LUBRICATION OF TRACK year for gauge face side and once in … on... · LUBRICATION OF TRACK COMPONENTS Lubrication of different components of track prolongs their life by reducing

LUBRICATION OF TRACK COMPONENTS

Lubrication of different components oftrack prolongs their life by reducing wearand tear. With a view to increase awarenessand ensure that correct procedures arefollowed in field. Following instructions onlubrications are to be followed.

1. LUBRICATION OF ERC CLIPSTo prevent corrosion and seizure of ERCwith MCI insert, regular greasing and oilingof ERCs should be done.a) Frequency the lubrication of ERCsand inserts at the time of initial Layingshould be done 100 % and thereafterfollowing schedule is prescribed.i) In corrosion prone areas & platform

lines: Once in a year.ii) In other areas: Once in 2 years.b) Material: Graphite Grease (Gr.0) of IS-408-1981c) Instructionsi) Greasing shall not be done in extremes ofsummer & heavy rainfall.ii) Not more than one ERC should beremoved at any time. To ensure thisKeyman should carry one pre-greasedmatching ERC greased with ‘0’ numbergraphite grease.iii) Keyman should do oiling & greasing @20 sleepers (80 ERCs) per day. Tosupplement the efforts of Keyman, extramen shall also be engaged to grease ERCsas it may not be possible for keyman aloneto complete the work.iv) In case mass lubrication of ERC is takenup, at least 15 sleepers shall be kept

intact between two sleepers on which ERChas been removed.v) ERC should be driven back up tocorrect length..d) Procedurei) After removal of the ERC, The eye ofthe insert shall be cleaned with suitablebrush. This brush may be used to cleaninside of insert.

The rail foot below the liner locationshould also be cleaned with wire brush andemery paper. The ERCs should be cleanedby wire brush & emery paper.

ii) After cleaning, grease graphite shall beapplied to the inside surface of eye ofinsert and Ieg of ERC.iii) Inside/outside ERC should beinterchanged.

2. GREASING AND SEALING OFLINER CONTACT AREAIn identified corrosion prone areas, the railliner seat should be greased using graphitegrease to the RDSO specification afterproper cleaning. The grease is also appliedall around the liner on the rail foot ongauge face side to prevent the ingress oftoilet droppings in the gap between theliner and rail foot, greasing and sealing ofliner contact areas shall be done once in

year for gauge face side and once in twoyear on non- gauge face of rail.

3. LUBRICATIONOF SEJs :a) Frequency

i) Fortnightlyii) At the time of distressing of LWRb) Instructionsi) Keyman will carry out oiling andgreasing of SEJ.ii) Keyman will check and also tightenfasternings at SEJ if necessary.iii) At the time of distressing of LWR,following procedure shall be adopted foroiling and greasing of SEJ under trafficblock.c) Procedure:1) Oiling and greasing of tongue and

stock rails of SEJ and tightening offastenings shall be donesimultaneously. This periodical oilingand greasing shall be done by keymanwithout dismantling/interferring withthe SEJ. Necessary oil/grease shouldbe applied externally on the fishingplanes of various parts of SEJ.

2) The complete oiling and greasing ofSEJ shall be done by dismantling theSEJ only at the time of de-stressing ofthe concerned LWR. The work shall bedone in sequence described belowunder traffic block:

3) i) The nuts and chairs of SEJ shall be

removed.ii) A gap shall be created between tongueand stock rail and their interfaces shall begreased after cleaning the faces with wirebrush.iii) Similarly interfaces of chairs andtongue rails and that of chair and stock railshall be greased after cleaning.iv) The stock of tongue rails shall be reset.v) Bolts of chairs shall be oiled and nutstightened after replacing the chairs.

