SOUTHERN RAILWAY - GAUGE CONVERSION –FROM PATTUKOTTAI TO KARAIKUDI –A study report

Internal Guide :

Ms. P Kanimozhi

AP-II, SoCE

SASTRA UNIVERSITY

External Guide :

Mr. A. Boopathy

XEN, Gauge Conversion,

Southern Railway, Trichy

Batch : 54

By

Shrinidhi V K

116001114

Topics

• Abstract

• Railway Section PKT - KKDI

• Project Details

• Preplanning / Planning/ execution & Control

• Existing and proposed line – MG to BG transition

• Agencies related to Railway construction & safety – RDSO, CRS

• Civil engineering elements in Gauge Conversion

• Recommendation & Conclusion

Abstract

Project Unigauge aims to standardise the rail gauges in India by converting most of meter gauge & narrowgauges tracks to broad gauge track. The current study of gauge conversion between Pattukottai andKaraikudi is a stretch of 77km involving reconstruction of station infrastructure, major bridges, minorbridges, realigning track, level crossing gates, and road-rail grade separators to match the currentstandards at optimized cost. The scope of the project is to analyze the basic elements and attributes torebuild the transport infrastructure along with the execution team. Study covers

• Overview of Railways

• Project Planning/ Execution and Control/ Closure

• Station Building and Passenger Amenities

• P-Way and Components

• Earthwork and Formation

• Bridges

Out of Scope:Design of Civil structureBudget, Cost allocation and financials

Gauge conversion progress -route km

Data references: 1. Paper by DMRC, Delhi Metro on Unigauge2. Wiki - https://en.wikipedia.org/wiki/Project_Unigauge

PKT – KKDIWhy Broad Gauge1. One of the last

MG lines in Southern Railway to be converted to BG

2. Non existence of BG/MG transshipment yard in the section

3. BG connects Ramanathapuram & Sivaganga dist. to Chennai via shortest route

List of stationsPattukottai -‘X’ ing (Proposed Jn)Ottankadu - HaultPeravuruni - ‘X’ingAyingudi - ‘X’ingArantangi - ‘X’ingValaramanikkam - HaultPeriyakottai – HaultKandanur – Puduvayal - ‘X’ingKaraikudi - Jn

Jn – Station with more than 2 lines enter into‘X’ ing – Station with points & crossing for train precedenceHault – Station where trains stop & go

Work assessment :Current MG line exists since 1920’s covers 77 kmsBridges requires reconstructionStation infrastructure require enhancement

Project Details

Sl. No Description Details

1 Distance Traversed 77 km

2 Districts Traversed Thanjavur, Pudukkotai, Sivagangai

3 Year of Sanction 2011-2012

4 Ruling Gradient 1 in 200

5 Max. Degree of Curvature 4-degrees

6 Number of Bridges Major – 14Minor – 257

7 Number of Tunnels Nil

Sl. No Description Details

8 P Way 60 kg for main line,52kg for loop line;PSC Sleepers of M+7 density with a ballast cushion of 270mm

9 LC/ ROB & RUB 61/ 17

10 LUS 39

11 Speed Potential of the Alignment

100 kmph

12 Period of Construction 7 years(Mayiladuturai – Karaikudi)4 years( PKT – KKDI) [ target 2016 – 17]

Power Lines – Lift / Shift to accommodate BG standardsROB / RUB – Provide sufficient vertical and horizontal clearanceLevel Crossing Gates– Swing gates replaced by lifting barriersAll vertical clearance should accommodate future Railway Electrification

PreplanningSource Activity

Railway Board Plans expansion, construction, conversion projects in India

Railway Board Sanctions Survey cost

Railway zone Conducts engineering cum traffic Survey

Railway zone Study existing infrastructure, identify work content to the current standards, cost, savings, internal rate of return (IRR)

Railway Board Receives Survey reports of various proposed works from Railway zones

Railway Board Collates various projects add as an item into budget based priority

Parliament Approves the budget

Input – Railway Board letter for survey approval – Dec 2004 for 15 lakhsEngineering Cum Traffic Survey report– May 2006

Survey Report Contents 1. History and technical

details of existing infrastructure

2. Geographical location3. Economy of region4. Other modes of

transports5. Justification of change6. Detailed work list with

current standard 7. Technical details like

track, earthwork, curves, gradients, bridges, level crossing gate, station infrastructure, passenger amenities

