(Annual) Report:2015-2016) TRACK RESEARCH, DESIGN & STANDARDISATION Single Shot Crucible Technique Including Vendor Development RDSO was advised to take necessary action to develop vendors for AT Welding with Single Shot Crucible so that the tenders for AT Welding invited by Zonal Railways wee.01.04.2016 are only with Single Shot Crucible. RDSO has recently developed the Alumino-Thermic welding techniques for 52 Kg (90 UTS) & 60 Kg (90UTS) rails with Compressed Air-petrol/LPG pre-heating, three piece pre-fabricated mould (manually pressed zircon- washed) using Single Shot Crucible fitted with Auto Tapping Thimble. Use of this technique will produce relatively cleaner welds, free from impurities & voids and in turn will lead to reduction in fallure weld ensuring the safety of track. (Single Shot Crucible) The development of AT welding technique with Single ‘Shot Crucible offered by firms is in progress for 52 Kg 90 UTS and 60 Kg 90 UTS ral sections. So far, three firs have been approved by RDSO for doing welding with Single Shot Crucible. The details of developments so far are as under: = Mis ITC, Kanpur Mis ITC, Kanpur has been approved for AT welding technique with Single Shot Crucible for 52 Kg (90 UTS) rails and 60 Kg (90 UTS) rails in the list of Part I1(Two) category of firms after satisfactory laboratory evaluation, fatigue test and feldtral = Mis Chakradhar Industries LLP, Mumbai M/s Chakradhar Industries LLP, Mumbai have been approved for AT welding technique with Single Shot Crucible for 52 Kg (90 UTS) rails and 60 Kg (80 UTS) rails in the list of Part I! (Two) category of firms after satisfactory infrastructure verification, laboratory evaluation, fatigue test and field trial = Mls Oberoi Thermit Pvt. Ltd., New Delhi Mis Oberoi Thermit Pvt. Ltd., New Delhi have been approved w.e.f. 28.06.16 for AT welding technique with Single Shot Crucible for $2 Kg (90 UTS) rails and 60 kg (0 UTS) rails in the list of Part il (Two) category of firms after satisfactory laboratory evaluation, fatigue test and field trial. Specifications for UBRD for Facilitating Global Tender and Further Trial Literature survey for various technologies available world over for rail fracture detection was done by RDSO and Status Report containing available technologies ‘and proposed action plan for development of Rail Fracture Detection System for Indian Railway Track was sent to Railway Board on 30.04.2013, Railway advised to process for field trials of Ultrasonic Broken Rail Detection (UBRD) System on two sections ‘of North Central and South Central Railways. Accordingly, functional requirement specification for UBRD System prepared by RDSO was approved by Railway Board with direction that RDSO shall invite Expression of Interest (Eol) based on the approved functional ‘specification for the Broken Rail Detection System, RDSO (Track Design Directorate) has invited global Expression of interest (Eol) on 19.02.2015 for short listing firms for development, supply, installation, testing and commissioning of Broken Rall Detection System working of principle of propagation of guided ultrasonic waves for real time detection of breaks in Rails/Welds and generating necessary alarms for protection of trains as per Functional Requirement Specifications issued by RDSO, for undertaking for field trial in 02 stretches of ‘approx. 25 km track length each on the Indian Railways. In response to the Eol, only one firm offer from Armaments Corporation of South Africa SOC Limited (ARMSCOR), South Africa has been received. The offer has been evaluated by a Committee of 03 Directors as per extant ISO procedure of RDSO and found in accordance to the Functional Specification of UBRD system. Accordingly, firm has been shortlisted by the Committee for undertaking trials of UBRD system being offered by the firm. The recommendations of the Committee have been sent to Railway Board on 11.06.2015 for advising further action tobe taken at DSO. Railway Board has instructed North Central Railway to call tender for the trail of UBRD system two sections of Indian Railways. North Central Railway has finalized atender and issued letter of acceptance on 11.04.2016 for trialon 50 kmlength. The workis likely to start soon. Rail ey scat Transmitter Receiver (Ultrasonic Broken Rail Detection (UBRD) System) Revision of CT-30 As A Result of Bracing Arrangement RDSO's Report No. CT-30 on “Continuation of Long Welded Ralls on Sharp Curves and Steep Gradients on Indian Railways” was submitted to Ralway Board for consideration vide letter no. CT/IM/LWR dated 30.08.2013. As per Railway Board's instructions vide letter no 2O11/CE-INTK/LWR dated 11.09.2013, Report No. Ct-30 was circulated to CTEs of Zonal Railways. The item “Continuation of Long Welded Rails on sharp curves and steep gradients" was deliberated in 84” and 85" Meetings of Track Standards Committee vide Item No. 1244 and 29/1297 respectively tesla (Drawing of Cross-Bracing Arrangements) Accordingly, lab trial of cross bracing arrangements has been completed by Track Machine and Monitoring Directorate of RDSO. Based upon the experience gained during lab trial, drawing no. RDSO/T-8329 has been modified suitable and approved for use in continuing trial LWRs on curves sharper than 5 degree. Aso, procedure and frequency of USFD testing of non- gauge face of outer rail on sharp curves has been finalized in association with M&C Directorate of RDSO. 6 L—E TRACK