TEST TRACK FOR INDIAN RAILWAYS

1. TEST TRACK FOR INDIAN RAILWAYS By ED(Testing) RDSO, Lucknow

2. 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

3. 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

4. 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

5. 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

6. 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

7. 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

8. 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

9. 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

10. 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.

11. 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

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

14. 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

15. 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

16. 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

17. 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

18. 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

20. Test Track-Implications for Future of Indian Railways

21. 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

22. 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

23. 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

24. 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

25. 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

26. 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

27. Thank You!!!