QUALITY & ENGINEERING - Rahee Brochure.pdf · Regd. Office: NH-6, P.O. Argori, Jangalpur, Howrah...

Kolkata Works

NH-6, P.O. Argori, JangalpurHowrah 711 302, West Bengal, IndiaPhone : +91 33 6455 2125/26Fax : +91 33 2669 8282email : [email protected]

Hyderabad Works

173/B/1A, IDA Bollaram Village, Jinnaram (M)Medak District 502 325, Andhra Pradesh, IndiaPhone : +91 8458 329 633Fax : +91 8458 279 885email : [email protected]

Rahee Track Technologies Private LimitedRegd. Office: NH-6, P.O. Argori, Jangalpur, Howrah 711 302, West Bengal, India

Phone : +91 33 6455 2125/26, Fax : +91 33 2669 8282, email: [email protected]: www.rtt.in

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Quality

RTT’s ISO 9001:2008 standard quality comes from exceptional quality management. To us, quality means offering our clients the best and safest products manufactured under the strictest quality standards, satisfying the three benchmarks – Complete Customer Satisfaction, Perfect Punctuality and Constant Improvement.

To achieve this, we continuously implement the most modern and stringent quality control systems in all our facilities. We also work closely with our affiliates to maintain their quality standards at superior levels.

Engineering ExcellenceRTT uses the latest technology for designing its track products. Our engineers can design turnout systems to non standard geometry for special applications, thus meeting the most challenging customer-specific requirements.

Efficient personnel and excellent technical capabilities ensure that customised solutions are put into practice within a short span of time.

The RAMS ManagementRAMS - Reliability, Availability, Maintainability and Safety – is the guideline which guide engineering at RTT. Within the scope of the RAMS Management, we carry out analysis of risks, reliability, maintainability and safety for each product.

The goal of RAMS is to minimise potential risks for humans and the environment and to maximize the reliability and safety of the products.

QUALITY & ENGINEERING

Rahee Track Technologies Private Limited

L E A D E R S I N M O D E R N R A I L W A Y T E C H N O L O G Y

RTT - PRODUCTION FACILITY

Rahee Track Technologies specializes in designing and manufacturing rail expansion joints, fastening systems, complete layouts, turnouts and turnout components like crossings and switch devices for railway tracks, including high-speed, heavy haul, urban and commuting railways, in all available rail profiles and required gauges as per international standards.

Rahee has been exporting fastenings, turnouts and turnout components to various countries since the last fifteen years and has an excellent export track record with the customers abroad. Rahee’s products are in use with Bangladesh Railways, Malaysian Railways, Srilankan Railways, Saudi Arabia and several other railways around the world.

With a team of highly qualified and experienced engineers, the company provides exceptional solutions and products to clients throughout the world.

Through modern engineering, exceptional quality and latest technology, Rahee guarantees efficient and competitive designs for a wide range of railway systems, along with a sustainable reduction in the cost incurred by superstructure maintenance and increased turnout availability.

C O M PA N Y O V E RV I E W


www.rtt.inL E A D E R S I N M O D E R N R A I L W A Y T E C H N O L O G Y

TURNOUTS

Innovative Turnout SolutionsRTT designs and manufactures turnouts systems for every traffic application:

All required gauges �

All available rail sections �

All required rail fastenings �

All possible angles and radii �

Regional as well as international Standards �

All track systems as slab track and ballasted track �

Heavy Haul, High Speed, Mass Rapid Transit Systems and Industrial Systems �

RTT has designed turnout systems for layouts like diamond crossings, symmetrical switches, turnouts taking off from curve, double turnouts, single cross-over and scissors cross-over. We have also developed need-specific innovative products and designs like