4. LUBRICATION OF PLATESCREWS AND RAIL SCREWS

The Plate Screws & Rail Screws providedon PSC sleepers on Turnouts, SwitchExpansion Joints, Bridge guard rails &Level crossings are getting corroded due toeither aggressive environmental condition.Due to the excessive corrosion ofPlate/Rail Screws, maintenance has beenbadly affected as the thickness of screwsgets reduced and interim they get jammed/loosened, resulting in loosing grip withplates and sleepers become useless.To minimize the occurrence of thisproblem, as a preventive measure,Lubrication of Plate Screws and RailScrews should be done. Grease graphiteused for this purpose shall be as per ISSpecification number IS: 408, Grade '0'.

a) Frequency:-(i) At new Turnout/SEJ/Bridge guardrail/Level crossing/ renewal sites, thegreasing of new Plate/Rail Screws shouldbe done while providing in the track.(ii) Once a year in areas not prone tocorrosion.(iii) Once in six months in corrosion proneareas.b) Instructioni) Prior survey shall be done to ascertainnumber of corroded Screws.ii) New Screws shall be procured as perassessed numbers and provided in place ofcorroded ones after applying '0'- GraphiteGrease/Black oil.c) Procedurei) Plate/Rail Screws should be removed oneby one from track.ii) Screw as well as Dowel be properlycleaned for corroded material from thesurface with the help of wire brush andthen dipped in Black oil uniformly both onthe surface of Plate/Rail Screw and Doweland fixed back.iii) Head of Plate/Rail screw should also beeither coated with hot Bitumen or othersuitable anticorrosive paint to avoidcorrosion.

5. LUBRICATION AT POINT ANDCROSSINGS

a) Tongue railGreasing of gauge face of tongue rails,outer rail of turn-in-curve and emergency

cross-over should be carried out once aweek.b) Cleaning and lubrication of points:Periodical cleaning and lubrication of slidechairs is to be done by –i) Signal staff for points interlocked withsignals or provided with locks. (generallyup to third sleeper from toe of the switch).ii) SSE/P.Way on hand operated points andremaining slide chairs of all pointsinterlocked with signals or provided withlocks.iii) Frequency: Once in fortnight.iv) In addition to above, oiling of bracketsand lugs should also be donesimultaneously, as contact area of thesemembers with stretcher bar is gettingcorroded resulting in thickness of stretcherbar bolts reduced and get jammed.

6. LUBRICATION OF OUTER RAILOF CURVE

It is well known that rail lubricationincreases the wheel and rail life bypreventing friction and decreasing the wearbetween the rail-wheel interfaces, savesenergy, and can reduce wheel noise. It canalso reduce lateral forces and flange climbforces that can lead to flange climbderailments.a) Gauge face of outer rail of curve havingradius 600 m and less should be lubricatedto avoid Rail face wear.

b) Frequency: i)

ii) At other location such as on straighttrack at location of rail wear caused due tosinusoidal movement : To be lubricatedonce in a month.For this purpose grease lubricator may beinstalled.Care must be taken to ensure that thegrease does not touch the rail top so as toavoid wheel slip.

7. LUBRICATION OF RAIL JOINT

a) Purpose: To facilitate the expansion ofrail joint and to retard wear on the fishingplanes of the rails and fish plate. Enable

gang under the direct supervision of at leastqualified permanent way supervisor.iii) The lubrication work should be carriedout under caution order and underprotection of engineering signals, as perpara 806 (2) of IRPWM.iv) Two consecutive joints on the same railor two opposite joints should not be openedfor lubrication at any time. Two gangmenshould sit on diagonally opposite jointsfacing the direction of train while doing thework.v) Each gangmen doing the lubrication ofrail joints should also carry magnifyingglass and a mirror for inspection of rails todetect cracks/defects. vi) Lubrication should be carried out insuch a way that all bolts head must comeon inner side in even year and on outer sidein odd year after lubrication.e) Procedure for Lubrication of RailJoints:Lubrication of rail joints involved greasingof the fishing planes of rails and fish-platesand oiling of fish-bolts. This should becarried out as follows:-i) Unscrew the nuts and place themopposite each bolt to ensure that they arenot inter-changed while being replaced inposition.ii) Lightly tap and remove the inside fish-plate.iii) Clean the fishing surface of the railsand fish-plate with wire brush and wipe offthe rust by waste cotton.iv) Examine the cleaned surface of railsand fish plate for any crack with the help ofmagnifying glass and mirror.

visual examination of rail ends for any crack/defects. Reduced wear on the fishingplanes is one of the preventives of the lowjoints.b) Frequency:i) Once in a year during the cold weathermonth after the monsoon (i.e. from Octoberto February)ii) Joints in buffer rails shall be lubricatedtwice in a year when the rail temperature isbetween td+150C and td-150C and when theaverage gap value is between 3 mm and 12mm.iii) Spare joggle fishplates provided to use inemergency: Once in a month by keyman.iv) Joggle fishplates: Once in a year aftermonsoon.c) Material: A stiff paste of plumbago(graphite) and kerosene oil. Black of orreclaimed oil may be used for fish bolts andnuts. Material requirement for 100 singlejoints in kg will be as under:

d) Instructions:i) The lubrication should not be carried outin extreme hot or cold weather, or duringrainy season.ii) Creep where heavy, must be adjustedbefore lubrication of joints.ii) Lubrication of rail joint should benormally carried out by permanent way

Material Quantity in kg.

