Measures to Ensure Safety for Maintenance

By

Sitesh Kumar SinghChief Engineer (Construction)/SE/ECR

East Central Railway

Construction Department

Indian Railways - An Overview and Trend

No. of bridges – 1,38,912

No. of >100 years old bridges – 35,437

No. of >60 years old bridges – 61,013

No. of Permanent Speed Restrictions (PSRs) – 94

No. of Temporary Speed Restrictions (TSRs) – 124

HDN

• 76% of freight

• 71% of overall traffic

Traffic Carried

• >65% of HDN running at more than 100% cap utilization

Cap Utilization

>40% of overall IR network operating at more than 100% cap utilization

Stressed resources incl. track & bridges 2

Changes in Loading standards

Loading Standard Year Max. Axle Load

of Engine (T)

Trailing Load (T/M) Long. Force (T)

Tractive

Effort (T)

Braking Force

Standard B 1903 18 1.20 T/FT - -

BGML 1926 22.9 7.67 47.6 10% of T.L.

RBG 1975 22.5 7.67 75 20% of T.L.

MBG 1987 25 8.25 10013.4% of T.L. + 25% of

Axle Load

HM 1995 30 12 135 - Do -

25T 2008 25 9.33 126 - Do -

DFC 2008 25 32.5 T/ 12.13 T/M 126 - Do -

3

Annual Gross Million Tonnes (GMT) growth

4

11.835 12.41513.575

15.5

21

31 31.5

0

5

10

15

20

25

30

35

1965 1970 1980 1990 2000 2010 2016

GM

T P

ER A

NN

UM

YEAR

Howrah – Barddhaman UP Chord Line

5

0

100

200

300

400

500

600

700

800

900

1000

1960 1970 1980 1990 2000 2010 2020

Cu

mu

lati

ve G

MT

Year

Cumulative GMT Growth Chart CGMT: 967

Howrah – Barddhaman UP Chord Line

GMT: 11.8

Objective & Motivation

Speed restrictions

• PSRs

• TSRs

Failure repercussion

• Important & major bridges

• Fractures

• Subsidence

Renewal loss

• Costly

• Traffic disruption

Challenges

Obtain REALISTIC evaluation

for infrastructure by fine-tuning

the existing SYSTEM to cater

to the hardships OBSERVED

in the field

6

Positive contributionInstrumentation

Analysis

Remedial measures

Major reasons of infrastructure weakness

7

Level crossings

Bridges

Rail/weld fractures

Points and crossings

Bad banks including trespassing

Fatigue conditions & lesser inspections

Overloading of wagons, Flat wheels

8

Suggested measures

Component Action to be taken Benefits

Level crossings

(i) Use of Rubberized pads. Needs to be standardized as already in successful use since 2005.RDSO has yet to approve it.

No use of earth & sand etc. as such:• Machine tamping can be done easily• No drainage problem• No deterioration in road surface &

rail clearances• Cheaper in long run as no special

PSC sleepers, blocks, bolts etc. are required.

• No need of overhauling & traffic block

(ii) Limited Height Subways with full covering. Standard drawings for different depths to be issued.

Can be provided at all locations

9

Suggested measures contd.

Component Action to be taken Benefits

(iii) Speed breakers to be replaced with rumble strips like highways

• Less breakdown of vehicles• Less speed reduction, will lead to

faster traffic dispersal

(iv) Retro-reflective painting of height gauges

• Act as warning to road vehicles

(v) Provide Siren in day time and bright yellow light during night

• Act as warning to road vehicles and loco pilots

10

Suggested measures contd.Component Action to be taken Benefits

Rails incldg. Pts & Xings

Guarantee Zero fractures before stipulated GMT –to achieve this:

(i) Bhilai Steel plant needs to upgrade its metallurgical tolerances, else

To achieve higher GMT & speed, quality upgradation is a must

(ii) Rails to be imported • Initial cost may be higher but it would ensure safety and prove to be economical from maintenance point of view

• Pre-mature renewal would be avoided• Performance of indigenous v/s

imported can be compared

(iii) Minimise S&T and electrical attachments to rails or P&Cs

• Attachments induce stress concentration zones

• Act as infringements during track machine mtc.

11

Suggested measures contd.

Component Action to be taken Benefits

L-Section of track

(i) Preferably to be elevated structure

• Level crossings & trespassing are avoided

• Must for higher speeds

• Less land is required

• No drainage problem

(ii) In densely populated areas, underground structure is the only option

• Costly but unavoidable• Can be done under water

(iii) In hilly areas with depth of proposed cutting more than 30m, tunnels to be constructed

• Easy to maintain• Economical

12

Suggested measures contd.

Component Action to be taken Benefits

Bridges Maintenance of track structure on bridges is the main cause of concern

(i) Use of Tie Tek sleepers to be standardised

• Its similar to wooden sleepers and already in use for more than 15 years

(ii) Preferable use of Steel Concrete Composite ballasted deck bridges

• Can be used for longer spans• Machine tamping can be done• Extra track fittings not required• Easy to maintain• Due to deck cover, there is less

deterioration in steel girder

13

Suggested measures contd.

Component Action to be taken Benefits

Inspections (i) Aerial cameras can be fitted to loco underframe. Control can be done from cabin

• No traffic block required for routine inspections

• Loco defects can also be captured

• Data monitoring can be done in real time

(ii) Special light inspection vehicles similar to TRC car/Tower wagon fitted with instruments & cameras in underframe to be deployed

• Fruitful inspections can be done and recorded

• Safe for maintenance staff• Track mtc. tools can also be

kept in the car with mtc. staff• Data transmission &

monitoring can be done in real time

14

Suggested measures contd.

Component Action to be taken Benefits

Inspections (iii) Outdated inspection schedules to be dispensed with

• Addition of every new schedule should drop equivalent no. of old stipulations

(iv) RDSO’s mandatory inspections should be dispensed with, though RDSO can continue to issue guidelines

• Ownership of quality will remain with the field official & they will be more updated

• It will reduce undue delays in stage passing/clearances

(v) Failure analysis to be mandatory

• Avoid reoccurrence of similar failure

• Corrective measures can be taken on pan India basis

15

Innovative suggestions

S. No. Suggestions Benefits

1 High speed turnouts for speed potential of 100 kmph

• Required for throughput enhancement

2 Platforms for high speed stopping trains on mainline

• Average speed can be increased

3 Existing tracks to be made compatible for running MAGLEV trains

• MAGLEV trains seem to be future of railways

4 Train operations to be centrally controlled

• Computer programming can facilitate this operation. Presently it is limited to RRI of stations only

• COIS & FOIS are only generating information. No post information application

5 Allow private players to run trains/operations in addition to existing railway system to generate competition

• This will bring modern technology• Minimize manpower• Improve safety & efficiency• Break railway monopoly

16

Innovative suggestions contd.

S. No. Suggestions Benefits

6 Change in trackman recruitment policy including training

• Physical strength should be the main criteria (like army recruitment)

• Higher qualification leads to exodus• Army like training should be done

7 Device automated maintenance system

• Manual Patrolling is not an effective solution

8 Set different standards for heavy density network (HDN) and low density networks

• Will provide focussed attention• Clear phasing/priority can be decided• Economical

17

Rubberised Pad at LC Gate in Gobra station

18

MAGLEV Train

19