INDIAN RAILWAYS TRACK MACHINE MANUAL SCHEDULE OF MAINTENANCE

INDIAN RAILWAYS TRACK MACHINE MANUAL, SCHEDULE OF MAINTENANCE, INFRASTRUCTURE FACILITIES ETC 1

TRACK MACHINE MANUAL First issued in 1998 by Rly Board. Updated in MARCH 2000. Correction Total slips issued – 17 9 chapters. 2

TRACK MACHINE MANUAL Chapter 1 - Organization and Duties of Officers and Staff. Chapter 2 - Features & Working Principles. Chapter 3 - Works required before, during & after deployment of track machines. Chapter 4 - Rules for movements and working of track machines. Chapter 5 - Planning, Operation & Monitoring of track machines 3

TRACK MACHINE MANUAL Chapter 6 - Periodical repair and maintenance of machines. Chapter 7 - Duties of divisional officers & staff in-charge P-Way. Chapter 8 - Staff requirement and other infrastructural facilities. Chapter 9 - Stores. List Of Abbreviations. 4

TRACK MACHINE ORGANISATION AND DUTIES OF OFFICERS & STAFF (CHAPTER 1 & 7) 5

TRACK MACHINE ORGANIZATION Under the overall charge of CE/TM or CTE(M/Cs) who will report to PCE through CTE. Organization is responsible for: - Field operation of track machines, - Repair and maintenance of machines, - Supervision and technical services including training, - Planning and deployment of machines. 6

TRACK MACHINE ORGANISATION (CONTD. ) CTE(M/C) Dy. CEs AEN OR CE/TM, / SENs - Normally 1 for field & 1 at HQ. (TM) - Normally one for each division, SSE/TM - One for each Division. SSE(Sr. Operator)/SE(Operator)- For each Machine 7

TRACK MACHINE ORGANISATION (CONTD. ) Each machine is manned by SSE Operator)/SE(Operator), Technicians/Mechanics semi-skilled/unskilled staff. Scale (Sr. and of staff as per para 8. 2 of chapter 8. Each Railway shall have a Zonal Base Depot and / or Satellite Depots headed by AEN/SEN for carrying out heavy repairs and intermediate overhauling. 8

DUTIES OF AEN/TM Inspection & maintenance of machines in effective working condition, Ensure adherence to stipulated schedules of maintenance, Ensure availability of staff, Ensure achievement of targets in respect of Quantity & Quality of output, Availability of consumables & fast wearing components, 9

DUTIES OF AEN TM…CONTD… Execution Of Works 1. To ensure that operation and maintenance works are carried out in stipulated manner and the best maintenance practices are followed, 2. The important/major repairs will be personally supervised by him, 3. Break down repairs should be organized and completed in the shortest possible time. 10

DUTIES OF SSE ( TM) He is responsible for: Satisfactory operation, maintenance & productivity of machines and quality of work. He should inspect the machines as per schedules laid down and submit the reports. He should be capable to operate machine when needed, shall be in possession of competency certificate & medical certificate, 19

DUTIES OF SSE ( TM) He will plan and ensure timely execution of maintenance schedules of the machines within specified time. He will investigate major failure of machine critically for corrective actions/remedial measures and for fixing responsibilities in case of failures occurring due to lapses of staff. He will obtain the first information reports during breakdowns, inspect the machines and take action for expeditious repairs. 20

DUTIES OF MACHINE OPERATORS He should be in possession of Competency Certificate for working of machine. He will ensure: Operation & Maintenance of machine. Pre-block maintenance to make machine fit for working. Initial setting for the block working and closing of work including ramping in and ramping out. Proper functioning of all systems, components & keeping watch on controls/indicators/gauges. 27

DUTIES OF MACHINE OPERATORS Precautions for special design mode operations such as curve slewing etc. Posting of fitters/khalasis at respective places around the machine for monitoring the work of various systems, carrying out during block maintenance(Greasing, oiling, tightening of bolts etc) & to attract attention of main cabin operator and assist him in case of malfunctioning of machine or due to track obstructions. Safe working of machine & staff. 28

DUTIES OF TRACK MACHINE FITTERS/MECHANICS To guide and supervise semi skilled/unskilled staff in maintenance/repairs. To remain vigilant during movement & working of machine and to inform the operator about any abnormalities. To ensure safety of machine & men from approaching train on adjacent lines. To carry out any other works assigned by the machine incharge. 33

DUTIES OF AEN/OPEN LINE IN REGARD TO TRACK MACHINE OPERATION (PARA 7. 1 OF IRTMM) Accommodation for Machine staff wherever camping coaches are not provided. Also provide facility of water supply, power supply & resting arrangement. He will arrange transportation of consumables, spares etc. as required, from machine depot to the site of work. 34

