Railway Engineering SECOND EDITION Satish Chandra Professov, Department of Civil Engineering, Indian Institute of Technology Roorkee M.M. Agarwal Retired Chief Engineev, Northern Railway OXFORD UNIVERSITY PRESS Oxford University Press is a department of the University of Oxford. It furthers the University’s objective of excellence in research, scholarship, and education by publishing worldwide. Oxford is a registered trade mark of Oxford University Press in the UK and in certain other countries. Published in India by Oxford University Press YMCA Library Building, 1J ai Singh Road, New Delhi 110001, India 0 Oxford University Press 2007,2013 The moral rights of the authorls have been asserted. First Edition published in 2007 Second Edition published in 2013 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, without the prior permission in writing of Oxford University Press, or as expressly permitted by law, by licence, or under terms agreed with the appropriate reprographics rights organization. Enquiries concerning reproduction outside the scope of the above should be sent to the Rights Department, Oxford University Press, at the address above. You must not circulate this work in any other form and you must impose this same condition on any acquirer. ISBN-13: 978-0-19-808353-5 ISBN-10: 0-19-808353-X Typeset in Times New Roman by Anvi Composers, New Delhi 110063 Printed in India by Adage Printers (P)L td., Noida 201301 U.P. About the Authors Satish Chandra is currently Professor, Department of Civil Engineering at the Indian Institute of Technology Roorkee. A PhD from IIT Roorkee, Dr Chandra is an expert in the area of highway materials and traffic-flow modelling and has published over 100 research papers. M.M. Agarwal retired as Chief Engineer, Northern Railway. Besides a career with Indian Railways spanning 33 years, he has also served German Railways and Zambia Railways. He is an expert on track technology and has published about 50 technical papers on track modernization and other related track matters, many of which have been discussed in international and national conferencesheminars. He has also authored Indian Railway Track: Design, Construction, Maintenance and Modernisation. He is the recipient of the national award for special work done on track maintenance and the President’s award for the best original book on railway tracks in Hindi. Preface to the First Edition There have been major technological developments in railways around the world in the recent past to meet the challenges of heavier traffic and higher speeds. In Indian Railways especially, the track structure has been modernized in a big way in the last three decades. Long welded rails, concrete sleepers, and elastic fastenings have been used on high-speed routes to provide stable and resilient structures. Metro railways are also being introduced in metropolitan cities to ease the problem of congestion on roads. Diesel and electric locomotives, which have superior performance capabilities, have replaced steam locomotives. In addition, modern signalling, automatic warning, and centralized traffic control systems are being adopted to ensure safety and maximum utilization of track capacity. It is very important for engineering students and new entrants into the field of railways to be aware of not only the fundamentals of railway engineering but also latest developments with regard to railway tracks, locomotives and rolling stock, signalling and interlocking, etc. ABOUT THE BOOK This book deals with all aspects of railway engineering, from fundamental concepts to modern technological developments, with special focus on Indian Railways. It is an amalgamation of the vast experiences of the authors-of teaching the subject as well as of serving in Indian Railways. The text presents the theories and field practices as well as the modern techniques in detail. CONTENTANDCOVERAGE The book treats the theoretical and practical aspects of the subject exhaustively and incorporates the latest provisions adopted by Indian Railways (IR). Chapter 1 presents a historical account of railways around the world with special focus on the important features of IR. Chapter 2 discusses the various gauges adopted by IR and the problems associated with multigauge systems. Chapter 3 explains the factors affecting track alignment. Chapter 4 describes the different types of engineering surveys required to be undertaken before launching a new railway project as well as the construction of new lines including doubling and gauge conversions. Chapter 5 presents the details of track specifications and structures for different gauges on IR. It also discusses the forces acting on a track and the stresses generated in track components. Chapters 6 to 10 describe the various components of a railway track-rails, sleepers, ballast, formation, and fittings and fastenings. It also discusses the recent provisions adopted by IR with respect to these components. Preface to the First Edition ix Chapter 11 explains the causes and remedial measures for creep in rails. Chapter 12 presents the basic aspects of the geometric design of railway tracks. Chapter 13 discusses the detailed design of the horizontal and vertical curves on a railway line. Chapter 14 and 15 elaborate on the various types of track junctions and their designs, layouts of turnouts, and the factors affecting speed on turnouts. Chapter 16 discusses rail joints and the methods used for welding rail joints. Chapter 17 describes the developments in welded railway tracks including long welded rails (LWRs) and continuous welded rails (CWRs). It also explains the detailed procedure for laying LWRs and the track specifications for long and short