ir p.way manual - Indian Railway

312 Pages·2004·3.62 MB·English

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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
(RAILWAY BOARD)
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INDIAN RAILWAYS
PERMANENT WAY
MANUAL
Second Reprint 2004
INTERNET VERSION - Embodying all advance
correction slips upto number 100 dated 21-06-2006
F O R E W O R D
(to First Edition)
The “Indian Railways Way and Works Manual” incorporating uniform procedure
and practices to be followed on Indian Railways was first published in 1954. With
the introduction of modernization of track structure, Mechanical maintenance of track
and introduction of high speed trains in seventies and thereafter, the provisions in
the manual relating to track needed updating. This has now been done by bringing
out a separate “Indian Railways Permanent Way Manual”. It is hoped that the
procedures and practices envisaged in the manual will help the Permanent Way
men in maintaining the track to better standards, ensuring safety, economy and
efficiency.
New Delhi, T. N. RAMACHANDRAN
Dated 17th July 1984 Member/Engineering, Railway Board
PREFACE
(to First Edition)
The Indian Railways Way and Works Manual was last published in l967. Since then there have been
considerable changes in the Track Standards, Maintenance practices and Track Monitoring. The Track
Standards Committee had, vide Item 678 of the 49th Report, recommended the appointment of an Officer on
Special Duty by the Railway Board for revising the Way and Works Manual. The Committee also recommended
that the revised manual should be split into three separate parts, for Permanent Way, Bridges and Works.
Pursuant to the above recommendations of the T.S.C., the following three officers worked in succession
as Officers on Special Duty and compiled this part of the manual dealing with Permanent Way :
Shri Y.G.Patwardhan .. Mayl978 - August 1979.
Shri P. O. Thomas .. August 1979 - January 1981.
Shri K. S. Swaminathan .. March 1982 onwards.
The Draft Chapters, as compiled, were then scrutinised by a Select Committee consisting of the
following Officers :-
Sarvashri
Y.G.Patwardhan .. Principal, IRIATT, Pune.
N.Gopalan .. Director Standards, Civil, RDSO
Y. P. Anand .. Director, Track, Railway Board.
J.S.Mundrey .. Chief Track Engineer, N. Railway.
N.S.Raghavan .. Chief Track Engineer, S. Railway.
Y. V.Aswathnarayana ..
}
Chief Track Engineer, E. Railway.
N.P.Ghose
Shri K. S. Swaminathan, Officer on Special Duty and CPDE/South Central Railway acted as Member
and Convenor of the Committee.
While revising the Manual, the provisions in the Indian Railway General Rules 1976, Indian Railways
Code for the Engineering Department, 1982 Edition and the accepted recommendations of the Committee set
up for Review of Track Standards for Broad Gauge and Metre Gauge have been taken into account.
The Manual of Instructions on LWR/CWR 1979, the Manual of Instructions on Directed Track
Maintenance, and instruction manual on Measured Shovel Packing have been incorporated as Annexures to
this Manual. The provisions of SWR Manual have been incorporated in the relevant chapters of the Manual as
major portion of the track in the Indian Railways is on SWR track.
In a volume of this type, it is not possible to provide for every contingency that may arise during the
course of the working, though every effort has been made to make the instructions comprehensive. The Chief
Engineers of Zonal Railways may therefore supplement, where necessary, the practices and procedures
contained herein with such further instructions/orders, as would suit local circumstances on their Railway.
Such instructions must not of course contravene any of the provision in this manual, the codes of the various
departments of the Railways, General Rules, or any of the statutory regulations in force.
The Railway Board will be glad to consider any comments and suggestion from Railway
Administrations. Any errors or omissions found in this Edition may be brought to the notice of the Board.
New Delhi, TIRATH PRAKASH
Dated 17th July 1984 Director, Civil Engineering Railway Board
FOREWORD TO FIRST REPRINT TO IRPWM (1986)
A separate “Indian Railways Permanent Way Manual” incorporating procedure and practices to be
followed on Indian Railways after modernisation of the track commenced in the seventies was first
published in 1986. It has been decided to reprint the existing IRPWM updating the same by incorporating
all the Advance Correction Slips issued so far (i.e. Advance Correction Slip Nos. 1 to 27). It is hoped that
this updated manual will help the Permanent Way Men in maintaining the track to prescribed standards.
