Master Copy for IRTMTCALD by IRICEN TRACK RELAYING

Master Copy for IRTMTC/ALD by IRICEN

TRACK RELAYING TRAIN (TRT)

Track Relaying Train • TRT is a system for complete mechanization of track renewal process. • Indian Railway is using TRT model no. P 811 -S manufactured by M/s Harsco Track Technologies, USA. • In 1990 -91 two track relaying trains were imported from Tampers, USA. • More mechanized than earlier machines.

Main Features • No auxiliary track is required for track renewal, • No need to fabricate track panels, • New Concrete sleepers are loaded in modified BRHs and taken to site, • Sleepers are laid in track one by one, • New rail panels, unloaded at site on sleeper shoulders and duly paired or fish plated are exchanged with old rails along with sleepers renewal, • No power block is required, • Track renewal of platform lines is possible.

Function of TRT does following operations one by one in same block: 1. Threads out old rails, 2. Removes old sleepers, 3. Levels and compacts ballast bed, 4. Places new sleepers, 5. Threads in new rails.

Track relaying train can perform three operations: 1. Complete track renewal, 2. Replacement of sleepers only, 3. Replacement of rails.

Technical Data Total length of TRT 58. 209 m in three parts. Total weight 144 tones Width of ballast bed prepared 2. 79 m Level of ballast bed Upto 441 mm below existing rail level. Reproduction of existing track geometry. Geometry of re-laid track Engine 350 HP Output 0. 4 KM per effective hrs

Technical Data Length-67. 05 mtrs Width(on bogies)-3. 15 mtrs Height(measured from top of rail)-4 mtrs Weight-170 Tons Distance between bogies axles-13. 8 m/17. 53 m Brakes- Compressed Air shoe brakes, hand brake with wheel control. Drive Train-500 H. P. diesel driving a variable-flow hydraulic pump for hydrostatic advance of the machine during work. Two variable flow pumps supplying the old tie pick-up system and rail guide system

Contd. Traction during operation- 4 powered bogies Minimum Curve- 12 degree(144 mtrs) in working and 18 degree (97. 5 mtrs) in running. Working speed- 600 mtrs/hour Travelling speed(Towed)- 80 kmph Ballast Regulation : over a width of 2. 79 mtrs Guide rail correction- +- 75 mm Plough height adjustment- 152. 4 mm Plow traverse inclination -38 mm

Contd. • • • Maximum length of ties handled -2. 75 m Operator stations-04 Fuel capacity -1666 litre Hydraulic oil capacity- 1741 litre GANTRIESLength-8. 58 m Width-3. 10 m Height-3. 10 m Gauge of Auxiliary rails-3. 05 m Speed – up to 32 kmph Fuel capacity-379 ltrs Capacity-18 -22 ties.

1. Driving Pumps = 4 nos. (32. 84 GPM+ 6. 19 GPM) For driving the four bogies. 2 Pump for vibration of Dynamic Plow Unit = 1 no. (14. 73 GPM) 3. Low Pressure System Pump = 1 no. (54. 00 GPM) For operation of conveyors NT-1, NT-2, NT-3, OT-1 and OT-2. 4. High Pressure System Pump = 1 no. (40. 94 GPM) For movement of self guided rollers for thread in and thread out. 5. Oil Cooing System Pump = 1 no. (30 GPM) For operation of 2 nos. hydraulic oil cooling motors. 6. Pump for OT pick system = 1 no. (40. 90 GPM) For Tusk Movement, clamping of Finger and assisting of Finger Movement.

Pumps & Motors PUMP P 1 P 2 P 3 P 4 P 8 P 7 P 10 P 9 P 11 MOTOR Power Car Front traction motor (2. 44 inches cube per revolution) Power Car Rear Traction Motor (2. 44 inches cube per revolution) Power Car High Speed Traction Motor (1. 93 inches cube per revolution) Handling Car Traction Motor (2. 44 inches cube per revolution) Beam Car Traction Motor (2. 44 inches cube per revolution) Low Pressure Circuit Pump. NT-1 Conveyor Motor OT-2 Conveyor Motor NT-2 Conveyor Motor (3. 6 inches cube per rev. ) NT-3 Conveyor Motor (3. 6 inches cube per rev. ) Compactor Motor (0. 71 inches cube per rev. ) Dynamic Pump Dynamic Plow Motor (18. 54 inches cube per revolution) Oil Cooler Circuit Pump 2 Nos. oil cooler motor (3. 02 inches cube per revolution) High Pressure Circuit Pump. Side Plow Sleeper end cylinder Plow tilt Up/Down cylinder Horizontal Slide external/retract cylinder Old Tie Pick up Circuit Pump. OT-1 conveyor platform in/out cylinder Old sleeper pick up Tie clamping fingers Tie entry assist fingers

