INTRODUCTION OF HEAVY AXLE LOAD OPERATION ON INDIAN RAILWAYS

1
INTRODUCTION OF HEAVY AXLE LOAD OPERATION ON
INDIAN RAILWAYS

• Presentation
• By
• Rakesh Chopra and H L Suthar
• ADDITIONAL MEMBER,and DIRECTOR
• Indian Railway Board

2
STRUCTURE OF PRESENTATION

• GROWTH
• _ NATIONAL.
• _ INDIAN RAILWAYS.
• INITIATIVES
• _ EXISTING TRACK AND
  STRUCTURES.
• _ MODERNISATION OF TRACK
  AND STRUCTURES.
• _ RESIDUAL CAPACITY AND
  DESIGN REVIEWS.
• DEVELOPMENT OF INITIATIVES
• _ INCREASE VOLUMES.
• _ PILOT
  PROJECTS ON HIGHER AXLE LOADS.
• _ IMPROVE THROUGHPUTS.
• EXPERIENCE GAINED.
• CONCLUSIONS.

3
GROWTH

• CORE INFRASTRUCTURE INDUSTRY IN INDIA COMPRISES
  
• CRUDE, REFINED PETROLEUM
  PRODUCTS, COAL,
• ELECTRICITY, STEEL AND CEMENT.
• ON IR ABOUT 75 OF FREIGHT COMPRISES COAL, STEEL
  CEMENT AND PETROLEUM PRODUCTS
• GROWTH OF THESE 05-06
  06-07
• 
  5.8 8.4
• GDP GROWTH 9
  9.2
• INFLATION 4.4
  5.12

4
TREND OF EARNING 0N IR
5
TRACK UTILISATIONIncrease in Traffic Density
6
Freight Projections
7
Track structure

• conventional
  modern
• RAILS 90R/52KG 72UTS
  52/60KG 90UTS HH
• 
  ON CURVES
• SLEEPERS WOOD/STEEL/CST
  PRC
• 1310/1540 /PKM
  1540/1660/PKM
• FITTINGS RIGID
  ELASTIC
• BALLAST 150/200mm
  250/300mm
• JOINTS FISH PLATED
  WELDED WITH SEJs
• SWITCHES STRAIGHT
  CURVED/TWS
• XINGS BUILT
  CMS
• SUBBALLAST NONE
  DESIGNED BLANKET

8
CAPACITY AND DESIGN REVIEWS

• TRACK MODULAS
• RAIL STRESSES
• SLEEPER DESIGNS
• FATIGUE IN RAILS
• IMPACT FACTOR
• BRIDGES SUPERSTRUCTURE
• SUBSTRUCTURE
• BEARINGS

9
Track Structure

• Survey of current practices, carried out by
  JRP-2, initiated by World Executive Council of
  UIC indicates the following relationship between
  Rail Section and Axle Load

10
Track Structure

• The Survey also indicates that rails with Higher
  BHN are being used for higher axle loads

11
Brief History of HAL introduction

• Original design of wagons is with 20.32 tonne
  axle load
• Carrying Capacity (CC) of wagons is derived from
  above axle load and same is stenciled on each
  wagon
• Later
• Loading Tolerance (LT) was permitted upto 2T
• Carrying Capacity has been enhanced by 2T, the
  Permissible Carrying Capacity (PCC) thus became
  CC2T and total load (TL) including LT as CC22T
  i.e. axle load as 21.32T
• PCC was enhanced further by 2T in November, 2004,
  universally for all wagons designed for 20.32T
  axle load and having air brake system i.e. TL as
  CC42T and AL 21.82T

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Pilot Projects

• In May 2005, PCC was further enhanced by 4T for
  BOXN wagons on identified iron ore routes as a
  Pilot Project for one year i.e. TL as CC82T and
  AL 22.82T
• Following precautions have been taken
• Maximum speed restricted to 60 kmph
• Introduced USFD examination to detect Gauge
  Corner Fatigue (GCF) defects
• Planned, installation of in-motion weigh bridges
  as loading points to prevent over loading
• Instrumentation of Bridges, planned, to measure
  longitudinal forces and stresses in members
• Installation of Wheel Impact Load Detectors
  (WILD)
• Quarterly review at PHODs level

