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IR-UIC-GRFC-22/23-03-07 DELIR-UIC-GRFC-22/23-03-07 DELHIHI

DO NOT USE WITHOUT PERMISSION OF AUDO NOT USE WITHOUT PERMISSION OF AUTHOR AND IRTHOR AND IR

11

INTRODUCTION OF INTRODUCTION OF HEAVY AXLE LOAD HEAVY AXLE LOAD

OPERATION ON OPERATION ON INDIAN RAILWAYSINDIAN RAILWAYS

PresentationPresentation

ByBy

Rakesh Chopra and H L SutharRakesh Chopra and H L Suthar

ADDITIONAL MEMBER,and DIRECTORADDITIONAL MEMBER,and DIRECTOR

Indian Railway BoardIndian Railway Board



22

STRUCTURE OF PRESENTATIONSTRUCTURE OF PRESENTATION

1. GROWTH: _ NATIONAL. _ INDIAN RAILWAYS.

2. INITIATIVES: _ EXISTING TRACK AND STRUCTURES. _ MODERNISATION OF TRACK AND STRUCTURES. _ RESIDUAL CAPACITY AND DESIGN REVIEWS. 3. DEVELOPMENT OF INITIATIVES: _ INCREASE VOLUMES. _ PILOT PROJECTS ON HIGHER AXLE LOADS. _ IMPROVE THROUGHPUTS.

4. EXPERIENCE GAINED.

5. CONCLUSIONS.



33

GROWTHGROWTHCORE INFRASTRUCTURE INDUSTRY IN INDIA COMPRISES : CORE INFRASTRUCTURE INDUSTRY IN INDIA COMPRISES :

CRUDE, REFINED PETROLEUM PRODUCTS, COAL,CRUDE, REFINED PETROLEUM PRODUCTS, COAL,

ELECTRICITY, STEEL AND CEMENT.ELECTRICITY, STEEL AND CEMENT.

ON IR ABOUT 75% OF FREIGHT COMPRISES COAL, STEEL CEMENT ON IR ABOUT 75% OF FREIGHT COMPRISES COAL, STEEL CEMENT AND PETROLEUM PRODUCTSAND PETROLEUM PRODUCTS

GROWTH OF THESE GROWTH OF THESE 05-0605-06 06-0706-07

5.8% 8.4%5.8% 8.4%

GDP GROWTH 9% 9.2%GDP GROWTH 9% 9.2%

INFLATION 4.4% 5.12 INFLATION 4.4% 5.12



44

TREND OF EARNING 0N IRTREND OF EARNING 0N IR

0

2

4

6

8

10

12

14

16

2001-02

2002-3 2003-4 2004-5 2005-6

%ANNUAL GROWYH



55

TRACK UTILISATIONTRACK UTILISATIONIncrease in Traffic DensityIncrease in Traffic Density

Traffic Density GMTKM per Running Track KM

15.3515.55

16.34

16.85

17.46

18.34

18.83

15

15.5

16

16.5

17

17.5

18

18.5

19

19.5

1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06Year

An

nu

al G

MT



66

Freight ProjectionsFreight ProjectionsFreight Projections

600

650

700

750

800

850

900

950

1000

1050

1100

2006-07 2007-08 2008-09 2009-10 2010-11

Year

GM

T

Scenario1

Scenario2

Scenario3

Scenario4



77

Track structureTrack structure conventional modernconventional modern

RAILS 90R/52KG 72UTS 52/60KG 90UTS HHRAILS 90R/52KG 72UTS 52/60KG 90UTS HH ON CURVES ON CURVES

SLEEPERS WOOD/STEEL/CST PRCSLEEPERS WOOD/STEEL/CST PRC 1310/1540 /PKM 1540/1660/PKM1310/1540 /PKM 1540/1660/PKMFITTINGS RIGID ELASTIC FITTINGS RIGID ELASTIC

