केवल कार्ाालर्ीन प्रर्ोग हेतु

For Official Use only

भारत सरकार - GOVERNMENT OF INDIA
रे ल मंत्रालय - MINISTRY OF RAILWAYS

Introductory Hand book

On
Track Machine
For S&T Staff

END User:SSE/JEs & Maintenance

Staff of S&T andP.WayDeptt. ofIndian
END User: SSE/JEs &
Railways
CAMTECH/S&T/2023-24/TM Maintenance Staff of S&T
November -2023 dept. of Indian Railway

INDIAN RAILWAYS CENTRE FOR ADVANCED MAINTENANCE TECHNOLOGY

Maharajpur, Gwalior (M.P.) – 474005
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 Introductory Hand book
On
Track Machine
for S&T Staff

CAMTECH/S&T/2023-24/TM
November-2023

Prepared by: Jitendra Singh Gour, SSE/Sig/CAMTECH

( Under the Guidance of Shri Avadhesh Kumar Yadav, Director/S&T/CAMTECH )

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FOREWORD

Mechanized track laying and maintenance has been introduced in a big way on
Indian Railways to meet the challenges of growing traffic and changed socio-
economic conditions. Safe and comfortable travel in a train is only possible on
tracks lying in the correct geometrical position. In order to maintain these
tracks, railway track maintenance machines play a very significant role. The
track machines help in making the difficult task of track maintenance easier and
complete the work in a better and efficient manner. In Indian Railways Tamping
machines ( Unomatic / Duomatic ), UNIMAT (Points and Crossing Tamper),
DTS ( Dynamic Track stabiliser ), Ballast Cleaning machine (BCM), SBCM
(Shoulder Ballast Cleaning Machine), Ballast Regulating machines (BRM), etc.
are such Track Machine used for Packing / Cleaning of entire ballast bed
without dismantling the track.
Engineering staff ( SSE/JE/P.Way & SSE/JE/TM) is primarily associated with
working of Track machine, however other departments like S&T & Electrical
should also have basic knowledge of Track machines in order to protect their
assets installed on Railway track from possible damage by track machine
working.
This handbook has been prepared to provide basic information about various
track machines used in Indian Railway to S&T Staff and safety precautions to
be taken while working of track machines.
I hope that the information given in this handbook will be quite helpful to the
S&T personnel associated with maintenance of track in Indian Railways and
taking preventive measures to avoid safety hazards.

CAMTECH, Gwalior JITENDRA SINGH

Date: November 2023 Principal Executive Director
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PREFACE

Maintaining the railway tracks is very crucial as there are many trains carrying people
and an abundance of goods that pass by these tracks. Any one act of negligence can
result in disaster. Also, the tracks are exposed to various climatic conditions that cause
the tracks to get damaged easily, therefore, it is important that the railway tracks are
maintained periodically and repaired as and when required. For speedy and efficient
maintenance of tracks, track machines like Tamping machines (Unomatic /
Duomatic ),UNIMAT (Points and Crossing Tamper), DTS, BCM, SBCM & BRM
are deployed in Indian Railways. Apart from Track Machine and P.Way staff, S&T
staff should also have basic knowledge of working of these machines, so that they can
prevent possible damage to signalling assets during maintenance of Railway tracks by
these track machines.

In view of the above, CAMTECH has prepared Introductory Hand book on Track
Machine which covers overview of different type of Track machines used in Indian
Railways and Guidelines / Safety precautions to be followed while working with
Track Machines for S&T Staff.

We are sincerely thankful to Railway Board, IRTMTC Prayagraj, RDSO, Lucknow,

IRICEN Pune, North Central Railway, and all personnel of Indian Railways who
helped us in preparation of this handbook.

Since technological up-gradation and learning is a continuous process, you may feel
the need for some addition/modification in this handbook. If so, please give your
comments on email address [email protected] or write to us at Indian
Railways Centre for Advanced Maintenance Technology, Maharajpur, Gwalior (M.P.)
474005.

