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Complete Mechanization Of Track Maintenance & Relaying In Indian Railways - A Blue Print

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Complete Mechanization Of Track Maintenance & Relaying In Indian Railways - A Blue Print

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Complete Mechanization Of Track Maintenance & Relaying In Indian Railways - A Blue Print

  1. 1. S ynopsis-Indian Railways with approximately 63000 kms track is one of the biggest railways of the world railway system. Track maintenance in the railway has undergone a sea change during the past 30 years due to continuous developments in various track components viz sleepers, fastenings and long welded rails. The track structure has become sturdier and it has become less amenable for manual maintenance. Therefore mechanized maintenance of track has become unavoidable and gradually track maintenance has started to be done in a big way by machines. Being fit for modern heavy track structure and giving quality out put far superior than what one can achieve manually, a blue print for 100% mechanization of track maintenance is being presented here. Similarly at present track relaying is being done manually as well as by machines. But the quality and progress of machines has outplayed what we achieve manually. Therefore a blue print of hundred percent mechanization of track relaying is also being presented. ! !! M aintenance activity involved 1-Through packing/Tamping 2.Slack attention to a-attention to bad spot generally on approaches of bridges , level crossing and at turnouts. b-packing of glued joints ,welded joints. c-attention of switch expansion joints (SEJ). d-minor rectification of alignment. 3-Casual renewal of track components. 4-Systematic overhauling . 5-Ballast profiling. 6-Emergency repairs viz.rectification of rail /weld fractures etc. 7-Destressing of LWR tracks. 8-Transportion,loading and unloading of P.Way material. 9- Ultrasonic testing of rails. 10-Lubrication of elastic rail clips. 11-Patrolling a-hot weather patrolling. b- monsoon patrolling. c- Cold weather patrolling d-Security patrolling e-Keyman daily patrol 12-manning caution and speed restriction boards. 13-Tree cutting for improved visibility. 14-Lubrication of rails and joints 15-Resurfacing of switches and crossings 16-Pre monsoon attention to drains /waterways Page 1 of 15
  2. 2. 17-Pulling back of creep and gap adjustment 18-Attention to level crossings 19-Periodic deep screening 20-Rail welding 21-Rail cutting /drilling and chamfering 22- M inor cess repairs quot; #$ % The track should be maintained either by conventional system of track maintenance or by three – tier system of track maintenance. In both the systems, track requires to be overhauled periodically with the object of restoring it to best possible condition, consistent with its maintainability. Periodicity of overhauling depends on several factors, such as type of track structure, its age, volume of traffic, rate of track deterioration, maximum permissible speed, system of traction, condition of formation etc. Annual programme for regular track maintenance Period Work 1 Post monsoon attention for about six Attention to run down stretches, one round of months through packing 2 Pre monsoon attention for about two Clearing of drains etc months 3 Attention during monsoon for about Attention to track as required four months (A) Conventional s ystem of track maintenance- in this track is maintained manually (B) Three tier system of track maintenance: - (1) 3- tier system of track maintenance shall be adopted on sections nominated for mechanized maintenance. This shall consist of the following 3 tiers of maintenance- (i) On track machines (ii) M obile maintenance units (iii) Sectional gangs (2) Large track machines for track maintenance include tie-tamping machines for plain track and points and crossings, shoulder ballast cleaning machines, ballast-cleaning machines, ballast regulating machines and dynamic track stabilizers. These machines shall be used as per the various instructions issued in Indian Railways Track M achines M anual. These machines shall be deployed to carry out the following jobs. (a) Systematic tamping of plain track as well as points and crossings (b) Intermediate tamping of plain track as well as points and crossings (c) Shoulder ballast cleaning (d) Ballast profiling / redistribution Page 2 of 15
