Implementation Supervision Consultant

The Louis Beraer Group Inc.,In joint venture with canarail Consultants Inc.,Systra SA and SCEC - Khatib & Alaml

Saudi Railway (SAR) Project

p9.11.15.03-1004-600-B-8 SAR-1742-10
Or. Shahld S.Khan Our Ref:SAR/CTW 100/3.6.76/1742/10
Projett Director CTWlOO OCS Ref: CTW 100/C1742l-1S.DOC
Contractor's Representative Your Ref: P: 122/070/2246
SaudiBin Ladln Group Date: 18th May 2010
P.0. Box 4542
Hafer- AI Batin

Dear Dr. Khan

ClvU and Track Works Contract CTW 100- Ras Az Zawr to Az.
labirah
Work lnstn&ctkm for De:Stressinc In Turnout Area (Rev
2)

In response to your submittal of the above work instruction, sent under cover of your letter,
reference no. P122/070/2246,dated 28th Aprfl2010.

Please be advised that your proposed WI for De-Stressing in Turnout Areas (Rev 2) is
hereby approved with code ( A"}.
11

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Your s .,.,
1 INCOMTNO POST PO
MSLC CTW-100 (P -

1 9 MAY 2010 :

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sincere ly

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Gary &nderson No• • .. ... . .. . .
.HS&E- . QM
Engineers Representative 2. / ....

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Work Instruction

Project Title: SAUDIRAILWAY (SAR) PROJECT- CTW100

Client: PUBLIC INVESTMENT FUND;

MiNISTRY OF FINANCE,
KINGDOM OF SAUOIARABIA

Sub contractor: SARCO- TSO JV

Issue Date: November 2009

Document: Work instruction for Turnout Area

de$tres$1ng:
2908-WI-002/AC Rev.2

----------------------- ---- --- ,_ .. ,

Designation Name
------
--------
Author Track Engineer H.Menj our
--·---------------- ····--··
Reviewed Track Project
by: Manager Andreas Chantzaras
-

Reviewed Technical
by: Manager Peter Perbey
Reviewed
by: Quality Manager Ahmadiftekhar
-- -- --·----
Approved Contractor
ldKhan
by: Representative r
----·

Pagel oflO
Content
Page

1. HISTORY OF REVISION 3

2. INTRODUCTION 3

3. SCOPE OF WORK 3

4. EQUIPMENT RESOURCES 3

5. STAFF 4

6. PRODUCTIVITY 4

7. METHOD 4

8. HEALTH AND SAFETY 8

9. COMMUNICATION 8

10. QUALITY CONTROL 9

11. APPENDIX 10

Turnout’s destressing quality form 2908-SP-02-F23 10

Correspondence: (not subject for re-submittal)


SARTSO JV to Saudi Binladin Group

Page 2 of 10
1. History of Revision
Description of Changes, Status of Revision.
Rev. No. Date Summary Reviewed by

0.0 14.11.2009 Issued A. Chabrol

1 03.03.2010 ISC Comments Incorporated M.Thangam
2 26.04.2010 ISC Comments Incorporated M.Menjour

2. Introduction
This work instruction is in addition to the track works method
statement.
The purpose of this work instruction is to provide a task-specific plan.
To provide site personnel with detailed information that is either not
included in the Method Statement, or needs to be re-iterated.
To enable the site manager/supervisor to communicate to his team,
the detailed specific instructions to carry out the task with regards to
resources, health & safety, quality controls, productivity...

3. Scope of work
The purpose of this work is to provide de-stressing for the turnout
and to connect it with the CWR (continuous welded rails). This
activity shall be performed once the turnout is correctly levelled and
its geometry complies with the specifications. The turnout itself shall
not be de-stressed.

