Track inspection tool, Study notes for Transportation Engineering
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rahul-vatsyn-mishra

Track inspection tool, Study notes for Transportation Engineering

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Track inspection tools and safety tools for maintenance work.
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Hkkjr ljdkj & GOVERNMENT OF INDIA jsy ea=ky; & MINISTRY OF RAILWAYS

egkjktiqj, Xokfy;j & 474 005 ¼Hkkjr½ Maharajpur, Gwalior - 474 005 (INDIA)  : 0751 - 2470869 & Fax : 0751 - 2470841

dsoy dk;Zky;hu mi;ksx gsrq For Official Use Only

रेल पथ नर ण औज़ार एव ंसंर ा उपकरण

TRACK INSPECTION TOOLS AND SAFETY EQUIPMENTS

कैमटेक@2014@ स@ट आई ट एस ई@1.0 CAMTECH/2014/C/TITSE/1.0

सत बर 2014/September – 2014

रेल पथ नर ण औज़ार एव ंसंर ा उपकरण

TRACK INSPECTION TOOLS AND SAFETY EQUIPMENTS

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i FOREWORD

Indian Railways have been striving continuously to improve track structure for heavier loads, longer and speedier trains. To keep the track in safe and fit condition, the various kinds of tools for measurement of track parameters and safety equipments are used for ensuring the safety of traffic and staff itself by P. Way staff in day to day maintenance and construction works.

The handbook prepared by CAMTECH incorporates various kinds of tools essential during inspection of track, equipments for safety of traffic and their importance is briefly described in the book.

It is expected that the handbook will be quite helpful to civil engineering personnel of Indian Railways engaged in these activities. Date: 26, September 2014 (A.R. Tupe)

Executive Director CAMTECH/Gwalior

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fnukad 24] flrEcj 2014¼,l- ds- lDlsuk½ mi funs'kd dseVsd] Xokfy;j

iiPREFACE

An essential ingredient in the successful running of a railway is a well maintained track system. Indian railway has a large rail network covering approximately a track length of 63465 kms, which require maintenance throughout the year. Track maintenance has undergone a change during the past 30 years due to continuous development in track components viz. sleepers, fastenings and long welded rails. Various kinds of tools for measurement of track parameters and safety equipments are used to keep the track in safe and fit condition. This booklet is prepared on the basis of work experience, RDSO’s specifications and manufacturers’ instructions. This booklet is not statutory and contents are only for the purpose of guidance. We welcome any suggestions from readers for further improvement. Date: 24, September 2014 (S.K. Saxena)

Dy. Director CAMTECH/Gwalior

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dz-la- izdk’ku dh rkjh[k la’kksf/kr Ik̀"B la[;k rFkk en la[;k

fVIi.kh

ISSUE OF CORRECTION SLIPS

The correction slips to be issued in future for this handbook will be numbered as follows: CAMTECH/C/2014/TITSE /1.0/CS. # XX date ....... Where “XX” is the serial number of the concerned correction slip (starting from 01 onwards).

CORRECTION SLIPS ISSUED

Sr. No. of

C.Slip

Date of

issue

Page no. and Item No. modified

Remarks

iii

iv वषय-सूची/CONTENTS

स. . S.No.

ववरण/Description पेज स. Page No.

ा कथन/Foreword i भू मका/Preface iiसंशोधन पच /Correction Slip iiiवषय सूची/Contents iv

1-0 प रचय/Introduction 1

2-0 रेल पथ मापन औज़ार/P. Way Measuring Tools

1

3-0 संर ा उपकरण/Safety Equipments 16 4-0 व वध औज़ार/Miscelleneous Tools 21 5-0 सूचक/Indicators 23

संदभ/Reference 26

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1.0 प रचय/Introduction

Indian railway has a large rail network covering entire length and breadth of country. The maintenance of track, which consists of rails, rail fastenings and fittings, is essential to keep the track safe and fit for heavy traffic. The staffs responsible for track maintenance require various kinds of tools for measurement of track parameters and for ensuring the safety of traffic and staff itself. This booklet is prepared on the basis of field experience, RDSO’s specifications and manufacturers’ instructions. In subsequent sections, the each kind of tool is described in brief for guidance of the P. Way staff. 2.0 रेल पथ मापन औज़ार/P. Way Measuring Tools Different tools are needed to record physical value of track parametersor measurement of particular track component. Here some measurement tools are being discussed: 2.1 ट ल के पैमाने/Steel Scale Stainless steel scales meant for measuring linear metre are available in size of 10cm, 15cm and 30cm. They are used to measure versines, gaps in SEJ, etc.

