For official use only Government of India - Ministry of Railways LESSON PLAN FOR TRAINING OF PERMANENT WAY SUPERVISOR [Induction Course - Phase II] CAMTECH/C/PWS/1.0 February - 2006 Centre for Advanced Maintenance Excellence in Maintenance TECHnology Maharajpur, GWALIOR - 474 020 Lesson Plan for Training of P.Way Supervisor [Induction Course - Phase II] Foreword P.Way Supervisor is the important person to ensure the safety in train operation since he daily carries out track work directly in his supervision. The objective of this lesson plan is to cover various aspects, which are essential to educate the P.Way Supervisor. This lesson plan contains detailed information regarding mechanised maintenance, incidental & special works (i.e. curves, points and crossing, level crossing, bridges, thermit welding), maintenance of SWR /LWR/CWR track, accidents and breaches, renewals, establishment. Civil engineering branch of CAMTECH has made excellent effort to bring out the lesson plan for training of P.Way Supervisor – Induction course (Phase – II) based on the modules issued by Railway Board. I am sure that this lesson plan will certainly prove to be extremely useful to the Instructor in Training Centres to train the P.Way Supervisors. CAMTECH/Gwalior R.N.Misra Date : 13.02 .2006 Executive Director Preface The railway track is the important and vital part of the Indian Railway. P.Way Supervisor is the most important person amongst the permanent way staff, directly involved in the maintenance of track. He plays a vital role for maintaining the track for safe movement of trains. The P.Way Supervisor needs to be educated thoroughly in his job. To have uniform syllabus all over Indian Railway, this lesson plan has been prepared based on the modules, published by Railway Board. This lesson plan will be of immense use to the Instructors of all training centres for giving training to the P.Way Supervisors. This lesson plan does not supersede any existing instructions from Railway Board, RDSO & Zonal Railways and the provisions of IRPWM, LWR manual, Track machine manual , Track manual, AT Welding manual etc. on the subject. This lesson plan is not statutory and contents are for the purpose of guidance only. Most of the sketches, data & information mentioned herein are available in some form or the other in various manuals, books and other printed matter. I am grateful to Shri Neeraj Shrivastava, STA/Civil/CAMTECH, who went through the complete text, collected information, data etc. and done editing work. Nice data entry has done by Shri Ramesh Bhojwani, Console Operator, IRCAMTECH. We welcome any suggestion for addition and improvements from our readers. CAMTECH/Gwalior Manoj Agarwal Date : 13.02 .2006 Director / Civil CONTENTS STAGE : Induction Course (Phase II) Sr. No. Mod. Description/Topic Page 60 No. Nos. Days Foreword ii Preface iii Contents iv Correction slip v 1.0 CE/164 Mechanised maintenance 1 9 2.0 CE/166 Incidental & special works 28 24 a) Curves b) Points and crossing c) Level crossing d) Bridges e) SWR track f) LWR/CWR track g) Creep h) Buckling of track 3.0 CE/169 Accidents and breaches 90 03 4.0 CE/170 Renewals 96 06 5.0 CE/174 Thermit welding 121 03 6.0 CE/175 Basic supervisory skills & personnel 131 12 a) Pay & allowances b) Seniority and promotion c) Leave rules d) Pass rules e) Conduct and discipline f) Advances & welfare measures g) Industrial and labour laws h) Retirement benefits 7.0 CE/176 First aid 176 03 *** ISSUE OF CORRECTION SLIPS The correction slips to be issued in future for this handbook will be numbered as follows: CAMTECH/2006/C/PWS/1.0/CS. # XX date ...…………....... Where “XX” is the serial number of the concerned correction slip (starting from 01 onwards). CORRECTION SLIPS ISSUED Sr. No. Date of Page no. and Item No. Remarks of C.Slip issue modified CAMTECH/C/2006/PWS/1.0 1 1.0 - MECHANISED MAINTENANCE 1.0 Mechanised maintenance Mechanised track maintenance, particularly with on-track machines, overcomes most of the limitations of conventional manual maintenance system. Its particular superiority lies in : . Its capability to maintain modern LWR track laid with concrete sleepers to close tolerances, required for high speed traffic. Its marked reduction on human effort, most of track maintenance operation being done automatically. Its high speed of operation, which is particularly beneficial for the restoration of track geometry after deep screening or relaying in the shortest possible time. The following track machines mainly used for mechanised maintenance: . Track tamping machines . Dynamic track stabiliser . Ballast handling machines 2.0 Track tamping machines Track tamping machines are of two types: . Off-track tamping machines . On-track tamping machines 3.0 Off-track tamping machines These machines are portable type and can be taken off the track in a short time. These tampers are like a hand tools