  3. 3. (e) Track stabilization (f) Periodical deep screening (3) Mobile Maintenance Units- (a) The mobile maintenance units (MMU) shall consist of two groups- (i) MMU-I one for each PWI’s section (ii) MMU-II one for each sub division (b) The functions of MMU shall be as below: MMU-I (Rail cum road vehicle based) One with each PWI in charge with a jurisdiction of 40-50 kms double line or 90-100kms single line: (i) Need based spot tamping (ii) In situ rail welding (iii) Casual renewals and repairs except planned renewals (iv) Over hauling of level crossings (v) Replacement of glued joints (vi) Rail cutting /drilling and chamfering (vii) Permanent repairs to factures (viii) Creep or gap adjustments involving machines (ix) Distressing of LWR/CWR (x) Loading/ unloading of materials (xi) Any other functions assigned MMU-II(Road vehicle based) one with each sub division (i) Reconditioning of Turnouts (ii) M inor repairs to the equipments of MMU (c) The MM U shall be equipped with the following equipments. These equipments shall be used according to the working instructions, as and when issued. List of Equipments for MMU-I (A) Communication equipment 1-walkie talkie 4 sets 2-portables field telephones 4 sets (B) Rail cutting / drilling equipment 3- disc cutter 1 4- rail cutting machine 1 5- rail drilling machine 1 6-chamfering kit 1 (C) Rail welding equipment 7. Rail welding equipment 2 sets 8. Weld trimmer 1 set 9. Rail profile grinder for welded joints 1 set (D) Spot tamping with lifting lining 10-Off track hand held tamper with generators 1 set 11-Lifting jack-hyrahlic/mechanical 4 sets 12-Lifting-cum-slewing device 2 sets (E) Destressing Equipment 13-Rail tensors-hydraulic/mechanical 2 sets Page 3 of 15
  4. 4. 14-Rollers,wooden mallets 1complete set for distressing 3 km LWR (F)Inspection gadgets 15-Inspection kit 1 No. 16-Gauge- cum- level 1 No 17-Rail thermometer 1 No 18-Vernier calipers 1 No 19-M icrometer 1 No (G)M aterial handling equipment 20-Rail dolly 6 no. 21-M ono rail wheel borrow 2 no. (H)Safety and protection equipments 22-Warning system 23-Red banner flag 24-Red hand signal flag 25-Green hand signals flag 26-Detonators (I)Gas cutting equipments with accessories 1set List of Equipments for MMU-II : (A)Points and crossing reconditioning equipment 1-Welding generator 1set 2-Arc welding equipment 1set 3-Hand held rail grinder 2sets (B)For minor repairs to equipments 4-Spanner of sizes 2sets 5-Turfer 2 6-Files of sorts 2sets 7-Bench drill 2 8-Vice bench 2 9-Bench grinder 2 (4) Section Gangs : The sectional gangs under 3-tier system of track maintenance performs the following functions: (a) Patrolling of track (i)Keyman daily patrol (ii)Hot/cold weather patrolling (iii)M ansoon patrolling (b) Waching vulnerable locations (c) Attention of emergencies viz. temporary repairs of fractures (d) Need based attention to bridges,turnouts, SEJs and approaches of level crossings (e) Greasing of ERCs,lubrication of joints ,casual changing of rubber pads and other fittings (f) M inor cess repairs (g)Cleaning of drains and boxing of ballast (h)Attention to loops Page 4 of 15
