Ballast Cleaning machine ALL IN ONE

Ballast Cleaning 

 INTRODUCTION

• Contamination of the ballast bed in the course of normal operation and due to the extremely varied environmental influences, plus the geological problems of the subsoil in total lead to a reduction in the durability of the permanent way.
• Ballast cleaning technology provides the prerequisites for economical maintenance of the track.
• In situ condition and engineering aspects of ballast are important conditions governing the stability and performance of railway track.
•In order to remain competitive with other mode of transportation, railway authorities have increased freight tonnage, traffic speed and frequency of train. These changes have led to increase wear from rails down to sub grade level. Hence effective design and proper ballast maintenance remain the best alternative.
•The dynamic effect of traffic causes breakdown of ballast particles accompanied by attrition of its grains. The fines thus generated decrease void volume and retain moisture. Due to decrease in permeability ballast loses its ability to drain the track consequently decreasing shear strength, stiffness and elasticity. Trapped water decreases the necessary interlocking,deteriotates track geometry, loosen fasteners. Hence ballast cleaning becomes essential.

Advantages 

• Required slopes can be given to the formation.
• Quality of ballast cleaning extremely good.
• Loss of ballast negligible, upto 10-15%.

YOU MAY ALSO READ:  The duty of TECH III,    PRE BLOCK WORK,     ABOUT BCM,   Know CSM,   TAMPING UNIT

Various operations 

• Screen excavated material and immediately return back good ballast.
• Grade track ballast to various sizes, distribute them as per requirement.
• Discharge spoil from front of machine to keep track free behind machine for re-ballasting.
• Can excavate all materials in ballast bed without screening, if required.
• Can provide sand blanketing between sub grade and ballast, if required.

Methods of Ballast Cleaning

1. Shoulder Ballast Cleaning

• Most cost effective way to remove sub-surface saturation problems.
• It breaks open mud pockets and releases trapped water to restore drainage.

2. Mobile Apparatus Ballast Cleaning

•A train consisting a ballast cleaning machine with a track lifting mechanism is used.
•The waste material is conveyed from ballast cleaning machines to freight cars through conveyor belt.
•It is a fast method of ballast cleaning.

3. Recent method

•Reconditioning of ballast is done at relatively high speed.
•Track Undercutters and Ditcher wheels are used to remove ballast.
•This is followed by screening in which reusable ballast is recovered from removed portion.
•Typical Ditcher wheels can remove ballast upto 5000 feet in 1 hour.
•Articulated system which can negotiate on small radius curves to maintain overall height is used.
• A dust suppression system consisting of main pressure lines is used.
• Spraying of liquid is employed to minimize effect of dust particles.

YOU MAY ALSO READ:  The duty of TECH III,    PRE BLOCK WORK,     ABOUT BCM,   Know CSM,   TAMPING UNIT

Ballast Cleaning Machines

1. High Output Ballast Cleaners ( HOBC )

• Proper utilization of HOBC is ensured by accurately predicting volume of ballast returned to track and new ballast needed for renewal.
• Site investigation prior to renewal is done. For this either samples from trial pits( TP ) are used or automatic ballast sampling is done.

2. FRM 80

•It’s a six axled articulate machine.
•First section consist of pick up device.
•Second section consist of screening unit, filling devices and conveyor belt.
•Entire ballast is picked up by cutters positioned on either sides.
•Picked up ballast is transported to cleaning units.
•Waste material falling out is dropped into hopper unit by spoil conveyor units.
•After cleaning sweeper unit restore the ballast profile.

Technical Data FRM 80

Total length, over buffers 39 470 mm
Total length (incl. Slewing conveyor belt) 41 970 mm
Length of excavation car 19 235 mm
Length of screening car 20 235 mm
Length of overhang of slewing
conveyor belt 2 500 mm
Height over top of rail max. 4 200 mm

MAINTENANCE SCHEDULE PART-II

All Maintenance Schedule

     This is the Second part of this series. If you have not study the first Part of Maintenance Schedule, I heartly requested to you for study that. 