BALLAST 150/200mm 250/300mmBALLAST 150/200mm 250/300mm

JOINTS FISH PLATED WELDED WITH SEJs JOINTS FISH PLATED WELDED WITH SEJs

SWITCHES STRAIGHT CURVED/TWSSWITCHES STRAIGHT CURVED/TWS

XINGS BUILT CMSXINGS BUILT CMS

SUBBALLAST NONE DESIGNED BLANKETSUBBALLAST NONE DESIGNED BLANKET

MAINTENANCE MANUAL MECHANISEDMAINTENANCE MANUAL MECHANISED



88

CAPACITY AND DESIGN CAPACITY AND DESIGN REVIEWSREVIEWS

TRACK MODULASTRACK MODULAS

RAIL STRESSESRAIL STRESSES

SLEEPER DESIGNSSLEEPER DESIGNS

FATIGUE IN RAILSFATIGUE IN RAILS

IMPACT FACTORIMPACT FACTOR

BRIDGES SUPERSTRUCTUREBRIDGES SUPERSTRUCTURE SUBSTRUCTURESUBSTRUCTURE BEARINGSBEARINGS

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9

Relationship between axleload and rail section used

45

50

55

60

65

70

75

80

10 15 20 25 30 35Axleload (t)

Ra

il S

ec

tio

n (

kg

/m)

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:

Track Structure



10

Relationship between axleload and rail hardness (tangent track)

200

250

300

350

400

450

10 15 20 25 30 35

Axleload (t)

Rai

l Har

dnes

s (H

BN

)

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

Track Structure



1111

Brief History of HAL Brief History of HAL introductionintroduction

Original design of wagons is with 20.32 tonne axle loadOriginal design of wagons is with 20.32 tonne axle load

Carrying Capacity (CC) of wagons is derived from above axle Carrying Capacity (CC) of wagons is derived from above axle load and same is stenciled on each wagonload and same is stenciled on each wagon

LaterLater– Loading Tolerance (LT) was permitted upto 2TLoading Tolerance (LT) was permitted upto 2T– Carrying Capacity has been enhanced by 2T, the Permissible Carrying Capacity has been enhanced by 2T, the Permissible

Carrying Capacity (PCC) thus became CC+2T and total load Carrying Capacity (PCC) thus became CC+2T and total load (TL) including LT as CC+2+2T i.e. axle load as 21.32T(TL) including LT as CC+2+2T i.e. axle load as 21.32T

– PCC was enhanced further by 2T in November, 2004, PCC was enhanced further by 2T in November, 2004, universally for all wagons designed for 20.32T axle load and universally for all wagons designed for 20.32T axle load and having air brake system i.e. TL as CC+4+2T and AL 21.82T having air brake system i.e. TL as CC+4+2T and AL 21.82T



1212

Pilot ProjectsPilot Projects

In May 2005, PCC was further enhanced by 4T for BOXN In May 2005, PCC was further enhanced by 4T for BOXN wagons on identified iron ore routes as a Pilot Project for wagons on identified iron ore routes as a Pilot Project for one year i.e. TL as CC+8+2T and AL 22.82Tone year i.e. TL as CC+8+2T and AL 22.82T

Following precautions have been takenFollowing precautions have been taken– Maximum speed restricted to 60 kmphMaximum speed restricted to 60 kmph– Introduced USFD examination to detect Gauge Corner Introduced USFD examination to detect Gauge Corner

Fatigue (GCF) defects Fatigue (GCF) defects – Planned, installation of in-motion weigh bridges as Planned, installation of in-motion weigh bridges as

loading points to prevent over loadingloading points to prevent over loading– Instrumentation of Bridges, planned, to measure Instrumentation of Bridges, planned, to measure

longitudinal forces and stresses in memberslongitudinal forces and stresses in members– Installation of Wheel Impact Load Detectors (WILD)Installation of Wheel Impact Load Detectors (WILD)– Quarterly review at PHOD’s levelQuarterly review at PHOD’s level



1313

Pilot Projects contdPilot Projects contd……In November, 2005 Pilot Project was extended for In November, 2005 Pilot Project was extended for Coal routes of CR in BOXN wagons, TL in this case Coal routes of CR in BOXN wagons, TL in this case was kept as CC+6+2T keeping loadability in view was kept as CC+6+2T keeping loadability in view (AL 22.32T).(AL 22.32T).Conditions were same as for CC+8+2TConditions were same as for CC+8+2TPilot Project period extended by one more year Pilot Project period extended by one more year i.e. upto Jun 2007.i.e. upto Jun 2007.More routes have been included gradually in both More routes have been included gradually in both the above projects, more commodities and the above projects, more commodities and wagons have also been includedwagons have also been includedPresently CC+6+2T is in operation nearly on Presently CC+6+2T is in operation nearly on 26000 route kms and CC+8+2T on 5000 kms 26000 route kms and CC+8+2T on 5000 kms