DUTIES OF AEN/OPEN LINE IN REGARD TO TRACK MACHINE OPERATION (PARA 7. 2 OF IRTMM) Periodical inspection of Track machines working once in a month/fortnight (Para 5. 3. 3 IRTMM- Modified vide ACS-14) covering Adequacy of allied track works, Quality of machine work, Safety aspects involved, Items pertaining to welfare of staff, Records such as program of tamping, actual tamping, variations, repeated tamping and speed restriction etc. 35

DUTIES OF AEN/OPEN LINE IN REGARD TO TRACK MACHINE OPERATION (PARA 7. 1 OF IRTMM) He will arrange for adequate lighting arrangements, in case of night working. He will monitor the output and quality of work done by machines. Coordination with other departments like Traffic, OHE and S&T in the field to facilitate machine working. 36

DUTY LIST OF SSE/SE/JE (P. WAY) IN REGARD TO TRACK MACHINE WORKING (PARA 7. 1 OF IRTMM) SSE/SE P. Way incharge of the section is responsible for pre-block operations, block operations(Other than machine operations) and post block operations. After closing of work by machine, checking of track condition, attention to track, if required for safety, ensuring track parameters are within safety tolerances and there are no infringements/obstructions, imposition of caution order, if required as per track condition. (By SSE/SE/JE P. Way who works with the machine). 37

DUTY LIST OF SSE/SE/JE (P. WAY) IN REGARD TO TRACK. MACHINE WORKING (PARA 7. 1 OF IRTMM) Issue of revised caution orders and modification and extent of speed restrictions including providing/shifting of engineering indicators to suit progress of work at the end of each day will be the responsibility of SSE/SE/JE (P-Way) working with machine. Transportation of tamping tools for reconditioning and bringing them back to site after reconditioning. Temporary storage and timely transportation of diesel oil, lub. oil, hydraulic oil and consumables from depot to machines 38 working in his jurisdiction.

DUTY LIST OF SSE/SE/JE (P. WAY) IN REGARD TO TRACK. MACHINE WORKING (PARA 7. 1 OF IRTMM) Survey of track geometry for working in design mode and making available the suitable data. He will ensure quality of work done by the machine and investigate with the help of machine operator, if the quality of work is not satisfactory. Protection of the work site and adjoining track wherever necessary. He will be responsible for arranging adequate precautionary measures for safety of staff working with the machine in the block section against danger of trains on the adjoining track. 39

DUTY LIST OF SSE/SE/JE (P. WAY) IN REGARD TO TRACK. MACHINE WORKING To ensure that machines are stabled at suitable sidings and at such stations to minimize idle run of machines and wastage of block hours in the entering and clearing of the block section. Calling necessary assistance of light engine, break down special as necessary, for clearing of block section in case of machine failure in block section. To arrange protection and watching of stabled machine To coordinate with other department like traffic, OHE and S&T to 40 facilitate working.

DUTIES OF SR. DEN/DEN (PARA 7. 1 OF IRTMM) 1. Responsible for sending annual requirement plan for track machines to HQ. (By 30 th September) 2. To initiate all preliminary works on receipt of draft Deployment Plan from HQ. (By 31 st January) 3. To ensure timely completion of all preparatory works for operation of machines as per Approved Deployment Plan. (By 31 st March) 4. To ensure that the prerequisites for introduction of various track 41 machines are complied with well in advance.

DUTIES OF SR. DEN/DEN (PARA 7. 1 OF IRTMM) 5. Wherever the frequency of tamping is more than the prescribed tamping cycle, necessary action should be taken by him to improve the track structure and eliminate the causes leading to frequent tamping. 6. To arrange for adequate external lighting when night working is involved. 7. To make arrangements for pre-block, during block and post block working, duly fixing agencies whenever required. 8. To ensure that detailed MOUs for day to day working are issued jointly with Sr. DOM based on MOUs issued by HQ. 42

DUTIES OF SR. DEN/DEN (PARA 7. 1 OF IRTMM) 9. To plan necessary works for providing cross overs and sidings for berthing of machines wherever necessary. 10. To ensure adequate arrangements for lighting, water supply and approach road etc. at such sidings. 11. To ensure that machines are utilized in continuous stretches as per planned programme avoiding frequent shifting of machines. 12. During inspection of the machine working at site, he will see the safety aspects of staff against danger of incoming trains on adjacent line/lines. 43

