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Maintenance of P.Way

Maintenance of P.Way. N.R.Kale AXEN/1. Responsibility of Engineering officials (Para 201). Devote careful and continuous attention towards the efficient upkeep of track. To achieve good and smooth running quality. Running quality should be adjudged by riding on - Locomotive

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Maintenance of P.Way

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  1. Maintenance of P.Way N.R.Kale AXEN/1

  2. Responsibility of Engineering officials (Para 201) • Devote careful and continuous attention towards the efficient upkeep of track. • To achieve good and smooth running quality. • Running quality should be adjudged by riding on - • Locomotive • Rear vehicle of fast trains. • Condition of track is best judged by- • Track recording cars • oscillograph cars • Portable accelerometer etc. • Maintain record of inspection. • Ensure compliance of inspections.

  3. Classification of Lines (B.G.)(As per CS No.109 Dated 15.02.08)

  4. Systems of Track maintenance-Para 203 • Conventional system of track maintenance • 3-tier system of track maintenance • Periodical overhauling ( 3 to 5 years) • After monsoon attention to run down length as early. Then start - • Overhauling/trough packing • Picking up of slacks - 2-3 days in a week

  5. 3-tier system of track maintenance • On track machines (OMU) • Systematic tamping of plain track/P&Cs • Intermediate tamping • Shoulder ballast cleaning • Ballast profiling/redistribution • Track stabilisation • Periodical deep screening • Mobile maintenance units (MMU) • MMU-I • MMU-II • Sectional gangs

  6. Mobile Maintenance Units (MMU) • MMU-I (For 90 to 100 km track) • Rail cum road vehicle based • Need base spot taming • In-situ welding • Casual renewal • O.H. of LCs • Replacement of GJs • Attending Rail failures • Creep or gap adjustment • Destressing of LWR/CWR • Loading unloading of materials • Any other work as assigned

  7. Mobile Maintenance Units (MMU) • MMU – II • Road vehicle based • One for each sub division • Reconditioning of P & Cs • Minor repairs to the equipments of MMU

  8. Mobile Maintenance Units (MMU) • Sectional Gangs • Patrolling of track –Daily, Hot/cold, Monsoon • Watching vulnerable locations • Attention of emergencies • Need-based attention to bridges, T/outs, SEJs, approaches of LCs • Greasing of ERCs, Lubrication of joints, casual changing of rubber pads/other fittingss • Minor cess repairs

  9. Mobile Maintenance Units (MMU)Sectional gang (Contd. …) • Cleaning of drains and boxing of ballast • Attention to loop lines • Creep and gap adjustment not involving machines • Cleaning of crib ballast for effective cross drainage • Pre & Post tamping attention • Assistance to OMU/MMU as required • Any other function as assigned

  10. Annual Programme for regular Track Maintenance ( Para 204)

  11. Record of Gang work (Para 206) • Gang diary • Gang chart • Scrutiny of records by ADEN/DEN during their inspection • Preserve records for 5 years by SSE/P.Way (C.S. No. 114) • Inspection of gang equipments to be recorded in gang chart/ gang diary by SSE

  12. Contd. … • Attention to Inspection notes • Record of work of Artisans and other workmen employed • Half Yearly reports on the condition of Permanent Way to be submitted by SSE to DEN through ADEN as per Annexure 2/19 (C.S.No 99)

  13. Section Register (Para 210) • Administration • Change in SSE/SE/PWS/Clerks • Change in Jurisdiction • Permanent Way • Formation – Section giving frequent trouble and remedial measures adopted if any • Track Structure • Track with SWR/LWR incidence of buckling

  14. Section Register (contd. …) • Grades – Details of regrading • Curves – Details of realignment • Ballast – Location having deficiency, details of deep screening • Creep adjustment • P.Way Renewals • Station yard and sidings – Extension or alteration done if any • Rail failures

  15. Section Register (contd. …) • Rail testing and renewals – Record of USFD testing and removal of defective rail/welds • Fish plate failures • Lubrication of rail Joints • Material under trial • Track recording • Bridges and floods • Record of rain fall • Damage due to floods • List of RAW • List of vulnerable locations where stationary watchman to be posted.

