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MODERN TURNOUTS

FOR

INTRODUCTION OF HIGH SPEED

ON

THE EXISTING TRACK

This paper covers :

1. Introduction

  • 2. Thick web switches Technical Superiority

Field Performance

Development of Design & Drawing

  • 3. Weldable CMS Crossing Technical Superiority Development of Design & Drawing

This paper covers :

  • 4. LWR through Turnouts

  • 5. Other Improvements in Turnouts

Explosive

Depth

Hardened

(EDH)

CMS

Crossing In-situ Reconditioning of CMS Crossing Swing Nose Crossing

Movable Switch Diamond

INTRODUCTION :

  • At present, Over-riding Switch(ORS) and CMS crossing are used over fan-shaped PSC Sleeper &

LWR is not provided through turnout.

  • Tongue rail of ORS is machined at bottom of foot for over-riding. Planning at head and foot of tongue rail makes its cross-section smaller and tongue rail and stock rail withstand loads combindely.

  • One joint of tongue rail with lead rail remains fish- plated on main line route.

  • CMS Crossing has fish-plated joints at heel and toe resulting in impact force and its ill-effects on the life of various track components besides running.

INTRODUCTION :

  • Track between turnout and SEJ have single rail panels resulting in many fish-plated joints at the station limit .

  • Fish-plated joints are difficult to maintain properly over PSC Sleeper.

  • Due

to

series of

turnouts at

station limit,

the

running deteriorates and TGI is generally low

compared to block section.

  • The maintenance of track at station limit such as

packing, overhauling and deep screening by machine is relatively difficult.

INTRODUCTION :

  • High Speed Track shall have stricter tolerance and hence any joint/gap is undesirable.

  • To eliminate fish-plated joints at and around turnouts, the following are proposed for high speed on main line side of turnout :

    • Thick Web Switch using asymmetric tongue rail

    • Weldable CMS Crossing

    • LWR through turnout

THICK WEB SWITCHES

  • Thick Web Switch(TWS) is technically superior to Over-riding Switch :

  • In respect of Safety

    • Asymmetric tongue rail has larger cross section with little machining

of

foot.

This results in

enhanced safety and there is no case of

breakage of tongue rail in TWS.

  • No twist in TWS leads to increased safety

  • Stock rail is held from both sides

  • Clamp point

lock

ensures

direct

locking

of

tongue rail with stock rail for complete

effectiveness of locking

Thick Web Switch Vs Over-riding Switch

THICK WEB SWITCHES

Superiority

in

respect

of

Maintenance

Requirement

  • Asymmetric tongue rail has thick web and high Iyy which results in high lateral rigidity. Less

 

distortion

takes

place

under

lateral

loads

resulting in less maintenance.

 
  • Elastic fastening used for holding stock rail on both sides. Less disturbance to track geometry resulting in less maintenance.

The above features leads to higher service life

and improved riding comfort in TWS in addition

to increased safety and reduced maintenance

effort

THICK WEB SWITCHES

Inference drawn from field performance of details of 219 sets of TWS

TWS already served 500 GMT and still in service

On an average, service life of TWS is twice that of ORS

Requirement of reconditioning compared to ORS

Housing of tongue rail with stock better in TWS

is

very

less

rails is much

TWS being sturdier requires less maintenance due to less disturbance of track geometry.

THICK WEB SWITCHES

RDSO developed

Design

and

Thick Web Switches (TWS):

Drawings

for

60 Kg 1 in 12 : Drg. No. RDSO/T-6154 60 Kg 1 in 8.5 : Drg. No. RDSO/T-6279 60 Kg 1 in 16 : Drg. No. RDSO/T-7075

  • Above TWS have been designed with

160 mm throw along with SSD Point Clamp Lock

Elastic fastening for inside foot of stock rail using ERC, leaf spring & wedge arrangement

THICK WEB SWITCHES

  • Specification for Thick Web Switches and End Forging also developed by RDSO :

Switches made from asymmetric thick web rails to be machined by CNC machine to achieve correct profile and prescribed roughness factor on all machined surfaces

The

minimum

length

of

forged

section

with

desired rail profile is 500 mm to accommodate 1

metre long

fish plate

and

transition

length

of

forging shall be in the range of 150 mm to 200 mm.

