Singapore LTA Circle Line VIPA-DFC Assembly

& Standard FASTCLIP

Operation & Maintenance

SG C830 Manual 02-09-23

CONTENTS 1. DESIGN CRITERIA 2. GENERAL DESCRIPTION 3. LIFE OF FASTCLIP COMPONENTS 4. ASSEMBLY OF THE BASEPLATE 5. HAND TOOLS FOR FASTCLIP ASSEMBLY 10330 & STANDARD FASTCLIP 6. NOMENCLATURE 7. LIMITED ACCESS E.G DERAILMENT GUIDE, WAVE GUIDE, THIRD RAIL 8. HOW TO USE INSTALLER LP (TBA) VIPA-DFC PLAIN LINE & PLAIN LINE IRJ 9. HOW TO USE INSTALLER LP 15708 STANDARD FASTCLIP TURNOUT & TURNOUT IRJ 10. HOW TO USE EXTRACTOR LP (TBA) (Brown) & LP 15151 (Cream) 11. HOW TO USE EXTRACTOR LP 15728 AT PLAIN LINE IRJ and TURNOUT IRJ 12. RAIL HEIGHT ADJUSTMENT 13. ASSEMBLY DRAWING 10330 14. COMPONENT DRAWINGS 8226, 10315 & 10543 15. INSPECTION FREQUENCIES & PREVENTATIVE MAINTENANCE 16. CARE OF THE 10 MM STUDDED RUBBER PAD 17. REPAIRING BROKEN SHOULDERS

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1. DESIGN CRITERIA
The Design Criteria of the Singapore LTA for Contract 803 (Circle Line) include at section 5.2.1 Track Forms the requirements: To enable defective rails to be replaced with new rails, provision shall be made for up to 10 mm of vertical adjustment of the rail height and The method of adjustment shall be so designed that the as-built track has the rail foot at the minimum in the first instance. The method of adjusting the height is described later in this manual. This height adjustment is achieved by inserting shims under the baseplate and changing the toe spacer shims to compensate for the change in clip deflection, due to the changing of the position of the baseplate. For the combination of spacers and shims to achieve the different amounts of height adjustment, refer to the tabulations on Assembly drawing 10330.

2. GENERAL DESCRIPTION
The Pandrol Brand FASTCLIP VIPA assembly, in accordance with Pandrol copyright drawing no. 10330, is based on a standard FASTCLIP assembly, with a baseplate. In accordance with the Design Criteria of Singapore Land Transport Authority (LTA), this has been modified to enable the rail height to be adjusted upwards by 10 mm under the baseplate.

3. LIFE OF FASTCLIP COMPONENTS

For straight track, Clips, Toe Insulators, Toe Spacers, Side-post Insulators and Pads are estimated to last 1000 MGT or 20 years, Shoulders are estimated to last 2500 MGT or 50 years On high speed curved track, Clips, Toe Insulators, Toe Spacers, Side-post Insulators and Pads are estimated to last 500 MGT or 10 years, Shoulders are estimated to last 2500 MGT or 50 years As an overall rule it is expected that Clips, Toe Insulators, Toe Spacers, Side-post Insulators and Pads will last longer than the life of the rail and Shoulders longer than the life of the sleeper.

4. ASSEMBLY OF THE BASEPLATE

FASTCLIP clips are delivered with their toe insulators (pt. no, 8494) factory fitted. All the other components are placed as shown on Assembly drawing 10330. The methods for installing and extracting the FASTCLIP clips, using hand tools, is shown later in this manual.

To avoid possible damage to the toe spacer shim, pt. no. 8226, during initial track panel fabrication is permissible that the toe spacer shims be omitted from the assembly until all track construction is completed. Clips should be inserted alternately from gauge and field sides, in order to maintain the rail In a relatively central position within the rail seat, thus preventing the rail from sliding to one side and pushing the Toe Spacer up into the path of the opposing clip. A small amount of distortion of the Toe Spacer is acceptable, but a gap of 4 mm or over between the side post insulator and the side of the shim indicate the shim is over-distorted and must be changed.

5. HAND TOOLS FOR FASTCLIP ASSEMBLY 10330 & STANDARD FASTCLIP

The method for using the standard hand tools is illustrated on the following pages. All the tools are designed to operate adjacent to the wave-guide and conductor rail. Part numbers and colour coding of tools are given in the table, below.