Clamp lock �

Trailable turnouts �

Dual guage turnouts �

In situ Glued Insulated Joint �

Turnouts for long welded rail track �

Head Hardened Switches & Crossings �

Special crossings that obviate the necessity of switches �

Thick web (symmetrical/asymmetrical) section switches �

Spring setting device or multiple drives using rods and lever �

Turnouts with sharp crossing angle for low speed and high axle load applications �

Clothoidal entry with tangential switch angle for divergent routes, thus reducing jerk �

Lubrication-free, low-maintenance slide chair with rollers or low-friction sliding inserts �

Different crossings like fabricated, welded, swing nose and cast manganese, with both �obtuse and acute angle

Rahee Track Technologies Private LimitedL E A D E R S I N M O D E R N R A I L W A Y T E C H N O L O G Y2

Optimised Turnout GeometryRail vehicle consist of various masses (“bodies”), linked by joints with different degrees of freedom and influenced by springs & dampers. When vehicles are in motion, these masses are interactive, a phenomenon known as multi-body dynamics.

RTT uses multi-body simulation programme to calculate the passage over turnouts of complete rail vehicles, considering influencing factors like vehicle data, speed, line layout, different wheel profiles and varying rail sections in the switchblade area. Every movement sequence is calculated, its effect on the track (wheel/rail) determined. The consequent forces, accelerations, displacements and other values are calculated in advance; the results are checked and validated in experiments through field tests and measured runs.

By varying the turnout parameters, optimised geometries with asymmetrical clothoids were developed. Long testing cycles can be minimised by this process.

The ideal turnout can be designed with an optimisation process. The variations of turnout parameter result in the use of asymmetrical clothoids.

RTT can offer turnouts that have optimised geometry and optimum wheel/rail transition conditions.

Rahee Track Technologies Private LimitedL E A D E R S I N M O D E R N R A I L W A Y T E C H N O L O G Y 3

Switches RTT’s state-of-the-art facilities design and manufacture switches as per client’s requirements.

Production

The switches are manufactured in accordance with technical terms of supply of IRS, UIC and CEN, supplemented by the specific requirements of the customers and the vast experience of RTT. The manufacturing process, employing the latest CAD/CAM systems, is optimally structured to lower:

Wear & Maintenance �

Accelerations �

Life-cycle costs �

Forces �

Thick Web SwitchesThese switches are made from specific asymmetrical tongue rail sections, forged at the end to match standard rail sections. The transition from one section to the other lies mostly in the clamped area at the end of the switch. Thus welding becomes superfluous in the flexible area.

The length of the forging can be adjusted to the specific connecting system such as welding, insulated fishplating or emergency fishplating. In order to reduce the setting forces and to influence the elastic line of the switch, it is possible to mill the base in the flexible area.

Advantages

Reduces jerks �

Considerably lengthens life span �

Leaves no welded joint in the complete, non-clamped switch area �

Ensures minimum distortion under moving load through high lateral rigidity �


Head Hardening RTT’s continuous inductive hardening process hardens rails up to 370 BHN and increases rail strength from 900 kg/mm2 to a minimum of 1080 kg/mm2. It also induces high wear resistance to the rails while improving their elongation and toughness.

RTT uses its head hardening process extensively while manufacturing turnouts.

Advantages

Increased rail life �

Low life cycle cost �

Low maintenance cost �

Spring Setting Device (SSD)Increasing the radius in turnouts (to minimise jerks and enhance passenger comfort) requires longer switch lengths. However, rails are not rigid in the longitudinal direction and hence do not provide required clearance even after reasonable opening at toe.

RTT’s SSD solves this problem by ensuring housing of the closed tongue rail while maintaining adequate minimum opening of open tongue rail for wheel passage. During the change of setting, the point machine/alternate drive arrangement moves the tongue rail at toe. This, in turn, closes the spring till half its movement; then, for the other half of the tongue movement, the spring thrusts the housed tongue rail against the stock rail to have complete housing. Meanwhile the open tongue rail on the other side opens up adequately for passage of wheel. This is suitable for moderately long switches.