WELDABLE CMS CROSSING

  • CMS crossing having different metallurgy compared to rail cannot be welded by conventional method.It is welded to rail section using an intermediate piece made normally of Ni-Cr Steel as shown below :

WELDABLE CMS CROSSING

  • In Weldable CMS Crossing, welded joint is provided between

the crossing and the adjoining

rails. Fish

plated joints are removed at the approach of the

crossing.

  • The hammering

action

of

rail

wheels

is eliminated

leading to riding comfort and enhanced life of track

components.

  • This further helps in reducing the maintenance efforts.

  • It is also possible to carry out LWR through points and crossings.

WELDABLE CMS CROSSING

RDSO has developed

Weldable CMS Xing:

Design and Drawings for

60 Kg 1 in 12 : Drg. No. RDSO/T-6412 60 Kg 1 in 8.5 : Drg. No. RDSO/T-6441

  • Special features :

Length increased

at

toe

and

heel

ends

for

matching of profile of normal rail

Sharp radius of curves eliminated

Vertical stiffeners provided at the bottom side of crossing in between the sleeper location for lateral rigidity to CMS crossing under dynamic load to

eliminate chances of crack

WELDABLE CMS CROSSING

WELDABLE CMS CROSSING

WELDABLE CMS CROSSING

  • Specification along with testing procedure for Weldable CMS Crossing developed to ensure quality control during manufacturing.

  • Specification of Weldable CMS Crossing is an improvement over the specification IRS-T29 for CMS Crossing

In respect of chemistry, the maximum limit of Ni, Mo, Cr, Cu and Al has also been specified.

The manganese shall not be less than 10 times the carbon content.

The radiographic examination has also been prescribed in entire cross-section for 80 mm length at ends of CMS Crossings to be welded with rail.

LWR THROUGH TURNOUT

LWRs

may be continued through turnouts with

following arrangements:

Use of Zu-1-60 thick web switches with elastic

fastenings and using distance blocks

27Ø HTS bolts in heel and

Use of ERC MK-V in complete turnout zone and up to 4 adjacent rail lengths on either side of turnout

Use of specially designed anti creep device behind heel of switch

Use of Weldable CMS crossing Use of creep anchors in lead portion

LWR THROUGH TURNOUT

  • As per calculation considering temperature zone IV and 60 Kg UIC rail, the resisting force is more than the induced thermal forces and hence the above arrangement of continuing LWR through turnout shall

be effective. Further 27Ø HTS bolts

at heel and

distance block will also resist thermal force by

transferring the same to the stock rail.

  • The total theoretical movement of tongue/stock rail due to rise and fall in temperature with respect to the distressing temperature comes to appx 7 mm and 15

mm respectively. The actual movement is likely to be less due to creep anchors at lead.

LWR THROUGH TURNOUT

OTHER DEVELOPMENTS

  • Explosive Crossing

Depth

Hardened

(EDH)

CMS

By explosive hardening, the initial hardness in wear prone area is increased from 220 BHN to 350 BHN enhancing the service life of CMS crossing before requirement of reconditioning

  • In-situ Reconditioning Of CMS Crossing

Necessary for Weldable

CMS Crossing. One

technology using translamatic robotic welder is

already

adopted.

development.

Other

technologies

are

under

OTHER DEVELOPMENTS

  • Swing Nose Crossing

The gap near nose of crossing can be avoided for better riding comfort and maintainability by the use of swing nose crossing.

  • Movable Switch Diamond

RDSO has developed design of 1:10 & 1:8.5 movable switch diamond in which movable obtuse crossing is used to avoid unsupported and

unguided length at throat of obtuse crossing. This

results in better ride quality and increased service life of track components.

Movable Switch Diamond

Movable Switch Diamond

CONCLUSION

  • Modern turnout for high speed on the existing track shall comprise of Thick Web Switch and

Weldable CMS Crossing with the provision of

LWR .

  • The

design,

drawing

and

specifications

for

above

turnout

components

have

been

developed

and

these

can

be

manufactured

indigenously.

CONCLUSION

  • Technology of explosive hardening and in-situ reconditioning shall lead to enhancement of service life of Weldable CMS Crossing. Thick Web Switches, being sturdier, require lesser maintenance effort and have more service life.

  • Introduction of such turnouts and maintenance do not require any special arrangement from

Signal Deptt.

THANKS

From :

A.K.Singhal, Exec. Dir./RDSO

A.K.Mishra, Director/RDSO