CAMTECH, Gwalior Avadhesh Kumar Yadav

Date: November 2023 Director (S&T)/CAMTEC
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TABLE OF CONTENTS

INDIAN RAILWAYS CENTRE FOR ADVANCED MAINTENANCE TECHNOLOGY 1

FOREWORD............................................................................................................................. i
PREFACE ............................................................................................................................... iii
TABLE OF CONTENTS ........................................................................................................ v
DISCLAIMER.......................................................................................................................... 1
OUR OBJECTIVE................................................................................................................... 3
Section 1 .................................................................................................................................... 5
GENERAL ................................................................................................................................. 5
1. Introduction : ...................................................................................................................... 6
(i) Track machines Hauled by Locomotives: ......................................................................... 6
(ii) Self-Propelled Track Machines:....................................................................................... 6
1.1 Types of Track Machines: .............................................................................................. 6
1.1.1 Tamping Machines: .................................................................................................. 6
1.1.1 Dynamic Track Stabilizer (DTS):............................................................................ 7
1.1.2 Ballast Handling Machines :.................................................................................... 7
1.1.3 Track Relaying Machines : ...................................................................................... 7
1.1.4 Rail/Switch Grinding and Milling machine: ........................................................... 7
1.1.5 Special Purpose Machines: ...................................................................................... 7
1.2 Operation and Working of Track Machine: .................................................................... 8
1.2.1 Responsibility of Track Machines: ............................................................................ 8
1.2.2 Supervision of Work of Track Machine(s): ............................................................. 8
1.2.3 Essential Duties of SSE/JE/P.Way Deployed with the Machine: ........................... 8
1.3 Responsibility of S&T Departments : ............................................................................. 8
Section 2 .................................................................................................................................... 9
TAMPING MACHINES ........................................................................................................... 9
2. Tamping machines: .......................................................................................................... 10
2.2 Types of Tamping machines: ......................................................................................... 10
Section 3 .................................................................................................................................. 12
DYNAMIC TRACK STABLISER.......................................................................................... 12
3. Dynamic Track Stabilizer (DTS): .................................................................................... 13
3.1 Types of Dynamic Track Stabilizer: ............................................................................ 13
Section 4 .................................................................................................................................. 15
BALLAST CLEANING AND HANDLING MACHINES .................................................... 15
4. Ballast Cleaning Machines (BCM): .................................................................................... 16
4.1 Function of Ballast Cleaning Machines (BCM) - ......................................................... 16
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4.2 TYPES OF BALLAST CLEANING MACHINE : ...................................................... 17

4.2.1 Plain Track Ballast Cleaning Machine (RM80) (Plasser India) ............................ 17
4.2.2 Points and Crossing Ballast Cleaning Machine (RM76) (Plasser India)............... 17
4.2.3 Plain Track and Points & Crossings BCM (RM80 92U) (Plasser India) .............. 17
4.3 Special Note regarding Deep Screening of Point Motor Sleepers : ............................. 18
4.4 Shoulder Ballast Cleaning Machine (SBCM): .............................................................. 20
4.4.1 Types of Shoulder Ballast Cleaning Machines: ............................................................ 20
4.5 Ballast Regulating Machine (BRM) : ........................................................................... 21
4.5.2 Types of Ballast Regulating Machines (BRM ) : ..................................................... 21
4.5.2.1 Without Hopper - ................................................................................................... 21
4.5.2.2 With Hopper .......................................................................................................... 22
Section 5 .................................................................................................................................. 23
SAFETY PRECAUTIONS ...................................................................................................... 23
5. Safety Precautions for S&T staff associated with Track Machine Working : .................. 24
5.1 Before Start of Work : ........................................................................................... 24
5.2 During Working ..................................................................................................... 25
5.3 After Completion of Work .................................................................................... 25
7. General Safety Precautions for Track Machine Working : .............................................. 26
REFERENCES ........................................................................................................................ 27
Introductory Hand book on Track Machine for S&T Staff

DISCLAIMER

It is clarified that the information given in this Handbook does not supersede
any existing provisions laid down in the Indian Railways Track Machine
Manual (IRTMM), Indian Railways P. Way Manual (IRPWM), Signal
Engineering Manual, Railway Board and RDSO publications. This document is
not statuary and instructions given are for the purpose of guidance only. If at
any point contradiction is observed, then IRTMM, IRPWM, IRSEM, & Railway
Board/RDSO guidelines may be referred or prevalent Zonal Railways
instructions may be followed.