New Delhi, (V. K. Agnihotri)
June 1999 Member Engineering
Railway Board
PREFACE TO FIRST REPRINT TO IRPWM (1986)
A Separate “Indian Railways Permanent Way Manual” was published in 1986 pursuant to the
recommendations of the 49th Track Standards Committee. With the passage of time, certain changes in
Track Standards, maintenance practices, track monitoring, etc. have occurred and Advance Correction Slips
have been issued from time to time. It was decided by the Railway Board to reprint the IRPWM incorporating
all the Advance Correction Slips No. 1 to 27. Further, as a separate LWR Manual (1996) has already been
published, Annexure-M2 of the IRPWM (1986) has been deleted.
Railway Board will be glad to consider any comments and suggestions from the Railway
Administrations.
New Delhi, (N. C. Bindlish)
June 1999 Additional Member Civil Engineering Railway Board
FOREWORD TO SECOND REPRINT TO IRPWM (1986)
“Indian Railways Permanent Way Manual” was published in the year
1986, as per the recommendations of the 49th Track Standards
Committee. Thereafter, it was reprinted in the year 1999, incorporating
Advance Correction Slip Nos. 1 to 27.
The present manual was issued in English only. It is now being
issued in diglot form ( Hindi as well as English ) for the first time. This
reprint incorporates Advance Correction Slips upto No. 93.
A Compact Diskett, containing the full content in PDF form has also
been attached to the back cover. This will facilitate the viewing of the
manual on a Personal Computer as well as for taking print, if
considered necessary.
It is hoped, that this updated manual will help the Permanent Way
men, in maintaining the track upto the prescribed standards.
New Delhi (S.P.S. Jain)
May, 2004 Member Engineering
Railway Board
CONTENTS
CHAPTER I
DUTIES OF PERMANENT WAY OFFICIALS/MEN
PART ‘A’ 1 - 3
Duties of Assistant Engineer/Assistant Divisional Engineer
General 101. Essential duties of Assistant Engineer 102. Knowledge of rules and regulations 103. Co-
ordination with officials of other departments 104. Inspection by higher officials 105. Inspection by Assistant
Engineer 106. Inspection of Permanent Way 107. Execution of Works 108. Measurement of Ballast 109.
Action in case of emergencies 110. Accompanying Track Recording/Oscillograph Cars 111. Control over
Expenditure 112. Training of probationers 113. Witnessing payments to staff 114. Inspection of office and
stores of Inspectors 115. Staff matters 116. Relinquishment of charge 117.
PART ‘B’ 4 - 9
Duties of Permanent Way Inspectors / Section Engineer (P Way)
Duties of Permanent Way Inspectors (in overall charge)
General responsibility 118. Knowledge of rules and regulations 119. Co-ordination with works, bridge
and staff of other departments 120. Keeping of materials 121. Accompanying on inspections of higher officials
122 Testing of running qualities of track 123. Routine inspection of track 124. Revised Schedule of Inspection
of track 124A. Safety of track 125. Check on Patrolling 126. Execution of works affecting Track 127. Action
in case of emergency 128. Inspection and maintenance of LWR/CWR Track 129. Measurement of Ballast
130. Station Yards 131. Witnessing payment to staff 132. Other Establishment matters 133. Correspondence
and records 134, Relinquishment of charge 135.
Duties of Permanent Way Inspectors (not in overall charge)
General responsibilities 136. Knowledge of rules and regulations 137. Co- ordination with Works,
Bridge and Staff of other departments 138. Routine Inspection of Track 139. Revised Schedule of Inspection of
track 139A. Annual maintenance works 140. Check on patrolling 141. Execution of works affecting Track 142.
Action in case of emergency 143. Maintenance of LWR/CWR Track 144. Witnessing payments to staff 145.
PART ‘C’ 10 - 10
Duties of Permanent Way Mistries
General responsibilities 146. Knowledge of rules and signals 147. Permanent Way Mistry in-charge of
gangs 148.