First Part of Maintenance Schedule 

After study this you may know:-

1. Different type of maintenance Schedule
2. Work in maintenance Schedule
3. The duty of TECH in maintenance Schedule

And many more

Now We study the Second Schedule Name:-
      SCHEDULE II or 50 ENGINE HOURS SCHEDULE
In Schedule II Many Major work we have to do related to ENGINE and also to other parts of machine. Now we discuss one by one.

FOR ENGINE

1. Grease radiator fan shaft.
2. Clean air cleaner element.
3. Clean radiator fins.
4. Clean filter element of Bowl glass.
5. Clean cyclonic filter bowl
6. Drain water/sediment from diesel tank.

YOU MAY ALSO READ:  The duty of TECH III,    PRE BLOCK WORK,     ABOUT BCM,   Know CSM,   TAMPING UNIT

FOR TAMPING UNIT

1. Check tightness of shoe plate bolts of guide column.
2. Check squeezing cylinder cover plate bolts for tightnesss.
3. Check tamping unit cylinder holding bracket bolts for tightness.
4. Check the nuts of 55 mm and 35 mm pin for tightness.

FOR LINING , LEVELING & LIFTING UNIT

1. Grease lining cylinder pivots.
2. Grease lifting unit guide column.
3. Grease rail clamp pivot pin.
4. Grease roller clamp housing.
5. Grease locking device pivots.
6. Inspect clamp roller locing bracket bolts for tightness.
7. Lubricate the track lifting cylinder pivots with lube oil.
8. Lubricate the clamp carrier pivots with oil.
9. Examine the clamp roller for wear and free mvement 
10. Check clearance of lifting rollers disc below rail head.

YOU MAY ALSO READ:  The duty of TECH III,    PRE BLOCK WORK,     ABOUT BCM,   Know CSM,   TAMPING UNIT

GEAR AND SATELLITE UNIT

1. Check oil level of all gear boxes and fill up to the mark, if required.
2. Grease flange covers of satellite gear boxes.
3. Check shock absorber.
4. Adjust satellite brake shoe.
5. Check and renew satellite support block.
6. Check foundation of axle support cylinders.

TROLLEY AND OTHER PARTS

1. Check nut & bolts of all trolley.
2. Grease pendulum bridge pivots.
3. Check for play in feeler rod.
4. Check wire chord tensioning arrangement.
5. Clean the depth transducers for free movement of chord wire carrier.
6. Check guide rod of transducer.
7. Check foundation and bracket bolts of compressor.
8. Check foundation bolts of brake cylinder.
9. Clean the water separator.
10. Clean air oiler.
11. Check cooling coil.
12. Check king pin pivot of driving & idler bogie.
13. Grease axle gear box of flange cover.
14. Grease torque arm pivot of driving bogie.
15. Grease link rod.
16. Check condition of brake shoe.
17. Check oil level of all gear box.
18. Inspect meggie spring.

ELECTRICAL PARTS AND BATTERY

1. Check electrolyte level of batteries.
2. Check alternator.
3. Check all limit switch. 
4. Check condition of all transducer.

This all Maintenance are done by Techinician and inspected by the Machine supervisor on schedule Basis.

YOU MAY ALSO READ:  The duty of TECH III,    PRE BLOCK WORK,     ABOUT BCM,   Know CSM,   TAMPING UNIT

MAINTENANCE SCHEDULE

All Maintenance Schedule

 After study this you may know:-

1. Different type of maintenance Schedule
2. Work in maintenance Schedule
3. The duty of TECH in maintenance Schedule

And many more

TYPE OF SCHEDULE MAINTENANCE:- Maintenance and repairs of machines shall be carried as per different Schedules I to VII. Schedule VI and VII pertain to Intermediate over Hauling (IOH) and Periodic over Hauling (POH) respectively. Normally two POH is required in the lifetime of machines.