PlanningSource Action

Railway Board Allocates funds to individual projects for the financial year

Railway zone Setup offices, identify officers & supervisors

Railway zone Projects consolidated under Chief Administrative officer

RDSO Authorizes design drawings, execution and testing methods

Headquarters Provides engineering plan to execution office

Execution Org. Prepare detailed estimates for approval

Execution Org. Work with PWD, highways to collect flood data

Execution Org. Work with collector for land acquisition, mobility to site locations and avoid proj delays from local bodies

Execution Org. Prepare schedule and identify contractors

Engineering Cum Traffic Survey report is one of the key documents for project initiation and is named Project Charter Execution organization validates the budget to current standards & cost to provide revised estimate if required

Planning…1. Study the

maintenance records2. Assess the change in

alignment, gradients, curves, earthwork required for the new line

3. Approach participating institutions like local laboratories, education institutions

Planning – Outgoing MG & Proposed BG

1. Engineering Cum Traffic Survey report2. Blanketing - RDSO SPECIFICATION No. : GE: IRS -2 (Final) - MECHANICALLY PRODUCED BLANKETING MATERIAL FOR RAILWAY

FORMATIONS INCLUDING GUIDELINES FOR LAYING / July 20053. Major Bridge – IRS Concrete Bridge Code (1997) with correction slips / Design & drawing – eg. RDSO/B-10258 - I girder 12.2,m spanfor 25

MT loading

Area Outgoing MG Proposed BG Additional Info

Permissible Speed 60 kmph 100 kmph Speed potential of BG

Track rails Not applicable 60 kg rail As per BG standards

Track soil / new in formation

Sand & Loose soil Soil study at regular intervals; Blanket layer

RDSO SPECIFICATION No. : GE: IRS -2 (Final)

Minor bridges Open rails; pipes RCC box Flood data PWD/highways

Ballast Cushion

Sleepers Various types to MG PSC concrete sleeper Procure from RDSO approved suppliers

Minor bridges Open rails; pipes RCC box Flood data PWD/highways

Major Bridges Well foundation / Steel plate or truss girder

Pile foundations / PSC “I” girder

Piles depth 25 to 40 m; 25 MT loading;RDSO drawings/specs. / test procedure

Planning – Outgoing MG & Proposed BG

1. Adarsh (ideal) stations - Rly Board commercial circular 50 of 2013 - RB/L&A/004/2013 13-Aug-20132. Circulating area - Rly board guideline 2005/LMB/02/267 dated 07-Dec-20153. Flooring standards for platforms, concourse, FOB and Waiting rooms – RDSO letter WKS/WS/05/FS dated 22-Sep-20094. Roofing materials for platform shelters – RDSO letter WKS/WS/05/FS dated 22-Oct-20125. Amenities for persons with disability – Rly board guideline 2012/LMB(PA)/08/04/Policy/PwDs 06-Jun-20136. Sponsor’s responsibility - Rly board guideline 2012/LM(PA)/03/08/Policy 26-Sep-2014 and correction slips

Area Existing MG Proposed BG Additional Info

Section Category D D Based on revenue

Station yard length Around 600 m length > 1 km btw top points Station yard length

Amenities - Platform Mostly Low level of 400 m length

High level at “X” ing stnof > 700 m length

Accommodate 20 + coaches;

Station Building Heritage buildings constructed over time in past

Expandable Standardcubicles based on the type of station

Ticketing, station manager, equipment, staff room, waiting halls, toilets, circulating area

Amenities - Drinkingwater

at select stations & select place(s)

RO water;For every 2 coaches approx. 50 m **

** at “X” ing stn – 1 water cooler / Push type tabs for economy / least 1 accessible for persons with disability

FOB / Subways Not applicable at “X” ing stn RDSO drawing ;FOB height for future Rly Electrification

Execution and ControlType Action

Minutes of Meeting (MoM)

Meeting with stakeholders and record minutes, follow up and close any of the open items

Quality Control Arrange various levels of inspection, record the findings and take corrective steps with appropriate approvals

External Agencies

Arrange RDSO, consignee inspection, Labs from institutions;Record them as per schedule item

Monitoring and Billing

Monitor schedules, record the progress, monitor the cost through billing through measurement books & schedules

