MECHANISED TRACK RENEWAL

1. MECHANISED TRACK RENEWAL

2. TRACK RELAYING TRAIN

3. Track Relaying Train • In 1990-91 two track relaying trains were imported from Tampers, USA. • More mechanised than earlier machines.

4. Salient Features • No service track is required for track renewal • No need to fabricate track panels • New Concrete sleepers are loaded in modified BRHs • Sleepers are laid in track one by one • New rails panels unloaded at site and placed on sleeper shoulders, exchanged with old rails along with sleeper renewal • No power block is required • Track renewal of platform lines is possible

5. Technical specifications

6. WORKING DIRECTION TRACK RELAYING TRAIN

7. TRT does following operations one by one in same block: • Threads out old rail • Removes old sleepers • Levels and compacts ballast bed • Lays new sleepers • Threads in new rails

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

11. NEW SLEEPER OLD SLEEPER PICK UP WHEEL

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

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

22. Other follow up machines: • Ballast Regulator • T.T.M. • D.G.S. • Rail Pick up unit with 3 modified BRHs, Road Crane and slinging arrangement

23. Track relaying train can perform three operations: • Complete track renewal • Replacement of sleepers only • Replacement of rails

24. Depot Activities • Unloading and stacking of old/new sleepers • Loading of new PRC sleepers on the modified BRHs with proper spacer • Loading of fastenings such as liners pandrol clips etc. • Unloading, stacking and despatch of old sleepers • Daily maintenance of machine • P.Way store, store for machine spare parts and consumables

25. Rake Preparations • Sleepers-loaded in modified BRHs with layer separation by wooden batten of size 75mmx75mm. • Pandrol clips and Liners – Loaded on modified BRH attached in rear of TRT. • Rubber pads – loaded in racks specially provided on machine.

27. SPACERS

28. Advance Track Preparations • Rail panels unloaded at site must be laid on sleeper shoulders and joints are welded/fish plated. • All obstructions within 1m of sleeper ends are removed • Level crossing to be opened up to 1m on both ends of sleepers to allow movement of dynamic plough of TRT • Unload minimum quantity of ballast before relaying operation so that adequate ballast is available for tamping and relaxing the speed

29. Advance Track Preparations Contd.. • In case of working on CST-9 sleepers, lips of reverse jaw sleeper is required to be cut or such sleepers are replaced in advance. • Fittings of alternate sleepers are removed in advance. Rest of the fittings are removed after arrival of machine. • Rail closer of about 7.3m length is introduced in existing track at the starting point. • Crib and shoulder ballast in rail closer portion is taken out.

30. Sequence of operation of TRT • The TRT is stopped at site of work in a position such that side plough is on first sleeper of cut rail. • Lowering of shoulder / side plough. • Removal of 7.3 meter long rails closures. • Lowering sled from beam car on to the rail seats of rail closures removed. • Bringing 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

31. 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 • Set cam wheel on to the rail and commence laying of new concrete sleepers by advancing the machine on automatic mode. • 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

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

33. Ballast Cleaning: • If BCM done 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: • Out put of BCM may not match with TRT • Requirement of speed restriction length will be much more

34. Traffic block requirement: 4 Hours • Out of total block granted, about 90 minutes of block period is consumed for following activities:-

35. 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 350m per effective hour of working and therefore in a total block of 4 hrs about 1 km track renewal will be done.

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

37. Speed Restriction: (Suggested)

38. Picking of Old Rails: • TRT Can thread out old rails up to 3m 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 BRHs hauled by utility vehicle on which road crane is mounted. • Road crane travels from utility vehicle to BRHs and loads single rails in BRHs one by one

39. Staff Requirement for TRT and Allied Machines: • Following machine staff are required for working of TRT

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

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

42. Precautions: • Hand should not be kept on rails for Gantries on modified BRH. • Speed of gantry to be regulated and one empty wagon must be kept for safety against over shooting. • Bridge between two BFR’s must be inspected daily for any cracks etc. • While travelling with locomotive, gantry should rest on the sleepers to give resistance. • Various assemblies should be chained and locked e.g. sled, Dynamic plough, Rolelrs etc.

43. Precautions Contd.. • When gantry is moving the Jaws should be fully lifted up • While parking, both the wheels of gantry must be on same wagon • All broken sleepers should be removed in advance

44. Precautions Contd.. • In case of the longer or eccentrically placed sleepers, may get struck up in the machine-- to be removed in advance. • Sled cannot jump a gap of two sleeper. • Sled has to be fastened properly while entry and rolling out of wheels other wise chances of derailment are there.

45. Thanks