBR-400R

c) Letter no. MC/TW dated 05.01.2015 for BRM/China

d) Letter no. MC/TW dated 6.01.2015 for MPT Unimat Split Head

MFI

e) Letter no. MC/TW dated 12.02.2015 for DTS/BHEL, Jhansi

1.2.6 Correction Slips to IRTMM-2000

Indian Railways Track Machine Manual (IRTMM) was published in the year 2000 after which various corrections have been made as per the exigency of field requirements etc. Following correction slips have been sent to Board for approval and are under consideration at Board: i) Correction Slip no. 18 (inspection schedule for track machine officials)

has been revised as per Board’s directives and sent to Board for approval.

ii) Correction Slip no. 20 (Changes in existing provision of Annexure 6.2 of IRTMM-2000) has been sent to Board for approval.

iii) Draft Correction slip no. 21 (Tamping depth) has been sent to Board for approval.

1.2.7 Evaluation of Comparative Performance of different types of Dynamic Track Stabilizers

A Study of the comparative performance of three different make DTS in use on Indian Railway has been done and the report is under finalization.

1.2.8 Drawing & specification of Track Machines Spares

Drawing & specification of following eight spares of different on track machines issued by RDSO:-

SN Machines Items

1. Unimat, Uni-3S & Uni-4S

Tool Tilting Cylinder (Part No.W33.201)

2. Tamping Express Eccentric Vibration Shaft (Part no. UD25-1101)

Eccentric Vibration Shaft (Part no. UD25-1102)

3. UNO, DUO, WST, UNI, Tamping Express

Piston for Brake cylinder of. (W33.205A)

Gland Bush For Brake Cylinder (Part No. W33.220)

Cover for Brake Cylinder (Part no. 33.139.3 )

Piston Rod for Brake Cylinder (Part no. UD160.52)

Sleeve for Brake Cylinder (Partno.UD216.451)

1.3 Small Track Machines

1.3.1 Development of Light Weight Push Trolley

The earlier approved push trolley had total weight 250 Kg was felt to be very high for use in high traffic density routes. Accordingly project was taken for developing a light weight push trolley. After field trial conducted with different material composition specification for Light Weight Push Trolley has been finalized. One vendor has also been approved by Railway Board for trial. Approval of two more vendors is in the process. The new trolley has weight of 125 Kg which is 50% less than the previously approved push trolley with same carrying capacity.

1.3.2 Multi sourcing of vendors

In connection with multi sourcing of vendors, four additional vendors for respective Small Track Machines have been approved. Further two vendors has been approved by EDTM to be put up in the next STMC meeting.

1.3.3 In connection with up gradation of vendors from Part-II to Part-I, ten vendors

for respective Small Track Machines have been upgraded.

1.3.4 On the basis of complaint from Zonal Railways two vendors for respective

Small Track machines have been downgraded from Part-I to Part-II. 1.3.5 Revision of specifications

Following specifications have been revised and sent to Railway Board for approval:-

i) Rail Profile Weld Grinder ii) Hydraulic Track Jack 15t capacity

4.3.6 Development of Vendors

Broad Functional Requirement of Rail Foot Profile Weld Grinder, Light weight Abrasive Rail Cutter, Light weight Rail Drilling Machine, Battery operated Rail Drilling Machine & ERC Inserter & Extractor finalized and EOI invited for development of Vendors.

Global EOI has been invited to developed Rail and Switch Grinding Machine 1.3.7 Correction Slip No. 5 to IRSTMM has been issued.

1.4 Track Laboratory


http://www.rdso.indianrailways.gov.in/works/uploads/File/Rail%20Foot%20Profile%20Weld%20Grinder.pdf











1.4.1 Testing of ERC - J samples

Testing of eight no. ERC – J samples including stress measurement, permanent set and load verses deflection test has been carried out under development of new design ERC – J clip, developed by track design directorate.

