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 6. Conclusion

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 fishplated 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 Requirement respect of Maintenance
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 is very less compared to ORS Housing of tongue rail with stock rails is much better in TWS TWS being sturdier requires less maintenance due to less disturbance of track geometry.

THICK WEB SWITCHES

RDSO developed Design and Drawings for Thick Web Switches (TWS):
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 Design and Drawings for Weldable CMS Xing: 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

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 27 HTS bolts in heel and distance blocks 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 27 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. Other technologies are under development.

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

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