Table of Contents 1. Introduction .................................................................................................................................... 3 2. DFCC Requirement on Rails ............................................................................................................ 3 3. Available manufacturers ................................................................................................................. 5 4. Options available for Length ........................................................................................................... 5 5. Transportation of Rails .................................................................................................................... 6 I. Transportation by Road .......................................................................................................... 6 II. Transportation by Rail ........................................................................................................... 13
Ministry of Railways (MOR), Government of India hasplanned to construct Dedicated High Axle Load Freight Corridor covering about 3363 kms on two corridors, Eastern Corridor from Ludhiana (Sahnewal) to Dankuni and Western Corridor from Jawaharlal Nehru Port, Mumbai to Tughlakabad/ Dadri near Delhi along with inter-linking of the two corridors at Dadri.
Dedicated Freight Corridor Corporation of India Ltd (DFCC), a public sector company has been set up under the Indian Companies Act 1956 for implementation of Dedicated Freight Corridor Project.
Eastern DFC Route will be approximately 1847 Km long from Dankuni to Ludhiana via Mughalsarai Allahabad Kanpur Tundla Aligarh and Khurja. Proposed alignment of DFC has been generally kept parallel to existing Indian Railway line except provision of detours at locations bypassing the major cities/towns.
Mughalsarai New Bhaupur Section (Double line 402 Kms) Phase 2 of the Eastern Dedicated Freight Corridor project starts from near Howrah end of existing Mughalsarai station of Indian Railways (between Mughalsarai-Ganjkhwaja stations) to New Bhaupur station (situated near the existing Bhaupur station of Indian Railways) via Mirzapur - Allahabad - Fatehpur - Prempur - Kanpur. Approximate total length in detour is 130 Kms.
This Phase 2 of the total project is divided into 2 contracts i.e. Contract Slice no. 201 and Contract Slice no. 202. There may be possibilities of awarding both contracts to a single contractor or separate contractors for individual contracts depending upon the evaluation of the technical and commercial bids.
2. DFCC Requirement on Rails
The total track length for the Phase 2 i.e from Mughalsarai to New Bhaupur is approx. 830 track kms. The total quantity of rail required considering 120MT/km is 830km*120MT/km= 99,600MT As per DFCCIL (APL-1 from Bhaupur to Khurja Ph 1), specification of the Rails is as follows:
The List of available manufacturers for the Grade 880 UIC 60kg are as follows: Domestic: Steel Authority of India Limited Jindal Steel and Power Limited
International Sr No. Company Name Country 1 Arcelor Mittal Luxemberg, Poland, Germany 2 Nippon Steel Japan 3 Voestalpine Schienen GmbH Austria 4 Tata Corus France
Apart from the above there are various manufacturers from China and Korea that manufacture rails of 880 Grade.
4. Options available for Length
The rails that are manufactured can be obtained in various lengths. The standard lengths that have been indicated in IRS T-12 2009 on the length of the rail procured are as follows: Balfour Beatty Group Limited EASTERN DEDICATED FREIGHT CORRIDOR PHASE-2 Rev no.: 01 RAIL HANDLING Date: 29/8/2013
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Rails of lengths greater than 26m i.e 130m or 260m are also possible. But as of now in india, SAIL hasnt supplied rails greater than 26m length directly from the manufacturing plant. So considering that the manufacturer can provide the rails in lengths greater than 26m, the options that are available with us are: 13m 26m 130m 260m 5. Transportation of Rails
The transportation of rails from the source location to the site can be done in two ways: I. Transportation by Road II. Transportation by Rail
I. Transportation by Road One of the modes of transport of the rails from the source i.e the steel plant to the site location can be transportation by road. The vehicle that will be used for the transportation by road shall be Trailers. The major constraint in transportation of Rails by road has been the length of the Rails. 13m rails (42ft) can be transported easily transported on trailers of 50ft flat bed. This is a standard trailer and is easily available. These are generally used in transportation of various other materials other than Rails like Steel rolled sections, steel pipes, steel channels etc. . Balfour Beatty Group Limited EASTERN DEDICATED FREIGHT CORRIDOR PHASE-2 Rev no.: 01 RAIL HANDLING Date: 29/8/2013
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According to IRC-SP-41, the minimum dimensions for the movement of the vehicle are as follows:
Figure 1: Minimum turning path for a Trailor according to IRC SP-41
26m rails (85ft) can also be transported on trailers but this will require special type of trailers with extended beds and has lot of problems during the transit operations.