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ISSUE OF CORRECTION SLIPS

The correction slips to be issued in future for this report will be numbered as follows:

CAMTECH/S&T/2023-24/TM XX date .......

Where “XX” is the serial number of the concerned correction slip (starting from 01
onwards).

CORRECTION SLIPS ISSUED

S. No. of Date of issue Page no. and Item Remarks

Correction No. modified
Slip

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Introductory Hand book on Track Machine for S&T Staff

OUR OBJECTIVE

To upgrade Maintenance Technologies and Methodologies and achieve

improvement in Productivity and Performance of all Railway assets and
manpower which inter-alia would cover Reliability, Availability and Utilization.

If you have any suggestions & any specific comments, please write to us:

Contact Person : Director (Signal & Telecommunication)

Postal Address : Centre for Advanced Maintenance Technology,
Maharajpur, Gwalior (M.P.)
Pin Code – 474 005
Phone : 0751-2470185
Fax : 0751-2470841
E-mail : [email protected]

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Introductory Hand book on Track Machine for S&T Staff

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Introductory Hand book on Track Machine for S&T Staff

Section 1

GENERAL

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Introductory Hand book on Track Machine for S&T Staff

1. Introduction :
Track machines are used for mechanized Track Laying & maintenance of Railway Track. For
the purpose of movement and working, Track machines are classified in following two
categories:

(i) Track machines Hauled by Locomotives:

TLE (Track Laying Equipment), TRT (Track Relaying Train), PCCM (Point & Crossing
Changing/Laying machine), MDU (Muck Disposal unit) are the machines generally falling in
this category. Rules for movement for material trains will apply to these categories of
machines. Other track machines when attached with the train/locomotive will also fall in the
same category.

(ii) Self-Propelled Track Machines:

For movement, these shall be worked as a train but will not need a guard or a brake van. One
camping coach or one BRN wagon or another self-propelled track machine, which may be
un-braked, shall permit to be hauled by the self-propelled track machine. SSE/JE/TM
operating the machine shall ensure safe running. This category of track machines may also
work with the non-self-propelled track machine as in (i) above for effective block utilization,
in the same block section.

1.1 Types of Track Machines:

( Ref. : Handbook on Track Machine for P. Way by IRICEN, Pune.)

Following major on-track machines are working on Indian Railways at present:

1.1.1 Tamping Machines:

a) Tampers without Satellite Unit-

i. 08-16 Unomatic.
ii. 08-32 Duomatic-
• 08-32 Duomatic (Plasser India)
• 08-32C Duomatic (Plasser & Theurer)
• 08-32 WST with flat car (Metex – JSC Moscow, Russia)
• VPR -02M without flat car (Kalugaputmash, Russia)
iii. UNIMAT (Points and Crossing Tamper):
• 08-275-2S UNIMAT (Plasser India).2
• 08-275-3S UNIMAT (Plasser India- with third rail lifting arrangement.)
• 08-475-4S UNIMAT (Plasser India- with arrangement for lifting and packing of
third rail.)
• Multi Purpose Tamper (Plasser India -Plain and Points and Crossing Tamper).
b) Tampers with Satellite Unit
i. 09-32 CSM ( Continuous action Tamping machine )
ii. 09-3x Tamping Express.
iii. 09-3x Dynamic Tamping Express.

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Introductory Hand book on Track Machine for S&T Staff

1.1.1 Dynamic Track Stabilizer (DTS):

i. DTS by Plasser.
ii. DTS by BHEL.
iii. DTS by Metex.

1.1.2 Ballast Handling Machines :

a) Ballast Cleaning Machines (BCM)-

i. RM-80 92I (Plasser India-for plain track).
ii. RM-76 (Plasser India- for turnout).
iii. RM-80 92U (Plasser India- for plain track and turnout).

b) Shoulder Ballast Cleaning Machines (SBCM)

i. FRM-80 (Plasser India).
ii. FRM-85F (Plasser India).

c) Ballast Regulating Machine (BRM)-

i. Without Hopper
• BRM Model 66-2/56-3 and (Kershaw).
• PBR 400R (Plasser India).
• BRM Model SPZ-210 K (Gemac Engg).

ii. With Hopper

• USP 2000 SWS (Plasser India).
• RPB-01 (Metex, Russia).

