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PM N IDEA D1.5 Image Analysis EC Contract No. FP7 - 234299 PM n IDEA D1.5 Image analysis - Component catalogue Due date of deliverable: 31/5/2012 Actual submission date: 31/5/2012 Leader of this Deliverable: R Carroll, Stagecoach Reviewed: Y Document status Revision Date Description 0 31/5/2012 First issue Project co-funded by the European Commission within the Seven Framework Programme (2007-2013) Dissemination Level PU Public Y PP Restricted to other programme participants (including the Commission Services) RE Restricted to a group specified by the consortium (including the Commission Services) CO Confidential, only for members of the consortium (including the Commission Services) Start date of project: 01/06/2009 Duration: 36 months Instrument: Small or medium-scale focused research project Thematic priority: Sustainable Surface Transport EC Contract No. FP7 - 234299 EXECUTIVE SUMMARY The partners in PM n IDEA include many measurement and sensor specialists with little knowledge of the railway environment. This document has been written to give an overview of the different components that can be found on tramways to allow the non-specialist to understand their use. For each component a description, use and typical degradation mechanisms or maintenance requirements are given along with images. The catalogue is not exhaustive but includes most of the common features found on a typical tramway, other components and different designs are in use on different tramways. PMI–D-STA–009.1 Page 2 of 49 31/05/2012 EC Contract No. FP7 - 234299 1. INTRODUCTION One of the aims of PM n IDEA was to carry out image capture and analysis of the track system of metro and tram networks to reduce the need for manual inspection and increase the subjectivity of the data reported. The research work has being carried out by image capture and analysis specialists who have only a limited knowledge of the railway environment and the features that can be observed. Therefore this document is a collection of photographs of different track components to aid identification and explain their use. It also provides information on the degradation mechanism of each component and the maintenance required to be carried out. The information contained is also useful to other sensor and measurement specialists not previously involved in railways or tramway who are developing inspection and monitoring technologies for track components. The information contained in the document has been provided by Warsaw Tram and Stagecoach Supertram networks, additional images have been taken from mainline railways where appropriate. The document includes the most common features found on these tramways but it should be borne in mind that other tramways will use different designs of components not included in this document. When carrying out work on other tramways, knowledge and images of the actual components in use should be gained. PMI–D-STA–009.1 Page 3 of 49 31/05/2012 EC Contract No. FP7 - 234299 2. COMPONENTS - BALLASTED AND SLAB TRACK 2.1 RAIL JOINTS 2.1.1 Standard Fishplated Rail Joint – 39E1 (BS80A) Rail Traction Bond 75mm 50mm Traction Bond Use: Joining two rails together Description: Two fishplates on either side of rail web secured by 4 bolts. An electrical bond can often be found associated with them. Degradation Mechanisms/Maintenance Requirements: Bolts are set to a fixed torque requiring checking to ensure they do not loosen. To allow expansion of the rails the fishplates require greasing, typically on a two yearly frequency. Cracks can occur in the fishplate or rail end Localised plastic deformation, “batter”, of rail ends, can lead to cracks PMI–D-STA–009.1 Page 4 of 49 31/05/2012 EC Contract No. FP7 - 234299 2.1.2 Heavy Duty Fishplated Rail Joint - 39E1 (BS80A) Traction Bond 420m Use: Joining of two rails together Description: Two fishplates on either side of rail web secured by 4 bolts. An electrical bond can often be found associated with them. Degradation Mechanisms/Maintenance Requirements: Bolts are set to a fixed torque requiring checking to ensure they do not loosen. To allow expansion of the rails the fishplates require greasing, typically on a two yearly frequency. Cracks can occur in the fishplate or rail end Localised plastic deformation, “batter”, of rail ends, can lead to cracks 2.1.3 Insulated Rail Joint Use: Joining of two rails together while maintaining electric isolation of one rail from another Description: Similar to fishplated joint but with insulating material between rail and fishplates and between rail ends. Can be 4 or 6 hole and most commonly, in the UK, with the gap between rail ends at 90 although 45 versions are available. The only visible part of insulated joints in grooved rail is the gap between rail ends and the insulation between, not to be confused with a broken rail. No electrical connection