2. INTERCHANGING OF RAILS A.Gunashekar ADEN.BPQ NAGPUR Division CENTRAL RAILWAY 1

3. Cause of Lateral wear 2

4. HOW TO INTERCHANGE IN STRAIGHT 3 We can not bodily lift the rail one by one and Shift from Left to Right

5. HOW TO INTERCHANGE IN STRAIGHT 4 We can not bodily lift the rail one by one and Shift from Left to Right

6. 200 m Equal length of 200 m is cut squarely opposite 5

7. One panel is slewed to the centre of track from LH side to RH It has slightly shifted to the right side IN THE DIRECTION OF WORK 6

8. How the panel is moving in the direction of Interchange (Straight) 7 500m When shifting from LH to RH,

9. How to Interchange (Straight) 8 500m

10. How to Interchange (Straight) 9 500m Length required to form reverse curve is pulled in the direction of work

11. How to Interchange (Straight) 10 500m

12. How to Interchange (Straight) 11 500m

13. How to Interchange (Straight) 12 500m And the panel has crept to Right side

14. One panel is slewed to the centre of track from LH side to RH It has slightly shifted to the right side IN THE DIRECTION OF WORK 13

15. Snaking length Other side panel is slewed over the first to otherside It has moved ‘s’ distance to the right side s 14

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19. ‘s’ distance is carried to the right side 18

20. s s After interchanging the panel has moved in the direction of work ‘s’ distance 19

21. Sameway the other panel has also moved to the right Two extra rails are to be replaced Four extra cuts are to be provided s 20

22. Snaking length s =60mm 21

23. 500 m Equal length of 500 m is cut out of square by 60mm opposite 60mm 22

24. One panel is slewed to the centre of track from RH side to LH It has slightly shifted to the left side IN THE DIRECTION OF WORK 23

25. Other side panel is slewed over the first to otherside It has moved ‘s’ distance to the right side 24

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28. ‘s’ distance is carried to the right side 27

29. ‘s’ distance is carried to the right side 28

30. s s After interchanging the panel has moved in the direction of work ‘s’ distance No extra rail replacement & no extra cut is involved 29

31. 200 m LG/R Interchanging of panels in curve Para.424 IRPWM Outer length of Rail is longer than inner Rail by LG/R 30

32. Para 424 IRPWM The excess length ‘d’ by which the inner rail gains over the outer rail is; d = LG/R 31 126.5 Sl.NoDegree of curve Length of Interchang planned d' in mm 11200 m200mm 21.5200 m300mm 32200 m400mm 42.5200 m500mm 53200 m600mm 63.5200 m700mm 74200 m800mm 84.5200 m900mm 95200 m1000mm 105.5200 m1100mm 116200 m1200mm

33. LG/R increasing against the direction of progress 32

34. 33 How to start interchange in CURVE We can not bodily lift the rail one by one and Shift from Left to Right Like in this animation

35. 34 How to start interchange in CURVE

36. 200 m 35 Outside panel is slewed to CENTRE OF TRACK. from LH to RH LG/R gap is left at LH and LG/R extended at RH

37. 200 m 36 Inside panel is slewed outside from LH to RH

38. 200 m 37

39. 200 m LG/R 38

40. 200 m 39 LG/R

41. 200 m 40

42. 200 m 41 LG/R

43. 200 m 42

44. 200 m 43

45. 200 m Sameway the other panel has also moved to the right Four extra rails are to be replaced Four extra cuts are to be provided 44 LG/R

46. LG/R + L a T - S 45

47. Marking of cut locations at starting 46

48. 200 m LG/R Equal length of 200 m is cut out of square by LG/R. To your surprise Far end cuts will become square. 47

49. 200 m 48 Outside panel is slewed to CENTRE OF TRACK. from LH to RH

50. 200 m 49 Inside panel is slewed Outside from LH to RH

51. 200 m 50

52. 200 m No extra rail replacement & no extra cut is involved 51

53. Criteria for Interchanging On Curve when lateral wear exceeds 8mm On Straight when cyclic wear exceeds 6mm On Straight when half service life of rail has passed Corrosion prone area where rail flange corrosion under liner’s seat is predominant on inside. Conversion of SWR in to LWR (also in Tunnels). Conversion of 3 rail panel into 20 rail panel in Ghat (Under trial to avoid excessive creep) 52

54. Clueless Interchanging and Bursting of Block 53

55. Clueless Interchanging and Bursting of Block Without PLANNING,if the Interchanging is carried out by deploying labours at both ends, the rail will buckle as it reaches the centre of panel, as shown in figure. First keep the Outer rail at middle of track, then the Inner rail to outside of curve. 54

56. Snaking length s =21.6mm 55

57. Different Locations 1. On Curves (In SWR) a) With Square Joints b) With Mid Staggered (Sharp Curves) 2. On Straight (LWR) 3. On Curve (LWR) 56

58. FACTORS AFFECTING THE LENGTH 1. LG/R increasing against the direction of progress 2. Snaking effect in the direction of progress 3.L T against the direction of progress 4. Welding Gap 57

59. Para 424 IRPWM The excess length ‘d’ by which the inner rail gains over the outer rail is; d = LG/R 58 126.5 Sl.NoDegree of curve Length of Interchang planned d' in mm 11200 m200mm 21.5200 m300mm 32200 m400mm 42.5200 m500mm 53200 m600mm 63.5200 m700mm 74200 m800mm 84.5200 m900mm 95200 m1000mm 105.5200 m1100mm 116200 m1200mm

60. Para 424 IRPWM The excess length ‘d’ by which the inner rail gains over the outer rail is; d = LG/R 59 126.5 Sl.NoDegree of curve Length of Interchang planned d' in mm 11200 m200mm 21.5200 m300mm 32200 m400mm 42.5200 m500mm 53200 m600mm 63.5200 m700mm 74200 m800mm 84.5200 m900mm 95200 m1000mm 105.5200 m1100mm 116200 m1200mm

61. 60 D =L a t

62. Consider 1 Km track with reverse curves of 300 m long each and 400m straight 1. The 300m of I st curve got to be Inter changed due to excessive side wear in LH rail 2. The 300m of II nd curve got to be Inter changed due to excessive side wear in RH rail 3.In the second Interchanging the 300m of I st curve got to be Inter changed due to excessive side wear in LH rail, for which I st or II nd class rails shall be arranged. 4.The released panel of the above shall be dollied to II nd curve and the second Interchanging shall be done 5. The released panel of the above shall be dollied to straight portion of the track and replaced.And the released rail can be kept reserved for future Interchanging. 61

63. Advantages Safety 1.Rail profile can be controlled and monitored 2. GFC defects are avoided from propagation. Economy 3. Number of welded joints are reduced 4.Optimum use of rail 62

64. 300 m 280 m LG/R 63 At the mid of curve make two cuts on inner and outer rails in perfect square with each other Measure equal distance,up to where the rail is worn and got to be Interchanged on both rails and make cuts on both rails. 300 m 280 m Keep the outer rail at the centre of track starting from LH end Take the inner rail to the outer side over the rail at centre of track from LH end Shift rail at the centre of track to the inner side from LH end Same way the RH side of curve is Interchanged from RH end NO CALCULATION AND NO THEORY Follow the steps below to Interchange any curve without closure rails

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