COPYRIGHT © AREMA 2010 12: 1 of 55 Module 12: Track Inspection & Maintenance.

COPYRIGHT © AREMA 2010 12: 1 of 55

Module 12:Module 12:Track Inspection & MaintenanceTrack Inspection & Maintenance


Objectives

Track Inspection• Importance of Track Inspection• Methods and Types of Inspection• Application of the Track Safety Standards• Specialized Inspection Vehicles

Maintenance Practices• Preventative Maintenance• Typical Activities• Production Activities• Integration of Maintenance in Design


Importance of Track Inspections

– FRA / Transport Canada Required

– First and Last “Line of Defense” against track related derailments

– Initial phase of planning for maintenance activities and future track upgrade programs

– Public and employee safety


Inspection Methods

– Hi-Rail Inspection

– Walking Inspection

– Train Inspection


Inspection By Hi-rail– Hi-Rail

• The hi-rail is a versatile vehicle that allows the inspector to traverse the track in one direction and return by road

• Provides flexibility/versatility

• Most common method utilized for scheduled and special inspections

• Most often one, and sometimes two Inspectors observing the track

• Scheduled per regulatory requirement and/or company policy

• Visual detection of defects

• “Feel” and sound of the track that may indicate the presence of a substandard condition


• Allows for a more detailed look at the track.

• Quantify defects with physical measurements

• Planned at various times of year, or;

• Company policy may dictate an annual walking inspection.

• Regulatory requirement for inspecting turnouts, track crossings and lift rail assemblies or other transition devices on moveable bridges to be performed “on foot”

Walking Inspections


• Provides a “feel” of the track under loaded conditions

• Frequency depends on amount and type of train traffic, anywhere from twice annually to monthly

• No regulatory requirement – Company Policy

Train Inspection


Types of Track Inspection

– Normal or Scheduled (Routine)• Regulatory Compliance• Company Standard

– Special Inspection• Specific Planned (i.e. Culverts, Rail Wear etc)• Emergency (Weather related, Incidents/Accidents)

– Specialized Inspection Vehicles• Rail Flaw Detection Vehicles• Track Geometry Vehicle


–Regulated, Mandatory inspection of Main track and sidings (Hi-rail or Walking)

–Monthly Inspection of “Other than Main” track, Turnouts & Special Track Work (Walking)

–FRA/Transport Canada outlines minimum inspection frequencies

–Report of tracks inspected, conditions found and actions taken are completed during the inspection.

Scheduled Inspections


Track Safety Standards

46 CFR 213 SUBPARTS A-F• GENERAL• ROADBED• TRACK GEOMETRY• TRACK STRUCTURE• TRACK APPLIANCES &

DEVICES• INSPECTIONS


Defects

• Defect Classification– Class of Track (Speed) Specific

• Quantitative

– Non-Class of Track Specific• Quantitative• Qualitative

• Defect Identification– Visual– Hidden

RepairRepair

RestrictRestrict

RemoveRemove


General

CLASS OF TRACK 1-5

Track Max. SpeedFreight

Max. SpeedPassenger

Excepted 10 N/A

Class 1 10 15

Class 2 25 30

Class 3 40 60

Class 4 60 80

Class 5 80 90

• 213.1 Scope of Part• 213.3 Application• 213.4 Excepted Track• 213.5 Responsibility for

Compliance• 213.9 Class of Track• 213.11 Restoration or Renewal

Under Traffic• 213.7 Designation of Qualified

Persons to Supervise Renewal & Inspect Track

• 213.13 Measuring Track Not Under Load

• 213.15 Penalties• 213.17 Waivers


Roadbed

• 213.33 Drainage• 213.37 Vegetation

REPAIR

RESTRICT

REMOVE


Track Geometry

• 213.53 Gage• 213.55 Alignment• 213.57 Curves -

Elevation & Speed Limitations

• 213.59 Elevation of Curved Track

• 213.63 Surface


Gage

Class of TrackThe gage must

be at least -But not more

than -

Excepted Track n/a 410-1/4

Class 1 Track 48 410

Class 2 and 3 Track 48 49-3/4

Class 4 and 5 Track 48 49-1/2


Alignment

Tangent Track

Curved Track

Class of Track

The deviation of the mid-offset from a 62 foot line may not be more than

The deviation of the mid-ordinate from a 31 foot chord may not be more than

The deviation of the mid-ordinate from a 62 foot chord may not be more than

Class 1 5 n/a 5

Class 2 3 n/a 3

Class 3 1-3/’4 1-1/4 1-3/4

Class 4 1-1/2 1 1-1/2

Class 5 3/4 1/2 5/8


Surface

• Run-off• Profile• Deviation In Crosslevel - Tangent • Reverse Elevation - Curves• Difference in Crosslevel• Harmonics


Run-off


Profile


Deviation In Crosslevel - Tangent &Reverse Elevation - Curves


Difference In Crosslevel


Harmonics


Track Structure• 213.103 Ballast• 213.109 Crossties• 213.110 Gage Restraint• 213.113 Defective Rails• 213.115 Rail End Mismatch• 213.119 CWR• 213.121 Rail Joints• 213.122 Torch Cut Rail• 213.123 Tie Plates• 213.127 Rail Fastenings• 213.133 Turnouts & Track