The provisions of Cross-Bracing arrangements, procedure and frequency of USFD testing on non-gauge face of outer rail on curves sharper than 5 degree and recommendations of TSC made in its 84” Meeting duly approved by Railway Board have been incorporated in modified report no. CT-30. Based upon the recommendations of modified report no. CT-30, draft instructions for Continuation of LWR/CWR on Sharp (Trial LWR on East Coast Railway) Curves and Steep Gradients on Indian Railways have also been framed. Modified Report No. CT-30 containing trial drawing no, RDSO/T-8329 and draft Instructions for Continuation of LWRICWR on Sharp Curves and Steep Gradients on Indian Railways has been submitted to Railway Board vide letter no. CT/IM/LWR dated 23.12.2015 for consideration and approval. Once approved, the modified report no. CT-30 and Instructions shall be Circulated to Zonal Railways for trials before regular adoption. Laying of LWR on sharper curve result in better maintainability of Track. Development of Draft Performance Specifications for Level Crossings Vide letter no, 2008/CE-VLX/50 dated 12.10.2010, Railway Board agreed for use of rubberized level crossing system on experimental basis without CRS sanction. Itwas conveyed that Railways can go ahead with the trial of aforesaid work on experimental basis over without CRS sanction. The item “Check rail in level crossing’ is TSC item and was deliberated in 85" Meeting of Track Standards Committee. In compliance of Railway Board's order on the recommendation of 85” Meeting of Track Standards Committee, RDSO has developed draft Functional Specification for RubberiPolymer/Composite material based surfacing at level crossings and sent to Zonal Railways vide letter no. CT/SRC/3/2/L-Xing dated 15.10.2015 for sending comments/suggestions, if any. On receipt of response of Zonal Railways, draftTRACK Functional Specification will be processed further as per RDSO's ISO guidelines. (Rubberized Surfacings on Level Cros: Development and Issuance of Guidelines for Noise and Vibration for Metros ‘The Noise and Vibration from Mass Transit Systems can adversely impact Environment during Construction and Operation. Government of India has approved number. of Metro corridors in many densely populated cities. ‘The future will see more such projects. This would need a frame work of Environmental aspects to be taken care of while going for such new developments as well as addressing related problems for existing Metro corridors, if any. Since the construction period remains limited, the Metro Rail Systems shall take necessary precautionary measures against Environmental Impact during construction in consultation with the State ‘Government. There was a need of one policy document which lays guidelines for Noise reference levels, Vibration impact eriteria for detailed analysis, Noise and Vibration mitigation measures, and ways of reducing ‘excessive Noise and Vibration caused by Metro Railway projects. In view of the importance of the subject, on the request of Delhi Metro, Ministry of Railways formed a ‘committee to go through the subject comprehensively and recommend necessary guidelines. A committee was formed by Railway Board including ED/TrackIRDSO for this purpose which has gone comprehensively in the subject of Metro Rail transit generated Noise and Vibrations, keeping focus to produce a document that provides details of basics of Noise and Vibrations (N&V) for the benefit of Engineers dealing with the subject as well as guide them to take required measures The draft guidelines by the committee has been approved by Railway Board and issued by RDSO on 29/09/2015. The guidelines provide recommended threshold values of N&V; carrying out impact assessment study both at the Design and Operation stages; taking required mitigation measures; etc. Metro Rail Transit System Guidelines for Noise and Vibrations me) k D ao) ‘September, 2015 crae “Track Design Directorate Research Designs and Standards Organisation Ministry of Railways, India Design and Development of Wider and Heavier PSC Sleeper for 25T Axle Load Railway Board vide letter dated 18.6.2013 instructed RDSO to examine issue of wider & heavier PSC Sleeper in view of following advantages * Increased width and weight providing higher frame resistance against buckling, chances of reducing de-stressing temperature with likely reduction in raillweld failures. * Increasedrailseatarearesulingin higher rubber padlife. RDSO accordingly developed various design options considering aspect of tamping and shape optimization and submitted to Railway Board, The design was approved by Rallway Board vide letter dated 11.03.2014 for trial casting at Concrete Sleeper Plant (CSP) under NER. After several iterations of design, trial casting and SBT (Static Bend Test)& fatigue testing, design with top rail seat width of 210 mm and bottom width of 280 mm (against 150 mm and 250 mm respectively in existing design) using 16 HTS wires (against 20 wires in existing design) has been finalized for wider sleeper which has been found successful in laboratory tests at RDSO. Two new drawings for 10mm thick Composite GRSP (RT- 8528) & Rail seat assembly (RT-8529) on wider sleeper (RT-8527) with 136RE & 60kg (UIC) Rail have also been prepared with other fastening components asunder: a) ERCMKII/V ——-RT-3701/RT-5919 b) GFN66Liner _—_RT-6938 & 6939 (with 60, ig UIC Rail) & RT- 6937 (with 136 RE Rail) a ah