1.1.3 Track Relaying Machines :

a) Track laying Equipment (Plasser India and Simplex)).

b) Track Relaying Train (TRT) .
c) Points and Crossing relaying Machine T-28 (AMECA-Make).

1.1.4 Rail/Switch Grinding and Milling machine:

a) Rail Grinding Machine

b) Switch Grinding Machine
c) Rail Milling Machine
d) Rail Inspection Vehicle

1.1.5 Special Purpose Machines:

a) Utility Track Vehicle (UTV).

b) Rail Borne Maintenance vehicle (RBMV).
c) Muck Disposal Unit (Plasser India)

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Introductory Hand book on Track Machine for S&T Staff

1.2 Operation and Working of Track Machine:

1.2.1 Responsibility of Track Machines:

For the purpose of operation, each machine shall be under the direct charge of SSE/JE/TM.
He shall be in-charge of the track machine and shall be responsible for safe movement and
working of track machine.

1.2.2 Supervision of Work of Track Machine(s):

The track machine(s) shall work under the direct supervision of an engineering official, not
below the rank of SSE/JE/P.Way. SSE/JE/P.Way shall also associate himself and co-ordinate
with station master for shunting of the track machine(s).

1.2.3 Essential Duties of SSE/JE/P.Way Deployed with the Machine:

He shall be the in-charge of the supervision of the work of track machine. He shall perform
following essential duties:

1) He shall be responsible for pre-block operations, block operations (other than machine
Operation) and post block operations as detailed for various machines.
2) He is responsible for protection of the site of work and adjoining track wherever
necessary. He will be responsible for arranging adequate precautionary measures for
the safety of staff working with machine in the block section against danger of trains
on the adjoining line(s). He shall arrange for track protection and provide look out
men for safety at site.
3) He shall co-ordinate with other departments like Traffic, OHE and S&T in the field to
facilitate smooth working.

1.3 Responsibility of S&T Departments :

Engineering staff ( SSE/JE/P.Way & SSE/JE/TM) is primarily associated with working of
Track machine, however S&T Department shall ensure availability of signal staff for
disconnection, reconnection etc. as required, particularly for the work of protection to cables,
removal and re-fixing of axle counters and screening of points and crossing.

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Introductory Hand book on Track Machine for S&T Staff

Section 2

TAMPING MACHINES

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Introductory Hand book on Track Machine for S&T Staff

2. Tamping machines:
A Tamping machine or ballast tamper is a machine used to pack (or tamp) the track ballast
under railway tracks to make the tracks more durable The tamper lifts each sleeper and the
rails up, and packs ballast underneath to achieve target or pre-determined parameter values,
with an aim to improve the track geometry.

2.2 Types of Tamping machines:

2.2.1 Tampers without Satellite unit:

The tamping unit and the lifting cum lining unit are mounted on the main frame of the
machine itself. The machine moves and stops at every sleeper for lining, levelling and
tamping.

2.2.1.1 08-16 Unomatic:

It is a Plain track tamper and with 16 tamping tools to pack one sleeper at a time.

Figure-1 : Figure-2
08-16 SH Unomatic (Plain Track Tamping Machine)
2.2.1.2 08-32 Duomatic:
It is a Plain track tamper and with 32 tamping tools to pack two sleepers at a time. The names
of the models of Duomatic tamping machines presently in use on Indian Railways; and the
name of manufacturer, are given below: -
• 08-32 Duomatic (Plasser India)
• 08-32C Duomatic (Plasser & Theurer)
• 08-32 WST with flat car (Metex – JSC Moscow, Russia)
• VPR -02M without flat car (Kalugaputmash, Russia)

Figure-3 : Figure-4
08-32C Duomatic (Plain Track Tamping Machine)

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2.2.1.3 UNIMAT (Points and Crossing Tamper):

Tamping unit of this machine is designed in a manner to allow independent operation of
individual tamping tool. This helps in tamping of almost all the sleepers in points and
crossings.
Various models of UNIMAT machines presently in use on Indian Railways with the name of
the manufacturers are as under: -
• 08-275 UNIMAT (Plasser India)
• 08-275-3S UNIMAT (Plasser India) with arrangement only for lifting of third rail.
• 08-475-4S UNIMAT (Plasser India) with arrangement for lifting and packing under
the third rail.