Periodical Repairs And Maintenance Of Machines (CHAPTER 6) 44

TYPES OF MAINTENANCE SCHEDULES (PARA 6. 2 OLD) 45

CS NO. 17 MAINTENANCE SCHEDULE OF TRACK MACHINES Machines Schedule Periodicity Duration Group-I Schedule – I. Daily One hour Track Laying Equipment Schedule –II 50 Engine hrs. Two hrs. (TLE), BRM, RBMV & UTV Schedule –III 100 Engine hrs. One day Schedule –IV 200 Engine hrs. Schedule –V 1000 Engine hrs. Schedule –VI (IOH) Schedule-VII (POH) 2000 Engine hrs. 6000 Engine hrs. Location In the Track Machine Siding -do-do- Two days -do- 7 days In Satellite Depot/Zonal Workshop In Zonal Workshop 15 days 1 st POH-45 In Zonal days, 2 nd POH- Workshop/CPOH 60 days Workshop Group

PERIODICAL REPAIRS AND MAINTENANCE O F M A C H I N E S …CONTD… Types of workshops: § § § Central Periodical Overhauling Workshop, (CPOH) Intermediate Overhauling Workshop (IOH)/Zonal Base Depot, Satellite Depot (Zonal), Mobile Workshop, Camp Coach Workshop. 47

P ERIODICAL R EPAIRS A ND M AINTENANCE O F M ACHINES …CONTD… Central Periodic Overhauling Workshop (CPOH) § At present, 2 CPOH Workshops at Allahabad and Vijaywada catering to POH of tamping machines. § POH of other machines carried out by Zonal railways, as prescribed by the OEMs. § List of facilities for a CPOH Workshop 48

PERIODICAL REPAIR & MAINTENANCE OF MACHINES …CONTD… Intermediate Overhauling Workshop/ Zonal Base Depot Normally, one IOH Workshop with each zonal railway, § Normally, two IOHs will be done before each POH, § For POH/IOH at lesser interval, approval of CTE(M/c) § § List of facilities for an IOH Workshop. 49

PERIODICAL REPAIR & MAINTENANCE OF MACHINES …CONTD… Satellite Depot: § To meet the spares and maintenance needs of 10 -12 machines, § Facilities: Stores for essential and consumable spares, § Housing track machines, § Carrying out repairs/assembly, replacements, § Offices for supervisors/officer-in-charge. § 50

PERIODICAL REPAIR & MAINTENANCE OF MACHINES …CONTD… Mobile Workshop-cum-Transport Van: § Each Zonal Railway should have adequate number of Mobile Workshops (Road Vehicles), § Attend each track machine periodically to cover schedules II to V & breakdown repairs, § Sufficient inventory & well trained staff, § Facilities: 51

PERIODICAL REPAIR & MAINTENANCE OF MACHINES …CONTD… Camp Coach Workshop: §Will be attached with each machine, §Contains provisions of small workshop, §Shall be manufactured and re-furnished as per RDSO’s drawing, §Functions are to carry out Schedules I, II & occasionally III, §List of equipments: 52

STAFF REQUIREMENT AND OTHER INFRASTRUCTURAL FACILITIES (CHAPTER 8) 53

STAFF REQUIREMENT Requirement of staff for machine working: § Staff for field operation § Staff for field supervision, technical & general services § Staff for repair and maintenance, excluding POH TABLE 54

S. No. Type of Machines Weightage Factor 1. Tampers, Rail Grinding Machines (each module of 16 stones). Dynamic Track Stabilizer, Mobile Flash Butt Welding Plant, Points & Crossing Laying Machine 1. 0 2. Ballast Regulator 0. 8 55

OTHER INFRASTRUCTURAL FACILITIES § Transport and Storage facilities for hydraulic oil, lubricants and fuel. § Transport for spare parts. § Communication facilities. § Repair and stabling lines for machines. § Resting facilities for staff. § Cash imprest. 56

OTHER INFRASTRUCTURAL FACILITIES (CONTD. ) Repair & stabling facilities: - In addition to sidings at SSE(P-Way)’s HQ, sidings of adequate length to stable machines and camp coaches shall be provided at stations 30 kms apart. - These Sidings shall have facility of electricity and water supply. Resting facilities for staff: Rest houses should be attached with each SSE(P-Way)’s office. § One camp coach will be provided with each machine. § List of equipment and facilities as per standard plans issued 58 by RDSO. §

OTHER INFRASTRUCTURAL FACILITIES (CONTD. ) Cash imprest § Suitable cash imprest with AEN/TMC for purchase of minor items of urgent and critical nature and to carry out urgent repairs from nearby local market. This imprest should also meet needs of communication such as STD. FAX etc. Rest Roster Work for 3 weeks followed by one week rest at HQ. § Maximum 12 hours duty on any day § 59

Thank 61