Main Units Of TRT and their functions 1. Beam Car (22. 34 m)Ø It is hinged with handling car and has one common bogie and one independent bogie. Ø Below this car, all the working units like old sleeper pick up, dynamic plow, sleeper flipper, indexing wheel, new tie conveyor, self guiding roller for guiding in and guiding out rails, are provided. Ø Sleeper spacing can be changed by changing index wheel. Ø Sled is hung from this car when not in use.

Main Units Of TRT and their functions 2. Handling Car (21. 05 m)Ø This car has one independent bogie and one common bogie with beam car. Ø All the conveyors are provided in this car. 3. Power car (14. 81 m) – Ø Ø This is 4 axle vehicle. TRT power unit is provided on half the length of this car and remaining half is used for loading of sleepers.

WORKING DIRECTION TRACK RELAYING TRAIN

Replacement of rail Machine working direction Threading out operation Threading in operation Machine working direction

NEW SLEEPER OLD SLEEPER PICK UP WHEEL

SPACERS

Sequence of operations of TRT 1. The TRT is stopped at site of work in a position that side plough is on first sleeper of cut rail. 2. Lowering of shoulder / side plough, 3. Remove 7. 0 meter long rails closures, 4. Lower sled from beam car on to the rail seats of rail closures removed, 5. Bring idle bogie of handling car on to the sled and lock (by bringing back the machine), Slew out old rails and move TRT ahead so that sled clears rail closure portion, Remove the old sleepers manually from the closure area and level the ballast portion, 6. 7.

Sequence of operation of TRT Contd. . 8) Old sleeper pick up wheel and dynamic plough are lowered in place cleared by removal of old sleepers, 9) Rail ends of proceeding day’s work shall be connected to the new rails laid on the sleeper shoulder, 10) Start removing old sleepers by pick up wheel, 11) Set cam wheel on to the rail and commence laying of new concrete sleepers by advancing the machine on automatic mode, 12. As TRT moves ahead, old rails are threaded out and new rails are threaded in with the help of 5 of guiding rollers provided all along the length of TRT.

Ancillary works • Rail Sleeper fastenings of old track are removed manually, • Clip applicator follows TRT for fixing ER Clips, • Utility vehicle consisting of self propelled BFRs with JIB crane lifts released cut rails in 13 m length from cess.

Other machines/equipment required: • Lip cutter to cut reverse jaws of CST-9 sleepers, • Locomotive to haul TRT and modified BFRs, • Modified BRHs containing new sleepers and fastenings, • Track Relaying Train and Gantries, • Clip applicator.

Other follow up machines: • Ballast Regulator, • TTM, • DGS, • Rail Pick up unit with 3 modified BRHs, Road Crane and slinging arrangement.

Pre Block Operations- Base Depot 1. Ensure proper selection of base depot site. 2. It should be centrally located (30 -40 kms lead). 3. It should have water, electricity and communication set up. 4. Accommodation for machine and P-Way staff should be available. 5. Sufficient stock of new sleepers, ERCs/fastenings, liners and rail pads should be available. 6. Ensure proper line and level of AT for 3400/3700 mm gauge for portal working.

Pre Block Operations- Base Depot 7. 30 BFRs should be modified for 1 set of TRT. 8. 160 sleepers are loaded in one BFR and about 15002000 sleepers should be loaded as required during block. 9. Wooden battens of 75 x 75 mm should be used between different layers of sleepers on outside of inserts to enable gripper to function properly. 10. Adequate quantity of ERCs, liners should be loaded in modified BFR attached in rear of TRT. 11. Rail pads should be loaded in racks specially provided in machine.