Crossings• 213.135 Switches• 213.137 Frogs• 213.139 Spring Rail Frogs• 213.141 Self-Guarded Frogs• 213.143 Frog Guard Rails & Guard

Face - Gage


Crossties

Class 4 and 5 Track

Tangent track andcurves 2 degrees

Turnouts andcurved track over 2

degrees

Class 1 Track 5 6

Class 2 Track 8 9

Class 3 Track 8 10

12 14

NUMBER OF NON-DEFECTIVE TIES REQUIRED PER 39’ RAIL LENGTH

Definition of Defective Tie

Number Non-Defective Ties Per 39’ Rail Length

Joint Tie Conditions Fulfilled

Non-Defective Ties Effectively Distributed


Rail Defects• Remedial Action Non-Class

Specific• Defects % Cross-Sectional

Area – Head– Transverse & Compound

Fissures– Detail & Engine Burn Fractures,

Defective Weld

• Defects Longitudinal– Horizontal Slit Head, Vertical

Split Head , Head & Web– Split Web & Piped Rail

• Bolt Hole Crack & Broken Base

• Ordinary Break, Damaged & Flattened Rail


Transverse & Compound Fissures

Transverse Fissure

Compound Fissure


Detail & Engine Burn Fractures, Defective Weld Defects

DetailFractures

Defective Weld

Engine Burn Fracture


Track Appliances & Track Related Devices

213.205 Derails• Clearly Visible• Free of Lost Motion • Maintained to

Function as Intended

• Properly Installed for Designated Rail Section


• Planned at specific times for specific items:

• Tie defect Counts

• Rail Wear Measurements

• Rail Grinding Requirements

• Culvert Inspections

• Gage Measurements

• Crossing Audits

• Known problem areas

• Extreme Heat or Cold (not always planned, but can often be anticipated)

Special Inspection (Specific)


• Unplanned

• Weather

• Natural Disasters

• Incident/Accident

Emergency Inspections


• Filled out while conducting the inspection

• List all deviations and the corrective action

• Kept on file for 1 year

• Type of inspection indicated on report

• Signed & dated

Inspection Records


Rail Flaw Detector Vehicle (RFD)

• Scheduled

• Regulatory required frequency for Class 3-5 track

• More frequent testing dictated by company policy

• Internal search for rail defects using NDT “Ultra-sonic testing equipment

• Specialized Equipment & Training required

Special Vehicle Inspections


Track Maintenance

• Normal Maintenance– Performed by small sections– Day to day maintenance– Emergency Repairs

• Program Maintenance– Capital projects


Normal Maintenance


Basic Track Work


Basic Signal Work


Weather Challenges


Maintenance of CWR


Drainage & Vegetation Control


Disasters


Program Maintenance

• Rail Grinding

• In-Track Rail Welding

• Road Crossings

• Production & Capital Maintenance– Rail Gangs– Tie Gangs– Surfacing– Undercutting


Rail Grinding• Purpose: Remove

Surface Imperfections in the Rail & Optimize Rail/Wheel Contact Area

• Out-of-Face & Switch Multiple Stone Grinders

• Grinds Main Track Based on Railroad Policy

• Grinds 6 to 15 MPH


In-Track Welding


Road Crossings


Production Gangs


Rail Gangs• Largest crews• 30 to 60 employees• Relay or Transpose

CWR• Gang Consist

– Unload CWR– Front End of Gang– Middle of Gang– Rear of the Gang

Speed Swing

Rail Train


Rail Gang Make-up

Galion Crane Laying RailTie Adzer

Spiker Rail Heater


Production Tie Renewal

• Production crew 12 to 30 employees

• 6 to 20 machines

• 400 to 2500+ ties per day


Tie Gang Make-upAnchor Spreader

Tie Inserter/Remover Spiker

Tie Handler


Mechanized Tie Gang


Production Surfacing

• Highly mechanized crews

• 4 to 20 employees • Typical Equipment

Includes:– Production Tamper– Jr. Tamper– Regulator– Stabilizer

MK IV Operator

CAT-09 Tamper

MK IV Tamper


Surfacing Gang Consist

Dynamic Track Stabilizer Ballast Unloading

Ballast RegulatorMK IV Tamper


Undercutting


Remember

What you Build

Must be Maintained


QUESTIONS?Authors:

Joseph E. Riley, P.E.

Federal Railroad Administration

(202) 493-6357

[email protected]

Larry Romaine

Rail America

(904) 538-6054

[email protected]

Gray Chandler

CSX (Retired)

(904) 213-1121

[email protected]

COPYRIGHT © AREMA 2010 12: 1 of 55 Module 12: Track Inspection & Maintenance.

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Transcript of COPYRIGHT © AREMA 2010 12: 1 of 55 Module 12: Track Inspection & Maintenance.