4. Equipment resources
 1 rail cutting machine
 1 mechanic hammer or rubber hammers
 2 clipping machine
 track tools
 rail seat rollers
 alumino thermit welding kit

Page 3 of 10
5. Staff
 1 Quality engineer
 10 labours
 1 alumino thermit team

6. Productivity
The normal hours of work are from 6AM to 12AM and 1PM to 5PM
but could be changed according to the temperature conditions

7. Method
Temperature
Destressing of turnout methodology depends on rail temperature:
 When the temperature is
o o
between 34 c and 42 c, the work can proceed, but will require
the use of a tensor.
 When the temperature is
o o
between 42 c to 47 c, the work proceed naturally without the
need of tensor
 When the temperature is
o
above 47 c, the de-stressing cannot proceed
o
 Below 34 c, destressing
of turnout cannot proceed. However
if the temperature failed while proceeding with the activity, the
destressing will be considered as compliant for a drop down to
o
29 c
- Prior to the destressing, fastenings will be cleaned in order to
keep the space free of sand between the rubber pad and rail foot.
- Establish accurate reference points along the free rail to be pulled
from each side of the joint.
- The rail is cut at a minimum of 18m form the extremity of the
turnout from where the incorporation will proceed in order to avoid
to pull with tensor directly on the turnout

Page 4 of 10
- The fastenings of the track are opened on a specific distance
from the cutting point depending on how the breathing zone of the
LWR has been affected after cutting. This distance is defined as
follow:
o If the CWR has already been destressed:
 min of 100m if the turnout was temporally welded
 min of 150m if the turnout was temporally clamped
o If the CWR has not been destressed yet: (R+100)/2
o In curve: (R+100)/2
o Maximum length to open is 600m
- Do not remove the fastening of the turnout itself
- rollers are placed between the rail and the seat of the rail every
12 sleepers
o o
Destressing of the turnout at neutral rail temperature 42 c to 47 c.
- The rail is hammered to keep it free of stress and allow its
elongation using mechanic hammers.
- The gap for the welding is created by cutting the rail (25mm with
Railtech PLA process).
- If the gap cannot be reach, a 6m piece of rail shall be
incorporated

Page 5 of 10
 o
Destressing of the turnout, at rail temperature below 42 c.
- The gap to be created is calculated as per the following formula:
a=(s-1)+0.0115xLx(44-T0)+b/2+ℓ/200x(44-T0)
Where: s is the welding gap (25mm for PLA process)
L is the length of track open
ℓ is the length of the turnout
T0 is the actual temperature of the rail
b is the movement of the anchoring zone
- The tensor are put in place
- The rail is hammered to keep it free of stress and allow its
elongation using mechanic hammers.
- At the same time the rails are tensioning to reach the gap for the
welding (25mm with Railtech PLA process).

Control of elongations, fastening & welding

- The elongation at the reference point is checked and recorded in
the turnout’s destressing quality form 2908-SP-02-F23
- Starting from the extremity of the length of track opened, the
rollers are removed and the rail fastened.
- The welding proceeds as per the W ork Instruction for Alumino
Thermit W elding 2908-WI-002/R.
- The area is finally cleaned

Page 6 of 10
 Destressing of continuous turnouts (This case will mainly concerned
yard tracks):


L‘
2

Lc

L  1
 If the distance between the
two turnouts is more than 12m but less than 200m (12m < Lc <
200m)
- The destressing of the extremities is made as defined previously
- The destressing of the middle part is made with the following formula:
o a =(s-1) + 0.0115 x Lc x (44-T0) + b/2 + ( 
1+ 

2 )/200 x (44-t0)

- The destressing shall be done one by one but the order does not
affect anything.

 Group of turnouts is less than

12m ( Lc < 12m)

- In that case we consider the two turnouts as only one:

L ℓ L‘

- The destressing is made using the following formula:

o a=(s-1)+0.0115xLx(44-T0)+b/2+ℓ/200x(44-T0)

Page 7 of 10
8. Health and safety
Risk identify Safety measure
Sparks from welding - Training
and grinding the rails
- Fire equipment
- Safety goggles
- Restricted area, exclusion zones,
warning signs

Injuries consequence of - High safety shoes

trips & falls by walking
on ballast

In all the cases, workers should use Personal Protective Equipment:

helmet, safety shoes, gloves, visible vest, safety glasses and ear
plugs when required.