  5. 5. (i)Creep and gap adjustment not not involving use of machines (j)Cleaning of crib ballast for effective cross drainage (k)Pre and post tamping attention (l)Assistance to MMU&OMU as required (m)Any other functions assigned & ! #$ % : Track relaying activities involves following activities: 1.Plain track relaying viz.CTR, TRR and TSR 2.Turnout relaying At present both these activities are performed both manually and by machines. : ' Track machines in Indian Railways can be divided in to two groups (A)Large track machines: following machines come under this category (i) Plain track tamping machines (b) 06-16 universal tamping machine (UT) (c) 08-16 unomatic (d) 08-32 duomatic (e) 09-32 continuous action tamping machine (f) 09-3x tamping express (ii) Points and crossings tamping machines (a) 08-275 Unimat (b) 08-275-3s Unimat (iii) M ulti Purpose Tamper (M PT) (iv) Dynamic Track Stablizer (DTS) (v) Ballast Cleaning M achine (a) RM -80 for plain track (b) RM -76 for points and crossings (vi) Shoulder Ballast Cleaning M achines (a) FRM -80 Plasser make (b) KSC-600 Kershaw M ake (vii) Plassers Quick Relaying System (PQRS) (viii) Track Relying Train (TRT) (ix) Points and Crossings Changing M achine T-28 (x) Sleeper exchanger and crane (xi) M obile Flash Butt Welding Plant K-355 APT (xii) Rail Grinding M achine (Loram) (B) Small Track Machines : list of the m/c which come under this category are as under Page 5 of 15
  6. 6. Sl no Type of machine 1 Abrasive rail cutter 2 Abrasive rail cutting wheel 3 Rail cutting machine (saw type) 4 Rail drilling machine 5 Hydraulic rail tenser 6 Hydraulic rail bender 7 Hydraulic rail joint straightner 8 Rail creep adjuster 9 Hydraulic sleeper spacer 10 Concrete sleeper breaker with angle grinder 11 Concrete sleeper drilling machine 12 Portable DC welding generator 13 Double action weld trimmer for AT welding 14 Rail profile weld grinder 15 Heavy duty hydraulic extractor for jammed ERC 16 Toe load measuring device (mechanical) 17 Electronic Toe load measuring device 18 M echanical track jack 19 Hydraulic track jack 20 Portable track lifting & slewing device (TRALIS) 21 Self propelled light weight trolley 22 Powered material trolley 23 Light weight rail cum road trolley 24 Jib crane attachable to BFR-BRH for handling concrete sleeper 25 Attachment for rail dolly for PRC sleeper 26 Powered rail hauling system 27 Hand held off track tamper 28 Portable ballast cleaner (semi mechanized) 29 Portable shoulder ballast compactor (   (A)Large Track Machines   ¡ ¢ £ ¤ ¥ ¦ § £ ¨ ¦ ¥ © ¥ © ¢ £ ¥ ¥ ¤ ¥ ¤ £ ¥ £ ¦ annexure I: (B)Small Track Machines :Data of small track machines is not available on date. However large numbers are used in the system. Page 6 of 15
  7. 7. ) * + , The total route kilomerters of IR is approx. 63500 ,of which approx.45700 is B.G.,approx.14300 is M .G.and balance is N.G.As per Uni Gauge Policy 1992 rest of M .G.and N.G.routes will be gradually converted into B.G.Due to this reason only complete mechanization in existing B.G.is considered.In this also mechanization is planned in 2 phases : PHASE 1:All A,B and C routes PHASE 2:Remaining routes In mechanization of maintenance existing 3-tier system will be adopted.MMU-I and MMU-II to be adopted in all divisions in IR which is presently used in only two divisions viz. Kota and ALD.The inherent problem in existing RCRV to be rectified by design/adopting superior vehicle.Small track machines to be provided to all sub divisions as per yardstick of IRSTMM.For this creation of posts of requisite skill staff to be done and to be recuited.The details of requirement of large track machines for complete mechanization ii given below: 6.1.PHASE 1 6.1.1.Complete Mechanization Plan For Track Maintenance of Group A, B and C Routes of IR Total Track km of Group A route on IR : 13937 km Total Track km of Group B route on IR : 15751 km Total Track km of Group C route on IR : 1541 km Total Track Km : 31229 km Total Turnout on running line of Group A route on IR : 12670 Nos Total Turnout on running line of Group B route on IR : 13737 Nos Total Turnout on running line