1414

Growth of axle loadsGrowth of axle loads

19

19.5

20

20.5

21

21.5

22

22.5

23

AXLE LOAD

ORE

ORE COAL,CEMENT+ALL COMMODITIES

PASTNOV O4

MAY 05 NOV 05



1515

TRENDSTRENDS

19

19.5

20

20.5

21

21.5

22

22.5

23

TONNES

ORE

0

2

4

6

8

10

12

14

16

2001-02

2002-3 2003-4 2004-5 2005-6

%ANNUAL GROWYH

NOV 04MAY 05



1616

Experience gained from Pilot Experience gained from Pilot ProjectProject

– Rapid wear of points and xingsRapid wear of points and xings– Excessive wearof rails on curvesExcessive wearof rails on curves– Faster crushing of rubber padsFaster crushing of rubber pads– New formation problem locationsNew formation problem locations– Rail head pitting because iron ore fallRail head pitting because iron ore fall– Increase in cases of wheel scabbing/wheel Increase in cases of wheel scabbing/wheel

burnt railsburnt rails– Increase in rail/weld failures especially in Increase in rail/weld failures especially in

weld failuresweld failures



1717

WAGON PROBLEMSWAGON PROBLEMS

There has been increase in wagon There has been increase in wagon defects.defects.



1818

Experience from Pilot Project yet Experience from Pilot Project yet to be completedto be completed

Wheel Impact Load Detectors are to Wheel Impact Load Detectors are to be installed to know the impact loads be installed to know the impact loads and to decide the dynamic coefficientand to decide the dynamic coefficient

Longitudinal forces on bridges and Longitudinal forces on bridges and stresses in members of stresses in members of superstructure of girder bridges are superstructure of girder bridges are yet to be measuredyet to be measured



1919

HAL future scenarioHAL future scenario

It is envisaged that 25T axle load operation will It is envisaged that 25T axle load operation will start from this year (2006-07)start from this year (2006-07)

Presently in BOBS wagons which are designed for Presently in BOBS wagons which are designed for 22.9T axle load22.9T axle load

Future plansFuture plans– Nearly 7000 route km on iron routes have been Nearly 7000 route km on iron routes have been

identified for upgradation for 25T ALidentified for upgradation for 25T AL– Nearly 4200 route km identified as feeder Nearly 4200 route km identified as feeder

routes to DFC. These will also be upgraded for routes to DFC. These will also be upgraded for 25T AL25T AL



2020

Provision in XIProvision in XIthth five year plan five year plan

Age cum condition basis renewals are planned Age cum condition basis renewals are planned (costing Rs 23085cr)(costing Rs 23085cr)

Upgradation of iron ore routes and feeder routes Upgradation of iron ore routes and feeder routes to DFC costing Rs 1800 cr are also plannedto DFC costing Rs 1800 cr are also planned



2121

Integrated Railway Modernization Integrated Railway Modernization PlanPlan

Modernisation of track structure along with track Modernisation of track structure along with track renewals renewals

Cent percent mechanisation of track maintenance and Cent percent mechanisation of track maintenance and renewal activitiesrenewal activities

Improved and mechanised USFD technology (SPURT Improved and mechanised USFD technology (SPURT cars)cars)

Data loggers on existing SRT and DRTData loggers on existing SRT and DRT

Improved AT weld technologyImproved AT weld technology



2222

STRATEGY FOR THE FUTURESTRATEGY FOR THE FUTURE

Improve through putImprove through put

Take care of Pilot Project experiencesTake care of Pilot Project experiences

Create future capacity.Create future capacity.

Wagon design.Wagon design.