Pre Block Operations- Base Depot 12. Unloading and stacking of new sleepers, 13. Unloading, stacking and dispatch of old sleepers, 14. Daily maintenance of machines, 15. P-Way store, store for machine spare parts and consumables, 16. Yard layout should be adequate for base depot to carry out above mentioned activities.

Advance Track Preparations 1. All corroded and broken ST/CST-9 sleepers should be marked (Replaced). 2. Foot by foot survey should be done to identify locations of lateral and longitudinal infringements. 3. There should not be any infringements within 1 m from the sleeper ends. 4. Ensure adequate availability of ballast before relaying for timely raising of speed after tamping. 5. Deep screening should be carried out in advance wherever feasible. 6. Excess ballast should be removed and ballast of shoulders and cribs should be brought down to the level of sleeper bottom.

Advance Track Preparations 7. Ballast bed should be fully consolidated. 8. 9. Check rails of level crossings should be removed. Level crossing should be opened up to 1 m on both ends of sleepers to allow movement of dynamic plow of TRT, All longer fish bolts and joggled fish plates should be removed. 10. New rails should be unloaded, paired, fish plated or welded in one piece and set at about 1. 50 m from track centre. Rails should be placed on foot with adequate support so as avoid shifting during working of TRT. 11. All obstructions like creep posts, alignment posts etc within 1 m of sleeper end should be removed.

Advance Track Preparations 12. All reverse jaws of CST-9 sleepers should be removed else lip be cut in advance. 13. All long wooden sleepers at joints should be removed or cut to size. 14. Interlaced sleepers of height different from remaining sleepers should be removed. 15. Jammed fittings should be loosened for easy removal. 16. Gauging of CST-9 sleepers should be done to avoid hitting of sled assembly during lifting.

Advance Track Preparations 17. 7 wooden sleepers should be laid at a location 5 sleepers behind rail cut and ballast around them removed for easy placement of plow. 18. The location of cut at new site of work should be so planned that it matches with the new rail end for threading at the start of work. 19. At the location of start, 2 rail pieces of 7. 30 m are cut and connected with well greased bolts. 20. Plan the location of cut in old track at the closing of worksite with some extra gap so that it matches with the rail end of new rail panel.

Advance Track Preparations 21. Walkie talkie sets for communication should be available with LP, SE/SSE(P-Way), machine staff and adjoining stations. 22. Ensure availability of S&T staff to connect any wire/rodding etc and OHE staff for opening of temporary bonds and bonding back. 23. Ensure removal of OHE bonds before block. Temporary bonding of OHE masts should be done by OHE staff while removing these bonds. 24. Ensure earth bonding of new panels. There should be minimum 3 bonds in each panel length of 300 meters.

Advance Track Preparations 25. Ensure removal of alternate keys of CST-9 and inside alternate keys of ST sleepers. Remaining keys should be checked for easy removal. 26. PSC sleepers of 2 rail lengths should be replaced with wooden sleepers to avoid loss of time. 27. High temperature de-stressing should be carried out as per provisions of LWR Manual, 1996.

Post Block Operations 1. Ballasting should be done immediately after relaying. 2. Thereafter, BRM, TTM and DTS should be deployed for raising of speed expeditiously to normal. 3. In situ welding of joints should be done before raising the speed to normal. 4. SEJs should be provided as per approved plan. 5. Check rails should be restored after final tamping. 6. De-stressing of LWR should be done immediately after welding rail panels into LWR.

Sequence of machines working at site RAIL PICK UP TAMPER + DGS BALLST REGULATOR ERC APPLICATOR Direction of work TRT RAKE LIP CUTTER

Ballast Cleaning: • If BCM is deployed in advance, ballast bed should be fully consolidated. • It will be desirable to deep screen the ballast by BCM either much in advance or much in rear due to following reasons: 1) Out put of BCM may not match with TRT, 2) Requirement of speed restriction length will be much more.