Advantages

Increases service life of tongue rail �

Ensures no reverse bend in tongue rail �

Works as a second drive for switches �

Eases installation process without affecting traffic �

In case of spring failure, tie bar remains connected to tongue rails ensuring safe traffic movement �

Rahee Track Technologies Private LimitedL E A D E R S I N M O D E R N R A I L W A Y T E C H N O L O G Y 5

Crossings RTT designs and manufactures Heat Treated Welded Crossings, Swing Nose Crossings and Fabricated Crossings. CMS Crossings can also be supplied by RTT.

Heat Treated Welded Crossing (HTW)RTT’s HTW crossing is a monolithic structure, where the Vee is formed from two separate pieces of rails, with a steel plate sandwiched in between. The plate is Electro-slag welded and planed to form a solid nose. The weld metal hardness, at the top of the rail head and in the weld cross section, ranges from 330 to 360 BHN.

The Wing Rails are head hardened through induction hardening method with subsequently controlled cooling, to obtain fine pearlitic grain structure. The Wing Rails and the Vee are bolted together by high tensile bolts, to form a complete HTW crossing. These crossings can withstand axle loads as high as 25 tonnes under varying traffic conditions and can be welded to the adjoining rails.

HTW crossing can be designed and manufactured as per the client’s specific requirements. RTT has designed and manufactured a wide range of such crossings as Acute, Obtuse, Diamond, Curved, Extended Nose Type, and Crossings with clothoidal entry.

Advantages

Cost effective solution �

Longer life cycle �

Easy to weld repair in situ �

Low maintenance cost �

Fit for high axle load and high speed �

Quicker delivery �


Kolkata Works


Hyderabad Works


Rahee Track Technologies Private Limited Regd. Office: NH-6, P.O. Argori, Jangalpur, Howrah 711 302, West Bengal, India


At RTT, modern engineering combined with highest manufacturing quality, guarantees excellent designs for a wide range of railway systems. It also ensures a sustainable reduction of the cost incurred on superstructure maintenance and considerably increases turnout availability.

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RAIL EXPANSION JOINT

Kolkata Works


Hyderabad Works




Rail Expansion JointSteel rails experience longitudinal movement due to varied temperature conditions. To compensate this movement in long welded rails, Expansion Joints are placed at certain distances. These joints have pre-calculated expansion gap to allow longitudinal movement of rails, thus preventing thermal stresses.

RTT’s patented and innovative design of Rail Expansion Joint is widely known as “Improved Switch Expansion Joint” in India. The design has been technically cleared and approved by the Ministry of Indian railways for mass usage on Indian rail track network. The design is successfully being used since years now, on one of the largest railway networks in the world.

The product comprises of a pair of non-bent Rails (Stock Rail and Tongue Rail) mounted on C.I Chairs with a gap (expansion gap) between the two juxtaposed rail ends. A third rail (gap avoiding rail) is securely bolted to the Stock Rail by bolts with high tensile strength to form an extension of the Stock Rail. The system also has check rails to reduce wheel hunting, especially for worn out wheels. They are bolted to the C.I Chairs fixed symmetrically opposite to the expansion gap. The check rails also act as angle ties to keep the sleepers in position. All wheel transfer areas are head hardened to increase service life.

Salient features of Improved SEJ

Excellent riding comfort �

Low life-cycle cost �

No undue stress on the rails �

Capable of being laid on curved tracks �

Head hardened wheel transfer zone leading to longer �service life

Smooth wheel transfer, increasing the life of rolling stock �

Capable of handling gaps up to 200 mm and more, with minor modifications �

Safe due to presence of check rails which guard against excessive play of worn out wheels �

Continuous support for wheel-set on rail; no jump or change in level of wheel-set while negotiating gaps �

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At RTT, modern engineering combined with highest manufacturing quality, guarantees excellent designs for a wide range of railway systems. It also ensures a sustainable reduction of the cost incurred on superstructure maintenance and considerably increases track availability.