driven by compressed air, electricity or petrol engine. Pneumatic tools require a compressor to provide the compressed air, and electric tools require a generator. Petrol tools are usually self contained with the engine and the tool in one machine. These machines generally work in between the train intervals and thus do not require any traffic block. They do not lift the track and therefore require the assistance of jacks for lifting and levelling. Off track tampers works in pairs from opposite sides of the sleepers diagonally under the rail seat to have maximum consolidation of ballast. The ballast is first loosened around the rail seat in the crib portion with the help of beaters for a distance of 450 mm on either side of the foot of the rail. The tamper is then inserted about 75 to 100 mm away from the sleeper so that enough ballast is available between the sleeper and the tamping tool blade. Tamping is achieved by vibratory or percussion action. Lesson Plan for Training of Permanent Way Supervisor February - 2006 (Induction Course - Phase - II) CAMTECH/C/2006/PWS/1.0 2 3.1 Type of off-track tamping machines These are generally of two types : . Vibratory type . Percussion type In vibratory type, the tamping is achieved by vibration as well as by self weight of the tamper while in percussion type the blows imparted causes tamping of ballast underneath sleeper. Such tampers being used in Indian Railways are as under : . Kango Tampers It is an electric tool, which causes tamping by impact to the ballast. The stroke combines the respective advantages of the impact and vibratory principles, to give a high consolidating energy, without raising the impact value high enough to break the ballast. Kango tamping tools are generally used in sets of four or eight tools driven from generators, supplying power to two or four tools. Further, to increase the mobility of Kango equipment, single tool generator sets are also used. Bosch Tampers These tampers consists mainly of four bosch GSH 11 C hammers that provide compaction under vibration. The vibratory strokes push the ballast particles in the hollow space, formed in advance while correcting track geometry with the help of track jacks. 4.0 On-track tamping machines These are self propelled machines, tamping of sleepers is done automatically through controls provided near the operator’s seat. On-track tamping machines are of two types : . Light on track tamping machines . Heavy on track tamping machines 5.0 Light on-track tamping machines These usually consist of two tamping units mounted on a common motorised trolley. These machines are not very heavy (1 to 1.2 tons) and can be taken off the track without much difficulty. They can tamp upto 250 sleepers per hour. Normally for these machines lifting and levelling of the track is to be done manually in advance. The travelling speed is about 10 kmph, and they are moved manually. The light on-track tampers used on Indian Railways are : . Chinese tampers . Phooltas tampers Lesson Plan for Training of Permanent Way Supervisor February - 2006 (Induction Course - Phase - II) CAMTECH/C/2006/PWS/1.0 3 5.1 Chinese tampers These tampers can only pack the sleeper and other functions like levelling and aligning etc. have to be done separately by manual methods. These tampers can work without block and can be off-tracked in a time of less than a minute. While working without block protection, suitable caution order, banner flag protection and hooter arrangements have to be made for safety of the track. 5.2 Phooltas Tampers These are comparatively light and less costly machines, meant for lifting, levelling and tamping of track, after deep screening of ballast, when the ballast resistance is low. It should be possible to permit a train speed of 25-30 kmph, after tamping with these tampers. These machines are not designed to work under compacted ballast condition normally encounter during routine track maintenance work. 6.0 Heavy on-track tamping machines These are heavy machines weighing 15 tonnes and above. The earlier machines were able to do tamping only, but the latest models can do lifting, levelling, tamping and lining of track automatically. They cannot be easily removed from the track, although some of them are provided with off-tracking equipment. They need long traffic block for economic working. Following on-track tamping machines are mainly used on Indian Railways : (i) Plain Track Tamping Machines . 06-16 Universal Tamping machine (UT) . 08-16 Unomatic . 08-32 Duomatic . 09-32 Continuous Action Tamping Machine (CSM) . 09-3x Tamping Express (ii) Points and Crossing Tamping Machines . 08-275 Unimat . 08-275-3S Unimat (iii) Multi-purpose Tamper (MPT) UT is a single sleeper tamping machine, while Duomatic tamps two sleepers at a time. In both these machines the entire mass of the machine has to be accelerated and braked at every tamping cycle.