of Group C route on IR : 1191 Nos Total Turnout on running lines : 27598 Nos A) Plain Track Tamping • Taking a tamping cycle of 18 months (approximately), tamping requirement every year will be 20819 km. • Taking block availability of about 2.5 hours per day, working of machine for about 24 days in a month and Taking block availability of about 2.5 hours per day, working of machine for about 24 days in a month and progress of about 900 m per gross block hour, each high output tamper would do about 650 km every year. • Total 35 high output tampers alongwith equal number of DTSs are required for this work . Page 7 of 15
  8. 8. B) Turnout Tamping • Taking a tamping cycle of 12 months (approximately), tamping requirement every year will be 27598 Nos. • Taking block availability of about 3 hours per day, working of machine for about 24 days in a month and progress of about 1 turnout per gross block hour, each turnout tamper would do about 850 turnouts every year. • Total 35 high output tampers are required for this work . C) Deep Screening • Taking a Deep Screening cycle of 10 years, screening requirement every year will be 3123 km. • Taking block availability of about 2.5 hours per day, working of Ballast cleaning machine for about 24 days in a month (for 8 months in a year) and progress of about 120 meter per gross block hour, each BCM would do about 60 km every year. • Total 57 BCMs alongwith equal number of BRMs,WSTand DTSs are required for this work . D) Shoulder Screening • Taking a Shoulder Screening cycle of 10 years, screening requirement every year will be 3123 km. • Taking block availability of about 2.5 hours per day, working of Shoulder Ballast cleaning machine for about 24 days in a month (for 8 months in a year) and progress of about 250 meter per gross block hour, each BCM would do about 120 km every year. • Total 29 SBCMs are required for this work. NOTE: In calculating machine requirement 10% extra machines have been taken for taking care their failures during service and for its schedule maintenance From above total requirement of machines for periodic maintenance activities is as under: S.No. Name of Machine Total Req. 1 High output tamper(CSM,O9-3X) 35 2 UNI 35 3 BCM 57 4 SBCM 29 5 DTS 92 6 BRM 57 7 WST 57 Page 8 of 15
  9. 9. 6.1.2. Complete Mechanization Plan For Track Relaying of A,B and C Routes of IR A)Plain Track Relaying: • Assuming that 7.5% of track to relaid every year .Total laying potential for a year comes 2342 km. . • Total number of TRT and PQRS available on IR are 8 and 40 sets respectively.Taking progress of TRT and PQRS as 12km per month and 5 km per month per set respectively.Total relaying to done by these machines in a year is 3197 km. Therefore no additional machine required. • In addition to these machines equal numbers of WSTs ,DTSs and BRMs are required for tamping and ballast profiling. B)Turnout Relaying • Assuming that 7.5% of turnouts to relaid every year .Total laying potential for a year comes 2070.. • Taking progress of relaying a T-28 as 12 turnouts in month.Total number of T- 28 required are 16 nos.. NOTE: In calculating machine requirement 10% extra machines have been taken for taking care their failures during service and for its schedule maintenance From above total requirement of machines for relaying as under: S.No. Name of Machine Total Req. 1 TRT 8 2 PQRS 40 sets 3 T-28 16 4 DTS 48 5 BRM 48 6 WST 48 In above table it is assumed that Unimats used in maintenance will be utilized in tamping of turnouts laid by T-28. Therefore total nos. of large track machines required for complete mechanization of maintenance and relaying is as under: S.No. Name of machine Total Available in Balance to be req. IR provided 1 High output tamper(09- 35 63 - 3X,CSM) 2 WST 105 71 34 3 UNI 35 63 - 4 BCM 57 65 - 5 SBCM 29 29 - 6 TRT 8 8 - Page 9 of 15
