DEDICATED FREIGHT CORRIDOR New Technologies and Maintenance Strategy

DEDICATED FREIGHT CORRIDOR New Technologies and Maintenance Strategy

DEDICATED FREIGHT CORRIDOR New Technologies and Maintenance Strategy Ashutosh Rankawat ED/WDFC 1 New Technologies 2 New Technologies Number of new technologies are being used in construction of DFC project. The need for use of new technologies has arisen on account of: (i) Design of infrastructure for Heavy haul train operation and (ii) Fast paced construction

Technology for Earthwork/Formation Embankment is designed for 32)-: 25% or more; Swelling pressure (SW):- 50 KN/.5 T axle load as per Guideline and Specification for Design of Formation for Heavy Axle Load issued by RDSO (RDSO/2007/GE:0014). Two layer system Formation: a prepared subgrade of 100 cm thickness (SQ2)-: 25% or more; Swelling pressure (SW):- 50 KN//SQ3 soil with CBR > 8) is provided between embankment and blanket. Stone columns: Compacted sand and/or gravel piles for improvement of bearing capacity in marine clay. Ground improvement for expansive soils (Black Cotton Soil). Items Technical Parameters Soil with Clay Contents(2)-: 25% or more; Swelling pressure (SW):- 50 KN/)-: 25% or more; Swelling pressure (SW):- 50 KN/)-: 2)-: 25% or more; Swelling pressure (SW):- 50 KN/5% or more; Swelling pressure (SW):- 50 KN/ Identification of Expansive soil m2)-: 25% or more; Swelling pressure (SW):- 50 KN/ or more; Differential Free Swelling (DFS) Index:- 30% or more. Treatment methods Providing cohesive non-swelling soil (CNS) layer, below the bottom layer of Mentioned in embankment fill. CNS treatment is new technology in Railways. Contract/GE:14 Replacement of BCS Soil. Typical Cross section of Embankment with CNS treatment

Blanket 1 2)-: 25% or more; Swelling pressure (SW):- 50 KN/ Subgrade 2)-: 25% or more; Swelling pressure (SW):- 50 KN/ 1 Embankment GL. 1 2)-: 25% or more; Swelling pressure (SW):- 50 KN/ CNS LAYER 0.75m 0.3m Stripping BLACK COTTON SOIL

2)-: 25% or more; Swelling pressure (SW):- 50 KN/ 1 GL. 0.3m Stripping 4 Bridges Designed for 32)-: 25% or more; Swelling pressure (SW):- 50 KN/.5 T axle load. Bridges are designed to withstand CWR/LWR forces based on Rail Structure Interaction (RSI) studies carried out in terms of UIC Code 774-3 R (Track/Bridge Interaction) so as to permit continuation of CWR/LWR on bridges. Track Structure For Main line and points & crossings: 60kg 1080 HH rails is used in WDFC. The rail seat of PSC Sleeper will be able to cater to 68Kg/m rail sections also by providing suitable liners. Ballast cushion on main line: Minimum 350 mm. 60 Kg rail canted turnouts are used: ensure smooth riding and reduce Rail &

Wheel wear. Permits speed potential up to 55 Kmph in loop lines. These turnouts are designed to withstand forces of CWR using curved thick web switches, Anti-creep devices and weldable CMS crossings on PSC sleepers. SALIENT FEATURES OF DFC TURNOUTS VIS-A VIS IR TURNOUTS DFC DESIGN IR DESIGN 1 in 12 1 in 8.5 Particulars 1 in 8.5 1 in 12 Cant Continuation of CWR Overall length of turnout (mm) Canted Permitted 30,768 Canted Permitted 42)-: 25% or more; Swelling pressure (SW):- 50 KN/,667

Non-canted Not permitted 2)-: 25% or more; Swelling pressure (SW):- 50 KN/8,789 Non-canted Not permitted 39,975 Items Technologies for fast paced construction Details (Frequency: 2)-: 25% or more; Swelling pressure (SW):- 50 KN/ tests per (i) 500 sqm for embankment, & (ii) 2)-: 25% or more; Swelling pressure (SW):- 50 KN/00 sqm. for subgrade) Dry density Nuclear moisture density gauge (NMDG) equipment and moisture is used for measuring dry density of compacted soil. content (NMDG - 100 tests / day; Sand replacement method 2)-: 25% or more; Swelling pressure (SW):- 50 KN/0 tests / day)

Second step plate load test is carried out to measure Strain strain modulus EV2)-: 25% or more; Swelling pressure (SW):- 50 KN/ of compacted soil. modulus EV2)-: 25% or more; Swelling pressure (SW):- 50 KN/ This parameter express deformation & strength characteristics of soil. (Frequency 1 test per Km.) New Track Construction (NTCs) machines are used for mechanized laying of track. Long welded panels up to 2)-: 25% or more; Swelling pressure (SW):- 50 KN/60 m. are being used in Track Linking laying of track thereby reducing in-situ rail welds. Machine Minimizes damages to track components like rails & concrete sleepers. Track linking progress of up to 40-45 TKm/month. Track Destressing Track Destressing is mechanized with super puller machines. Destressing progress of up to 3.0 Rail Km. Construction Slip forms are used for fast construction of piers & of bridge with

abutments DFC bridges with high piers are being slip form constructed with slipform construction method. 6 Technologies for Electrical works High rise OHE with 7.54 m height suitable for double stack operation on Western DFC. First in the world at such MMD. Use of 2)-: 25% or more; Swelling pressure (SW):- 50 KN/x2)-: 25% or more; Swelling pressure (SW):- 50 KN/5 kV AT Feeding System Improved voltage regulation High Power density >1.5 MVA/RKM. Traction sub stations at distance of 60-70 km apart. More efficient system as power losses are less. Reduced electromagnetic interference. For earthing of traction return current, overhead Aerial Earth Conductor (AEC) has been used instead of structural bonds. Buried Earth Cable (BEC) used for effective earthing. Rail Earth Clamp: Rail traction bond connection using rail earth clamps Eliminates drilling of holes in the rails. 7

Technologies for Electrical works Use of Gas insulated substation (GIS) in case of space constraint for TSS locations. Use of auto fault locators for locating OHE faults precisely (within 2)-: 25% or more; Swelling pressure (SW):- 50 KN/00 m). Use of Modular Cantilevers: Pre-assembled cantilevers Light weight and made of AL alloy tubes and AL casting fittings. Easy to install and replace in field. Use of Scott Connected Traction Transformers: Three-Phase transformers Have reduced unbalance compared to single phase system More energy efficient Have capacity up to 100MVA. 8 Technologies for fast paced construction of Electrical works Cylindrical foundations are used to facilitate mechanized construction of OHE foundation. S. No. P&M

Capacity per machine per day 1 Tractor Augers 8-12 Nos. 2 Track Mounted Augers 8-12 Nos. 3 RRV Palfinger

10-14 Nos. 4 RRV Colmar 20-25 Nos. 5 RRV Tescar 20-25 Nos. Mobile concrete trains & batch mixtures are used for concreting of OHE foundations. Technologies for fast paced construction of Electrical works S. No P&M Capacity per

machine per day 1 Geismar Mast grabber 45 Nos. 2 F-15 Crane 12 Nos. 3 RRV - working Platform & articulated boom - Geismar Used for working at heights 4

RRV working Platform - Palfinger Used for working at heights 5 Auto Tensioning Wiring Train OMAC 6 TKM 6 Railway UTV with Crane Phooltas (UTV) & Palfinger (Crane) 6 TKM Mechanized OHE Construction Work Foundation Auguring by Colmar Foundation Concreting by Boom Placer

Mast Erection by Palfinger Erected Masts 11 Mechanized OHE Construction Work PHOTOGRAPHS CONCRETE TRAIN FOR MAST FOUNDATIONS 12 Technologies for S&T works Signalling Design: Four aspect Automatic Signalling with Inter Signal Distance of 2 kms. Use of distributed Electronic Interlocking. The EI at station also controls adjoining 3 Auto Location Huts (ALHs) on either side connected through Optical fibre. Use of Multi Section Digital Axle Counters (MSDAC) as Train Detection/track occupancy device. In Block sections one additional supervisory MSDAC is provided @ 1 per every two main line axle counters.

Emergency Communication between Driver- Guard- Station through GSM-R Technology. Locomotives will be provided with CAB radio. Base Transmission Stations (BTS) are designed with overlapping to prevent call dropping even if one BTS site becomes non-functional. Train Protection and Warning System (TPWS): Intermediate Balises will provide updates of the Signal information ahead to ensure optimal running at the same time providing full safety. Train Management and Diagnostic System (TM&DS): The Operational Control Centre (OCC) will be provided with Train Management system which will aid the Controller in paper less train running. Over view Video screens will provide the location 13 Technologies for fast paced construction in signaling works Bricks have been replaced by half round RCC pipes for protection of cables. Use of Location boxes has been made bare minimum by providing Auto Location Huts (ALH).

Electronic cable markers have been used to eliminate above the Ground Cable markers. Jig boring is being used at vulnerable locations for trench less cable laying. Maintenance Strategy 15 Maintenance strategy Mechanized inspection, monitoring and maintenance of assets with state of the art equipment with very lean organisation is planned. GIS mapping of assets will be done for asset management. Concept of integrated maintenance depot (IMD) and integrated maintenance sub -depots (ISMD) spaced at a distance of approximately 160 RKm & 80 RKm respectively. Rail cum Road vehicles (RCRV) at each ISMD and Rail borne mobile vehicle at each IMD will provide mobility to the maintenance gangs. A depot will be headed by a Depot manager supported by two depot civil engineers, two depot electrical engineers and one depot S&T engineer. Each depot will have civil, electrical and S&T maintenance gangs with 30-34, 4-7 and 4-6 MTS respectively. It is proposed to undertake following core maintenance activities in-house:Day to day maintenance, visual inspections, monitoring of track

infrastructures, planning of renewals, maintenance of track machinery etc. The following maintenance activities are planned to be outsourced:Planned renewal of rails, sleepers and ballasts, ballast supply and loading in to hoppers, maintenance of RCRV, maintenance of building & civil structures, special maintenance & repairs of bridge, power supply installation equipment at TSS/SP/SSP, general power services at stations. Maintenance strategy:- Inspection The track inspection will be carried out through track recording car (TRC) fitted with high resolution cameras capable of recording video at high speed. The track geometry & condition of track components recorded through video camera will be transmitted to maintenance control centre for generating maintenance action reports. It is planned to implement bridge health monitoring system by continuous real time recording & monitoring of important bridge parameters like HFL, mid span deflection, displacement/deflection of bearings, pier tilt, shifting of girders etc. of important bridges through bridge instrumentation. OHE inspection will be carried out through OHE recording car (OHRC) fitted with video cameras on pantograph capable of taking measurements at a speed of 100 Kmph. OHRC will record OHE parameters like contact wire diameter, gradient, height, stagger, force exerted by contact wire on Pantograph, loss of contact, hot spot, arc detection, voltage

measurement & mast implantation. Manpower- DFC vs Global Railways Reporting Description BNSF CSX GTC NS Executives, Officials and Staff Assistants 7,746 5,133 1,321

5,854 Maintenance of Way and Structures 9,854 6,118 1,868 5,662 Maintenance of Equipment and Stores 8,040 4,342 813 5,736

Transportation (other than Train and Engine) 1,965 1,202 343 1,255 1,26 8 Transportation (Train & Engine) 15,86 9,985 2,263 4 41,77 25,560 6,323 9

10,870 17,24 6 45,99 6 Total 27,59 4 UP 10,6 46 11,2 53 9,39 9 DFCC

(Propose d) 730 1,813 (Civil) 2,342 (Systems ) 1,360 (Ops & Safety) 129 6,226 Route-Kms - 100% Owned 22,21 15,183 UP 25,42 Ave.3,406 CSX 15,688 GTC 5,871 NS DFC BNSF

and Operated Burlington No 7 (US) 18 C (Canad (Dutch) (Union6 rthern Santa F27,30 19,238 Track-Kms - 100% Owned a) 6,546 17,92Pacific 30,05 6,462 e (US) ) 8 and Operated 1 9 Per Route- 1.9 1.62

1.07 1.82 1.81 1.6 1.83 Thanks What is 2x25 kV AT Feeding System 02/12/2020 www.dfccil.org 20 OHE Layout

Four aspect Automatic signalling OHE Works PHOTOGRAPHS SPAZIO PT500, MULTIUTILITY MACHINE FOR OVERHEAD CATENARY SYSTEM 23 Rail handling depot USE OF TECHNOLOGY - A step towards Sustainability 25 Technology for Electrical works High rise OHE with 7.54 m height suitable for double stack operation on Western DFC. First in the world at such MMD. Use of 2)-: 25% or more; Swelling pressure (SW):- 50 KN/x2)-: 25% or more; Swelling pressure (SW):- 50 KN/5 kV AT Feeding System to improved voltage regulation & power density >1.5 MVA/RKM. It also permits traction sub stations at distance of 60-70 km apart. The system is more efficient as power losses are less. It has reduced electromagnetic interference, For earthing of traction return current overhead Aerial Earth Conductor (AEC) has been

used instead of structural bonds. in addition Buried Earth Cable (BEC) is also used for effective earthing. A new technique for rail traction bond connection using rail earth clamps has been used thereby eliminating drilling of holes in the rails. Use of Gas insulated substation (GIS) where there is space constraint has been provided. Use of auto fault locators for locating OHE faults precisely (2)-: 25% or more; Swelling pressure (SW):- 50 KN/00 m). Use of light weight aluminum alloy pre assembled modular cantilevers made of AL alloy tubes and AL casting fittings. 26

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