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2.2 नापने का फ ता/Measuring Tape It is a common measuring tool. A measuring tape is a flexible form of ruler. It is used for measuring the dimensions in all engineering works. It is available in different sizes i.e. 2, 3, 5, 15, and 30 meter. It consists of a fiber glass, linen and metal strip with linear measurement markings. It is graduated at every millimeter. Its flexibility allows for a measure of great length to be easily carried in pocket or toolkit and permits one to measure around curves or corners. 2.3 रेल तापमापी/Rail Thermometers Rail thermometer used to measure the temperature of the rail at site. The following are the types of approved thermometers for measuring rail temperature:-

A) चु ंबक य आधार कार रेल तापमापी/Magnetic Base Type Rail Thermometer

(RDSO specification No. TM-67 dt. 28 .01 .2002 rev. 01 of 2010) The thermometer is designed to firmly stick to the rail top by magnetic action of the base of the thermometer when placed on the top of rail head and stand in vertical position. It is be capable to measure the rail temperature correctly to the specified accuracy and tolerance

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within six minutes. Red, Yellow & Green colour code for easy understanding for P. Way staff.

Technical Features:

 Overall length : 200 + 5 mm (including casing)

 Overall length of capillary tube: 186 + 2 mm

 Least Count : 1.00C

 Accuracy : +1.00C

 Temperature Range : - 50 C to + 850C.

 Weight : Within 120 gms.

 Temperature Recording Time : Within six minutes.

B) डायल कार तापमापी/Dial Type Thermometer This is a bi-metallic type thermometer, which is provided with magnet for attaching it to the rail. The thermometer is attached on the shady side of the web of the rail. A steady recording of the rail temperature is reached within 8 minutes.  Measuring Range : -300C to 700C  Least Count : 10C  Magnet Base : For Best Holding To Rail.  Weighs : less than 60 gm.  Diameter : 50 mm

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 Thermometers have three hands to give instantaneous, maximum and minimum temperatures.

C) सतत रेल तापमापी/Continuous Rail Thermometer

RDSO (No.TM/TL/119) rev. 13.09.2012 This device is used for continuously displaying rail temperature, storing the data at pre-set interval and transferring this data to PC through USB port of PC. This unit can be placed at nearby cabin to continuously monitor and store the rail temperature. The Device shall be capable of continuous operation during the varying atmospheric and climatic conditions as follows:  Ambient temperature : 0 to 550C  Altitude : Sea level to 700 m  Maximum rail temperature : 850 C

Technical Features'

 Alphanumeric LCD display size : (minimum 97 mm X 22 mm) of two line with 16 characters each.

 Resolution : 0.10 C

 Accuracy : + 10 C

 Measurement Range : -05 to 850 C

 Memory : Non-volatile- up to 18 months on hourly basis.

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 LCD Display pattern : 18/09/1411:30 18.20 C (Date) (Time) (Temp.)

2.4 टो भार मापन यं /Toe load measuring device: The toe load measuring device consists of a pre-calibrated helical spring having a steel pointer attached to a lever arrangement through a link hanger for gripping elastic rail clip. When the spring is compressed by turning a rotating handle at the top of the device, the toe of the clip gets pulled up and compression of the spring causes a pointer to indicate displacement on a graduated scale. The Toe load (in Kg) exerted by the spring on the toe of the clip is measured by multiplying the displacement of the pointer and the spring constant. The device is supported on three legs, two resting on the sleeper and one on the rail head. Use: Toe load measuring device is used to determine the toe load of elastic rail clips during service in the field.

Salient features:

 Weight (max.) : 12 Kg  Capacity of the spring to

measure toe load : 1400 Kg  Material of the main spring : Silico-manganese spring

steel conforming to Grade 55 of IS: 3195 – 1992.

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2.5 इले ॉ नक टो भार मापन यं /Electronic toe load measuring device: Electronic toe load measuring device has a load cell of 2000 kg capacity and an LCD panel integrated with suitable electronic circuitry. This device has got a lever arrangement attached to it in order to grip the toe of a elastic rail clip. When the load cell is compressed by turning a rotating handle, the elastic rail clip gets pulled up. The force applied on load cell is converted into load (in kg.) and displayed directly on LCD. Use: It is used to measure the toe load of elastic rail clips in service. Salient Features:  Load cell capacity : 2000 Kg.