Contractual Control

Meeting, Communication with contractors at every stage

Work with Local Authorities

Work / negotiate with local authorities for transport of materials, additional construction work space if any occupied to execute the assignment

Consolidate inspection, testing, progress reports of individual civil structures and report to headquarters in prescribed formats.Work on actual cost, ETC and calculate project efficiency periodically

Challenges & remedies 1. One of the bridge site

doesn’t have sufficient land to reconstruct. Piles are reoriented over the existing well foundation & approval received

2. Unavailability of adequate land for the raised embankments on either side resolved with retaining walls

3. Approach to one of the site was unavailable due to local people’s day to day access path to nearby cemetery; Discussion with local authorities for alternate way

4. Railway lands nearby station area encroached by public was retrieved through collector / revenue authorities

Execution / Control – ReportsSummary ReportTargets & Status

Mile Stone Chart with Contractual letter

Safety - Indian Railways – Review 5 years

Reference: https://factly.in/indian-railway-accidents-statistics-review-last-5-years/

Review of train accidents -5 years (2009-10 to 2013-14):1. Large number of accidents happen at level crossing & derailments 2. More than 80% of the accidents are caused by Human Failure (Railway Staff or Otherwise)3. Number of accidents per million kilometers run has come down in the last few years4. Equipment failure accounts to only 2.2 % as against 86% by human failures5. Measures taken to reduce human dependencies e.g. Electronic interlocking at stations monitored by section controller; Gate

interlocking systems, etc

RDSO – Research Design and Standard Organization

RDSO is the sole R&D organisation of Indian Railways. It functions as the technical advisor to Railway Board Railway zones and production units.

Functions:

• Development of improved and new designs

• Development, adoption, absorption of new technology for use on Indian Railways

• Development of standards for materials and products specially needed by Indian Railways

• Provides technical investigation, statutory clearances, testing and consultancy services

• Inspection of critical and safety items of rolling stock, locomotives, signalling & telecommunication equipment and track components

• RDSO’s multifarious activities have the attention of railway and non-railway organizations in India and abroad

•For PSC Girder bridges:18.3m span – B1026212.2m span – B10258

•For ROB:18m span – B1175636m span – B11758

•RCC Box – B10152

•LUS – B10153

CRS - Chief Commissioner of Railway Safety

The Commission of Railway Safety, working under the administrative control of the Ministry of Civil Aviation of the Government of India, deals with matters pertaining to safety of rail travel and train operation.

The statutory functions laid down in Railway Act (1989) are of an inspectorial, investigatory & advisory nature.

Key roles

• Inspection of new lines, doublings, Gauge Conversion etc prior to introduction of passenger traffic

• Investigation into Serious Railway Accidents

• Proposals requiring Railway Board’s Sanction

• Proposals requiring sanction at CRS level

Opening Document•Request letter with a set of predefined enclosures and annexure that are submitted by the railways•Its done by the construction/ execution organization•Prepared before handing over the project to the maintenance dept•Source: Railway Gazzette•Info on section history, location, type of track structure, section category, summary of LC, major and minor bridges, curves, earthwork, speed restrictions, etc•Certificates for completion, curve list and abstract, test results, list of speed restrictions in the section.

Passenger Amenities To Be Provided• Platform

• Foot over bridges

• Toilets

• Signage

• Stalls & Trolleys

• Circulating area

• Entry & Exit

• Illumination & energy saving

• Mobile & Laptop charger

• Air cooling system

• Floorings

• Booking counters

• Dustbins

• Amenities for persons with disability

Minimum Essential Amenities - When a station is constructed, certain minimum amenities are required to be provided at each category of station (on the basis of projected traffic/earning).Recommended Amenities - The requirement of actual amenities based on traffic should be worked out and any augmentation based on this, will be known as Recommended Amenities.Desirable Amenities - Desirable amenities are those amenities which are considered desirable to improve customer satisfaction and interface process at the station.