Figure-5 : Figure-6
UNIMAT (Points and Crossing Tamping machine)

2.2.1.4 Multi-Purpose Tamper (Plain and Points and Crossing Tamper):

This machine is designed for spot attention on plain track as well as point and crossing.
Various models of Multi-Purpose Tampers, presently in use on Indian Railways are as given
below: -
• UNIMAT Compact (MPT) (Plasser India),
• UNIMAT Compact Split Head (MFI) (Plasser India).

2.2.2 Tampers with Satellite unit:

These machines are provided with a satellite unit, which moves independent of the main
machine in working mode. The machines falling in this category are: -

2.2.2.1 09-32 CSM (Plain Track Tampers):

It is a Plain track tamper designed for lining, levelling, twist correction and tamping of
sleepers. It has tamping unit with 32 tamping tools to tamp two sleepers at a time.

2.2.2.2 Tamping Express (09-3X) (Plain Track Tampers):

It is a plain track tamper designed for lining, levelling, twist correction and tamping of
sleepers. It has 48 tamping tools to tamp three sleepers at a time.

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Introductory Hand book on Track Machine for S&T Staff

Section 3

DYNAMIC TRACK STABLISER

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3. Dynamic Track Stabilizer (DTS):

During maintenance operations such as tamping, lifting, slewing, deep screening etc. the
lateral resistance of track gets reduced which rebuilds gradually with passage of trains. This
consolidation can also be achieved faster, uniformly and more effectively by means of a
Dynamic Track Stabilizer.The DTS vehicle is determined for the ballast bed stabilization
by means of the vibration consolidating on the tracks and turnouts especially on the high
speed tracks.

3.1 Types of Dynamic Track Stabilizer:

There are three make of DTS machines in use over Indian Railways:

i) DTS- DGS 62N (Plasser, India):

This machine is used for plain track and turnouts with two stabilizing units with a vertical
load of max. 356 kN

Figure-7 DTS- DGS 62N (Plasser, India)

ii) DTS - VKL-404IN (BHEL, India):

This machine is the four-axle double bogie special track vehicle with its own drive of two
axles (nose hung traction motors) in one bogie. The Power transmission of machine is electric
AC / DC.

Figure-8 DTS - VKL-404IN (BHEL, India)

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iii) DTS - DSP-C8T (METEX -JSC, Moscow Russia) :

This machine (DSP-C8T) is Supplied by M/s Metex, JSC, Moscow (Russia). This machine is
of two bogies having wheel diameter of 860mm and maximum Axle Load 15.0 t. The design
Speed of machine is 75 Kmph when running on its own power and 80 Kmph when running in
train formation as a dead vehicle.

Figure-9 DTS - DSP-C8T (METEX -JSC, Moscow Russia)

***

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Section 4

BALLAST CLEANING AND HANDLING MACHINES

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Introductory Hand book on Track Machine for S&T Staff

4. Ballast Cleaning Machines (BCM):

The ballast bed fulfils important functions as the binding element between sleepers and
substructure. It distributes the loads of the trains uniformly onto the track substructure and
assures a firm, un-shifting position of the sleepers. To withstand these dynamic impacts the
ballast bed has to be very elastic. The good function depends on the depth of the ballast bed,
the size of the ballast stones and the degree of fouling.

Fouling occurs under normal operational loads. This causes the edges of the ballast stones to
break off, settlement of the stones and friction processes. Overall, this causes an increase in
the proportion of fines which reduces the elasticity of the track, the water permeability and
the durability of the track geometry. As a consequence, there will be irregular settlement of
the track which tamping can compensate only for short periods. From a certain point in time
it will be more economical to clean the entire ballast bed. This work can be performed highly
efficiently using ballast bed cleaning machines

Using ballast bed cleaning machines, the ballast can be cleaned without dismantling the track.

4.1 Function of Ballast Cleaning Machines (BCM) -

( Ref.: Indian Railway Tack Machine Manual (IRTMM).)

BCM loosens and excavates full section of fouled track ballast from crib, below sleepers and
shoulders, collects it by continuous movement of endless cutter chain with fingers, depositing
it to a set of vibrating screens, where muck is separated and thrown out by a waste conveyor
and the screened/clean ballast is transferred back to the track through chute.