Location:-Schedule I to IV at the Track Machine Siding point. Schedule V is in Satellite Depot/Zonal Workshop.  Schedule VI is in Zonal Workshop and Schedule VII is in Zonal Workshop/CPOH Workshop.

Read More:- 

         The duty of TECH III

            PRE BLOCK WORK

              ABOUT BCM
               Know CSM
                 TAMPING UNIT

Duration of Schedule:-

• Schedule I:- One hour
• Schedule II:-  Two hours
• Schedule III:- One day
• Schedule IV:- Two days
• Schedule V:- 7 days
• Schedule VI:- 15 to 45 days as per manual (IOH)
• Schedule VII:- 45 to 105 days as per manual (POH)

---–---------------------------------------------------------------

What should we have to do in different Maintenance Schedule?

🔜➽This question we discuss the actually what do we do in any maintenance schedule in details.

           

     Now we start with Schedule I or Daily Schedule or Two hours working Schedule.

 FOR Engine:-

1. Check water level or radiator and top up, if required.
2. Check the level of engine oil & top up, if required.
3. Check the belt tension and correct, if required.
4. Check fuel level & top up, if required.
5. Check the leakage from engine hoses, water pump seal etc and do the needful.
6. Check the leakage from the fuel pump, injectors, fuel supply, and return pipes.
7. Check oil level and leakage from the compressor.
8. Check engine oil pressure on load after two hours working.
9. Record the maximum engine temperature of the day's work.
10. Check air filter indicator.

FOR General

1. Check oil level in all gearbox.
2. Check the bolts of cardon shafts.
3. Check & fill the reservoir for lubrication of tamping arm bearing. (55mm pin)
4. Check & fill the reservoir for lubrication of vibration shaft bearings up to the mark.
5. Check and top up the wick lubricator for lubrication of guide columns.
6. Grease connecting rod bearing 35mm pin and vibration shaft bearing.
7. Grease squeezing cylinder bearing.
8. Check the leakage from hydraulic hoses and do needful.
9. Check to look device of all unit.
10. Check condition of T.T Tools.
11. Grease all lining rollers pins.
12. Grease all guide rollers of the satellite.
13. Check satellite axle support rollers bolts.
14. Check torque support of satellite
15. Lubricate all ball & sockets/bush bearing.
16. Check engaging/disengaging of the satellite.
17. Check to charge ammeter of batteries.
18. Drain water from air receiver.
19. Check and top up hydraulic oil tank.
20. Record the maximum temperature of hydraulic fluid during the day's work.
21. Top up the air oiler.
22. Drain the water separator.
23. Check all the functions of the machine before block working.

These all records kept in a daily Schedule Register in custody of Technician and inspected by the machine supervisor on daily basis. 

Read More:- 

         The duty of TECH III

            PRE BLOCK WORK

              ABOUT BCM
               Know CSM
                 TAMPING UNIT

PARTS OF TAMPING UNIT

TAMPING UNIT

After study this you have a knowledge about

Main parts of a Tamping Unit

ABOUT TAMPING TOOLS

Main Parts of A Tamping Unit are as follow:-

1. Vibration Shaft
2. Fly Wheel Cover
3. Vibration Shaft Main Bearing Oil Reservoir
4. Tamping Arm Bearing Oil Reservoir
5. Filling Point Vibration Shaft Bearing
6. Big squeezing cylinder
7. Big Tamping Arm
8. Small Tamping Arm
9. Clapper cylinder
10. Hydraulic Distributer
11. Tamping Bank/Main Frame
12. Small squeezing cylinder

Read More:- 

         Duty of TECH III

         PRE BLOCK WORK

         ABOUT BCM
         Maintenance Schedule

The two high pressure tamping units work according to the non-synchronous uniform pressure tamping principle. Force equilibrium between the tamping tools, directioinal vibration in the squeeze direction and the ideal vibration frequency of 35Hz gives completely uniform tamping. For work in curves, the unit can be centred automatically over each rail. During each cycle, two sleepers can be tamped with the help of 32 tamping tools.

A brief discription of vaious pars of Tamping Unit

 A brieff desciption of various parts of Tamping Unit is given below.

1. Tamping Bank:-  Tamping Bank is the Main Frame of tamping unit on which all the other parts are assembled. It requires two numbers per machine for CSM machine.
2. Tamping Arms;- There are four Amall and four Big tamping arms are present in a tamping unit. These are connected with Big and Small squeezing cylinders respecively.
3. Vibration Shaft and its Accessories:-  Vibration Shaft is an eccentric Shaft. It is  used to generate required vibrations to help in tamping tool penetration in the ballast. Vibration Shaft is fixed in taming bank; squeeing cylinders are mounted on vibration Shaft.
4. Guide Rods:-  Through Guide Rod tamping unit is connected with the machine and it guide the tamping unit during UP/DOWN movement.
5. Small Squeezing Cylinders:- Small Squeezing Cylinders are connected with small arm is used to squeeze the ballast in addition to that it transfers vibration from vibration shaft to the tools. A pair of male and female small cylinders is present in a unit.
6. Big Squeezing Cylinders:- Big squeezing cylinders are connected with Big Arm is used to squeeze the ballast in addition to that it will transfer vibraition from vibration shaft to the tool. A pair of male and female big cylinders present in unit.
7. Fly Wheel Motor Side:- Fly wheel is used to store energy. It is connected with vibration motor using part clutch.
8. Flywheel outer Side:- It is fitted opposite to motor side. It is used to store enegry.
9. Cover Guard Outer:- It is used to cover the outside fly whel and Also as oil Resevoir for the librication of centre arm pin assembly and main bering. Each reservior has one oil level gauge and one breather assembly.
10. Plate Guard:- It holds the vibration motor in perfect alignment and covers the flywheel in motor side.
11. Vibration Motor:-  Vibration Motor is used to rotate vibration shaft at 2100 rpm with 150 kg/sq. cm hydraulic pressure, it converts hydraulic enegy into mechanical energy.
12. Hydraulic Distributor:- It distributes the pressurized hydraulic oil and supplies to squeeze.
13. Bearings:-  Bearings are used on vibration shaft for easy rotation 10 roller bearings & 1 ball bearing is used in CSM T/U. 
14. 35 MM Pin:- it is used to connect squezing cylinders with tampijng arm; it is fitted in taming arm after proper cooling in freezer requires 12 per unit. It moves with tamping are while vibration/ squeezing.
15. 55 MM Pin:- It is used to hold tamping arm, it is fitted in taming arm after proer cooling in freezer at proper interferefnce requires 8 per unit, it moves with tamping arm while vibtating/squeezing.
16. Bronze Bushes:- 

• Bushes for Centre Arm Pin:- These are used for centre arm pin bush movement 16 fbushes are required per unit. It is made by centrifugal casting method. It is pressed in main frame of tamping unit to hold tamping arm.
• Bushes for Guide Column:- These bushes are used in tamping unit guide rod bore for free movement of tamping unit in up down movement. It requires 4 per unit.

TAMPING TOOLS

1. Tamping Tool:- Tamping tools are the final performers of tamping machine during tamping. That's why quantity of tools and shape of tools are considered very important for the quality  of pacing. Wear of tamping tool blade is permitted only up to 20% of blade areas More than 20% worn out tools need replacement for proper quality of packing of ballast under sleeper.

• According to Material:

1. Forged Steel Tool With Hardness of 280 BHN:- Forged Steel Tamping Tools wear and tear at blade portion becomes more and it reduces the blade size. It needs re-welding to maintain the proper size of blade after 10-15 km working.
2. Tungsten Carbide Tip Tool (TCTT):- TCTT Type Tamping Tools has long life. It gives approx. 250 km life without any maintenance. In these tools, at the location of squeezing face Tungsten Carbide Tips are Welded.

• According to Design:

1. Taper Shank:- This is the old version of Tools, in this tool head of the tool has a tapered shape. This is used on old CSMs
2. Parallel Shank:- This is the new version of tools, in this tool head of the Tool does not have a tapered shape. This is used on new CSMs.

• According to Size of Blade: 

1. Full Tool:-   These tools have Tool Blade of Size 140 x 70 mm. These tools are used normally far side of rail head.
2. Half Tools:-  These Tools are used near side of rail head. Due to fear of infringement with rail length of blade is chosen less than 140 mm. Width of blade is same as Full Tools.

INTRODUCTION OF CSM

A Brief note about CSM Machine

The qualities of CSM are as follows:

1. Excellent quality or work
2. Higher working speed
3. Reduction of running costs
4. Highest working comfort
5. Easy combination with other operations

Read More:- 

         Duty of TECH III

         PRE BLOCK WORK

         ABOUT BCM

         

The Advantages of CSM are as follows:

• Highest tamping due to non-synchronous uniform pressure tamping principle
• Optimum tamping frequency of 35 Hz
• Directional, linear vibration
• 50% higher work
• Unrivalled working comfort
• Reduced wear

Read More:- 

         Duty of TECH III

         PRE BLOCK WORK

         ABOUT BCM

Savings with CSM:

• Lower maintenance costs due to high tamping output
• Lower operational hindrance costs due to optimum utilisation of short intervals between trains
• Reduction of running costs due to less consumption of spare parts.

Silent Features  of CSM:

1. Fully Auto Working
2. Output-2200 to 2400 sleeper/Hr.
3. maximum Permissible Speed 60 kmph
4. Both cabin driving
5. Twist correction
6. Multichek System
7. Satellite Frame 
8. Servo Valve for lining & lifting
9. Continuous working
10. Laser lining 
11. Laser levelling
12. Trailer
13. Side consolidator
14. Data Recorder
15. Programmable Logic Control (PLC) System
16. ALC Equipped
17. SPS Diagnosis Equipped CMS Equipped

Read More:- 

         Duty of TECH III

         PRE BLOCK WORK

         ABOUT BCM

Major Assemblies of CSM Machine:

1. Engine
2. Tamping Unit
3. Main Frame
4. Satellite Frame
5. Lifting cum Lining Unit
6. Gear Box
7. Sensing Bogie
8. Hydraulic System
9. Pneumatic System
10. Power Transmission System

Read More:- 

         Duty of TECH III

         PRE BLOCK WORK

         ABOUT BCM

KNOW ABOUT BCM

This is important for the aspirants of TECH III in LDCE Exams in SR Railways.
Topic Name :-

A Brieff note about BCM Machine.

Machine Catagery:- Balast Handling.
Machine Type :- BCM (Balast Cleaning Machine)

Model No :- 

  BCM

 RM-80

RM-76

KBC-600

Number of Wheals used :- 8
Maximum Speed:- Self Propelled 40KMPH
In Train Formation 40KMPH
Model use on various Track:-
On Plan track BCM :- RM-80 KBC-600
On P&C :- RM-76
Progress Rate:-
RM-80 : 650 cube metter
RM-76 : 550 cube metter
KBC-600 : 650 cube metter

Engine Used :

 Model No :- Deutz-BF 12L 513C
No of Engine : 02
Firing Order : 1-8-5-10-3-7-6-11-2-9-4-12
No of cylinder : 12
Cooling Type : Air cooled
Capacity(BHP) : 453@2300 RPM

Also read : DUTY OF TECH III , PRE BLOC WORK , ABOUT CSM

Basic Units :

1. Excavating Unit
2. Screening Unit
3. Conveyer system for distribution of ballast and disposal of muck
4. Track lifting and slewing Unit.
5. Recording unit.