  10. 10. 7 PQRS 40 set 40 set - 8 T-28 16 25 - 9 BRM 105 39 66 10 DTS 140 65 75 In above analysis it is assumed that when BCMs is not working for 4 months , its follow machines can be utilized by open line for attention after track recording and ballast profiling.These machines can also be given to construction organization for that period. 6.1.3.Additional Staff requirement: This is given below: Staff for field operation: S.No. Name of machine Astt. Charg Highl Skille Khala Total Forem eman y d si/Kh an cum skille fitter alasi cum operat d helper senior or operat or 1 WST 34 34 68 34 102 272 2 BRM 66 66 66 66 198 462 3 DTS 75 75 75 75 150 450 Staff for field supervision, technical and general services: S.No. Category Nos. 1 Assistant engineer 41 2 Foreman 41 3 Highly skilled fitter 81 4 Sr.clerk-cum-material chaser 41 5 Semi-skilled 122 Total 326 Staff for repair and maintenance: S.NO. Category Nos. 1 Assistant engineer (track machines) 20 2 Shop superintendent (track 20 machines) Page 10 of 15
  11. 11. 3 Asst. Shop superintendent (track 20 machines) 4 Asst. foreman (track machines) 41 5 Charge man (track machines) 20 6 Track machine maintainer (HSK- 243 I/HSK-II/skilled) 7 Head clerk 20 8 Senior clerk 20 9 Draftsman 20 10 Clerk-cum- typist 41 11 DSK 20 12 Store man/material chaser 61 13 Track machine khalasi (unskilled) 284 Total 830 6.2.PHASE 2 6.2.1.Complete Mechanization Plan For Track Maintenance of Remaining B.G.Routes of IR Total Track Km : 32304 km Total Turnout on running lines : 28548 Nos A) Plain Track Tamping • Taking a tamping cycle of 18 months (approximately), tamping requirement every year will be 21536 km. • Taking block availability of about 2.5 hours per day, working of machine for about 24 days in a month and progress of about 900 m per gross block hour, each high output tamper would do about 650 km every year. • Total 36 high output tampers alongwith equal number of DTSs are required for this work . B) Turnout Tamping • Taking a tamping cycle of 12 months (approximately), tamping requirement every year will be 28548 Nos. • Taking block availability of about 3 hours per day, working of machine for about 24 days in a month and progress of about 1 turnout per gross block hour, each turnout tamper would do about 850 turnouts every year. • Total 37 high output tampers are required for this work. C) Deep Screening • Taking a Deep Screening cycle of 10 years, screening requirement every year will be 3230 km. • Taking block availability of about 2.5 hours per day, working of Ballast cleaning machine for about 24 days in a month (for 8 months in a year) and Page 11 of 15
  12. 12. progress of about 120 meter per gross block hour, each BCM would do about 60 km every year. • Total 57 BCMs alongwith equal number of WSTs, DTSs and BRMs are required for this work. D) Shoulder Screening • Taking a Shoulder Screening cycle of 10 years, screening requirement every year will be 3230 km. • Taking block availability of about 2.5 hours per day, working of Shoulder Ballast cleaning machine for about 24 days in a month (for 8 months in a year) and progress of about 250 meter per gross block hour, each BCM would do about 120 km every year. • Total 29 SBCMs are required for this work. NOTE: In calculating machine requirement 10% extra machines have been taken for taking care their failures during service and for its schedule maintenance From above total requirement of machines for periodic maintenance activities is as under: S.No. Name of Machine Total Req. 1 High output tamper(CSM,O9-3X) 36 2 UNI 37 3 BCM 57 4 SBCM 29 5 DTS 93 6 BRM 57 7 WST 57 6.2.2Complete Mechanization Plan For Track Relaying of Remaining B.G.Routes of IR Total Track Km : 32304 km Total Turnout on running lines : 28548 Nos A)Plain Track Relaying: • Assuming that 7.5% of track to relaid every year .Total laying potential for a year comes 2423 km. . • Taking progress of PQRS set as 5km per month .Total relaying to done by this machine in a year is 60km. Therefore 44 number of PQRS sets needed . • In addition to these machines equal numbers of WSTs ,DTSs and BRMs are required for tamping and ballast profiling. B)Turnout Relaying • . Assuming that 7.5% of turnouts to relaid every year .Total laying potential for a year comes 2141. Page 12 of 15
