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 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

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 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.

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

Present status Detailed estimate for construction of test track to be made by NWR RDSO 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 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

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

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

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 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

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-SHTM Before 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!!!