0308 – Practical training for skill contestants 2 – Common problems and solutions in turnout maintenance -3-​ Loose parts, failure and defects

01Causes

Failure of turnout components is an important issue that causes turnout function failure and affects driving safety. Improper daily maintenance and overhaul are the main reasons for the failure of turnout components, which are as follows:

1.1 Poor daily maintenance

The tamping is not thorough, resulting in dark pits and hanging plates in the turnout components, aggravating the impact and vibration of the turnout, causing the parts to loosen and fail. The main manifestations are:

The bolt sleeve of the iron pad connecting the concrete sleeper fails

The flat washer between the iron pad and the bolt is separated

The gap between the turnout switch rail and the switch does not meet the regulations

The gap between the turnout guardrail and the switch does not meet the regulations

The spacing between the turnout rail sleepers does not meet the regulations

The daily maintenance inspection is not meticulous, and missed inspections and repairs lead to parts failure. The main manifestations are:

Loosening of transverse bolts of guardrail

Failure or loosening of connecting bolts of spliced ​​full-length turnout sleepers

Loosening of top iron bolts

Excessive wear of the tip of the turnout frog rail

Excessive wear of the side wall of the turnout frog rail

Excessive wear of the end of the turnout guardrail

Excessive wear of the tip of the turnout switch rail

1.2 Neglecting the repair of parts

Failure to repair parts with wear, corrosion, deformation and other defects in time leads to failure of parts.

The maintenance system is not sound, and there is a lack of regular inspection of key parts, resulting in the inability to effectively guarantee the quality of parts.

1.3 Poor technical operation

Failure to follow the specifications during the installation process results in incorrect installation of parts, substandard torque, and failure of parts.

The technical level and operating skills of the construction personnel do not meet the standards, resulting in low construction quality.

The quality monitoring of the construction process is not in place, and problems in the construction are not discovered and corrected in time.

1.4 Inspection omissions

During daily inspections, only geometric dimensions are paid attention to, and the inspection of the turnout frame dimensions and the status of spare parts is ignored, resulting in loose or missing parts.

The inspection system is imperfect, and there is a lack of assessment and reward and punishment mechanisms for inspectors, resulting in inadequate inspection work.

02 Preventive and remedial measures

Strengthening daily maintenance and overhaul is an important measure to increase the service life of turnouts, reduce maintenance costs, and ensure driving safety. In response to the above-mentioned causes, the following measures should be taken:

2.1 Strengthen daily maintenance

Carry out maintenance operations in strict accordance with maintenance regulations to ensure the quality of tamping, promptly remove debris from the turnout roadbed, and keep the turnout drainage unobstructed.

Strengthen daily maintenance inspections to ensure that "no one is missed, no one is missed", and timely discover and repair defective parts.

Establish a sound daily inspection system, clarify the responsibilities of inspectors, regularly inspect turnouts, and keep inspection records.

2.2 Timely repair parts

For parts with wear, corrosion, deformation and other defects, they should be replaced or repaired in a timely manner and should not be used with defects.

Establish a sound parts overhaul system, and regularly conduct ultrasonic flaw detection, magnetic particle flaw detection and other tests on key turnout parts to ensure the quality of parts.

Improve the spare parts management system, do a good job in the procurement, acceptance, storage and distribution of spare parts, and ensure the quality and quantity of spare parts.

2.3 Standardize technical operations

Strengthen the training of technical operators and improve the technical level and operating skills of construction personnel.

Strictly implement construction specifications to ensure construction quality.

Strengthen the quality monitoring of the construction process, and promptly discover and correct problems in construction.

Establish a sound technical operation management system and severely investigate and punish illegal operations.

2.4 Improve the inspection system

Expand the scope of daily inspections. In addition to checking the geometric dimensions, it is also necessary to focus on checking the turnout frame dimensions, spare parts status, etc.

Establish a sound inspection and assessment system and seriously investigate and hold accountable for problems found during the inspection.

Regularly assess the inspectors to improve their professional level and sense of responsibility.

Conclusion

By taking the above measures, the failure of turnout components caused by improper maintenance and overhaul can be effectively reduced, the overall quality and use level of turnouts can be improved, and driving safety can be ensured.