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Pilot Projects contd

• In November, 2005 Pilot Project was extended for
  Coal routes of CR in BOXN wagons, TL in this case
  was kept as CC62T keeping loadability in view
  (AL 22.32T).
• Conditions were same as for CC82T
• Pilot Project period extended by one more year
  i.e. upto Jun 2007.
• More routes have been included gradually in both
  the above projects, more commodities and wagons
  have also been included
• Presently CC62T is in operation nearly on 26000
  route kms and CC82T on 5000 kms

14
Growth of axle loads
ORE
ALL COMMODITIES
COAL,CEMENT
ORE
PAST
NOV O4
NOV 05
MAY 05
15
TRENDS
ORE
NOV 04
MAY 05

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Experience gained from Pilot Project

• Rapid wear of points and xings
• Excessive wearof rails on curves
• Faster crushing of rubber pads
• New formation problem locations
• Rail head pitting because iron ore fall
• Increase in cases of wheel scabbing/wheel burnt
  rails
• Increase in rail/weld failures especially in weld
  failures

17
WAGON PROBLEMS

• There has been increase in wagon defects.

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Experience from Pilot Project yet to be completed

• Wheel Impact Load Detectors are to be installed
  to know the impact loads and to decide the
  dynamic coefficient
• Longitudinal forces on bridges and stresses in
  members of superstructure of girder bridges are
  yet to be measured

19
HAL future scenario

• It is envisaged that 25T axle load operation will
  start from this year (2006-07)
• Presently in BOBS wagons which are designed for
  22.9T axle load
• Future plans
• Nearly 7000 route km on iron routes have been
  identified for upgradation for 25T AL
• Nearly 4200 route km identified as feeder routes
  to DFC. These will also be upgraded for 25T AL

20
Provision in XIth five year plan

• Age cum condition basis renewals are planned
  (costing Rs 23085cr)
• Upgradation of iron ore routes and feeder routes
  to DFC costing Rs 1800 cr are also planned

21
Integrated Railway Modernization Plan

• Modernisation of track structure along with track
  renewals
• Cent percent mechanisation of track maintenance
  and renewal activities
• Improved and mechanised USFD technology (SPURT
  cars)
• Data loggers on existing SRT and DRT
• Improved AT weld technology

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• STRATEGY FOR THE FUTURE
• Improve through put
• Take care of Pilot Project experiences
• Create future capacity.
• Wagon design.

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IMPROVE THROUGH PUTS

1. FASTER TRAINS ON EXISTING SECTIONS
2. HIGHER SPEEDS ON TURNOUTS
3. REMOVAL OF PERMANENT SPEED RESTRICTIONS PROGRAMME
4. MECHANISATION OF TRACK WORKS AND REDUCTION OF
   WORK SITES
5. HIGHER SPEEDS AFTER WORKINCREASE OF TRAIN PATHS
6. REDUCTION IN NUMBER OF LEVEL CROSSINGS
7. GO FOR NEED BASED MAINTENANCE-IMLPEMENT ON LINE
   TRACK AND BRIDGES MANAGEMENT INFORMATION SYSTEMS
8. IMPROVE TERMINAL HANDLING FACILITIES.

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Take care Pilot Project experiences

• AT welds reduced,
• Roll longer rails
• Thick Web Switches
• Cleaner rails
• Introduce Rail grinding

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Contd---

• Proper power needs to be provided for trains to
  prevent cases of stalling/scabbing etc
• To identify these trains from Normal goods trains
  special name (SUMO) is being given
• Induct new materials and technology
• Improve wagon designs
• Redo Feeder routes for above wagons and DFC
• Need Based Track maintenance and 6 hr possessions
  for track works

26
Create Future Capacity

• Construction of Dedicated Freight Corridor.
• Eastern
• Western
• -Expected Investment Rs 30,000 cr
• -Expected period of
• completion 5 yrs from start
  dt

27
PROPOSED FREIGHT CORRIDORS
LUDHIANA
Sanctioned projects
DELHI
KOLKATA
MUMBAI
VIJAYAWADA
VASCO
CHENNAI
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Dedicated Freight Corridors- Planning Parameters