SECTION PT. NO 8 10 LP (TBA) LP (TBA)

COLOUR Green Brown

DESCRIPTION Double FASTCLIP-VIPA - INSTALLER Double FASTCLIP-VIPA - EXTRACTOR Standard FASTCLIP INSTALLER Standard FASTCLIP EXTRACTOR Double FASTCLIP-VIPA & Standard FASTCLIP EXTRACTOR

TRACKS IN MAINLINE & DEPOT PLAIN LINE TURNOUT PLAINLINE TURNOUT IRJ IRJ Yes Yes No No Yes No No No

9 10

LP 15708 LP 15151

Blue Cream

No No

Yes Yes

No No

Yes No

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LP 15728

Orange

No

No

Yes

Yes

6. NOMENCLATURE

The Three Captive Stages of FASTCLIP.

Pre-assembled, parked position. All components are captive and the rail is threaded into place.

Installed position. The FASTCLIP is providing a selftensioning elastic clamping force.

Insulator Change Position. The FASTCLIP is withdrawn to the rear detent. The clip and toe insulator remain captive, the side post insulator can be removed.

7. LIMITED ACCESS E.G DERAILMENT GUIDE, WAVE GUIDE, THIRD RAIL All hand tools are designed to work on limited access applications. 8. HOW TO USE INSTALLER LP (TBA) VIPA-DFC PLAIN LINE & PLAIN LINE IRJ
1. Driving the clip forward from the Extracted or Insulator Change position. 1.1 Locate the jaws over the front of the shoulder. 1.2 If necessary to clear a Huck bolt the tool must first be inserted under the bolt, as shown. Note 1 During initial track panel fabrication, it is possible that toe spacer shim, pt. no. 8226, can be deformed or damaged if it is not completely seated on the rail, or baseplate, or if there is a gap between rail and baseplate, or baseplate and sleeper. It is therefore permissible that the toe spacer shims be omitted from the assembly until all track construction is completed. Note 2 On installation a gap of up to 4-mm is permitted between the side post insulator and toe spacer

1.3

Drive the clip to the Parked position.

2.

Driving the clip from the Parked position

2.1 2.2

Set the pin in the hole shown Insert one side under the Huck bolt, if necessary.

2.3

Ensure the jaws are correctly located over the front of the shoulder.

2.4

Pull on the handle until refusal.

The fully driven position permits the outer limbs of the clip to touch the rear of the post insulator, or to be up to 3 mm back.

If necessary to clear the Huck bolt at an IRJ, lean the tool, as shown Remove the hand tool

9. HOW TO USE INSTALLER LP 15708 STANDARD FASTCLIP TURNOUT & TURNOUT IRJ
1. Locate the jaws over the front of the shoulder. At insulated rail joints, it may be necessary to insert the tool under the head of the Huck bolt, as shown.

2.

Drive the clip to the Parked position.

3. 3.1

Driving the clip from the Parked position Re-position the pin, as shown and engage the tool, if necessary, under the Huck bolt

3.2

Pull on the handle until refusal

3.3

Remove the hand tool, if necessary leaning the tool to clear the IRJ Huck bolt.

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10. HOW TO USE EXTRACTOR LP (TBA) (BROWN) & LP 15151 (CREAM)

(A) Locate the tool on the shoulder with the handle held back as shown. The nose of the tool is forward of the toe insulator.

Ensure the tool is located correctly in the shoulder.

(B) Push forward on the handle until the clip reaches the backstop (parked position).

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(C) Continue to push forward on the handle. The back stop lifts and the clip is withdrawn, first to the Side Post Insulator Change Position,

push further and the clip can be completely removed.

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11. HOW TO USE EXTRACTOR LP 15728 AT PLAIN LINE IRJ AND TURNOUT IRJ
NOTE. This tool is not recommended for use on plain line, because there is a possibility of the insulator being removed from the clip. 1 Locate the tool so that the hooks engage in the rear arch of the clip

Engage the frame over the shoulder

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Pull the clip out

Release the hooks by means of the foot-operated arm.

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12. RAIL HEIGHT ADJUSTMENT

This is achieved by inserting shims under the baseplate and replacing the toe spacer shims to compensate for the change in clip deflection, due to the change of the position of the baseplate. METHOD 1. Extract the lower, baseplate clips to the Insulator Change Position along the length of rail, which is to be replaced. Insulator change position

Baseplate clip

2. 3. 4. 5.