Arrangement for load verses deflection test

1.4.2 Testing of Toe Load using in service 6.2 mm thick Composite Groove

Rubber sole pads laid in track for performance evaluation.

As per Track Design Directorate note no. CT/GFP/Composite/DK Steel dated 03.03.2014 and QA/Civil Directorate Note no. CT/GRP/Composite/DSK dated 12.05.2014 measurement of toe load using in service 6.2mm Composite Grooved Rubber sole pad has been taken by using one no. new and 170 nos. old composite GRSPs at the bottom of selected rail seat in 60 kg rail assembly.

A test setup was made with 2.0 meter long 60 Kg rail on 03 no. sleepers having spacing 60.0 cm. in open store near track lab. One rail seat of the middle sleeper was selected for conduction of tests. All the remaining five rail seats of test setup were having new GRSP and GFN liners fitted with ERC MK-III provided by Track Design Directorate.

Photograph of test setup

The recording of data with the help of electronic toe load measuring device has been done as follows:

a. Two readings of toe-load of ERC MK-III were taken on middle sleeper

with new composite GRSP. b. Two reading of toe-load of ERC MK-III were taken on the same

location as above against each in-service composite GRSPs c. Electronic toe load measuring device used for measurement of toe

load was verified for its calibration in track lab. on 12.02.2014.

Electronic Toe Load Measuring fixed on test frame

Toe load of New ERC provided by Track Design Directorate has been recorded against each composite GRSPs (01 new & 170 old) two times with the help of electronic toe load measuring device from 12.05.2014 to 10.06.2014 in presence of SSE/QAC Test report has been send to QA/Civil Directorate vide this office note no. TM/TL/9 Vol VII dated 17.06.2014.

1.4.3 Development of Toe Load Measuring Device which can directly measure toe

load being exerted by ERC on Liner

As per Track Design note no. CT/EF/Policy dated 22.05.2014 ME has desired that a Toe Load Measuring Device be developed in such a manner that there is a load cell/strain gauge etc. that can be fixed at the toe point over line so that actual toe load which is being exerted by ERC can be measured.

In view of above concept First of all for measurement of toe load of ERC a thought was given to make a load cell on liner. For this a vender Votive Marketing Ltd. was consulted. He searched web and manufacturers of load cell and finally came to conclusion that a load cell of size that can be placed in between liner and toe is not available that can give the load of ERC up to 1500 kg.

While discussing a thought came in mind that why not we use ERC as load cell, finally we started working on this line.

Stress analysis is been done on ERC after fixing strain gauge on first curve of ERC which is the sharpest curve of ERC. After doing trial on this theory we came to a conclusion that if we use electronic circuit of Electronic Toe Load Measuring Device and calibrate it by using strain gauged ERC then the toe load of ERC can be found after fixing it on rail.

This trial was carried out on 03.05.2014, Votive Marketing Ltd. modified the circuit of Electronic Toe Load Measuring Device. Calibration of Electronic Toe Load Measuring Device was done using Strain gauged ERC.

Calibration of ERC on UTM Strain Gauged ERC on Track The calibrated ERC placed on PSC Sleeper the readings obtain was not similar to toe load taken by Electronic Toe Load Measuring Device on same ERC. Again the research started, a new three types of Load Cells were prepared:-

i) By placing strain gauges on the bottom of liner by removing 2mm metal.

ii) By cutting the metal of size 10mm X 28mm from metal liner where the elliptical portion of the clip rest on the liner and will make it as load cell and this portion will be placed on GFN liner by cutting grave in it of same size.

iii) By making a load cell of size 10mm X 15 mm in place of above and will do the same as above.

The following work was carried out and none of them were successful.

1. Cleaning of surface of liner was done.

Surface cleaning for fixing of strain gauges

Strain gauging work on removing 2mm metal.

After strain gauging the Metal liner was placed on UTM on jig for calibration as shown in figure below

Liner Load application on liner

Calibration process: After placing the liner as shown above load was applied on liner in step of 10 kg and strain corresponding to it was recorded Result: No repeatability in calibration recorded, after first cycle of loading.