• First Phase Eastern and Western Routes
• 2700 km Double Line Corridor
• Fit for Speeds up to 100 Kmph
• Capable of 30-32.5 Tonnes Axle Load
• Capable of Double Stack Container operation.
• Computerized Train Control System

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Dedicated Freight Corridors- Planning Parameters

• Adoption of liberal MMD
• Tare to pay load ratio of 4-5
• Longer loops of 1.5 km
• Feeder routes fit for 25 tonne axle load
• Mineral routes for 25 tonne axle load

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Wagon design

• Presently most of the wagons are designed with
  20.32T AL
• Wagons are being designed with 22.9T and 25T AL
• To maximise the output track loading density
  (TLD) is being enhanced (from lt8.25t/m to nearly
  9.33t/m and finally upto 12t/m for 30/32.5T AL)
  i.e. wider and high wagons will be used
• Production likely to start by end of next
  financial year

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Infringements on Feeder Routes, Inside Stations
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Proposed MMD for Dedicated freight Corridor
9 FEET 6 INCH CONTAINER HT 6.81mt WHEEL DIA
860mm ?
33
Proposed SOD for Feeder Routes on Eastern Corridor
Clearance for Electrification is yet to be
decided?
34
Proposed SOD for Double Stack Containers on
Feeder Routes
7300
7300
Clearance for Electrification is yet to be
decided?
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CONCLUSION

• PENDING COMPLETE VALIDATION OF PILOT PROJECTS
  PATH CHOSEN APPEARS CORRECT
• CONSOLIDATE PILOT PROJECT RESULTS AND PREPARE
  FUTURE ACTION PLAN
• QUICK INDUCTION OF TRIED AND TESTED TECHNOLOGY
• 4. PUT IN PLACE QUICKLY CIVIL ENGINEERING MIS
  ON LINE SYSTEMS.
• 5. DEVELOP NEW DESIGNS FOR COSTRUCTION,
  OPERATION AND MAINTENANCE OF DEDICATED FREIGHT
  CORRIDOR AND FEEDER ROUTES.
• 6. PLAN AND MAKE AVAILABLE RESOURCE INPUTS
  FOR ABOVE.

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• Thank you for listening
  

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Track structure design

• For 25T AL operation following are considered
• Rails 60kg 90UTS (HH on curves)
• Sleepers PSC with 1660nos per km
• Fastening- elatsic fastening (ERC, GRP, liners)
• PC - fan shaped (PSC) layout curved
  switches (TWS prefered)
• Ballast cushion- 300mm, 350mm (recommended)

38
Track structure design

• To achieve economy existing track structure
  consisting of following track structure is
  considered adequate for speeds upto 60kmph
• Rails 52kg 90UTS
• Sleepers PSC with 1540 nos per km
• Ballast cushion- 250mm

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Structure of presentation

• Track structure
• Track modulus and Rail stresses
• Brief history of HAL
• HAL operation
• Planning in XIth five year plan and IRMP
• Wagon design
• Experience gained
• Track structure design for 25T AL
• Track Management System

40
Track modulus

• As the track structure has undergone lot of
  changes, it become necessary to reassess the
  track modulus
• Studies were conducted by RDSO and based on
  results track modulus has been modified as under

41
Rail stresses

• Based on modified track modulus, track stresses
  have been calculated
• Different methodology is adopted to find
  suitability of existing infrastructure and design
  for new structures

42
Track structure change

• Change in track structure could be possible due
  to creation of SRSF fund (2001-02) and sufficient
  provision of funds under DRF thereafter
• In previous 6-7 years large number of track
  renewal works have been executed.
• Modern track structure is provided alon with
  renewals, depending on route classification and
  annual traffic density
• Especially during Primary renewals

43
Track Mangement System

• IR has introduced Track Management System (TMS)
  quite early (1990-91)
• It was introduced as Pilot Project
• It however could not be implemented fully
• Lot of changes has taken place in IT and
  communication technology, since then
• Now proposes to introduce TMS cum Management
  Information System