The main functions of BCM are:

(1) Screening of fouled ballast and disposal of muck away from track.
(2) Restore clean ballast cushion, thereby improving the elasticity (resilience) of ballast
bed.
(3) Provide cross slope of formation.
(4) Improve drainage of track.

Ballast cleaning and handling machines are used for handling of ballast during various
maintenance and renewal operations. These machines are broadly categorized as: -

(1) Ballast Cleaning Machines (BCM) – for screening of ballast.

(2) Shoulder Ballast Cleaning Machines (SBCM) – for screening of shoulder ballast.
(3) Ballast Regulating Machines (BRM) – for redistribution and profiling of ballast.

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4.2 TYPES OF BALLAST CLEANING MACHINE :

Three types of ballast cleaning machines are presently available on Indian Railways:
4.2.1 Plain Track Ballast Cleaning Machine (RM80) (Plasser India)

This machine is capable of deep screening of plain track only and is not capable of working
on turnouts.

Figure – 11: Plain Track Ballast Cleaning Machine ( RM80 )

4.2.2 Points and Crossing Ballast Cleaning Machine (RM76) (Plasser India)

This is capable of deep screening of plain track as well as points and crossings without
dismantling any component of points and crossings.

4.2.3 Plain Track and Points & Crossings BCM (RM80 92U) (Plasser India)

This machine is similar to RM76 model except that it can handle heavier track structure with
ease.

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Figure-12 : Plain Track and Points & Crossings Ballast Cleaning Machine (RM80 92U)

4.3 Special Note regarding Deep Screening of Point Motor Sleepers :

(Ref.: N.Rly , New Delhi JPO No. 219-W/61/TMC/P&C/JPO dated 05.05.2022 for Deep
Screening of Point & Crossing by BCM )

It is very vital that some sleepers at special locations cannot be deep screened by BCM. For
homogeneous ballast bed and uniform running, such sleepers should not be left without deep
screening. Such sleepers are to be invariably deep screened by special means as under:-

(a) Sleeper nos. 3 & 4 for 1 in 8.5 & 1 in 12 T/Os and sleeper nos. 2 & 3 for 1 in16 T/O are
of longer length for fixing S&T motor. Extra length of these sleepers is extended on LH or
RH side of turnout and may/may not be laid in favorable direction. If extension of point
motor sleepers are on RH side w.r.t. to working direction of BCM, then these sleepers are in
favorable direction and it is possible to deep screen them by BCM without any need of
removing the point motor sleepers (however, point motor disconnection will be required).

(b) If extension of point motor sleepers are on Left Hand side of working direction of BCM,
then these sleepers are in unfavorable direction and it is not possible to deep screen them by
BCM. In such case, if feasible, direction is to be corrected in a prior advance joint block with
S&T, so that for future deep screening such problem do not arise. If correction of direction is
not feasible due to site/space constraint, these sleepers are to be removed during same traffic
block of BCM and reinserted after BCM working. If done in same block, it will require
additional time. Typical situations are explained in Annexure-B as follows:

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4.4 Shoulder Ballast Cleaning Machine (SBCM):

The machine is used for cleaning of shoulder ballast to improve the drainage of track.

4.4.1 Types of Shoulder Ballast Cleaning Machines:

Presently, two types of SBCM are available on Indian Railways.-

(1) Shoulder Ballast Cleaning Machine - FRM 80 (Plasser India).

Figure-13 SBCM - FRM 80 (Plasser India).

(2) Shoulder Ballast Cleaning Machine - FRM 85F (Plasser India).

Figure-14 SBCM - FRM 85F (Plasser India).

Both the machines are similar except that the muck in FRM 80 is thrown on the backside
while that in FRM 85F is thrown in the front.

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4.5 Ballast Regulating Machine (BRM) :

These machines are used for ballast transfer, spreading and profiling operations. The machine
can move ballast towards centre of track or away from centre of track, transfer ballast across
the track and transfer ballast from a surplus zone to deficient zone.

4.5.2 Types of Ballast Regulating Machines (BRM ) :

Ballast Regulating Machines working on Indian Railways are classified into two categories as
below:

4.5.2.1 Without Hopper -

These machines are provided with shoulder plough, front/center plough, brooms, and
conveyor belts. These are four-wheeler vehicles. Different models of BRM’s working on
Indian Railways are:

(a) BRM Model 66-2/56-3 and 66-4 (Kershaw).