2323

IMPROVE THROUGH PUTSIMPROVE THROUGH PUTS

1.1. FASTER TRAINS ON EXISTING SECTIONSFASTER TRAINS ON EXISTING SECTIONS

2.2. HIGHER SPEEDS ON TURNOUTSHIGHER SPEEDS ON TURNOUTS

3.3. REMOVAL OF PERMANENT SPEED RESTRICTIONS PROGRAMMEREMOVAL OF PERMANENT SPEED RESTRICTIONS PROGRAMME

4.4. MECHANISATION OF TRACK WORKS AND REDUCTION OF WORK MECHANISATION OF TRACK WORKS AND REDUCTION OF WORK SITESSITES

5.5. HIGHER SPEEDS AFTER WORK—INCREASE OF TRAIN PATHSHIGHER SPEEDS AFTER WORK—INCREASE OF TRAIN PATHS

6.6. REDUCTION IN NUMBER OF LEVEL CROSSINGSREDUCTION IN NUMBER OF LEVEL CROSSINGS

7.7. GO FOR NEED BASED MAINTENANCE-IMLPEMENT ON LINE GO FOR NEED BASED MAINTENANCE-IMLPEMENT ON LINE TRACK AND BRIDGES MANAGEMENT INFORMATION SYSTEMSTRACK AND BRIDGES MANAGEMENT INFORMATION SYSTEMS

8.8. IMPROVE TERMINAL HANDLING FACILITIES.IMPROVE TERMINAL HANDLING FACILITIES.



2424

Take care Pilot Project experiencesTake care Pilot Project experiences

AT welds reduced, AT welds reduced,

Roll longer railsRoll longer rails

Thick Web SwitchesThick Web Switches

Cleaner railsCleaner rails

Introduce Rail grindingIntroduce Rail grinding



2525

Contd---Contd---Proper power needs to be provided for trains to Proper power needs to be provided for trains to prevent cases of stalling/scabbing etcprevent cases of stalling/scabbing etc

To identify these trains from Normal goods trains To identify these trains from Normal goods trains special name (SUMO) is being givenspecial name (SUMO) is being given

Induct new materials and technologyInduct new materials and technology

Improve wagon designsImprove wagon designs

Redo Feeder routes for above wagons and DFCRedo Feeder routes for above wagons and DFC

Need Based Track maintenance and 6 hr Need Based Track maintenance and 6 hr possessions for track workspossessions for track works



2626

Create Future CapacityCreate Future CapacityConstruction of Dedicated Freight Corridor.Construction of Dedicated Freight Corridor.

EasternEastern

WesternWestern

-Expected Investment Rs 30,000 cr-Expected Investment Rs 30,000 cr

-Expected period of-Expected period of

completion 5 yrs from start dt completion 5 yrs from start dt



2727

PROPOSED FREIGHT CORRIDORS

MUMBAI

DELHI

CHENNAI

KOLKATA

LUDHIANA

VIJAYAWADA

Sanctioned projects

VASCO



2828

Dedicated Freight Corridors- Dedicated Freight Corridors- Planning ParametersPlanning Parameters

First Phase – Eastern and Western First Phase – Eastern and Western RoutesRoutes2700 km Double Line Corridor 2700 km Double Line Corridor Fit for Speeds up to 100 KmphFit for Speeds up to 100 KmphCapable of 30-32.5 Tonnes Axle LoadCapable of 30-32.5 Tonnes Axle LoadCapable of Double Stack Container Capable of Double Stack Container operation.operation.Computerized Train Control SystemComputerized Train Control System



2929

Dedicated Freight Corridors- PlanningDedicated Freight Corridors- Planning ParametersParameters

Adoption of liberal MMD Adoption of liberal MMD

Tare to pay load ratio of 4-5Tare to pay load ratio of 4-5

Longer loops of 1.5 kmLonger loops of 1.5 km

Feeder routes fit for 25 tonne axle loadFeeder routes fit for 25 tonne axle load

Mineral routes for 25 tonne axle loadMineral routes for 25 tonne axle load



3030

Wagon designWagon design

Presently most of the wagons are designed with Presently most of the wagons are designed with 20.32T AL20.32T AL

Wagons are being designed with 22.9T and 25T Wagons are being designed with 22.9T and 25T ALAL

To maximise the output track loading density To maximise the output track loading density (TLD) is being enhanced (from <8.25t/m to nearly (TLD) is being enhanced (from <8.25t/m to nearly 9.33t/m and finally upto 12t/m for 30/32.5T AL) 9.33t/m and finally upto 12t/m for 30/32.5T AL) i.e. wider and high wagons will be usedi.e. wider and high wagons will be used

Production likely to start by end of next financial Production likely to start by end of next financial yearyear