between rails. Degradation Mechanisms/Maintenance Requirements: Degradation of insulating material leading to electrical breakdown Wear debris embedded in insulation can lead to short circuiting. A common problem for metros in tunnels. Plastic deformation of rail ends can reduce insulation gap leading to short circuiting. PMI–D-STA–009.1 Page 5 of 49 31/05/2012 EC Contract No. FP7 - 234299 2.1.4 Aluminothermic (AT) Welded Rail Heat Affected Zone (HAZ) Weld Original Original Metal Rail Rail Use: Joining of two rails together Description: Joining of rails through use of filler material cast from above, ground prior to use. Degradation Mechanisms/Maintenance Requirements: Incorrect weld procedure can lead to failure. “Dipping” of welds (over several metres) can create dynamic forces in rail and can lead to failure “Cupping” (differential wear of surface) of weld can create dynamic forces and lead to corrugation 2.1.5 Flash Butt (FB) Welded Rail Use: Joining of two rails together Description: Joining of rails through heating and forging two rails together with no filler material. The weld is narrow than aluminothermic welds. Rail surface ground prior to use. Degradation Mechanisms/Maintenance Requirements: “Dipping” of welds (over several metres) can create dynamic forces in rail and can lead to failure “Cupping” (differential wear of surface) of weld can create dynamic forces and lead to corrugation PMI–D-STA–009.1 Page 6 of 49 31/05/2012 EC Contract No. FP7 - 234299 2.1.6 39E1 (BS80A) Rail Expansion Joint (breather or adjustment switch) 420mm Use: Joining of two rails together allowing expansion of the rails in hot temperatures Description: Joining of rails with two machine flanges alongside each other allowing movement caused by temperature variation but maintaining an unbroken running surface. Degradation Mechanisms/Maintenance Requirements: Bolts are set to a fixed torque requiring checking to ensure they do not loosen To allow expansion the plates require greasing, typically a yearly frequency. Cracks can occur in machined rail ends Plastic deformation, “batter”, of rail ends. Electrical bonds can become detached or can be stolen If incorrectly set up and/or in extreme weather condition then expansion can be excessive or insufficient. PMI–D-STA–009.1 Page 7 of 49 31/05/2012 EC Contract No. FP7 - 234299 2.1.7 Lateral Expansion Joint - 54E1A1(UIC54B) rail 200mm 420mm Use: Joining of rails together allowing room for lateral movement of a structure. Description: Rails laid on a steel bed so that they can move to accommodate the movement of the structure. Tie bars hold the rails to gauge. Rails used are of an asymmetric type. Also incorporates standard rail expansion joints. Degradation Mechanisms/Maintenance Requirements: Bolts are set to a fixed torque requiring checking to ensure they do not loosen. Tie bars may be subject to fatigue. PMI–D-STA–009.1 Page 8 of 49 31/05/2012 EC Contract No. FP7 - 234299 2.1.8 Transition Rail Use: Joining of flat bottom to grooved rail Description: A flat bottom rail joined to a grooved rail near the change from embedded track to ballast. The head width of the rail on both sides of the join will be different, the amount depends on the rail profiles. The groove is flared out at the end. Degradation Mechanisms/Maintenance Requirements: Similar to standard rail: wear, corrugation etc. Cracks around the end of the groove or near the weld (if applicable) 2.2 RAIL FASTENINGS 2.2.1 Pandrol e-clip with 1:40 (cast) base plate on timber sleeper 200mm 140mm Use: Supports and fastens rail Description: Cast base plate, bolted (coach screw) to wooden sleeper on which rail sits fastened by Pandrol E-clips, no rail pad. Rail inclined at 1:40. Degradation Mechanisms/Maintenance Requirements: Bolts fastening base plate to sleeper can loosen Pandrol clips can move out of housing. Pandrol clips can corrode and/or break Timber sleepers can crack/degrade PMI–D-STA–009.1 Page 9 of 49 31/05/2012 EC Contract No. FP7 - 234299 2.2.2 Pandrol e-clip with vertical (cast) base plate on timber sleeper 420mm Use: Supports and fastens rail Description: Cast base plate (both vertical and 1:40 inclination plates used) coach bolted to wooden sleeper on which rail sits fastened by Pandrol E-clips. Vertical Rail. Degradation Mechanisms/Maintenance Requirements: Bolts fastening base plate to sleeper can loosen Pandrol clips can move out of housing. Pandrol clips can corrode and/or break Timber sleepers can crack/degrade 2.2.3 SB Rail Clip on Concrete Sleeper Use: Supports and fastens rail Description: Rail is separated by separator (rail pad) from sleeper and fixed anchor on sleeper by spring clip Degradation Mechanisms/Maintenance Requirements: Spring clip can move out of housing Spring clip can corrode and / or break Insulator can be damaged PMI–D-STA–009.1 Page 10 of 49 31/05/2012 EC Contract No.
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