Traffic block requirement: • Out of 4 Hours of total block granted, about 110 minutes of block period is consumed for following activities: 1) 20 mins 2) Time taken by machines to reach site of work. Setting up of TRT in working- 3) Winding up operations- 40 mins 4) Clearing block section- 20 mins 30 mins Total: 110 Mins

Contd. . • Therefore, it is necessary to work TRT in a minimum block of 4 hrs duration so that machine could be used optimally. • The rated output of machine is about 350 m per effective hour of working and therefore in a total block of 5 hrs about 1 km track renewal will be done.

Requirement of block for other related activities: • Unloading of ballast and rails in 1 to 2 block sections ahead, • Working of other machines such as BRM, TTM, DTS etc. just behind relaying, • Welding, provision of SEJ etc.

Picking of Old Rails: • TRT can thread out old rails up to 3 m away from centre of track, • Released old rails are cut into single rail lengths by gas, • Single rails are then picked up by rails pick up system consisting of 3 modified BFRs hauled by utility vehicle on which road crane is mounted. • Road crane travels from utility vehicle to BFRs and loads single rails in BFRs one by one,

Staff Requirement for TRT and Allied Machines: • Following machine staff is required for working of TRT- Total staff on TRT 6 Operators, 8 Fitters, 14 Khalasis.

Contd. . • Permanent Way Staff: • P-Way Supervisors and Gangmen are required for following operations- Ø For removing eight sleepers manually at the start of work, supporting rails on rollers, restoration of track at the close of work etc. Ø Removing sleeper fastenings for working of TRT etc. Ø Fixing of liners and ERCs in concrete sleepers, dropping of fittings from BFR. Ø Correcting spacing and squaring of sleepers, if any, etc.

Contd. . Ø Placing rubber pads on rail seats of sleepers, Ø Connecting rails with fishplates, Ø Gas cutting of rails. • Number of P-Way staff required for above operations will depend on the system of working on individual Railway System.

Precautions Ø Ballast bed of newly deep screened track should be fully consolidated so that there is no fear of settlement of ballast bed during TRT working. Ø Excess ballast should not be unloaded in advance as this causes excessive drag on the machine traction. Ø All the keys should not be opened in advance. They can be opened up only as the machine rake approaches the site.

Precautions Ø One should not stand close to the machine or modified BFRs. Ø No one should stand on BFR while the gantry is moving over with new/old sleepers. Ø Gantry should not be allowed to stand with its wheels on different BFRs. Ø No one should be allowed to sit on the rail seat , without work, meant for liner/rubber placement. Ø No one should climb on the top of TRT without OHE block in electrified section.

Precautions Ø Hand should not be kept on rails for Gantries on modified BFRs, Ø Speed of gantry to be regulated and one empty wagon must be kept for safety against over shooting, Ø Bridge between two BFRs must be inspected daily for any cracks etc. , Ø While travelling with locomotive, gantry should rest on the sleepers to give resistance, Ø Various assemblies should be chained and locked e. g. Sled, Dynamic Plough, Rollers etc.

Precautions Ø Contd. . When gantry is moving, the jaws should be fully lifted up, Ø While parking, both the wheels of gantry must be on the same wagon, Ø All broken sleepers should be removed in advance. Ø Ensure proper protection of track, post lookout men with hooter in good working order to give warning of approaching train on the other line. Ø Utmost caution should be taken during raising and lowering of clamps to avoid infringements to adjacent lines.

Precautions Contd. . Ø Longer or eccentrically placed sleepers which may get stuck up in the machine, should to be removed in advance, Ø Sled cannot jump a gap of two sleepers, Ø Sled has to be fastened properly during entry and rolling out of wheels other wise there are chances of derailment.

Check list for Critical items of TRT Machine • • • Has the oil level in the hydraulic tank checked and topped up? Has the lube oil level in the engine checked and topped up ? Whether the gauges are in working order ? Is the emergency back up system in working order and has it been checked as per laid down frequency i. e. in 100 hrs schedule. Have all parts which are connected to the machine been secured against tilting and shifting ? Has oil level in diesel tank checked and topped up ? After filling HSD oil tank, has it been ensured that engine is not started before 2 hours of filling ? Are the oil pressure&temperature safety circuits of engine in working order ? Has it been ensured that adequate distance of 120 mtrs maintained by the following machine from TRT rake in block section while running ? Has the L-Xing been opened in the width of 3 mtrs in advance for deploying of TRT to avoid time loss ? Whether speed certificate of 40 kmph has given to Supervisor P. Way incharge by Track Machine Inch. ?