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STEEL SLEEPERS

Steel sleepers are used for standard railway tracks and turnouts subjected to medium or heavy axle loads. They are lightweight and dimensionally more accurate than wooden or concrete sleepers. Their multiple advantages, including lower cost compared to wooden sleepers, make them an effective technical solution for modern rail networks.

RTT offers a wide range of steel sleeper designs, including ones for heavier axle loads and higher speeds.

Steel Sleeper with elastic fastening Steel Sleeper with rigid fastening

Production

RTT’s Steel Sleepers are manufactured in accordance to specific technical requirements of customers. The manufacturing process, employing latest CAD / CAM systems to design and optimise production, is optimally structured to reduce wear and lower forces, maintenance and life-cycle costs.

The sleepers are cut to length; the ends pressed in a forging die. Depending upon the type of fastenings specified by the client, holes are punched or base plates / shoulders are welded onto the steel sleeper.

Technical characteristics

Rail fastening for low track load Directly by means of clips and t-bolts

Rail fastening for higher loads Base plate welded to sleeper tops and used with elastic rail clip or hook in shoulders with fast clip/ elastic rail clips

Electric insulation Electric insulation On request by means of bolted plastic pads or insulators with rubber pads

Rahee Track Technologies Private LimitedL E A D E R S I N M O D E R N R A I L W A Y T E C H N O L O G Y

Steel Sleeper with pandrol fastclip fastening system Steel Sleepers stacked at RTT Workshop

The benefits of RTT’s steel sleepers are

Fully recyclable �

Improved stability �

Reduced maintenance �

Uniform and consistent quality �

Can be supplied in small batches �

Time and cost savings at installation �

Simple site preparation and installation �

Minimal “Imprest” stock requirement �

Lightweight design enabling easy handling �

High resistance to lateral displacement in ballast �

Convenient during accident and flood restorations �

Ideal solution for sharp curves and steep gradients �

Equally amenable to both manual and machine tamping �

Environmental benefits due to reduced ballast requirement �

Can be laid on inferior ballast such as sand or gravel albeit with �appropriate speed restrictions

Rahee Track Technologies Private LimitedL E A D E R S I N M O D E R N R A I L W A Y T E C H N O L O G Y

Kolkata Works


Hyderabad Works




Steel Sleeper profiles available with RTT


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GLUED INSULATED JOINTS


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Kolkata Works


Hyderabad Works




Glued Insulated JointsGlued insulated joints in rails separate electric circuits in tracks and turnouts. As they are used in continuously welded rails (CWR), these joints transfer longitudinal forces arising in the track. They can be assembled in situ or at workshop. Designed to withstand tests as per ‘Manual for Glued Insulated Rail Joints (1998) of the Indian Railway’, they also meet International Standard requirements.

Glued insulated joints are used in tracks that meet certain requirements regarding stability, good tamping and sleeper quality. It consists of glass fibre cloth insulated fishplates, a corresponding number of insulated high-tensile bolts and end post made of insulating material. Every fabricated / assembled joint is checked for vertical and lateral alignment. Joints are also subjected to pull-out and insulation resistance tests, in dry as well as wet conditions.

Advantages

Reduced noise �

Greater riding comfort �

Reduced maintenance costs �

Reduced wear in wheel overrunning area �

Technical characteristics

Types of sleepers Wood and concrete

Rail sections All common rail sections

Heat treatment of joints Hardened or preferably made from head hardened rails

Bonding With appropriate bonding and hardening agents

Manufacturing locations In the factory: Ideal conditions regarding cleanliness, temperature and manufacturing procedure because rail ends and surface of steel parts to be bonded must be spotlessly clean

At site: As per client’s instructions

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QUALITY & ENGINEERING - Rahee Brochure.pdf · Regd. Office: NH-6, P.O. Argori, Jangalpur, Howrah...

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