Figure-15 BRM Model 66-2/56-3 and 66-4 (Kershaw).

(b) PBR 400R (Plasser India) –

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Figure-16 PBR 400R (Plasser India)

(c) BRM Model SPZ-210 K (GemacEngg ).

Figure-17 BRM Model SPZ-210 K (Gemac Engg ).

BRM Model SPZ-210 K (GEMAC ENGG) has centre plough while other two models have
front plough.

4.5.2.2 With Hopper

These machines have a system of collecting excess ballast from over sleeper to the hopper via
broom and conveyor belt arrangement. The collected ballast is unloaded at the shoulder
wherever required through a chute opening.
(a) USP 2000 SWS (Plasser India).
(b) RPB-01(Metex, Russia).

These are bogie type 8-wheeler vehicles. They are provided with center plough along with
brooms provided in the middle i.e. between bogies.

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Section 5

SAFETY PRECAUTIONS

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5. Safety Precautions for S&T staff associated with Track Machine Working :
( Ref.: N.Rly , New Delhi JPO No. 219-W/61/TMC/P&C/JPO dated 05.05.2022 for Deep Screening of Point &
Crossing by BCM )

5.1 Before Start of Work :

❖ Detailed Joint survey of all the points and crossings of the station/yard and preparation
of joint assessment report should be done at least 7 days in advance by the inspectors
in-charge of Engineering (P.Way), S&T, TRD, Electric(G) & TI/ASM/SS.

❖ Arrange to issue proper disconnection notice where any work on Electric Point
Machine or Electrical Detector involves disconnection or S&T connections like lock
rod, Stretcher bar need to be removed during the working of track machine.

❖ Identify the locations of buried cable coils likely to be damaged during working of
track machine.

❖ It may be noted that lifting of rod operated point is very difficult and cumbersome
activity and hence to be avoided.

❖ Selection of working line (main line/loop line) is to be decided based upon working
direction of BCM and turnout layout (RH/LH).

❖ Point sleepers may be inspected and if are in unfavorable direction scheme to correct
the sleepers and point motor on favorable side may be worked out.

❖ Identified hidden obstructions like rail, sleepers, drains, CC foundations etc. are to be
removed in advance.

❖ Polarity bonds, L-bonds, structure bonds, cross bonds required to be disconnected and
reconnected during BCM/UNIMAT block are to be identified in advance. Alteration to
electrical track bonding, if required, is to be done by Engineering department in terms
of Para 664(2)(b) of IRPWM-June 2020.

❖ Before disconnecting structure bonds, necessary temporary connection by rail

jumpers/8 SWG GI wire is to be made from the nearest track/mast/earth pit. When the
OHE is alive, no structure bond should be disconnected without arranging temporary
Earthing. The work of disconnecting/reconnecting structure bond is to be done under
supervision of Electrical supervisor/staff.

❖ Rail jumpers/wires required for arranging temporary connection as well as

wires/bonds/ insulation sleeves to be used for post BCM/UNIMAT work, are to be
arranged well in advance.

❖ To carry out S&T preliminary works, Supervisory staff and S&T Black Smith will be
provided by S&T Department, however, Engineering department shall provide
required trackmen/contractor labour to assist S&T supervisors sufficiently in advance
of the traffic block. This staff will be continued under S&T supervisor until
completion of the line block.

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Introductory Hand book on Track Machine for S&T Staff

❖ Identified hidden S&T cables are to be removed in advance. Cables having less than
1.0 meters depth from the rail level and coming in cutting width of BCM are to be
identified and relocated/or fresh cable should be laid appropriately in advance block.

❖ If any cable laying is required and feasible, same shall be done at an adequate depth
across the affected track portion. Engineering department shall provide necessary
trackmen / contractor labour for such work and such trackmen/contractor labour will
work under supervision and direction of S&T supervisor.

❖ S&T staff should fully equip themselves with adequate tools, drilling machines, cable
bits, wired TUBs, cable termination boxes etc. to attend the block.

❖ S&T Department shall arrange for disconnection and removal of S&T gears such as
Axle counter, track circuit including TLJB boxes, roddings, S&T cables etc.

❖ If the block is taken during night hours, adequate lighting is to be provided by

engineering department.

