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 programme
Total cost of Rs.5.98 crores (revised to Rs 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!!!