 Operating temperature : -5 to +700 C

 Measurement accuracy : + 0.5% of rated capacity

 Display : 8 or 16 character alphanumeric display

 Sensitivity : Fast return to zero

 Operating Source : Rechargeable battery Pack.

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2.6 ैक गेज /Track Gauges

These are used for measuring track gauge of running rail, cross level, super elevation and flange way clearances.

1) व युत - रो धत ैक गेज सह समतल/Insulated track gauge cum level: Model STD-1

 Highprecision gauge cum level with easy to read dial type cant device and built in spirit level. Accurate to 1 mm.

 Made of extruded steel tubing.  Used for inspection and maintenance of Track. 2) व युत-रो धत ैक गेज सह समतल/Insulated track gauge cum

level: Model ST-2

 A versatile and accurate tool for track maintenance.  Made of robust extruded steel tubing.

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 Has a built in sensitive spirit level.  Determines gauge variation, cant and cross level. 3) व युत-रो धत ैक गेज सह समतल/Insulated track gauge cum

level: Model ST-3

A rugged tool for track maintenance & laying of track.

 Made of robust extruded steel tubing.  Requires optional spirit level  Determines gauge variation, cant and cross level.

4) MODEL LG-2(I)

 Made of high tensile aluminium extrusion.  Determines track gauge variation, cant and cross level.  Requires optional spirit level॰ (I) ि ट लैवल/Spirit level: This is used to measure horizontal difference in rails to check cross level in plane track and cant in curve track. It is having a glass capsule with liquid (usually alcohol) and an air bubble inserted in it. This capsule in mounted on a metallic rectangular block. When placed on a surface if the bubble stay in a centre between two marking the surface is horizontal.

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 Made of high tensile alloy Aluminium tubing.  Has double housing to withstand falls.  Provided with arrangement for subsequent adjustment.  Accurate to 0.70 mm / meter.

5) क टम न मत ैक गेज सह समतल/Custom Built Track Gauge cum Levels

Custom Built Gauges:  Gauges used in track laying to maintain center line of curved track

as per the designed alignment.  Gauges with modified rail seating for use with raised check rails

and conductor rails.  Gauges with simultaneous measurement of check rail gauge

and flange way clearances along with the usual running gauge and cant measurements.

 Digital track gauges.

2.7 रेल वयर गेज/Rail Wear Gauge (model rwg-1): It used to measures head wear and side wear (gauge face wear).

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Feature:

 Spring loaded for faster and accurate readings.  Gives direct readings, no calculations required.  Available for UIC 60Kg / 52kg & 90R sections.  Measuring range of 0-19 mm.

2.8 रेलपथ मापन कट/Permanent Way Measuring Kits

The SSE/P.Way Tool Kit helps the SSE/P.Way for conducting measurements of different parameters of track structure in routine or otherwise. The Kit is available in two models TK-1 and TK-2 contains the quality made, precise measuring tools / instruments as follows: PIE Brand SSE/P.Way Tool Kit Model TK-1, consisting of following items.

1. Clearance Gauge BG 2. Shim Feeler Gauge 3. Stepped Feeler Gauge 4. Tapered Gauge 5. Gap Gauge 6. Rail thermometer 7. Pair of versine holder 8. Versine scale 9. Nylon cord 10. Magnifying Glass 3" 11. Adjustable Mirror for checking cracks 12. Vertical Wear Measuring Gauge Model -VWG 1 13. Steel scale 12"/300 mm 14. Outside caliper 150 mm 15. Inside caliper 150 mm

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16. Spirit Level 17. White clad pocket steel tape 3 m long 18. White clad pocket Steel tape 20 meters. 19. Straight edge 10 cm. 20. Pocket torch. 21. Cant Board 22. Data book with pen 23. Calculator ( Mathematical ) 24. Flexible Curve-for Rail Profiles. 25. Track Square

Model TK-2 along with one no. Folding Track Gauge (Model STF-1) in separate box. The gauge has inbuilt Spirit Level.

2.9 वरसाइन मापन कट/Versine Measuring Kits:

It is used for measurement of horizontal alignment and laying curves. Consists of two holders, nylon cord and a scale for measuring versine.