  16. Section Register (contd. …) • Miscellaneous • Availability of labour on section • Details of Encroachment and steps taken to remove them • Infringement particulars • Accidents attributed to P.Way. • List of reference books available in the section • Any other information necessary

  17. Para 211-Permanent plan and diagram ADEN shall have a set of following – • IRS track manual or IRS type plans pertaining to track section and turnouts of their section. • Plan and longitudinal section of the line. • Drawing of bridges, LC, protective work and yard layout of their section. • Permanent diagram of their section.

  18. Records of Material under trial (Para 212) • Register – To be maintained by ADEN • Particulars of entries • Trial lengths – If possible, near ADEN’s H.Q. • Indication plates • Submission of register to DEN • SSE’s Records – To be scrutinized by ADEN during inspection

  19. Other para of chapter no.2 • Para 213 – Strength of gang. • Para 214 – Musters • Para 215 – Custody of gang tools • Para 216 – Section limit boards • Para 217 – Km and gradient posts • Para 218 – Telegraph pole Numbers • Para 219 – Verification of land boundaries

  20. Para 220 - Provision of Trolley refuse as per CS No 116 of IRPWM

  21. Para 222 – Felling of trees obstructing views. • Para 223 – Side drains, catch water drains and water ways.

  22. MANUAL MAINTENANCE OF TRACK

  23. Through Packing (Conventional maintenance by beater packing) • This is the main activity of track maintenance under manual track maintenance. • Trough packing is done on a programme basis after the monsoon from one end of the section to the other. • Generally started from 1st October of every year.

  24. Sequence of activity • Through packing consists of the following works being done systematically in the following sequence • Opening of road • Examination of rail, sleepers and fastenings • Squaring of sleepers • Alignment of track

  25. Contd. … V) Gauging vi) Packing of sleepers vii) Repacking of joint sleepers viii) Boxing ballast section and tidyng

  26. Opening of road Under this operation, ballast is opened out on either side of the rail seat for a depth of 50 mm below the bottom of sleeper with the help of shovel or Powrahs. The width of opening should be up to end of sleeper on out side and on the inside it should be 450 mm for B.G, 350 mm for M.G and 250 mm for N.G.

  27. Examination of rails, sleepers and fastenings • Rails should be examined, the underside for corrosion, the ends for cracks, the head for side wear. • Sleepers should be inspected for their condition and soundness particularly at the rail seat. Defective if any to be replaced. • All Fastenings are checked and tightened, missing fittings are recouped. • Kinks if any, in the rails are removed by jim-crowing

  28. Squaring of sleepers • Gauge variations and kinks inevitably results from sleepers getting out of square. • The spacing of sleepers on the sighting rail should first be checked and correctly chalk marked the transferred to opposite rail using the square at every point. • Squaring should be done by planting the crow bars firmly against the sleepers and pushing it.

  29. Aligning the track • The alignment of the track is normally checked by “eye judgment”, sighting the rail from a distance of about 50 meters • Slewing is done by about 6 persons by planting the crow bar deep in the ballast at an angle not exceeding 30 degree from the vertical.

  30. Gauging –Tolerances for BG/MG, NG (With respect to 1676mm)

  31. Packing of sleepers • The base rail is sighted by mate with eye along the lower edge of the head of rail and the dip or low joints are lifted correctly to ensure a perfect longitudinal level of the sighting rail • The adjacent sleeper to be packed. • Attend opposite rail after checking with cross level at every 4th sleeper and every joint. • No joint or dip should be lifted higher than the proper level.

  32. Contd. … • The sleepers are than packed by beaters • 4 men/sleeper • First break cores with the pick end then use blunt end for packing. • First pack the rail seat then towards end and inside the track. • The Beaters should not be lifted above the chest level.