Amenities

Platform

• Side Platform

• Island Platform

Flooring• Earthen Flooring

• Block Flooring

• Vacuum Dewatering Concrete

• Cantilever roofing - supported at one side by one column; free at the other side (laterally)

• Butterfly roofing – supported at both the sides (laterally)

Roofing

BLOCK FLOORING

EARTHERN FLOORING

VACVUM DEWATERED FLOORING

P-Way Components• Rail

• Sleepers

• Rail Fastening Assembly

Elastic rail clip

Grooved rubber pad

Liners : metal ; glass filled nylon

Earthwork

• Ballast

• Sub- Ballast

• Blanket

• Sub – Grade

• Natural Ground

LWR : 500m CWR : >500m ( block – block)LWR/ CWR : Prone to buckling, so regular maintenance SWR : 3 x13mRail welding : Mobile Flash Butt Welding, Alumino – Thermic WeldingUse mobile flash butt welding machineBlanket : Usage of Pug mill, rollers to provide consistent mixture & compaction

Bridges• Steel girder bridges are to be converted into PSC

Girder Bridges

• Well Foundation to be replaced with Pile Foundation

• Rail open minor bridges to Box bridges Pway

Key man path

Deck

Girder

Pedastal

Trestle Beam

Pier

Pile Cap

Pile

Site Activities

• Every Major bridge site has well established tools equipment that enable faster construction with the required quality. For example, Total stations, RMC (Ready Mix Concrete) plant, laboratory (cube moulds, slump cone, compression testing machine), Matt Machines (Killy Operated equipment for pile foundation), welding equipment, pre stressing and post tensioning systems with hydraulic jacks & pumps, grouting pumps, jig & tool, gauges, etc,.

• Earthwork and Blanketing sites are equipped with nearby pug mills, movers, compaction rollers, laboratory with soil test equipments & tools

• Station work fabrication unit is established by inspected templates that enable cutting, drilling, welding, layout & assembly processes for construction foot over bridges

• Management targets to have Mobile flash butt welding machines, Ballast spreaders, track laying tools, to expedite construction activities at a later stage of this project

Recommendations And Scope For Further Studies

The outcome of this study reveals the scope for future study in Indian Railways on the following aspects.

• A study on automation and construction of railway tracks.

• A study on design, fabrication and erection of foot over bridges.

• A study of soil properties of natural soil and necessity of blanket.

• A study of station redevelopment to world class infrastructure e.g. Trichy Jn.

• A study on construction of major bridges and minor bridges.

Conclusion

• Railway line helps in developing economy in the region

• Railway works like Gauge conversion, doubling of lines, constructing new lines involve quite a few activities

• Current individual project study is to establish the relationship between what is studied academically and how it is applied in larger project

• Practical knowledge on P-Way Components, Bridge construction, station infrastructure, Planning and Execution.

• Review of designs and site conditions.

• Recommend analysis of design, project planning, execution & control as Future scope to individuals and teams

• Railway makes use of lab facilities, students & faculty members of local colleges and universities to test, analyze their inputs from field. Undertaking projects & assignments will help the upcoming students and the university to get into the remunerable assignments

References

1. Indian Railway Bridge Manual, Railway Board, 1998

2. Indian Railway Permanent Way Manual, Railway Board, 2004

3. Manual for Standards and Specifications for Railway Station, Railway Board, 2009

4. Comprehensive Instructions for provision of Passenger Amenities at stations, Railway Board , 2012

5. Passenger Amenities works under MPLADS (Member of Parliament Local Area Development Scheme), Railway Board, 2014

6. Revised guidelines on Passenger amenities for passenger/persons with disabilities, Railway Board, 2013

7. Guidelines for provision of passenger amenities at Railway Stations through individuals, NGO, trusts, charitable institutions, corporate, etc,., Railway Board, 2014

8. Standardization of specification of flooring, roofing materials for platform covering in station premises, Guidelines issued by RDSO, 2013

9. Preparation of estimates, guidelines issued by Railway Board, 2008

10.Handbook on Inspection of Bridges, issued by CAMTECH, Centre for Advanced Maintenance Technology, Gwalior under RDSO/Railway Board

11. Case study on Method Statement for Construction of PSC Girders, BrijeshKumar Mishra, 2008

12.Case study on the Rehabilitation of Historic Bridges, The SRI FoundationRioRancho, New Mexico, 2011

13. Comparison case study on Pile Foundation vs. Well Foundation, H.N. JAISWAL

14.Case study Replacement of bottom chord member and strengthening of the girder of Road Over Bridge at Katihar yard, Yogesh Verma, 2008

15. Expert Group for Modernization of Railways.Indian Railways (IR), Ministry of Railways, Government of India, 2012

THANK YOU