2. Load cell was made on by cutting the metal of size 10mm X 28mm from

metal liner where the elliptical portion of the clip rest on the liner as shown below:

This load cell was placed on GFN liner by cutting grave in it of same size as shown below:

Calibration of load cell was done on UTM again no repeatability was found during loading and unloading process. Load cell failed after single process of loading and unloading.

3. A load cell of size 10mm X 15 mm was made as shown below:

This load cell was placed on GFN liner by cutting grave in it of same size as shown below:

Calibration of load cell was done on UTM again no repeatability was found during loading and unloading process. And the load cell failed

1.4.5 Ballast resistance Trial at Malihabad Lucknow section

A field trial related to ballast resistance test was conducted at malihabad-Lucknow Down section near malihabad station yard. One of the major

parameter to measure the consolidation of track is the lateral ballast resistance of track/ sleeper. The study is being done to find the rate of consolidation with traffic and also to check the GMT traffic equivalence of DTS.

1.4.6 Dynamic testing of BG Mono-block pre-stressed concrete sleepers to

drawing No RDSO/T- 8306(capacity – 25.0t)

Track Design Directorate vide note no. CT/SRC/3/2/FPT dated 16.0.2014 provided a test scheme for Dynamic testing of three monoblock PSC sleepers to Drawing No. RDSO/T-8306. Dynamic testing of this sleeper was started on 17.10. 2010.

.

Test arrangement For Dynamic testing of PSC sleeper on Rail Track Panel Fatigue testing machine

Test Scheme:

Before dynamic testing:

Static load was applied at one rail seat centre and increased gradually till a fine crack at rail seat bottom for a height of 15 mm appears. This cracking load was recorded.

Dynamic Testing Parameters were as follows: Load Range – 2.5 ton (24.5 KN) to 21.9 t (214.8 KN) Test Span – 640 mm Frequency – 8.33 Hz Total Cycles – 2.0 million

Crack propagation was measured after completion of every 0.5 million cycles of loading

After dynamic testing:

After completion of 2.0 million cycles the same rail seat was tested under gradually increasing static load till its fracture/failure and corresponding load at its failure was recorded. The other rail seat i.e. untested rail seat of the sleeper was tested under gradually increased static load till the fracture/failure of the sleeper and corresponding value of load was recorded. Testing of three no. sleeper was completed on 26.11.14.and the test report has been sent to Track Design Directorate vide this office letter no. TM/TL/58 Vol.-IV dated 03.12.2014

1.4.7 Other Important Work Done in Track Laboratory

S.N. Name of work Progress

1. Calibration of OMS 39nos.

2. Testing of ERC MK-III (Developmental) 16 Nos.

3. Testing of ERC MK-V (Developmental) 08 nos.

4. Testing of ERC J-clips (Developed by Track Design Directorate)

08 nos.

5. Inspection of electronic toe load measuring device 24 nos.

6. Calibration of helical springs for mechanical toe load measuring device

02 nos.

7 Testing of Composite Grooved Rubber Pad 210




1. TM-181 Report on usefulness of High Speed Grinding Over Indian Railways

2. TM-182 Existing specification of Points and crossing Renewal Machine and study of different similar machines manufactured by leading manufacturers world over

3. TM-183 Check list for inspection of WST (VPR-02M) without flat car kalugaputmash

4. TM-169 (Rev.-I)

Inspection Check List for (UNIMAT-4S)

5. TM-184 Inspection Check list for UNIMAT Spilt head MFI

6. TM-106A (Rev.-1)

Inspection Check list for Tamping Express (09-3X)

7. TM-185 Laying of Track Tolerances on new chord for speed band of less than < 100 kmph & >100 < 110 kmph

8. TM-186 Inspection check list for Ballast Cleaning Machine (RM-80-92U)

achievements during the year 2016-17 1.1 track …...cleaning machine model frm-85f, manufactured by...

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