TEST TRACK FOR INDIAN RAILWAYS

By ED(Testing)

RDSO, Lucknow

Why Testing?Statutory requirements as per Policy

Circular No 6 of Rly. Bd. For new/modified design rolling stock

Check safety Get natural frequency in various modes Check comfort level for passengers Performance rating of locos

Existing tests for new stock Detailed oscillation trials separately on service track (run-

down) maintained as per Main line standards C&M Vol-I standards (Rajdhani Track )

Confirmatory oscillograph car run on tracks above 110Kmph where induction is planned Usually on Rajdhani Routes

For trains involving new rolling stock EBD for speeds exceeding 110 for passenger & 75 kmph for

goods Computer simulation is adequate for lower speed

Coupler force trials of trains Rating & performance trials of locos

New rolling stock induction process Design & issue of speed certificate by RDSO Detailed oscillation trials

Joint safety certificate by PHoDs of zonal railway where trials are proposed

CRS sanction Actual trials

Issue of final speed certificate by RDSO after CRS approval

Zonal railways use new stock after CRS approval

Present Problems in testing Difficulty/ delay in obtaining CRS sanction Non availability of block / through path in

busy sections Track parameters are not precisely known Track parameters change after every run due

to track disturbance by normal traffic Safety related problems of adjacent track on

double line sections

Present problems in testing (contd)

Track / OHE fitness certificate is required after runs beyond sectional speed

Non-contiguous test stretch cause to & fro movement after every run

Need to reverse the locomotive after every run

Problem of berthing facilities of staff coaches Excessive TA of Test Unit staff

Why Test Track? Delay in formalities related to CRS sanction

No CRS sanction required for trials on test track

Testing on dedicated track No disturbance to normal traffic Precisely controlled track parameters No safety related problems on service track Testing time likely to drastically reduce

History of Test trackTest track at Mughalsarai sanctioned in

works programme1986-87 Total cost of Rs.5.98 crores (revised to Rs

12.45 crore in 1993) 4 km of closed loop with 1.1 km of

reversing cross- over was planned Railway Board reviewed and abandoned

the project in 1998 due to various problems

History of Test track (contd)Railway Board sanctioned Test Track in

2002 –03 for Rs 87.3 crores Proposed site in Kanpur-Lucknow

dropped due to protests by local people against acquiring their land in 2003

Proposal for test track in Jodhpur-Barmer area accepted by Board in March 2004

Present proposalTotal cost Rs 87.3 crores12 Kms stretch of straight section7.5 kms of Endurance test loopCurves incorporated in endurance loopTrack to main line maintenance

standards ( upto 120 Kmph) Additional 12 Kms straight costing Rs 25

crores for 160 kmph dropped by Rly Bd.

Endurance TestsFor track and rolling stock components

To estimate life of components Facility for accelerated service trials, FAST

When lead of service train insufficient Cost of condition monitoring very high Usually for railways where maintainer of

component not part of the system Actual service trials follow FAST

Present status Detailed estimate for construction of test

track to be made by NWRRDSO is making detailed estimate of

Facilities Instrumentation Equipment

Problems in existing proposal Test track length inadequate

Total length of 12 kms against 35 kms required Track for speeds upto 120 kmph only

Rajdhani track not provided. Does not have station yards which is essential

for oscillation trials Reversal of locomotive required after every run Curves in a separate endurance loop

Stoppage of endurance tests during testing on curves

Problems due to SiteTest track has to be closed during

summers due to sand storms Need for facility/staff to remove sand

breeches after every summer/sand-stormSand dunes near test trackSalt minesNo potable ground water

Problems due to Site (contd.)Jatropha Carcus is unlikely to act as

Sand barrier Stray Cattle barrier

Poor rail connectivity Dust/sand storm to effect visibility,

which is very critical for testingLow land inside loop

Low Cost Alternative Identify “single train only” sections like RJK-

SHTS section of MB division of NR 22.9 Km track 30 Kmph max speed Only one pair of train which is also not very

popular One level crossing Three halts/stations Other track features like bridges, culverts and

curves

Low Cost Alternative (contd) Upgrade the track to mainline standard with

reversal facility at SNK Existing train service can continue when there

is no trial Stop service train on the day of trial

All runs in one series can be completed in one day Since only one pair of train hence no problem About 3 kms of precise track parameters required General sanction can be sought from CRS as no

passenger safety would be involved

Cost Comparision of Present Proposal with Conversion of RJK-SHTS Sec

3.89

13.611.8

16

23.01

2.81 3.84 3.5

9.500295

87.950295

0

15.572

04

0 03.84 3.5 2.96032

29.87232

Landacquistion

Cost of track Earth work &Bridge

ROB/RUB Electrification Signalling Building Equipment Other costs Total

Present

Proposed

Test Track-Implications for Future of Indian Railways

Integrated Modernisation Plan (2005-2010)

Trains upto 300 Kmph Future rolling stock design efforts to be for this

speed potential, hence test track for 300 kmph needed

Safety related issues to become primary concern Crash-worthy rolling stock to be designed Better understanding of technical issues related to

derailments More reliable rolling stock and track

Test Track- Additional Use Track stress analysis under dynamic

conditions are possible only on test track Lateral forces recorded at rail level

Also help in calibration of measuring wheels

Analysis of effect of track parameters on rolling stock behaviour possible only on test track

Test Track-Additional Use (contd)

Crashworthiness tests can be doneStudies related to derailment possible

Telemetric data acquisition and remote controlled train can be planned

Re-railing/accident relief equipment may be required in derailment/collision related studies

Test Track Know-How Lack of adequate information related to

Other possible uses of test track Equipment and technology Technical and managerial problems related to test

track No information on high speed rolling stock

testing Safety related issues Testing procedures and precautions Testing personnel safety Construction related details

Proposed Action Plan Introduce mainline testing in RJK-SHTMBefore implementing the project, visit

world’s leading test track centres Interact with experts Observe actual testing Study available technology and equipment Understand problems, possible solutions

and their cost-effectiveness

Proposed Action Plan (contd.) Review existing proposal based on

knowledge gained for a cost-effective alternative related to Facilities Location Length Shape ( closed loop or straight) High speed test track Testing Procedure and analysis

Thank You!!!