Through Weld Renewal -03

8/2/2019 Through Weld Renewal -03

1/40


2/40

SKV welds - limitations Fatigue life only 50 % of Rail

Skill of welder very important

Quality control difficult

Heating

Tapping

fusion

The Age of weld also becomes a factor


3/40

SKV welds - limitations

Requires very close in service monitoring

USFD

Joggle fish plating

Hindrance in track maintenance

Its Failure Biggest concern for P way Engineers


4/40


5/40

The Plant

Plant mounted on a Road Truckmodified to run on track also

Speed on track 5 kmph

Unlike Rail cum Road vehicleTurn table not provided

Earthwork to be done incontinuity of LC road to align

the vehicle along the track

Fencing to be removed tofacilitate turning of vehicle


6/40

Working- On track

Welding of running rail on which plant is standing ispossible

Being done in construction projects, however Problemof high joint/ mismatching of rail head has beenreported

Progress in open line will be limited because oflimitation of traffic blocks


7/40Working- Off track

Welding can be done in depotmade at suitable location

Each depot requires a level ground ofabout 80-100 x 10 mts. The top surfacepreferably should be at sleeper toplevel.

Length of depot = lenth of weldedpanel +length of feed rail + workingspace.

Length of panel - decided by the

handling and trucking effort requiredto take the panel and put it along thetrack for TRR.

Presently 3 rail panel is being made in

depot


8/40

Working- From 4RP to

4 rail SW Panels welded in depot arekept in between the rails on the track forfurther in situ welding

Short Panels are not inserted in trackand welded to avoid getting high

joints

In between the rails sufficient levelworking space is available

Running rail will infringe the workingof plant if rail kept outside


9/40

Working- From 4RP to By keeping 4 RP on the roller in between the rails as

is done in depot Proper head matching and properbutting force for welding is ensured


10/40

Working- From 3RP to

The mix of depot and in situ weldingensures Good progress as

And three fourthjoints are welded indepot.

only one fourth joints welded inblock


11/40

Where is the other end ?

Welded panel of any lengthas required can be madesubject to track features likeLC gate , bridge, points and

Xing, SEJ etc.


12/40

Steps


13/40

DepotDepot


14/40

Depot

Welded 4 RP

Free rail


15/40

Squareness

testing

Railcutting


16/40

Bringing it to depotBringing free rail todepot


17/40

Web grindingWeb grinding for propercurrent passage


18/40

Depot weldingDepot Welding


19/40Grinding of Weld


20/40Geometrical tolerance test


21/40

USFD testing


22/40

Spreading Welded 4 RP along track


23/40

Putting the plant on track


24/40

Welding along the track

Welding on Track


25/40

TRRThe Panel


26/40

Progress

3 hr block being taken every day

Approx 15 joints done in block

Correspondingly 15 4RP to be made in depot hence 45joints to be done every day in depot

To make one KM track panel it will take 3-4 workingdays


27/40

Tests Parameter validation of plant

Squareness of rail cut

Geometric tolerance of weld after grinding

USFD testing

Load test


28/40

Training Two day course for supervisors in f lash butt welding

plant Moulaali

Operator given training and tested

Need for a training centre

Welding contract Cost (f t k


29/40

Welding contract Cost (for trackwhere free rail has been converted into LWR

with only SKV welds ) Cost of each welding = 2700

Cost of weld per KM = 170 x 2700 = 4.5 lakhs

It includes

handling of Rail in depot,

Handling of short welded panel for in situ welding,

grinding of Rail web current passage,grinding of weld for profiling,

USFD testing, and cost of pull out test


30/40

Cost of ancillary workApprox 2.5 lakh per km

It includes

Making two cut for each welded joints ie 320 cuts perkm

trucking out 3 RP from depot to trackTRR

Making Depot at every two KM


31/40

Other precautions/activities


32/40

Measuring the corrosion pit

M t h ki f il d t


33/40

Match marking of rail ends to

ensure head matching

P i i f ld i i f li


34/40

Painting of old corrosion pit of liner

contact

S li f li t t


35/40

Sealing of liner contact area


36/40

Long welded panel kept on rollers


37/40

Problems faced Synchronizing the work

Feeding the rail

Locations without manned LC gate


38/40

Challanges How to do three RP TWR

Scheme and schedule will be entirely different


39/40


40/40

Problems faced Synchronizing the ancillary and welding work

Feeding the rail to depot

Through Weld Renewal -03

Documents

Transcript of Through Weld Renewal -03