Description of Machine:

The machine is powered by two independent power units (Total engine out put : 666kw) with air cooled Deutz Diesel engines type BF-12L 513C which drive the pump distribution gears via cordon shafts. The front engine powers the hydraulic pumps for

all conveyor belt drives,
lifting movements and
the hydraulic propulsion, 

both is working and travelling mode. The rear engine provides power for hydraulic pumps for the excavation chain drive and the screen drive and also powers the hydraulic propulsion for travelling.
The chassis has study welded construction. The frame and other units are joined by welding. The machine is equipped with buffers and draw bar on either end.

About Bogies

There are two powered bogies, each having two power axle. The powered axles of both bogies are driven by a hydraulic motor through a gear and a hydraulic multiple disc clutch. In working mode, the speed is variable from 0 to 1000 meter/hr. There is a working and driving cabin at the front end of the machine having all controls necessary for travel and work. this cabin is located right in front of the cutter bar which gives the operator a good view not only of controls and panels but also of the working units.

Braking system

The machine is equipped with a pneumatic block brake acting on all powered wheels. There is hand operated braking valve for direct pneumatic braking. The machine also has a through brake pipeline to facilitate movement in train formation.

Battery

There is a 24V DC plant for lights, battery charging, electric control and monitoring systems of the diesel engines. and flood lights during night working.

Purpose of the using the Chain in BCM

For excavating the ballast, there is endless scraper chain located between the bogies and running under the track when working. The chain is basically composed of scraper blades with  fingers, intermediate links and bolts.
Chain speed is variable between 2.4 to 4.0 metres per second.

The excavation chain is guided in two slanted lateral channels and one horizontal channel. The top of the lateral guides are pivoted to the machine frame and hydraulically adjusted. The lower part of the chain guide is parallel to the machine body and is made of wear resistant steel. For protection against dust, noise and for safety reasons, the lateral guides are covered with solid rubber sheets which open by hinges.
At the beginning of work at a site, the cutter bar is inserted underneath the sleepers and connected to the lateral guides by quick action locks. Hydraulic hoists are provided for easy handling of the cutter bar. At the end of the work at a particular site, the cutter bar is removed.

Screening unit of BCM MACHINE

The screening unit consists of three vibrating sieves of the following square mesh sizes:

Upper screen :80mm
Middle screen :50mm
Lower screen : 36mm

The vibrations are provided by hydraulically driven rotating fly weights. In super-elevated curves, the entire unit is hydraulically adjusted by the operator to keep it horizontal.

The distributing conveyors receive the cleaned ballast and distribute it evenly across the entire surface of track right behind the excavating chain.

Waste dropping system

From underneath the screening unit, the waste drops to the conveyor belt which carries it to a hydraulically adjustable belt controlled from the cabin. The waste can be discharged outside the track by means of the tilting waste conveyor.

Track lifting Unit

A track lifting and slewing unit is located next to the cutter bar for adjusting the excavation depth and for avoiding the obstacles.

DUTY OF TECH III IN TRACK MACHINE, INDIAN RAILWAY

              my creation/ mukeshome001

                

                DUTIES OF TECH III 

The track machine fitters/mechanics attached with the machine and the zonal/sub-zonal depots shall assist the machine in charge in operation and maintenance of various Track Machines.

The main functions of Track Machine Fitters/Mechanics are:-

Also read :   PRE-BLOCK WORK , ABOUT BCM   , ABOUT CSM

1. To attend to the daily and weekly maintenance schedules of the machine and record the compliance in the logbooks.
2. To extend help during other maintenance schedules/service checks by the Service Engineers.
3. Keep in his custody the various tools and equipment necessary to attend repairs and ensure their working condition.
4. Guide and supervise the semi-skilled/ unskilled staff in attending to the maintenance /repairs.
5. To remain vigilant during movement and working of the machine and to inform the operator of any abnormalities.
6. To ensure the safety of the machine and men from approaching trains on adjacent lines.
7. Any other work assigned to him by the machine in charge who is defined in the para1.4.2.