  13. 13. • Taking progress of relaying a T-28 as 12 turnouts in month.Total number of T- 28 required are 17 nos.. NOTE: In calculating machine requirement 10% extra machines have been taken for taking care their failures during service and for its schedule maintenance From above total requirement of machines for relaying as under: S.No. Name of Machine Total Req. 1 PQRS 44 sets 2 T-28 17 3 DTS 44 4 BRM 44 5 WST 44 In above table it is assumed that Unimats used in maintenance will be utilized in tamping of turnouts laid by T-28. Therefore total nos. of large track machines required for complete mechanization of maintenance and relaying is as under: S.No. Name of machine Total Available in IR after A,BC Balance to be req. routes complete provided mechanisation 1 High output 36 28 8 tamper(09- 3X,CSM) 2 WST 101 - 101 3 UNI 37 28 9 4 BCM 57 8 49 5 SBCM 29 - 29 6 PQRS 44 set 14 set 30set 7 T-28 17 9 8 8 BRM 101 - 101 9 DTS 137 - 137 In above analysis it is assumed that when BCMs is not working for 4 months , its follow machines can be utilized by open line for attention after track recording and ballast profiling.These machines can also be given to construction organization for that period. 6.2.3. Additional Staff requirement: This is given below: Page 13 of 15
  14. 14. Staff for field operation: S.No. Name of machine Astt. Charg Highl Skille Khala Total Forem eman y d si/Kh an cum skille fitter alasi cum operat d helper senior or operat or 1 CSM,09-3X 8 8 16 8 24 64 2 WST 101 101 202 101 303 808 3 UNI 9 9 9 9 18 54 4 BCM 49 98 98 49 196 490 5 SBCM 29 58 58 29 116 290 6 PQRS sets - 60 - 60 60 180 7 T-28 16 8 16 8 24 72 8 BRM 101 101 101 101 303 707 9 DTS 137 137 137 137 274 822 Staff for field supervision, technical and general services: S.No. Category Nos. 1 Assistant engineer 123 2 Foreman 123 3 Highly skilled fitter 245 4 Sr.clerk-cum-material chaser 123 5 Semi-skilled 368 Total 982 Staff for repair and maintenance: S.NO. Category Nos. 1 Assistant engineer (track machines) 61 2 Shop superintendent (track 61 machines) 3 Asst. Shop superintendent (track 61 machines) 4 Asst. foreman (track machines) 123 5 Charge man (track machines) 61 Page 14 of 15
  15. 15. 6 Track machine maintainer (HSK- 736 I/HSK-II/skilled) 7 Head clerk 61 8 Senior clerk 61 9 Draftsman 61 10 Clerk-cum- typist 123 11 DSK 61 12 Store man/material chaser 184 13 Track machine khalasi (unskilled) 859 Total 2513 - • At present there are sufficient number of machines available on IR to switch over to complete mechanisation of track maintenance and relaying on Group A, B and C routes. But for better quality shortfall of WSTs, BRMs and DTSs to be made good. • For remaining B.G. routes complete mechanization will take some time .The track machines are sanctioned through various RSP and it has been planned to achieve full mechanisation by 2012 as per IRMP (2005-2010). Therefore it is expected that by 2012 these will also completely mechanised. • There is already shortage of staff for existing track machines in some zonal rlys and due to additional staff required for new track machines this problem only aggravate. Therefore planning of creation of posts and their recruitment need to hasten. • Zonal railways have tendency to carry out works, specially screening, relaying of turnouts etc manually at the cost of quality of the output. We may have to impress upon the zonal railways to work sincerely and honestly towards achieving complete mechanisation of track maintenance. Page 15 of 15

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