TEST TRACK FOR INDIAN RAILWAYS

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TEST TRACK FOR INDIAN RAILWAYS

• By ED(Testing)
• RDSO, Lucknow

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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

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Existing tests for new stock

• Detailed oscillation trials separately on service
  track (run-down) maintained as per
• Main line standards
• CM 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

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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

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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

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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

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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

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History of Test track

• Test 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

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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

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Present proposal

• Total cost Rs 87.3 crores
• 12 Kms stretch of straight section
• 7.5 kms of Endurance test loop
• Curves incorporated in endurance loop
• Track to main line maintenance standards ( upto
  120 Kmph)
• Additional 12 Kms straight costing Rs 25 crores
  for 160 kmph dropped by Rly Bd.

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Endurance Tests

• For 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

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Present status

• Detailed estimate for construction of test track
  to be made by NWR
• RDSO is making detailed estimate of
• Facilities
• Instrumentation
• Equipment

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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

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Problems due to Site

• Test track has to be closed during summers due to
  sand storms
• Need for facility/staff to remove sand breeches
  after every summer/sand-storm
• Sand dunes near test track
• Salt mines
• No potable ground water

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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 testing
• Low land inside loop

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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

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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

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Test Track-Implications for Future of Indian
Railways
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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

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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

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Test Track-Additional Use (contd)

• Crashworthiness tests can be done
• Studies 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

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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

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Proposed Action Plan

• Introduce mainline testing in RJK-SHTM
• Before implementing the project, visit worlds
  leading test track centres
• Interact with experts
• Observe actual testing
• Study available technology and equipment
• Understand problems, possible solutions and their
  cost-effectiveness

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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

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Thank You!!!