through weld renewal -03
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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
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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
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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
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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
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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
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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
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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
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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
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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.
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Steps
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DepotDepot
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Depot
Welded 4 RP
Free rail
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Squareness
testing
Railcutting
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Bringing it to depotBringing free rail todepot
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Web grindingWeb grinding for propercurrent passage
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Depot weldingDepot Welding
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USFD testing
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Spreading Welded 4 RP along track
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Putting the plant on track
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Welding along the track
Welding on Track
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TRRThe Panel
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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
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Tests Parameter validation of plant
Squareness of rail cut
Geometric tolerance of weld after grinding
USFD testing
Load test
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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
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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
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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
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Other precautions/activities
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Measuring the corrosion pit
M t h ki f il d t
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Match marking of rail ends to
ensure head matching
P i i f ld i i f li
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Painting of old corrosion pit of liner
contact
S li f li t t
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Sealing of liner contact area
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Long welded panel kept on rollers
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Problems faced Synchronizing the work
Feeding the rail
Locations without manned LC gate
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Challanges How to do three RP TWR
Scheme and schedule will be entirely different
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Problems faced Synchronizing the ancillary and welding work
Feeding the rail to depot
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