Check list for Critical items of TRT Machine • • • Whether the sleeper loaded on BFR properly on 75 x 75 mm cross section wooden battens and not eccentric before movement of rake. Whether it has been ensured that rails have been fixed on the BFRs for loading of Ist layer of sleepers and BFRs are free from ballast ? Are all the safety items available with machine as per para no. 4. 4. 3 of IRTMM and its correction slip no. 15. Have you ensure for proper physical locking before departure from site. ? Has it been ensured that the proper lighting arrangement is there in night working. ? Has it been ensured that proper working of air brake of machine is working properly for stopping the rake/machine in case of emergency. ? Has it been ensured that all 4 dowels and 2 locks of each rail bridge between BFRs are not broken and has been fixed. ? Has the gas cutting equipment been readily available and loaded by SE/P. Way with the machine. ? Has been ensured that 7 wooden sleepers for opening and closing of TRT worksite been made the part of TRT. Has OHE Block been taken besides traffic block. ? Whether OHE block taken before permitting any person on top of the machine. ?

Check List for machine operator towards safe operation of machine • • Personal: Is valid Track Machine competency certificate available-SR 4. 65/3(a) Is valid Medical Fitness certificate available-SR 4. 65/ (b) (iii) Is valid route learning certificate of the section available-SR 3. 78 (6) & JPO issued on 27. 06. 2012 Is the machine staff self declared that liquor/intoxication not taken by him prior to report ON Duty-SR 2. 09 (1&2) Yard: Is track machine stabled(normally)on a non-running line-SR 4. 65/7(ii) Is the shunting order T-806 issued from SM/ASM to bring the machine in running line from the siding/stabling line. SR 4. 65/5(i), SR 5. 13/2 (i) Is shunting staff with proper shunting order available during shunting of machine-SR 5. 13(1)

• Is T-465 (Machine following permit) issued for movement of more than 1 machine & max. 3 machines for light path from one station to another station-SR 4. 65/1(x) • Is T-409 issued to work all machine (max. 5 track machine. SR 4. 65/1(vii) • Is facing point locked by clamp for movement of machine. SR 5. 14/1(a) • Is hand brake applied in machine to prevent rolling in siding. SR 4. 65/7(iv) • Is brake feel test conducted before proceeding from siding. SR 4. 31/1(a)(ii)

Block Section Working: • Is JE/SE of P. Way available on machine for working in block section IRTMM-2000 -4. 2. 2 & SR 4. 65(2)(b) • Is protection Performed at work site in block section by SSE/JE (P. Way)-IRTMM-2000 -4. 2. 2 SR 4. 65(2)(b) • Is PTW issued by OHE supervisor for working of machine in electrified area-IRTMM- 2000 - 3. 64(viii)&SR 17. 04(1) (a) (b) • Are all physical locking of working unit of machines checked after availing block-As per inspection check list issued by RDSO

• Are all the safety items checked for working condition. IRTMM- 2000 -c. s. no. 15 • Is JE/SSE of P. way travel on last machine in work & proceed mode & first machine in work & return mode. SR 4. 65/5 c(i) SR 4. 65/5 f(i) • Is 369 -3 b issued to pass the last stop signal at DANGER position while returning-SR 4. 65/5 f(i) • Are all restriction followed as detail given in caution order -SR 4. 09(1) • Is continuous whistling being done while approaching to L-xing- IRTMM. 2000 -4. 6. 4 & SR 4. 65(1)(h)

• Is the machine moving cautiously at very low speed which shall under no circumstances exceed 10 kmph in foggy weather/poor visibility/dust strom etc. -GR 9. 07(5) • Is minimum 120 meter distance kept machine to machine while travelling & 50 meter while working-SR 4. 65/1 X(i) And SR 4. 65/6 iii • Is speed of Machine kept up to 40 kmph when moving in a convoy- SR 4. 65/1/X(j) • IS TTM working in same direction as of BCM- As per check list for tampers issued by HQ • Is temporary whistle board is provided by SE/JE/P. Way on adjoining track at Track Machine work site- IRTMM 2000 -4. 6. 8. (ii)