  33. Contd. … • Ensure that no sleeper is centre bound in case of wooden/Steel sleepers. • In case of CST-9 plates main packing should be done at corners. • On pot sleepers tamp by crow bars through holes on top of the pot. • Mate will check the packing by tapping with wooden mallet before boxing.

  34. Repacking of Joint sleepers The joint and shoulder sleepers are once again repacked before boxing of ballast and the cross levels checked.

  35. Boxing to ballast section and tidyng • Ballast section is than properly boxed and dressed with the help of a special template • The cess should be dressed up and level maintained • Too high cess affect drainage and too low cess result in ballast spread and wastage.

  36. Systematic Overhauling • Normally commenced after completion of one cycle of through packing • Consists of following operation • Shallow screening and making up of ballast section • All items included in through packing • Making up the cess

  37. Shallow Screening • Open out the ballast 50 to 75 mm blow the bottom of sleeper. • For machine maintained track 75 to 100 mm. • Shoulder ballast to be removed to the full depth. • Screen the ballast and put back in to track.

  38. Precautions for O.H. • Ensure that extra quantity of ballast is available at site. • The core under the sleepers must not be disturbed. • Between two sleeper cribs, where work in progress, there should be at least two cribs where ballast is not disturbed.

  39. Contd. … • Overhauling work should be taken up only in alternate rail length to preserve the track geometry. • In LWR overhauling should be done only in winter when rail temp not exceed td +10 • In breathing length td +/- 5 degree C. • Cess when high, should be cut along with overhauling.

  40. Deep Screening of Ballast Purpose for deep screening • To improve drainage of track • To improve elasticity of the track • To maintain track geometry • To improve running of the track

  41. Contd. … When Deep Screening is required? • Prior to CTR • Prior to TSR • When the caking of ballast has resulted in unsatisfactory riding. • Before conversion of fish plated track in to LWR • Entire track once in ten year

  42. Contd. … • In case of bad formation , treatment should be carried out along with deep screening. Prior Survey • Longitudinal section of the track to be taken indicating the RL at every 30 meters. • In station yard, on the through lines, cross section at every 50 meters indicating platform level, rail level, clearance of OHE

  43. Contd. … On the basis of longitudinal and cross sections, the final levels will be decided keeping in view - • The depth of ballast cushion to be provided. • The relative implications of lifting or lowering • The possibility of eliminating humps, sags and unevenness in the existing longitudinal section.

  44. Preliminary works for D/Screening • Arrangement of additional ballast at site. • Cess to be brought up to correct level in relation to the final Rail level. • Pegs should be provided at 30 meter distance, indicating final Rail level. • Realignment of curve in advance. • Sleeper renewal if required, in advance.

  45. Procedure for D/Screening • Remove ballast from space ‘A’ and ‘B’, Support the rail with wooden blocks. • Remove ballast from under sleeper ‘1’ • Screen the ballast and place back under sleeper ‘1’and pack. • Remove wooden blocks from space ‘A’ • Remove the ballast from space ‘C’, screen and place at ‘A’

  46. Procedure for D/Screening A ! 2 C 3 D 4 B E GL

  47. Contd. … • Support the rail with wooden blocks at ‘C’ • Remove ballast from under sleeper ‘2’,screen, put back and pack. • Remove the ballast from space ‘D’, screen and place at space ‘B’ • Remove the ballast from under sleeper ‘3’, screen. put back and pack the sleeper. • Lift the track to final level

  48. Contd. … • Work to be done opposite to direction of traffic in D/line section. • No unscreened length should be left between screened length. • When ballast is removed from any sleeper, ensure that at least four fully supported sleepers are there between next sleeper tackled.

  49. Contd. … • Lifting should be limited to 50 mm at a time. • Before closing the day work, ensure proper packing, cross levels and grade run off. • Work should be done under SR 20 kmph. • Speed should be increased gradually as per schedule given in IRPWM. • Work must be done in the presence of certified PWS (competency certificate should be issued by CTE)

  50. Proposed schedule for relaxing speed restriction (Manual Packing)

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