2.10 रेल वेि डंग सीधे कनार /Rail Welding Straight Edges

It is one meter long straight edge, provided with notch in the center, made from wear resistant alloy steel. It is used in welding process

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for rail ends alignment and after welding to check straightness of welded rail joint.

2.11 पुश ॉल /Push Trolley The trolley, which consists of wheel, trolley frame, axle and detachable seating arrangement, shall be light in weight so that four persons can easily lift the trolley and make it off the track on the face of an approaching train. The trolley shall have an arrangement to fix pushing handles on both side (rear and front) and detachable stone guard arrangement. Use: The Push trolley is used by Railway officials for track inspection. It is sturdy and robust in design, light weight and easily dismantle-able to load on brake-van/SLR for shifting from one station to other. It is run by pushing the same from back side with the help of two detachable handles.

Technical Features:

 Nominal Gauge : 1676 mm  Wheel Dia. (at tread) : 400 mm  Wheel Base : 900-1000 mm (approx)  Wheel thickness (average) at tread : 6 mm  Flange Thickness(average) : 9 mm  Pay load capacity : 0.7 ton (min.)  No. of spokes : 4

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 Seating capacity : 3 persons at front  Trolley Frame Dimension : 1450 mm X 1550 mm (approx.)  Umbrella/Hood type :Light weight, Collapsible

/detachable  Overall weight : up to 125 Kg.

2.12 व चलनेवाला ह के वजन ॉल /Self propelled Light Weight Trolley The trolley comprises of a light metallic tubular frame with two sets of axles powered by an I.C. engine mounted on the frame. The trolley has seating arrangement in front and rear. Use: The self propelled light weight trolley is used by Railway officials for track inspection and to reach accident/work site quickly. Salient features:  Track gauge(nominal) : 1676 mm (BG) / 1000 mm (MG)  Pay load capacity : 400 Kg (minimum)  Seating capacity : 2 in front and 2 at the rear.  Self weight : 90-95 Kg  Speed : Maximum 20 Km/h  Gear system : 2 speed gear box or hand

` operated clutch device to increase/ decrease the speed.

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 Engine : Petrol / diesel / kerosene driven engine of min. 2 HP rated

capacity.  Fuel tank capacity : Adequate for a run of 60 km  Wheels : Cold pressed steel, drop forged

steel, cast steel or light alloy wheels with self adjusting ball bearings.

 Insulation : Wheels / trolley is insulated so that it does not activate switches & signals while moving in track circuited areas.

 Brakes : Foot pedal operated brakes or mechanical hand brake. The trolley has also mechanical parking brakes.

 Head lights and horn : Head lights, tail lights and an electric horn to be provided.

The trolley has:

i) Provision for showing a red flag by day and a red light by night. ii) Suitable detachable guards to remove stone ballast from rail top. iii) A light weight detachable hood. iv) A moulded plastic/G.I. sheet made tool kit of adequate size to

keep detonators, search light, diary, stationery, P. Way inspection kits etc.

2.13 अ य गेज और उपकरण/Other Gauges and Tools: These are some gauges to measure different parameters on track.

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T-SQUARE

CALIPER

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3.0 संर ा उपकरण/Safety Equipments

These are tools/equipments used for safety of track and as well as working personals.

3.1 हाथ संकेतक झ डा/Hand Signal Flag

During day a flag or flags are normally be used as hand signals. Green flag is used as proceed hand signal. Red flag is a stop hand signal. A banner flag is a temporary fixed danger signal, consisting of a red cloth supported at each end on a post and stretched across the track at a distance of 600 metres on Broad gauge and 400 metres on M.G. and N.G.

RAIL WEAR MEASURING DEVICE

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3.2 डंडा/Staff suitable for exhibition of red lamp or red flag 3.3 लंबी अ त र त चैन/Long spare chains with loops at both

ends, with stop marked disc attachment at the center to cover the full width of the gate, for use in case the gates/barriers are damaged.

3.4छोट चैन/Small chains on Level crossing, When the locking arrangement is of the hasp and staple type with padlocks, two spare chains with loops at both ends should be provided for locking the gates when the locking arrangement goes out of order. 3.5 पटाखे/Detonators or fog signals are appliances which are fixed on the rails, and when an Engine (or vehicle) passes over them, they explode with a loud sound so as to attract the attention of the Driver.

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