9. Communication
All communications are centralized in Hatifa.
The communications are in English.
The train drivers are always connected by radio.

Before all intervention on the track authorization must be taken

from the control master and red flag (or red light at night) shall
be put on the track 50 meters on both side of the working area.
After work, the foreman must inform the control master that the
track is ready for circulation or removed the red signals.

In certain cases speed restriction can be applied after opening

the track to circulation

Page 8 of 10
 10. Quality control

ITEM METHOD FREQUENCY VALUE CONTROL RECORD

BY
Rail Using rail Every Must be between Quality 2908-SP-02-F23
o
temperature thermometer destressing 34 to 47 c engineer
Gap of Using ruban meter Every As per calculation Quality 2908-SP-02-F23
cutting destressing engineer
Elongation Using ruban meter Every As per calculation Quality 2908-SP-02-F23
at reference destressing Engineer
point

All measuring devices shall be calibrated every 6 months by an

authorized company and calibration certificates shall be submitted
before using in production.

Page 9 of 10
 .:::::.qcwHL.:.J.:JU
SAUDI BINLADIN GROUP "9'
PUBLIC BUILDINGS & AIRPORTS

11. Appendix

Turnout's destressing quality form 2908-SP-02-F23

Page 10 of 10
 Siding AZ If case of continuous turnouts:
Tunout's destressing quality form Turnout number:
Distance Lc between the two
turnouts:
Ref: 2908 -SP-02-F23
Type: 1/9 - 1/14
Date: Date: Date:
DIRECT HEEL Kmp of cutting: DEVIATED HEEL Kmp of cutting: TOE Kmp of cutting:
Kmp end of detressing zone: Kmp end of detressing zone: Kmp end of detressing zone:
Rail temperature: Tº = ºC Rail temperature: Tº = ºC Rail temperature: Tº = ºC
s-1 = 25-1 = 24
s-1 = 25-1 = 24 s-1 = 25-1 = 24

Rail TºC 34 35 36 37 38 39 40 41 42 43 Rail TºC 34 35 36 37 38 39 40 41 42 43 Rail TºC 34 35 36 37 38 39 40 41 42 43

b/2 3 2 2 1 1 1 0 0 0 0 b/2 3 2 2 1 1 1 0 0 0 0 b/2 3 2 2 1 1 1 0 0 0 0
b/2 = b/2 = b/2 =
Length of track opened: L= m Length of track opened: L= m Length of track opened: L= m
0.0115 x L x (44-Tº) = 0.0115 x L x (44-Tº) = 0.0115 x L x (44-Tº) =
Length of turnout: ℓ= m Length of turnout: ℓ= m Length of turnout: ℓ= m
ℓ/200 x (44-Tº) = ℓ/200 x (44-Tº) = ℓ/200 x (44-Tº) =
Theoretical gap: Theoretical gap: Theoretical gap:
a = (s-1) + 0.0115 x L x (44-Tº) + b/2 + ℓ/200 x (44-Tº) = mm a = (s-1) + 0.0115 x L x (44-Tº) + b/2 + ℓ/200 x (44-Tº) = mm a = (s-1) + 0.0115 x L x (44-Tº) + b/2 + ℓ/200 x (44-Tº) = mm
Gap realised: Gap realised: Gap realised:
Elongation at reference point: Elongation at reference point: Elongation at reference point:
Max{0,57(46-t)} = mm Max{0,57(46-t)} = mm Max{0,57(46-t)} = mm
Moy{0,57(44-t)} = mm Moy{0,57(44-t)} = mm Moy{0,57(44-t)} = mm
Min{0,57(41-t)} = mm Min{0,57(41-t)} = mm Min{0,57(41-t)} = mm
Right side Left side Right side Left side Right side Left side
Mark n° Mark n° Mark n°
Move Diff Move Diff Move Diff Move Diff Move Diff Move Diff

R0 R0 R0

R1 R1 R1

R2 R2 R2

R3 R3 R3

R4 R4 R4
Established by SARTSO Representative: Checked by SBG Representative: Approved by ISC Representative: