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DEDICATED FREIGHT CORRIDOR

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:

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DEDICATED FREIGHT CORRIDOR

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  1. DEDICATED FREIGHT CORRIDOR New Technologies and Maintenance Strategy AshutoshRankawat ED/WDFC 1

  2. New Technologies 2

  3. 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

  4. Technology for Earthwork/Formation • Embankment is designed for 32.5 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/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). 4

  5. Designed for 32.5 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. 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.

  6. Technologies for fast paced construction 6

  7. 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 2x25 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

  8. 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 200 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

  9. Technologies for fast paced construction of Electrical works • Cylindrical foundations are used to facilitate mechanized construction of OHE foundation. • Mobile concrete trains & batch mixtures are used for concreting of OHE foundations.

  10. Technologies for fast paced construction of Electrical works

  11. Mechanized OHE Construction Work Foundation Auguring by Colmar Mast Erection by Palfinger Erected Masts Foundation Concreting by Boom Placer

  12. Mechanized OHE Construction Work PHOTOGRAPHS CONCRETE TRAIN FOR MAST FOUNDATIONS

  13. 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 of all trains at a glance. • Clamp Lock Point machines with Switch Setting Device (SSD) can handle thick web switches with 220 mm stroke. 13

  14. 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.

  15. Maintenance Strategy 15

  16. 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

  17. 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. Maintenance strategy:- Inspection

  18. Manpower- DFC vs Global Railways

  19. Thanks

  20. What is 2x25 kV AT Feeding System www.dfccil.org

  21. OHE Layout

  22. Four aspect Automatic signalling

  23. OHE Works PHOTOGRAPHS SPAZIO PT500, MULTIUTILITY MACHINE FOR OVERHEAD CATENARY SYSTEM

  24. Rail handling depot

  25. USE OF TECHNOLOGY - A step towards Sustainability

  26. 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 2x25 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 (200 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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