Railquip, inc. Rerailing System

Overview
The Railquip, inc. Rerailing Systems are currently used on many transit systems and railroads in more than 70 countries. The System is designed with a double-acting re-pressure system that enables you to completely and accurately control all operations to the nearest mm. All hydraulic components are protected against accidental lowering, overload, and misoperation. Each component operates smoothly and accurately even under full load.

System components can be purchased that allow you to rerail all types of railroad vehicles from the lightest transit vehicle to the heaviest locomotive.

Core Equipment

Control Unit
The Control Unit is the central point from which all operations of the rerailing process can be controlled. It allows the connection of four hydraulic components. You can connect more components by using distributor valves (order no. 09-2200). The Control Unit is contained in a portable frame with carrying handles and is supported by four rugged legs.

Hydraulic Power Units
The Hydraulic Power Unit can be equipped with a variety of power sources including a four-stroke gasoline engine, a diesel engine, or an electric motor. The units can also be purchased in regular size or small size. The electric motor models can also be equipped with an integrated Control Stand. The units range in weight from 121 pounds to 291 pounds. The hydraulic flow ranges from 0.60 gallons per minute to 3.0 gallons per minute.

You can also purchase a Hand Pump Power Unit. This is an complete and independent unit for small rerailing jobs. These units are especially useful where you cannot use a combustion engine, e.g. due to explosion hazard.

Finally, you can purchase an Add-On Power Unit that attaches to a work vehicle's hydraulic system. These units are typically plumbed into the hirail gear power source.

Hydraulic Lifting Jacks
The Lifting Jacks are the workhorses of the rerailing operations. As you can see in the following table, a large variety of sizes are available.

All Lifting Jacks are constructed of high-strength light-metal alloy and operate with pressure of 300 bar or approximately 4410 psi. All jacks are equipped with pressure protection that prevents accidental lowering of the load, e.g. severed hose. The jacks are designed to operate smoothly and safely under full load conditions.

Flat-type, or "pancake" Lifting Jacks are available to deal with extremely low lifting points. Most Lifting Jacks, including the "pancake" jacks can be equipped with piston support pieces and cylinder support rings to increase the effective jacking height.

Finally, in addition to the standard line of Lifting Jacks, a large selection of specialty jacks is available.

Displacing Jacks
When combined with Counter Supports and Roller Carriages you can laterally push or pull a lifted load with the Displacing Jacks on top of the Rerailing Bridge. The Displacing Jack has a pushing capacity of 13 US tons and a pulling capacity of 6.7 US tons.

Roller Carriage
The Roller Carriage is used to support and laterally move the lifted load on top of the Rerailing Bridge. Roller Carriages can be purchased in a variety of heights and in pivoting and non-pivoting versions.

Rerailing Bridges
The Rerailing Bridges allow you to use your lateral displacing equipment to push or pull your train back onto the track. The Bridges are constructed of an extruded high-strength light-metal alloy. The surface is protected by a special anti-corrosion compound. The Bridges are equipped with four extendable carrying handles. Bored holes are on the top side of each Bridge to allow the anchoring of your lateral displacement equipment.

You can purchase the Rerailing Bridges in two heights, 3.7 inches (95 mm) or 7 inches (180 mm). Over an unsupported span of 4.9 feet (1.5 m) the 3.7 inch high Bridge can support 11 US tons and the 7 inch high Bridge can support 67 US tons. A fully supported 7 inch high Bridge can support 134 US tons and a fully supported 3.7 inch high Bridge can support 67 US tons.

All Bridges can be coupled together using a Bridge Coupler to extend the working length.

Optional Equipment
You can purchase many pieces of optional equipment that can help you solve rerailing problems. Three of the most important include,

• Uprighting Equipment - This equipment set consists of a cable ladder, rocker bearing supports, and special head pieces that can help you upright a car that has turned over.
• Haulage Device - The haulage device is basically a hydraulic winch that is anchored to the track enabling you to pull track vehicles.
• Auxiliary Trucks - These units can be placed underneath inoperable car trucks enabling you to transport the disabled vehicle over the rail without causing further damage to the track or the vehicle.
• Air Bag System - The Air Bag System is very useful in difficult rerailing situations such as tunnels where vertical and lateral jacking clearances are limited. The System operates with standard compressed air and is equipped with a hydraulic air compressor that connects directly to the main rerailing Power Unit. The System can also be equipped with portable compressed air cylinders.
• Rescue Devices - These hydraulic cutters and spreaders are used to rescue trapped personnel and to clear other derailment debris. The devices are powered by the rerailing Power Unit through a specially designed pressure intensifier.

Operational Success Factors

Safety
Safety must be your first priority at any derailment site. Definition of a total safety plan is beyond the scope of this guide, but some important safety items to consider include:

• Red Tag Lockout - You must ensure that all of the electrical power is deenergized and the appropriate breakers locked in the open position.
• Personal Protective Equipment - You must ensure that all people accessing the work site have and are using any required personal protective equipment such as safety vests, hard hats, eye protection, hearing protection, gloves, safety shoes, etc.
• Site Security - You must ensure that unnecessary people are not in the work site to protect them from injury and to minimize confusion. You can use crime scene tape to mark the work area.
• Shifting Equipment - Derailed equipment is inherently unstable and is prone to unanticipated shifting.
• Utilities - You should locate all utilities relevant to the site including overhead wires and underground systems.
• Explosion Hazards - If you are working in an underground structure be sure to follow your company's explosion prevention procedures that may prohibit the use of combustion engines.
• Lighting - When you are working at night make sure you have adequate lighting. Proper lighting will improve the work quality and production and provide a safer work environment.
• Jacking Support - Ensure that all of your jacks are adequately supported before beginning lifting operations. It is recommended that you have an adequate supply of hardwood in the appropriate thicknesses and lengths. Rough oak lumber and hardwood railroad crossties are good choices. You will also need a supply of hardwood wedges. Position your jacks and supports very carefully, especially in areas where the track is superelevated.

Leadership
It is critical that one, and only one person be in charge of the rerailing operation.

Interdepartmental Cooperation
Cooperation between all departments is a critical success factor, especially between the track, power, signal, vehicle, and operating departments. If they are available on your property, other departments such as Public Relations and Police can provide invaluable assistance.

Training
The rerailing team must be thoroughly trained and drilled - prior to any derailment. Your local fire department can serve as an excellent training and drilling model. It is recommended that the rerailing team conduct periodic drills and that the team be provided with communications devices to ensure that they can be contacted when needed. It is also recommended that the vehicle, track, and bridge departments be represented on the team.

Maintenance
You must maintain your rerailing equipment to ensure success. It is recommended that you establish a scheduled preventive maintenance program to address these requirements.

Ancillary Tools
You will need certain additional hand tools to be successful. It is recommended that you examine your rail vehicle and have the tools necessary to disconnect components such as trucks, couplers, and communications antennas.

Rerailing Equipment Storage
It is recommended that you store your equipment in modular units so that the equipment can be deployed rapidly. Some systems have invested in dedicated carrier vehicles while others have opted for palletized storage units that can be quickly loaded onto the Rerailing Hirail Trailer or other work vehicles.

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