PART ‘D’ 11 -14
Duties of Mates, Keymen and Gangmen
General
Knowledge of rules and signals 149. Safety of the line 150. Equipment at site of work 151. Musters and
Gang Charts/Diary books 152. Observance of sleeper packing during passage of train 153 Precautions when
view is obstructed. 154. Tidiness of section 155. Safe custody of tools 156. Action when line is unsafe or in the
event of accident 157. Patrolling during abnormal rainfall 158. Commencing work affecting safety of trains
159. Weekly inspection of gang length by mate 160. Preventing trespass and theft of Permanent way fittings
161. Relief arrangement in emergencies 162. Assistance to Posts and Telegraph staff 163. Assistance in
protection of trains 164. Assistance in placing fog signals 165. Responsibilities of the Mate in LWR track 166.
Duties of Keyman
Selection and training of Keyman 167. Keyman’s daily inspection 168(1). Roster duty hours of Keyman 168(2).
Equipment of Keyman 169. Duties of Keyman 170. Keyman’s book 171.
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CHAPTER II
THE MAINTENANCE OF PERMANENT WAY
PART ‘A’ 15 - 29
General Instructions
Responsibility of Engineering officials 201. Classification of lines 202. Systems of track maintenance
203. Annual programme of track maintence 204. Maintenance planning 205. Record of gang work 206. Attention
to Inspection Notes 207. Record of work of artisans and other workmen employed 208. Special reports on the
condition of Permanent way 209. Permanent Way Inspector’s section register 210. Permanent way plans and
diagrams 211. Records of materials under trial 212. Strength of gangs 213. Musters 214. Custody of gang
tools 215. Section Limit Board 216. Kilometre and gradient posts 217. Telegraph pole number 218. Verification
of land boundaries 219. Trolly refuges 220. Standard dimensions 221. Felling of trees obstructing view 222.
Side drains, catch water drains and water-ways 223.
PART ‘B’ 30 - 55
Regular Track Maintenance
Through packing—Conventional maintenance by beater packing 224. Maintenance by Measured shovel
packing (deleted) 225. Track maintenance by machines 226. Systematic overhauling 227. 3-tier system of
track maintenance 228. Picking up slacks 229. Observance of sleepers under passage traffic 230. Sample of
standard section off track 231. Checking work of gangs by PWI 232. Lifting of track 233. Lowering of track 234.
Distance pieces to platform lines 235. Fouling marks 236. Inspection and maintenance of Points and Crossings
237.
PART ‘C’ 56 - 65
Works incidental to regular track maintenance
Deep screening of ballast 238. Side and catch water drains and water-ways 239. Drainage in station
yards 240. Lubrication of rail joints 241. Counteraction and adjustment of creep 242. Buckling of track 243.
PART ‘D’ 66 - 73
Sleepers and Fastenings
Laying of sleepers 244. Wooden sleepers 245. Cast iron sleepers 246. Steel trough sleepers 247.
PART ‘E’ 74 -83
Rails and Fastenings
Standard sections of rails 248. Causes of rail deterioration 249. Rail maintenance to reduce rail
deterioration 250. Maintenance of rail joints 251. Inspection of rails in service 252. Action to be taken in the
case of rail fractures/weld failures 253. Stacking of rails 254. Handling of rails 255. Rail closures 256. Rail
failures 257 Careful usage of fish-plates 258. Combination fish-plates 259. Fish plate failures 260.
PART ‘F’ 84 - 91
Ballast and Ballast Depots
Type of ballast in use 261. Size of ballast 262. Ballast profiles/Sections/Depths of cushion 263.
Assessment of ballast requirements 264. Collection and training out of ballast 265. Depot collection of
ballast 266. Along side collections 267. Handing over charge by AEN 268. Unloading ballast along the line
269. Surplus ballast along the line 270. Ballasting new formation 271.
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PART ‘G’ 92 - 97
Track structure on Bridges
Rail and rail joints on Bridges 272. Bridge timbers 273. Use of rail free fastenings in girder bridges
274. Provision of guard rails on bridges 275. Provision of walkways 276. Inspection and maintenance of
track on approaches of bridges 277. Inspection and maintenance of Track on bridge proper 278.
PART ‘H’ 98 - 99
Maintenance of Track in track circuited areas
Precautions to be taken while working. 279. Insulated joints 280. Glued insulated joints 281.
