NORTHERN RAILWAY Headquarters Office, Baroda House, New Delhi. No. 798-W/2/3/Policy/Pt.XVII 04.10.2022 Sr.DEN/Co-ord. Northern Railway, DRM's Office, FZR, UMB, DLI, MB& LKO ‘Sub: - Winter precautions to prevent Rail/Weld fractures — Safety of Track. Winter season is going to set in and during winter season, the incidences of raillweld failures are normally high. It is imperative that such incidences are checked to the possible extent. Railway Board have also issued the instructions from time to time for the measures to be taken to control the incidence of rail/weld failures. In brief, the following actions are to be taken: - Visual examination of Rail ends should be done to detect any cracks emanating from bolt holes in terms of Para 611(2) of IRPWM 2020 and corrective action should be taken as per Para 620 of IRPWM 2020 and CE circular no. 209. The fish bolt holes should be with proper chamfering. The concerned ADEN should personally ensure that Chamfering Kit is available as per Para 620(7) of IRPWM 2020, with all SSEs/P.Way and used positively for chamfering whenever a new hole is drilled. They should be well acquainted with procedure of chamfering of bolt holes. IN order to reduce rail/weld fractures, shallow screening of pumping joints and rectification of joint sleeper spacing should be done wherever required All the joggled fish plate joints should also be examined and lubricated including bolt holes before onset of winter. The inspection and measurement of corrosion in corrosion prone locations and moderate corrosion prone locations should be done as per CE circular no, 258-R1. The preventive measures to reduce corrosion of rails and greasing of ERCs, inserts, liner seats including sealing of liners should be done as per CE circular no. 258-R1. (Sep.2013) and 261R-1 (June 2016). Rails having corroded flange should be kept under special watch & suitably protected. Inspection of LWRs/CWRs &SEJs must be carried out by SSE/P.Way as per table 1A and 1B of IRPWM 2020 and attended as found necessary. Destressing of LWR/CWR shall be completed wherever due. Pre-winter Geatressing planning should be apprised to this office by 15-10-2022,De-stressing of LWR/CWR to be done wherever incidences of fractures are higher or movement of SEu’s is erratic or beyond permissible limits. At locations where temporary de-stressing has been done during summer while doing deep-screening or other works, distressing of LWR should be don per the manual. For operation in loaded condition up to 60kmph for minimum standard of 52kg rail (90 UTS), destressing temperature for LWR in temperature zone IV would be reduced by 5°C (tm to tn+5). For operation in loaded condition up to 60 kmph and upto 75 kmph for minimum standard of 60 kg rail (90 UTS), for temperature zone IV as per IRPWM, distressing of LWR at reduced temperature (tm to tm+5) shall be completed before onset of winter season. If de-stressing in Zone IV is not done at lower temperature, loaded wagon will run at 60kmph during the winter period of 1%* November to 28"/29" of February of next calendar year. Frequency of USFD testing shall be strictly followed as per USFD manual and existing instructions. There should not be any section overdue for USFD testing. SSE/P.Way/ADENs/DENs/Sr.DENs should monitor and regularly check the work of SSEJ/USFD. USF testing of SEUs through hand probing to be ensured along with rail testing. The minimum frequency of testing for welds on major bridges & bridge approaches (100m on either side) and in tunnels & on tunnel approaches (100m on either side) shall be as per Para 8.15.2 USFD manual 2022. This frequency is onee in a year. It needs to be ensured that all AT welds on important and major bridges and their approaches (100 m) are tested before onset of winter as per standing instructions (Rly. Bd's Engineering Standing order No.34/3/1 (Revision-I) dated 10/11/2004) In case of defective weld (DFWO/DFWR) on major bridges & bridge approaches (100m either side) and in tunnels & on tunnel approaches (100m either side), action will be taken as per Para 8.14 of USFD manual 2022 The defective welds “DFWN" shall not be allowed to remain in service. All USFD defects within 4 meters and on major bridges & bridge approaches (100m either side) are to be treated as IMR defects and action as per Para 6.4 of “Manual for ultrasonic testing of rails/welds 2022" should be taken, The provisions for providing joggled fish plates on AT welds issued vide this office letter no. 393-W/19/USFD/JFP/DFWIPt-. | dated 01.03.17, should strictly be followed in the field. Analysis of rail/ weld fractures should be done on the Division to identify fracture prone locations and take necessary preventive measures. To detect the fractures during winter months, Key man’s duty roster should be changed to have early morning patrol so that failures, if any, can be detected in time. All the arrangements for cold weather patrolling should be made as per para 1005(4) of IRPWM 2020.A close watch on rail temperature should be kept and temperature record register should be maintained by SSE/P.Way & fed in TMS on daily basis. Cold weather patrolling must be introduced as per para 1005(3) of IRPWM 2020. Keymen and Patrolman should be provided with GPS tracker as per Railway Board letter no. 2017/CEIUTK/Policy/Part dated 17.11.2017 for monitoring patrolling to facilitate quick communication. Gap survey should be done in SWR territory and gap adjustments be done where needed. Creep should be measured and action taken to arrest it (Para 320 of IRPWM 2020) For urgent temporary repairs of locations of rail/weld fractures, spare joggled fish plates, clamps/bolts, wooden blocks should be kept at every km., gate lodges, and gang huts. The “Joint Procedure Order” issued by CTE & CPTM regarding rail /weld fractures repair and restoration of speed to normal should be followed. The detailed report of all the fractures along with the remarks of concerned officers in the respective columns, and sketch/photo of the fracture, should be uploaded in TMS within stipulated time period of 48 hrs, without fail. It has also been noticed that photographs of fractures are not being uploaded in many cases. It is advised that instructions issued vide this office letter no. 798-W/2/3/policy/Pt. XVII dated 13.9.2019 regarding uploading min. 06 nos. Photographs from different angles for every fracture should be strictly followed. No rail cuts should be allowed to continue in the track for more than 24 hours and it must have speed restriction of 30Kmph in LWR/CWR track. No untested rail should be put in track. LWRICWR in RF/WF prone locations should be identified and measures like recoupment of missing fittings and de-stressing at lower temperature for winter season should be taken as per requirement. Ensure zero missing fittings by recouping deficiency, if any, on priority. The in-situ AT welding should be done under speed restriction by trained staff having competency certificate and proper equipment. Adequate guidelines for the required duration are provided in Para 4.3 of Manual for Fusion Welding of Rails by Alumino- Thermic Process, as per which duration of traffic block will be 70 to 75 minutes. The instructions ‘have also been reiterated vide Pr. CE letter no. 319-W/168/Pt. XII dated 7.8.18. The block position should be personally monitored by Sr. DEN/Cs, Sr. DEN/ Lines & DEN/Lines. The new AT weld done in-situ shall be joggle fish plated with two clamps and supported on wooden block til tested as good by USFD. In case of renewals with 10/16/20 rails panels, speed restriction not exceeding 75 kmph must be observed till the joints are welded The above instructions are an extract of important items on the subject and for full details the relevant circulars and letters should be referred to. It is imperative on the part of Divisional officers to see that all safety precautions are taken by field staff right up togang men & they are aware of rules and requirements for ensuring safe train operation in cold weather. Also, during trolley inspections, knowledge of the staff and compliance of these instructions should be checked & ensured y Pramod Kaha Sharma) Chief Track Engineer Copy to 4. Secy./Pr.CE - for information of Pr. CE 2. CBE, CE/P&D, CE/G, CE/MRTS, CE/TSP, CE/TMS, CE/TMC, CE/HQ, CE/RC/HQ for information and necessary action please.