1. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 1 INTRODUCTION OF HEAVY AXLE LOAD OPERATION ON INDIAN RAILWAYS PresentationBy Rakesh Chopra and H L Suthar ADDITIONAL MEMBER,and DIRECTOR Indian Railway Board

2. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 2 STRUCTURE 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.

3. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 3 GROWTH 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 AND PETROLEUM PRODUCTS GROWTH OF THESE 05-06 06-07 5.8% 8.4% 5.8% 8.4% GDP GROWTH 9% 9.2% INFLATION 4.4% 5.12

4. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 4 TREND OF EARNING 0N IR

5. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 5 TRACK UTILISATION Increase in Traffic Density

6. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 6 Freight Projections

7. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 7 Track structure conventional modern conventional modern RAILS 90R/52KG 72UTS 52/60KG 90UTS HH ON CURVES ON CURVES SLEEPERS WOOD/STEEL/CST PRC 1310/1540 /PKM 1540/1660/PKM 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 MAINTENANCE MANUAL MECHANISED

8. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 8 CAPACITY AND DESIGN REVIEWS TRACK MODULAS RAIL STRESSES SLEEPER DESIGNS FATIGUE IN RAILS IMPACT FACTOR BRIDGES SUPERSTRUCTURE SUBSTRUCTURE SUBSTRUCTURE BEARINGS BEARINGS

9. IR-UIC-GRFC-22/23-03-07 DELHIDO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 9  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. IR-UIC-GRFC-22/23-03-07 DELHIDO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 10  The Survey also indicates that rails with Higher BHN are being used for higher axle loads: Track Structure

11. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 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 CC+2T and total load (TL) including LT as CC+2+2T 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 CC+4+2T and AL 21.82T

12. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 12 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 CC+8+2T 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 PHOD’s level

13. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 13 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 CC+6+2T keeping loadability in view (AL 22.32T). Conditions were same as for CC+8+2T 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 CC+6+2T is in operation nearly on 26000 route kms and CC+8+2T on 5000 kms

14. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 14 Growth of axle loads OREORE ORE COAL,CEMENT+ ALL COMMODITIES PAST NOV O4 MAY 05 NOV 05

15. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 15 TRENDS OREORE NOV 04 MAY 05

16. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 16 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. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 17 WAGON PROBLEMS There has been increase in wagon defects.

18. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 18 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. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 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. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 20 Provision in XI th 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. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 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

22. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 22 STRATEGY FOR THE FUTURE STRATEGY FOR THE FUTURE Improve through put Take care of Pilot Project experiences Create future capacity. Wagon design.

23. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 23 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 WORK—INCREASE 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.

24. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 24 Take care Pilot Project experiences AT welds reduced, Roll longer rails Roll longer rails Thick Web Switches Cleaner rails Introduce Rail grinding

25. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 25 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. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 26 Create Future Capacity Construction of Dedicated Freight Corridor. Eastern Eastern Western Western -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

27. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 27 PROPOSED FREIGHT CORRIDORS MUMBAI DELHI CHENNAI KOLKATA LUDHIANA VIJAYAWADA Sanctioned projects VASCO

28. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 28 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

29. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 29 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

30. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 30 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 <8.25t/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

31. IR-UIC-GRFC-22/23-03-07 DELHIDO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 31 Infringements on Feeder Routes, Inside Stations

32. IR-UIC-GRFC-22/23-03-07 DELHIDO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 32 Proposed MMD for Dedicated freight Corridor 9 FEET 6 INCH CONTAINER HT =6.81mt WHEEL DIA 860mm ?

33. IR-UIC-GRFC-22/23-03-07 DELHIDO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 33 Proposed SOD for Feeder Routes on Eastern Corridor Clearance for Electrification is yet to be decided?

34. IR-UIC-GRFC-22/23-03-07 DELHIDO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 34 Proposed SOD for Double Stack Containers on Feeder Routes 73007300 73007300 Clearance for Electrification is yet to be decided?

35. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 35 CONCLUSION 1.PENDING COMPLETE VALIDATION OF PILOT PROJECTS PATH CHOSEN APPEARS CORRECT 2.CONSOLIDATE PILOT PROJECT RESULTS AND PREPARE FUTURE ACTION PLAN 3.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.

36. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 36 Thank you for listening Thank you for listening

37. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 37 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) –P&C - fan shaped (PSC) layout curved switches (TWS prefered) –Ballast cushion- 300mm, 350mm (recommended)

38. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 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

39. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 39 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. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 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. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 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. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 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. IR-UIC-GRFC-22/23-03-07 DELHI DO NOT USE WITHOUT PERMISSION OF AUTHOR AND IR 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