Release the studded rubber baseplate pads, as advised in the section Care of the 10 mm Studded Rubber Rail Pad. Select the combination of spacers and shims as shown on Assembly Drawing 10330, to achieve the height adjustment required to align the new with the existing railheads. The different thicknesses of spacers and shims are identified as shown on the drawings 8226 and 10543. Re-assemble using tool LP (TBA).

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13. ASSEMBLY DRAWING 10330 14. COMPONENT DRAWINGS 8226, 10315 & 10543

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15. INSPECTION FREQUENCIES & PREVENTATIVE MAINTENANCE

It is recommended that a visual track inspection is carried out every 3 months, or as part of the Users, or Maintenance Contractors, planned inspection and maintenance of rails, joints, switches, crossings, track alignment, track support, sleepers, bearers, rail fastenings, line-side security, level crossings, line-side structures etc. Under extreme or severe conditions, which are not directly related to the track fastenings, i.e. incorrect track maintenance equipment usage, certain unsatisfactory damage can occur. By undertaking a regular, routine visual assessment a good indication as to the service performance or incidental damage can be assessed. The visual assessment should cover all the rail fastening components, the visual inspection areas marked with a * will require a closer inspection of the rail fastening components and it is suggested that a small sample of these components be inspected once every 12 months. The replacement of isolated damaged, corroded or missing components is not urgent and can be delayed until a convenient time for track maintenance. What to look for when visually inspecting rail fastenings components Action to be taken

Cast Shoulder
Damaged shoulder head If rail is still laterally and vertically restrained, monitor during next visual assessment, if not treat as if the shoulder head was missing. Consider drilling out the shoulder stem and gluing in a new shoulder if the adjacent concrete is not damaged

Shoulder head missing

Cast Baseplate
Damaged clip housing If rail is still laterally and vertically restrained, monitor during next visual assessment, if not replace the baseplate.

PANDROL FASTCLIP clip

Worn clip Clip not fully installed Missing clip Broken clip Monitor # Pull clip fully into position Replace clip Replace clip

Toe Insulator & Spacer

Worn insulator/spacer * Broken insulator/spacer Missing insulator/spacer Distorted to spacer Monitor # Replace insulator/spacer Replace insulator/spacer Monitor and replace if a gap of 4-mm or over appears between the toe spacer and side post insulator

Side-post Insulator
Worn insulator * Broken insulator Missing insulator Monitor and replace if wear exceeds 3 mm or track gauge is affected Replace insulator Replace insulator

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What to look for when visually inspecting rail fastenings components

Action to be taken

PANDROL e - clip
Worn clip Clip not fully installed Missing clip Broken clip Monitor # Pull clip fully into position Replace clip Replace clip

e clip Nylon Insulator

Worn insulator * Broken insulator Missing insulator Monitor # Replace insulator Replace insulator

Studded Rubber Pad

Extruded pad * Worn pad * Missing pad Consider replacing or repositioning the pad if 75% or less of the rail foot area is resting on the pad. Monitor # Replace pad

Hard (e.g. HDPE) Pad, Shim or Spacer

Worn pad * Broken pad Missing pad Monitor # Replace pad Replace pad

# = Consider replacing if toe insulator, toe spacer and pad together with the reduction in clip toe height exceeds 6 mm. All safety critical defects are detectable by visual inspection. Singapore LTAs rail clips are coloured yellow to enable monitoring by use of on-board video equipment.

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16. CARE OF THE 10 MM STUDDED RUBBER PAD

PANDROL 10 mm studded natural rubber pads are designed to provide vibration attenuation and to protect sleepers, ballast and formation from shock loads, which would otherwise cause rapid deterioration of sleepers, ballast and track geometry. They are tough, but have to be used sensibly. Under certain environmental conditions the rubber pad type may adhere to the underside of the rail foot as the rail is lifted. A simple spatula type tool can be used to locally free the pad.

Pad distortion resulting from pulling the rail through the rail seat.

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17. REPAIRING BROKEN SHOULDERS

In the unlikely event of the FASTCLIP shoulder being damaged, possibly by being struck accidentally by heavy vehicle tracking machinery on or off the rails, a procedure has been developed to repair sleepers in track. The technique utilises core drilling equipment and epoxy grout to replace shoulder housings. The technique requires training and is detailed in a separate method statement.

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