MECHANISED TAMPING

1. MECHANISED TAMPING

2. Duties of AEN/OL in regard toTrack Machine operation • Arrangement of accommodation for Track machine staff in summer or wherever coaches are not provided • facility of water supply • power supply • resting arrangement • Periodical inspection of Track machine working once in a month (Para 5.3.3 IRTMM) covering • adequacy of allied track works • quality of machine works • safety aspects involved • item pertaining to welfare of staff • Records such as program & progress of tamping, speed restriction etc.

3. Duties of AEN/OL in regard toTrack Machine operation • Transportation of consumables, spares from machine depot to the site of work • Lighting arrangement, in case of night working • Coordination with other departments like traffic, OHE and S&T for better performance of machine.

4. Inspection Schedule of Machine bySrDEN/DEN/Open Line (CS-14) • CSM, BCM, FRM(SBCM), UNIMAT, DTS, Tamping Express • once in 2 months when working in section • T-28, PQRS, RGM, TRT • At least once in a month • Work site tampers, BRM, SEM, UTV and all other machine • As per need

5. Inspection Schedule of Machine byAEN/Open Line (CS-14) • CSM, BCM, FRM(SBCM), UNIMAT, DTS, Tamping Express • once in a months when working in section • T-28, PQRS, RGM, TRT • At least once in a fortnight • Work site tampers, BRM, SEM, UTV and other machine • At least once in a period of working in their section

6. Inspection Schedule of Machine byAEN/TM

7. Tamping • Imparting compacting energy to the ballast at below bottom of sleeper to give well packed supporting bed. • RETENTIVITY of tamping is important due to dynamic nature of load. • Various modes of Tamping • Manual tamping - low Retentivity • Off track/hand held tempers - medium Retentivity • On track tempers - high Retentivity

8. Tamping

10. Tamping Unit fitted on Duomatic Machine

11. Tamping Unit For Tamping Express

12. Tamping Unit fitted on Tamping Express

13. Important Tamping Parameters • Vibration frequency • Vibration motor pressure • Correct depth of insertion • Squeezing pressure • Squeezing cycle time • Tools • Pre/post Tamping operation

14. Vibrations 35 Hz - upward force and a durable lift is generated < 30 Hz resistance to tines penetration is high > 40 Hz liquefaction of Ballast

15. Vibration motor pressure Vibration Motor pressure = 130-150 kg/cm2 Low Vibration Motor pressure results in • Low depth of penetration • Squeezing effect is less • More time required for squeezing

16. Correct Location of Tool for Squeezing 10 to 12 mm • Gap between top edge of tamping tool blade & bottom edge of sleeper • Flat bottom sleeper - 10-12 mm • Metal sleeper - 22-25 mm

17. Setting correct depth of insertion Tamping depth - as per Track structure and taking into Account ‘Zero Error’ Zero setting • Set the depth to zero & lower the tines • Top of tine shall be 10-12 mm below rail top • If not then zero correction be found out, lower (-ve), Higher (+ve) correction Tamping depth in working cabin in digital potentiometer

19. 60 Kg - 388+12 = 400 mm 52 Kg - 372+12 = 384 mm Paint Marking on Tool arm 60 Kg - 172 + 6 + 210 = 388 mm 52 Kg - 156 + 6 + 210 = 372 mm 10-12mm

20. Effect of incorrect depth Less depth squeeze bottom of sleeper & not ballast hence ineffective packing effort

21. Effect of incorrect depth Excess depth Squeezing out of ballast from the high gap between bottom of sleeper and top of tine, loose pockets in ballast , non uniform compaction hence retentivity will be poor. We will end up packing area where packing is not required.

22. Voids under sleeper

23. Squeezing pressure • Based on type of sleeper (Para 3.1.3-IRTMM) to ensure good quality output of machine • Lower pressure • The packing will not be effective • Higher pressure • Track may start lifting due to squeezing pressure

24. Squeezing pressure

25. Three movements Penetration -Tamping tines (tools) penetrate into the ballast Squeezing - movement of tines squeeze the ballast Sinosuidal oscillation (Vibration) percussion action on ballast TAMPING Process

26. Tamping cycle penetration Squeezing Lifting up Travelling ahead Squeezing Time Each unit is equal to 0.2 second • Squeezing Pressure Retention time is set in Tamping Time selector switch in working cabin - • For maintenance as per IRTMM • 0.4 sec to 0.6 sec. However higher for caked Ballast (0.8 to 1.2 Sec) • New Track / Deep screened track • Low Squeezing Pressure Retention time = 0.4 sec (0.8 Sec)

27. TAMPING CYCLE Tamping Cycle (approximately 4/4.5seconds) Machine Direction Travelling ahead Squeezing (0.4 to 0.6 seconds) (0.8 to 1.2 Seconds) Time saving in 3 cycles = 0.6/1.2sec Lowering of tamping unit Lifting up

28. Tools(tines) • Missing tools- not permitted • Wear < 20%. • Tools are held tight fit. Tools Missing

29. Pre-requisite for Tamping • Minimum clean cushion of 150mm • Adequacy of ballast in crib & shoulder for general lift of 10/20 mm for each tamping operation

30. Pre-Tamping Operations • Field survey- to fix track profile • Marking of • Design slews & transition correction • General lift/Design lift • Start & end of transition curve • Super elevation on curve • Heaping of ballast in tamping zone • Attention to low, hogged & battered joints • Making up of low cess • Improvement of track drainage

31. Pre-Tamping Operations (Contd.) • Recoupment of fittings & fastenings • Squaring/spacing & replacement of broken/damaged sleepers • De stressing of LWR • Removal of guard & check rails • Gauging • Opening of L/crossing, Guard Rails, JFP etc.