31

Infringements on Feeder Routes, Inside Stations



32

Proposed MMD for Dedicated freight Corridor

9 FEET 6 INCH CONTAINERHT =6.81mtWHEEL 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?



3535

CONCLUSIONCONCLUSION

1.1. PENDING COMPLETE VALIDATION OF PILOT PROJECTS PATH PENDING COMPLETE VALIDATION OF PILOT PROJECTS PATH CHOSEN APPEARS CORRECTCHOSEN APPEARS CORRECT

2.2. CONSOLIDATE PILOT PROJECT RESULTS AND PREPARE FUTURE CONSOLIDATE PILOT PROJECT RESULTS AND PREPARE FUTURE ACTION PLANACTION PLAN

3.3. QUICK INDUCTION OF TRIED AND TESTED TECHNOLOGYQUICK INDUCTION OF TRIED AND TESTED TECHNOLOGY

4.4. PUT IN PLACE QUICKLY CIVIL ENGINEERING MIS ON LINE PUT IN PLACE QUICKLY CIVIL ENGINEERING MIS ON LINE SYSTEMS.SYSTEMS.

5.5. DEVELOP NEW DESIGNS FOR COSTRUCTION, OPERATION AND DEVELOP NEW DESIGNS FOR COSTRUCTION, OPERATION AND MAINTENANCE OF DEDICATED FREIGHT CORRIDOR AND FEEDER MAINTENANCE OF DEDICATED FREIGHT CORRIDOR AND FEEDER ROUTES.ROUTES.

6.6. PLAN AND MAKE AVAILABLE RESOURCE INPUTS FOR ABOVE. PLAN AND MAKE AVAILABLE RESOURCE INPUTS FOR ABOVE.



3636

Thank you for listening Thank you for listening



3737

Track structure designTrack structure designFor 25T AL operation following are For 25T AL operation following are consideredconsidered– Rails Rails 60kg 90UTS (HH on curves)60kg 90UTS (HH on curves)– Sleepers Sleepers PSC with 1660nos per kmPSC with 1660nos per km– FasteningFastening- elatsic fastening (ERC, GRP, liners)- elatsic fastening (ERC, GRP, liners)– P&C - P&C - fan shaped (PSC) layoutfan shaped (PSC) layout curved curved

switches (TWS prefered)switches (TWS prefered)– Ballast cushion- Ballast cushion- 300mm, 350mm 300mm, 350mm

(recommended)(recommended)



3838

Track structure designTrack structure design

To achieve economy existing track To achieve economy existing track structure consisting of following track structure consisting of following track structure is considered adequate for structure is considered adequate for speeds upto 60kmphspeeds upto 60kmph– RailsRails 52kg 90UTS52kg 90UTS– SleepersSleepers PSC with 1540 nos per kmPSC with 1540 nos per km– Ballast cushion-Ballast cushion- 250mm250mm



3939

Structure of presentationStructure of presentationTrack structureTrack structureTrack modulus and Track modulus and Rail stressesRail stressesBrief history of HALBrief history of HALHAL operationHAL operationPlanning in XIth five year plan and IRMPPlanning in XIth five year plan and IRMPWagon designWagon designExperience gainedExperience gainedTrack structure design for 25T ALTrack structure design for 25T ALTrack Management SystemTrack Management System



4040

Track modulusTrack modulus

As the track structure has undergone As the track structure has undergone lot of changes, it become necessary lot of changes, it become necessary to reassess the track modulusto reassess the track modulus

Studies were conducted by RDSO Studies were conducted by RDSO and based on results track modulus and based on results track modulus has been modified as underhas been modified as under



4141

Rail stressesRail stresses

Based on modified track modulus, Based on modified track modulus, track stresses have been calculatedtrack stresses have been calculated

Different methodology is adopted to Different methodology is adopted to find suitability of existing find suitability of existing infrastructure and design for new infrastructure and design for new structuresstructures



4242

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



4343

Track Mangement SystemTrack Mangement System

IR has introduced Track Management IR has introduced Track Management System (TMS) quite early (1990-91)System (TMS) quite early (1990-91)

It was introduced as Pilot ProjectIt was introduced as Pilot Project

It however could not be implemented It however could not be implemented fullyfully

Lot of changes has taken place in IT and Lot of changes has taken place in IT and communication technology, since thencommunication technology, since then

Now proposes to introduce TMS cum Now proposes to introduce TMS cum Management Information SystemManagement Information System

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