PART ‘J’ 100 - 104
Maintenance in Electrified areas
General instructions 282. Special instructions 283. Maintaining continuity of track 284. Catch sidings
285. Additional precautions in A. C. Traction area 286. Fire in Electrified areas 287. Permanent Way Tools 288.
Treatment of persons suffering from Electric shock 289. Accident to power lines of outside bodies 290.
PART ‘K’ 105 - 110
Treatment of Formation
Classification of formation 291. Nature of formation problems 292. Site investigations 293. Soil
investigations and testing 294. Remedial measures suggested 295.
CHAPTER III 111 - 129
PERMANENT WAY RENEWALS
Classification of renewals 301. Factors governing Permanent Way renewal 302. Planning of Renewals
303. Track renewal programme 304. Track standards for renewals 305. Planning for posting of staff and other
facilities 306. Traffic facilities for renewals 307. Speed restrictions 308. Project Report for track renewal works
309 A. Preliminary Works 309 B. Unloading of rails, sleepers and fastenings 310. Methods of carrying out
renewal 311. Relaying with Mechanical equipment 312. Complete relaying Method (Manual) 313. Piecemeal
method of Relaying (Manual) 314. Essential points to be observed during linking 315. Track laying standards
316. Renewal of points and crossings 317. Sleepers in yards and running lines 318. Rails in station yards 319.
Classification and use of released materials 320. Marking of Permanent Way material 321. Identification of
different qualities of rails in field 322. Works to be attended after completion of relaying 323.
CHAPTER IV
CURVED TRACK AND REALIGNMENT OF CURVES
PART ‘A’ 130 - 139
General
Determination of radius 401. The reference rail 402. Gauge on curves 403 Definitions 404. Safe Speed
on curves 405. Superelevation, cant deficiency and cant excess 406. Length of transition curve and setting
out transitions 407. Running out superelevation 408. Indicators/Boards provided in curves 409. Speed over
turn-out curves 410. Permissible speed over curved main line at turn-outs 411. No change of superelevation
over turn-outs 412. Curves of contrary flexure 413. Curves of similar flexure 414. Curves with cross overs
415. Curves with diamond crossings 416. Extra clearance on curves 417. Compensation for curvature on
gradient 418. Vertical curve 419.
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PART ‘B’ 140 - 153
Realignment of Curve
Running on curves 420. Criteria for realignment of a curve 421. Stringlining operations 422. Realigning
curves on double or multiple lines 423. Cuttings of rails on curves 424. Joints on curves 425. Check rails on
curves 426. Wear on outer rail of curves 427. Measurement of rail wear on sharp curves 428.
CHAPTER V
WELDING OF RAILS : LAYING AND MAINTENANCE OF SHORT WELDED RAILS,
LONG WELDED RAILS AND CONTINUOUS WELDED RAILS
PART ‘A’ 154 - 154
Welding of rails
General 501. Alumino Thermit Welding of rails 502. Tolerances allowed in the case of Flash butt welds
503. Short pre-heat welding process 504.
PART ‘B’ 155 - 159
Short welded rails
Definitions 505. Track structure for SWR 506. Conditions of laying 507. Laying of short welded rails 508.
Maintenance of short welded rails 509. Gap survey and adjustment of gap 510. Conversion of SWR into
LWR 511.
PART ‘C’ 160 - 162
Long welded rails/Continous welded rails
Reference to LWR/CWR Manual 512.
CHAPTER VI 163 - 184
TRACK RECORDING, ANALYSIS AND MONITORING
Introduction 601. Track recording by Mechanical/Electronic equipment 602. Track recording Cars 603.
Mechanical Track recording Car 604. Electronic Track recording Car 605. Frequency of Track recording 606.
Track categories for various parameters 607. Analysis of track recording Car charts 608. Arrangements for
running TRC 609. Actual running of TRC 610. Action to be taken on TRC charts 611. Brief explanation of
recordings 612. Monitoring of riding quality of track 613. Hallade track recorder 614. Oscillograph Car 615.
Analysis of Oscillograms and interpretation of results 616. Use of oscillograph car recordings 617. Portable
accelerometers 618.