❖ Level crossings should be opened in advance so as to enable machine to work, and any
infringement in cutting zone on road of LC shall be identified & removed prior to
block. Sleepers should be arranged for replacement of unserviceable sleepers at level
crossing.

❖ For Points and Crossing, UNIMAT should be used for tamping.

5.2 During Working

❖ It should be ensured that S&T staff is available as necessary during working of Track
Machine.
❖ Block requirement should be jointly signed by Engineering, S&T and TRD
supervisors and block cancellation should be jointly given by all the three
departments.
❖ Ensure that damage to buried cable or cable coils, track lead junction box and other
S&T connections are avoided during working of track machine.

5.3 After Completion of Work

❖ Ensure that the S&T apparatus disconnected for work of Track Machine
(UNIMAT/BCM) is restored to its original state and working satisfactorily after
thorough testing and arrange to issue reconnection notice.
❖ After deep screening of point zone, Engineering Department is to ensure manual
packing/UNIMAT packing.
❖ S&T Department will re-fix their assets and connections. However, re-fixing of
traction bond will be done by Engineering dept. in terms of Para 664 (2)(h) of
IRPWM-June 2020. Confirmation of completion of bonding work is to be done
jointly by TRD and Engineering staff before giving joint fit memo of points and
crossings.

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Introductory Hand book on Track Machine for S&T Staff

❖ Engineering supervisor will ensure proper setting/housing of tongue rail and working
of points to the satisfaction of S&T supervisor at work site & will obtain written
acknowledgment from S&T supervisor on the fit memo to be given to operating staff.

❖ If the block is taken during night hours, adequate lighting is to be provided by

Engineering department. The lighting arrangements should be continued till
completion of engineering work and to facilitate completion of S&T / Electrical
works for reconnection adjustment and restoration of normal working of points, track
circuits and axle counters, re-fixing of electrical bonds, OHE adjustment etc.

❖ After completion of work, joint fitness of turnout point by Engg., S&T & TRD is to
be conveyed to ASM at the earliest. In exceptional cases, where due to some technical
reasons, re-fixing of S&T installations is taking more time, to avoid detention of
trains, Engineering fitness may be given first and trains may be passed by clamping of
point and issue of appropriate paper authority by ASM/SM. Thereafter joint fitness of
turnout is to be given at the earliest.

7. General Safety Precautions for Track Machine Working :

1. Track machine working is likely to produce a dusty atmosphere and/or heavy noise
pollution. Hence extra care is necessary at site to ensure safety of workers. For this,
Hooters are provided on the track machines. These hooters warn the staff working
on/around the track machine about approaching train on adjoining track. S&T Staff
should be alert and keep himself safe if any Hooters sound while working of Track
Machine.
2. Always wear Safety helmets / Shoes and masks to avoid inhaling dust.
3. Always keep your eyes open for other men working close to the machine.
4. Do not forget to look out for signals, switches and track obstructions.

***

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Introductory Hand book on Track Machine for S&T Staff

REFERENCES

1. Indian Railway Signal Engineering Manual (IRSEM) Version-3, July-2021.

2. Indian Railway P.Way Manual (IRPWM), June-2020.
3. Indian Railway Tack Machine Manual (IRTMM).
4. Handbook on Track Machine for P. Way by IRICEN, Pune.
5. https://www.plassertheurer.com/en/machine/overview
6. https://bhel.com/sites/default/files/dts-operation_and-maintainence_manual-
dts-nkou-320-05_-98-1474885551.pdf
7. Chief Engineer/NR/NDLS letter No.219-W/61/TMC/P&C/JPO dated 22.05.2022

27
 QUALITY POLICY

To develop safe, modern and cost effective railway technology

complying with statutory and regulatory requirements, through
excellence in research, designs and standards by setting quality
objectives, commitment to satisfy applicable requirements and
continual improvements of the quality management system to cater
to growing needs, demand and expectations of passenger and
freight traffic on the railways through periodic review of quality
management systems to achieve continual improvement and
customer appreciation. It is communicated and applied within the
organization and making it available to all the relevant interested
parties.
 INDIAN RAILWAYS
Centre for Advanced Maintenance Technology
Maharajpur, Gwalior (M.P.), Pin Code – 474005