Plumbago (Dry graphite powder)

5

Kerosine oil (second quality)

3.5

Black or reclaimed oil (only for bolts and nuts)

2.75

Radius of curve

Frequency of greasing

when traffic is up to 20 GMT per

year

Frequency of greasing

when traffic exceeds

20GMT per year

Curve sharper than 350 m radius

Once in two days

Daily

Curve sharper than 600 m radius

Once a week Twice a week

Curve with radius 600 m

or more

Once in two week

Every week

Hkkjr ljdkj & GOVERNMENT GOVERNMENT OF OF INDIAINDIAjsy ea=ky; & MINISTRY MINISTRY OF RAILWAYS OF RAILWAYS

ैक घटक का नेहनLUBRICATION OF TRACK

COMPONENTS

कैमटेक/ स/2014/एल ट सी/1.0CAMTECH/C/2014/LTC/1.0दस बर / December- 2014

egkjktiqj] Xokfy;j & 474 005 ¼e-iz-½ Maharajpur, Gwalior – 474 005 (M.P.) : 0751-2470869, Fax: 0751- 2470841E-Mail : [email protected]

dsoy dk;Zky;hu mi;ksx gsrq(For Official use only)(For Official use only)

v) Apply a thin layer of a mixture ofplumbago and kerosene oil mixed to form afine paste on the fishing-planes of the railand fish-plates.vi) Remove the fish-bolts one at a time andafter oiling put each back in the reversedirection.vii) Lightly tap and remove the out-sidefish plate.viii) Treat the other fish plate and fishingsurface of the rails similarly.ix) Replace fish-plate and nuts. Tighten tothe extent possible with the standard fish-bolts spanner, the inner two bolts beingtightened first without overstraining thebolts.x) Care should be taken to ensure that allthe time there is one fish plate and not lessthan three fish-bolts without connecting thetwo rails.Both the fish-plates should be fitted and atleast one fish-bolts and nut on either side ofeach joint should be tightened when a trainis approaching the site of work. This mustbe done before the banner flag protectingthe site of work is, ordered to be removed.xi) Particular of work of lubrication donewith dates should be recorded in thesection Register of Permanent WayInspector.

f) Certificate of Lubrication: - Every yearin April, SSE/P.Way should submit to theAssistant engineer, Certificate oflubrication of fish-plated joints withexceptions, if any, giving reason. Copies ofthese certificates should be forwarded byAENs, with comments to the DEN/Sr.DEN/DSE for scrutiny and record.8. LUBRICATION AT THE TIME OFTRACK RENEWALFishing surface of rail and fish plate shouldbe greased before putting the fish plate inposition.

9. LUBRICATION OF GIDERBRIDGES

a) Bearing of girder bridges: Sliding androller rocker bearings should be clearedand greased once in three years.b) LWR/CWR on bridges provided withrail-free fastenings and partly box-anchored (with single span not exceeding30.5 metre and having sliding bearings atboth ends)The sliding bearings shall be inspectedduring the months of March and Octobereach year and cleared of all foreignmaterials. Lubrication of the bearings shallbe done once in two years.c) Fitting on channel sleepers should beoiled periodically.d) Hook bolts: Hook bolts on girder bridgesshould be oiled periodically to preventrusting.10. LUBRICATION AT THE SITE OFDEEP SCREENING, TSR AND TRRa) On the work sides, where work ofdisturbance of ballast bed such as deepscreening, TSR and TRR is being done, itmay be advisable to apply grease to gaugeface of both rails.

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DisclaimerThe contents of this pamphlet are for guidance onlyand are not statutory. If you have any suggestion &comments on contents of the pamphlet, please writeto: Dy.Director (Civil), CAMTECH, Maharajpur,Gwalior (M.P) – 474 005

The content of this documents are taken fromIRPWM, LWRM, IRBM and CE circulars ofIndian Railways.