CHAPTER VII
ACTION DURING ACCIDENTS INCLUDING BREACHES AND PRE-MONSOON
PRECAUTIONARY MEASURES
PART ‘A’ 185 - 193
Action during accidents including breaches
Observance of Rules 701. Report of accident to Station Master/Railway servant-in-charge of Block hut
702. Accidents impairing through traffic 703. Action at site 704. Report to the Chief Engineer 705. Attendance
of Police at site 706. Examination of site and preparation of sketches 707. Recording particulars at site of
accident 708. Use of recorded data 709. Repairs to damaged track 710. Procurement and arrangement of
labour
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711. Diversion 712. Transhipment 713. Funds required during Emergencies 714. Obstructions found on track
715. Flooded Causeways/Dips 716. Special precautions when track is submerged 717. Driver’s report on
defects in track 718. Abnormal occurrences attributable to locomotives and other rolling stock 719. Accidents
not affecting through traffic 720. Records of accidents 721. Accident statements to the Railway Board 722.
PART ‘B’ 194 - 201
Pre-monsoon precautionary measures
General precautions to be taken before monsoon 723. Materials for emergencies 724. Service spans
and Rail clusters 725. Railway affecting works (including Railway affecting tanks) 726. Vigilance over Railway
affecting tanks during heavy rains 727. Weather warnings and action to be taken 728.
CHAPTER VIII 202 - 215
ENGINEERING RESTRICTIONS AND INDICATORS AND USE OF DETONATING AND
FLARE SIGNALS
Work involving danger to train or traffic 801. Carrying out of works, in case of emergency 802. Responsibility
of the Railway servant in-charge of the work 803. Precautions before commencing operations which would
obstruct the line 804. Categories of Engineering works 805. Works of short duration 806. Works of long duration
807. Temporary Engineering Fixed Signals—Location and details 808. Procedure for passing trains at stop-
dead restrictions 809. Procedure for Blocking line for Engineering purposes 810. Work at time of poor visibility
811. Temporary signals in emergency 812. Periodical Notice of Engineering restrictions 813. Permanent speed
restriction indicators 814. Indicators (General) 815. Detonating signals 816. Care and custody 817. Stock with
Engineering staff 818. Use of detonators 819. Testing 820. Life of detonators 821. Disposal of time-barred
detonators 822. Safety range 823. Flare signals—Description 824. Use of flare signals 825. Safeworking of
Contractors 826.
CHAPTER IX 216 - 243
LEVEL CROSSING AND GATEMAN
General location 901. Classification of Level Crossings 902. Categories of Roads 903. Standards for
different classes of level crossings 904. Gates and locking arrangements 905. Skew level crossings 906.
Normal position of gates 907. Gate lamps and blinders 908. Traffic and Engineering gates 909. Equipment at
level crossings 910. Siting of gate-lodges 911. Appointment of Gatemen, rosters and medical fitness certificates
912. Duties of Gatemen 913. Maintenance of level crossing, examination of gate - equipment and Gateman in
rules 914. Level crossing registers 915. Level crossing indicators 916. Visibility requirements for unmanned
level crossings 917. Provision of speed breakers on the approaches of unmanned level crossings 918. Census
of traffic at level crossings, unmanned/manned 919. Unmanned ‘ C ‘ class level crossings 920. Track structure
in level crossings 921. Manning of the unmanned level crossings through Member of Parliament Local Area
Development Scheme (MPLADS) 922. Level Crossings on National Highways/ State Highways and other
important roads 923. Provision of new level Crossings/Manning/Demanning/Elimination 924. Criteria for
Replacement of existing level crossings (other than those provided on ‘Deposit Terms’) with road Over/Under
Bridges on cost sharing basis 925.
CHAPTER X 244 - 252
PATROLLING OF THE RAILWAY LINE
Types of Patrolling 1001. Protection of line in case of Emergency 1002. Commencement and termination
1003. Preparation of Patrol Charts 1004. Distribution of Patrol Charts 1005. Patrol Books and Systematic
Patrolling 1006. Equipment of patrolman 1007. Selection of Patrolman 1008. Certificate to be submitted by
P.W.I. 1009. Duties of Patrolmen 1010. Action when damage is observed 1011. Responsibility of Engineering
Officials in the matter of Patrolling 1012. Action by A.E.N. and P.W.1. on receipt of information regarding
Damage to the Line 1013. Vulnerable locations (Points) 1014.
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