32. Pre-Tamping Operations (Contd.) • Removal of obstructions, wooden blocks & joggled fish plates • Removal /adjustment of traction bonds

33. Tamping of Turnouts by UNIMAT Pre-Tamping Operations • In addition, to the provisions for Tamping of plain track; additional aspects to be taken care • Layout including Sleeper spacing as per relevant drawings • Battered or worn nose of crossings should be replaced/Reconditioned. The warped or bent sleeper underneath nose of crossing should be attended.

34. Tamping of Turnouts by UNIMAT Pre-Tamping Operations • additional aspects to be taken care (contd..) • High points on the turnout and approaches should be determined and the general lift should be decided • A general lift of minimum 10 mm should be given • Associate S&T and Electrical staff to complete their portion of work

35. Post-Tamping Operations • Checking & tightening of loose fittings • Replacement of broken fittings • Proper consolidation of ballast between the sleepers & shoulder and profiling • Re fixing of guard & check rails • Gauging • Re-fixing of JFP/OHE bonds

36. Tamping of Turnouts by UNIMAT Post-Tamping Operations • In addition, to the provisions for Tamping of plain track; • additional aspects to be taken care; • Checking and tightening of Loose/Broken fittings • All the S&T and Electrical connections removed before tamping should be restored • Dressing of Ballast and Checking Parameters

37. Acceptance criteria(IRTMM Para 3.1.4)

38. Para of LWR Manual Relevant to Track Machines Working • Para 6.2.1 – General • I) a) Track structure consisting of other than concrete sleeper in LWR/CWR – The regular maintenance in LWR CWR shall be confined to hours when rail temperature is between td + 10oC and td – 30oC and shall be completed well before onset of summer. If rail temperature after maintenance operation exceeds td + 20oC during the period of consolidation as per para 1.18 the speed restriction of 50 Kmph on BG and 40 Kmph on MG shall be imposed when shoulder and crib compaction has been done and 30 Kmph and 20 Kmph respectively when shoulder and crib compaction has not been done in addition to posting a mobile watchman.

39. Para of LWR Manual Relevant to Track Machines Working (contd.) • b) Track structure consisting of concrete sleepers – The regular track maintenance in LWR/CWR shall be confined to hours when the rail temperature is between td + 10oC and td – 30oC and shall be completed well before onset of summer. • If rail temperature after maintenance operation exceeds td + 20oCduring the period of consolidation as per para 1.18 the speed restriction of 50 Kmph on BG and 40 Kmph on MG shall be imposed.

40. Para of LWR Manual Relevant to Track Machines Working (contd.) PARA 6.2.2 • Maintenance tamping – Tamping on LWR/CWR with general lift not exceeding 50 mm in case of other sleeper including correction of alignment shall be carried out during the period when prevailing rail temperatures are as per para 6.2.1 (i) together with precautions laid down therein. • Lifting of track – Lifting where needed, in excess of 50 mm in case of concrete sleeper/25 mm in case of other sleepers shall be carried out in stages with adequate time gap in between successive stages such that the full consolidation of the previous stage as per para 1.18 is achieved prior to taking up consecutive lift.

41. Para of LWR Manual Relevant to Track Machines Working (contd.) • Consolidations of track is a process of building up ballast resistance to the tendency of movement of sleeper either initially before laying LWR or making up subsequent loss of resistance by anyone of the following • For track structures consisting of sleepers other than concrete sleepers • Passage of atleast 3,00,000 gross tonne of traffic on BG and atleast 1,00,000 gross tonne of traffic on MG when compaction of ballast is done using hand operated compactor/consolidator or rammers. • Passage of atleast 50,000 gross tonnes on BG or atleast 20,000 gross tonnes of traffice on MG or a period of two days whichever is later, when compaction is done by means of mechanised shoulder and crib compactor.

42. Para of LWR Manual Relevant to Track Machines Working (contd.) • For the track structure consisting of PSC sleepers, passage of atleast 50,000 gross tonnes of traffic on BG or atleast 20000 gross tonnes of traffic on MG and period of 2 days whichever is later • At-least one round of stabilization by Dynamic track stabilizer (DTS) • For newly laid LWR/CWR, atleast 3 rounds of packing, last 2 of which should be with on track tamping machines.

43. Thank You