Rail lifting and handling:
As per DFCCIL (APL-1) document, following specification on the handling of rails has been indicated: Balfour Beatty Group Limited EASTERN DEDICATED FREIGHT CORRIDOR PHASE-2 Rev no.: 01 RAIL HANDLING Date: 29/8/2013
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The high carbon and alloy steel used in the manufacture of rails renders the rails very sensitive to shock or impact loading, bruising, notching or marking on the surface, and the point or line loading. This is especially true in handling the longer rails being produced in the rail mills welding plants. The staff handling such rails are required to:
o Use strings made of flat link chains or holders of specific material. The attachments can be classified into two types: Single rail lifting Multi rail lifting There are various suppliers of these lifting attachments such as: Geismar Engcon Camlock etc.
o Use of magnetic devices is preferable. o Use multipoint slinging for lifting of rails. As per the Flash Butt Welding manual by RDSO the recommended lifting points are as follows:
o Stack the rails on firm, level and well drained ground.
o Stack subsequent layers on the uniformly placed spacers o Place rails of shorter length in upper layers o Handle rail gently without sudden impact. o Use protective clothing, gloves and helmet of distinctive colour
Location of Unloading: Unloading of the rails can be done at two locations:
At the depot location At intermediate locations such as level crossing, junction stations, crossing stations etc. Balfour Beatty Group Limited EASTERN DEDICATED FREIGHT CORRIDOR PHASE-2 Rev no.: 01 RAIL HANDLING Date: 29/8/2013
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At the depot location:
Unloading the rails at the depot location shall involve extra expenditure on transporting the rails again from the depot to the site location and hence this option can be avoided.
At intermediate locations such as level crossing, junction stations, crossing stations etc.: One of the best locations for unloading the rails shall be the intermediate level crossing, junction stations, crossing stations locations where there will be enough space to unload the rails and stack them in layers.
The unloaded rails stacked on the cess of the formations at these locations shall be lifted and placed on the formation using a using a 360deg excavator with a special lifting attachment as mentioned above.
After the rails are placed on the formation, the rails are then welded using a mobile flash butt welding plant.
II. Transportation by Rail The most economical way for the transportation of rails from the steel plant / the rail manufacturing unit to the site location shall be by rail. The scope of transportation of rails by Indian Railway route shall be in the scope of the manufacturer/supplier. The rails can be obtained by Indian Railway network from the following domestic vendors: Steel Authority of India Limited Jindal Steel And Power Limited Rails of all lengths can be obtained on Railway Rakes i.e. 13m, 26m, 130m and 260m. The rails of 13m lengths can be transported easily using the standard flat wagons i.e. BFR or the BRNA wagons. As per the discussion held with Mr. Bajaj of Jindal Steel and Power Limited, the rails of length greater than 13m needs to be transported using special flat wagons known as the BLL flat wagons. For the carriage of 260m long panels, JSPL has submitted the request for allotment of wagons to Indian Railways. In these flat wagons, at the coupler location there are these flat plates which have the roller attachment on which the rails will be mounted. As per the information obtained from JSPL, one rake of BLL wagons i.e. 40 no.s of wagons can carry 260m rail panels for quantity equivalent to 17kms of Track length.
Handling of rails of 260m while unloading of rail panels: The loading arrangement of the rails for the 260m long rails shall be under the scope of the manufacturer/supplier. The unloading of the rails however will be under our scope and the necessary arrangement for the unloading process shall be arranged at the unloading point.
The high carbon and alloy steel used in the manufacture of rails renders the rails very sensitive to shock or impact loading, bruising, notching or marking on the surface, and the point or line loading. This is especially true in handling the longer rails being produced in the rail mills welding plants. The staff handling such rails are required to:
o Use strings made of flat link chains or holders of specific material. Multi rail lifting