• • • P-Way: Has proper loading of PRC on BRN/BRH (before loading, floor free from ballast, wooden batten 75 mm x 75 mm in full length of 20 PRC, each layer consist 20 PRC) in base depot. Has all the 4 dowels in Bridge rail and hold the locking pin Base Depot. Has long/broken/extremely rough bottom surface PRCs has removed in Base Depot. Has empty crib ballast 4” to 5” from top of sleeper ? Has shoulder ballast (cess side) preferably keep bottom level of PRC (Especially the locations at broken PRC) Has fastening (ERC’s) are free to move/not jammed ? Has squaring of sleeper ensured ? Has the broken sleeper are removed ? Has any lateral obstruction min. 50 cms from the end of PRC removed ?

• Has water pipes etc. buried in the ballast lowered down 10” to 12” below the bottom of PRC or removed ? • Has long size fish plate bolts joggle plate removed. • Has during night working sufficient light at interval of 30 Mtrs in operator side, in the length of work to be targeted + the length of rake provided ? • Has SEJ fell in length to be targeted removed ? • Has isolated locations of hard bed overhauled ? • Is the Contractor Supervisor & sufficient work force available to depute the particular locations ? • Has the ramping out at the time of closing the work with the 7 wooden sleepers?

• Has prior block removed the Crib ballast completely between the previous laid 7 wooden sleepers for ramping ? • Rail disc cutter equipment/gas cutting equipment set complete (2 set), with operator to work at two isolated locations simultaneously are available ? • Has the corroded/broken sleeper removed ? • Has reverse jaw cut down in all the CST-9 sleeper. • Availability of minimum following equipments/tools with work force of 50 labour. Crow bar 14 Nos. Rake ballast-8 Nos. Hand Panji = 08 Nos. Spanner = 04 Nos. , Big kundi (to pull broken sleeper) = 04 Nos. , Tommey bar small = 4 Nos, Rail tongue = 4 Nos, Mortar pan 4 Nos, Powraha- 4, M. S. Plate 18” = 12 Nos. , M. S. Plate 12” = 12 Nos, Chisel = 2 Nos, Rail Closure of size 10 to 30 mm = 06 nos. etc.

• Has it been ensured that proper protection of work site done with banner flag & detonators during block to follow the lookout caution on adjacent line ? • Joint Survey for pre attention work with PWI & machine Incharge carried out in advance. • Has it been ensured that the level crossing should be opened/ overhauled properly in advance • Has it been ensured that the electrical cables buried in the ballast lowered down 10” to 12” below the bottom of PRC sleepers?

Do’s • All machine assemblies/parts which are connected to the machine have been secured against tilting & shifting. • Ensure that the proper lighting arrangement is there in night working. • The gas cutting equipment shall be available and loaded by SSE/P. Way with the machine. • Ensure that the adequate distance of 120 m maintained in between machine in block section while running. • Ensure that the RE Mast protection device opened during block. • Specific person shall be deputed for alert to the staff by remote control hooter. • All the safety items shall be available with machine as per Para No. 4. 4. 3 of IRTMM and its correction slip No. 15. • OHE block shall be taken before permitting any person on top of machine.

DON’Ts • • • Do not drive the machine at excessive speed. It should be within prescribed limiting value as per para 2. 4. 4 (i) of IRTMM. Do not forget to look out for singles, switches, TRD logistic and track obstruction. Do not permit Non-competent staff to operate the machine. Do not tow the machine if the final drive is engaged Do not allow any staff to enter into the working area i. e. such as conveyors belts, cutting chains, screen unit etc. till the operation of machine stopped & ensure that the staff deputed for any obstruction in working area & come out. Instruct the staff for using Tommy bar/crow bar/long screw drivers to remove any obstruction of the working unit. There should not be engagement of hands or other body parts during obstruction of unit. Do not climb on the top of machine without OHE block in electrified section. Do not stand close to the machine working area. Do not work without helmet in block section. Wear safety jackets during working. If warranted, prime-mover unit i. e. engine should be made off while removing any obstruction aroused during working. Wear quality shoes (Anti-skid) during working on machine to avoid entangling with moving parts of machine.