Dealing With Failures

8/3/2019 Dealing With Failures

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By

B.GOUTHAMAN ADEN/GY

J.R.MARGADARASI ADEN/NEDHARGIANSINGH XEN/DOT/


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SHRI A.K.GOEL, DIRECTOR IR

SHRI NEELMANI, PROF/ TRACK

SHRI, V.B.SOOD,PROF/BRIDGES


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A.A. S E JS E J

G E N E R A L F E A T U G E N E R A L F E A T U

Service life of SEJ rails are not c

and certainly weaker than normal r

SEJ fails after service life of abou

high traffic density route.SEJ rails are being made out of n

planing, heating and bending proce

Failure rate of stock rails are very h

of tongue rails.Crack propagation at initial stage n

by keyman as foot & web of s

covered by MS brackets


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SEJ stock rail fracture at its thro

reduction of section, induction of sharheating and bending while manufactur

In latest design, stock rails are strengthMS flat but lot of SEJ already laid in tra

conventional type.

Flat can prevent onset of fracture, but a

fracture the flat also give up.

GENERAL FEATURES (Contd.)GENERAL FEATURES (Contd.)


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EFFECTS OF SEJ STOCK RAIL FRAEFFECTS OF SEJ STOCK RAIL FRA SEJ s are designed to have gap from

and fracture occurs in the gap.

SEJ stock rail give up at about 20-4from the point of section reduction (thromm tail end is left unsecured againstmovement.

Above piece keeps moving away by action of plying wheels and cause with wider gap in track especially in win

Worst situation occurs early in case odue to unfavourable movement diretrains.

Prolonged situation under unrestriccause working out of rotatable brackthe fractured rail piece blown out.


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Escape of stock rail piece mak

rail laterally unsupported and

leads to derailment by mountingon stock rail or failure of tongue

Timely report of SEJ fracture by

guard on audible base is remote

Emergency repair by keyman on

is very difficult and detention

service is high.

EFFECTS OF SEJ STOCK RAIL FRACTUEFFECTS OF SEJ STOCK RAIL FRACTU


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PROTECTIVE MEASURE AGAINSPROTECTIVE MEASURE AGAINSSUGGESTION NO 1 : FISH PL

Provision of a multi holed fish platongue rail at suitable distance from e

rail for all the conventional SEJs. Distance between end of stock rail t

be X/2 incase of end SEJ an

intermediate SEJ, X being the total SEJ.

Fish plate does not interfere wmovement of breathing length on eithe


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On fracture of stock rail, fish platemovement of separated rail piece breasonable distance and thus ensu

i. Prevents excessive gap betweefractured ends.

ii. Helps the rail piece end at sec

position within the M.S. bracket.iii. Rail piece continue to share w

and transmit over tongue rail.

iv. Provide lateral stability to ton

gauge maintained.v. Prolongs the failure free perioother components of SEJ

PROTECTIVE MEASURE AGAINST MISH


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PROTECTIVE MEASURE AGAINST MISH

On detection by keyman/g

emergency repair is possible by

of fish plate using suitable holes


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SUGGESTION NO.2: IMPROVED TRACK

Existing track circuiting system does not

fracture

Modification of bonding of stock rail beyo

tongue rail may indicate track circuit failudetection.

SUGGESTION NO 3: CASTLE NUT

Castle nut arrangement for all T heaprovided which ensures non-loosening

prevents working out of bolts from grove


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FRACTURE PREVENTION MEAS

Service life of SEJ to be assessed on GMT carr

renewed as and when becomes due instead of

CTR/TRR.

SEJ rails to be critically examined for possible c

while fortnightly lubrication. Systematic USFD testing by hand probing.

Elimination of wooden blocks provided below st

as they are hindrance for effective packing of tw

sleepers cause stock rail subjected to undue re

stresses under every wheel.

Laying of improved SEJ/Modified SEJ whose pe

quite satisfactory.


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M O D I F I E D S E

STOCK RAIL


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B.1 in 12 Fan Shaped LayoutB.1 in 12 Fan Shaped Layout -- Failure oFailure o

P&C tongue rails are laterally unsupposwitch length (sleeper No. 3-20) and pwhen they are in set condition with their re

rail.

One of the tongue rail in set condition an

open by a distance of throw and held in prod.

Lateral support given directly by stock raJOH and further by slide blocks (Sl.No. 15

tongue rail is set.MS flat reinforcement provided to outer w

rails from ATS to JOH presently.


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Experience indicates fracture of tongplace just after JOH when subjected to

wheel load independently where at 100%does not exists.

Fractured un-set straight tongue rail t

of lead rail continuity and in case of cu

rail, position will be free lead curve from

Both the above situation cause the fralmost touch stock rail and create infflange way clearance of the un affecte

fatal situation for the facing direction m

Failure of tongue rail (Failure of tongue rail (ContdContd


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LEADING STRETCHER BAR

Ist FOLLOWING STRETCHER BAR

III rd FOLLOWING STRETCHER BAR(JOH)

IInd FOLLOWING STRETCHER BAR

CRITICAL SE

OF TONGUE

PUNE Y


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CROSS SECTIONS AT JOH & H

SECTION


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Thank you

III rd FOLLOWING STRETCHER BAR (J O H)

END OF WEB STIFFNER

CRITICAL SECTION OF

TONGUE RAIL


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Failure of tongue rail (Failure of tongue rail (ContdContd

Failure of tongue rail not detected by as the tip is properly set.

Serious infringement prevails even to involved route of T/out and also emrepair of failed T/Rail is complex, mo

over the affected P&C is preferred oattention and certification by JE or Sand not by K.Man/G.Mate.


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S U G G E S S I O N SS U G G E S S I O N S

MS flat stiffener to be extended over theon the reduced tongue rail section i.eblock.

Above arrangements helps in providstrength to the weaker tongue rail and

independent deflection of broken tongustock rail.

Spring setting device as second throw ball switches to avoid rubbing at rear potongue rail at JOH by running wheels.

Being the weaker and unsupported ,tongbe critically examined by K.Man daultrasonically at regular interval.


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Dealing With Failures

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