welded rails. Chapter 18 describes the calendar system of track maintenance being followed by Indian Railways, which includes the conventional track maintenance operations of through packing, systematic overhauling, and picking up slacks. Chapter 19 details the track drainage system, along with the drainage of station platforms, yards, and subsurface drains. Chapter 20 describes the modern methods of track maintenance followed by Indian Railways employing track machines. It presents the details of measured shovel packing (MSP) equipment on IR. The chapter also describes Directed Track Maintenance (DTM)-IR’s annual programme-and its future scope. Chapter 21 elaborates on the methods of track rehabilitation and the renewal of track components. It also discusses some new machines used by IR for track renewal. Chapter 22 discusses accident and disaster management, which assumes significance because of greater emphasis being placed on safety by Indian Railways. Chapter 23 describes level crossings and the measures taken to prevent accidents at such crossings. Chapter 24 includes the design and maintenance features of locomotives and other rolling stock. Chapter 25 provides the details of train resistances and their evaluation. It also defines tractive effort and hauling capacity of locomotives. Chapters 26 and 27 include details of station yards and the various equipment used in railway stations, respectively. Chapter 28 discusses the construction of new railway lines, track material required for BG tracks, doubling of railway lines, and gauge conversion. Chapter 29 exclusively discusses suburban railways in metropolitan cities, which is the latest trend in the Indian context, so that this subject is fully appreciated by the readers. Chapter 30 is devoted to the specialized subject of railway tunnelling, describing the various techniques of construction and maintenance of tunnels in different types of soils. Chapter 31 on signalling and interlocking gives the details of various signals, interlocking techniques, and modern developments concerning train control. Chapter 32 discusses the various modernization plans of IR, covering tracks, locomotives, and rolling stock for high-speed trains, with the aim of widening the readers’ understanding of the scope of railway engineering. x Preface to the First Edition ACKNOWLEDGEMENTS While writing this book, references have been made to several Indian Railways codes and manuals and other documents published by RDSO (Research Design and Standards Organisation, India). We have liberally used these documents and gratefully acknowledge RDSO. We are grateful to our family members for their moral support and cooperation while the book was being written. Though every care has been taken to produce an error-free text, some errors may have gone unnoticed. We will be grateful to the users of the book for bringing any such errors to our notice, so that these can be rectified in subsequent editions. Constructive suggestions and comments for further improvement of the content are welcome. Satish Chandra M.M. Agarwal Preface to the Second Edition Railway engineering is a versatile subject that acquaints students systematically to the whole gamut of activities that take place in railways, starting from planning, design, and construction to operation and maintenance. Therefore, it is quite natural that the subject encompasses a wide range of engineering disciplines including civil, computer science, electrical, mechanical, and production engineering. Indian Railways has long been regarded as instrumental in India’s economic development. However, it is currently passing through a difficult phase where the challenges are many. In general, despite being the most energy-efficient as well as eco-friendly mode of transport, the share of the Railways in total traffic carried has gone down drastically. In addition, there is a serious resource crunch that is pulling Indian Railways down. To face this challenge head on, the Railways has plans to boost its traffic output by expanding the existing network. Further, modernizing the existing infrastructure, improving the passenger facilities, and most important of all, making rail travel safe and comfortable are seen as the long-term solutions to attract more passengers. Indian Railways, over the past few years, has embraced many technological changes in order to meet the challenges of modern rail traffic. In fact, it has never shied away from modernization- always eager to evolve in new ways. The Indian Railways Vision 2020 acts as a blueprint for inclusive geographical and social development with environment sustainability. As part of Vision 2020, the Ministry of Railways seeks to raise railway revenues to a gross domestic product (GDP) ratio of 3 per cent, which has remained at around 1.3 per cent in the past decade. Such growth will naturally require the expansion and modernization of Indian Railways at a rapid pace. Incorporating the latest developments that have taken place in Indian Railways during the past decade, this revised edition discusses the measures taken by the Railways, along with their technical details, to meet the challenges described. NEW TO THE SECOND EDITION The text has been extensively revised with suitable changes in most chapters. A balanced amalgamation of fundamental concepts and modern technological developments, with special focus on Indian Railways, the revised edition presents the following: New chapter on the Dedicated Freight Corridor project of Indian Railways Updated statistical data on Indian Railways and a detailed discussion on Vision 2020 Detailed discussion on modern methods of track maintenance A complete procedure on how to calculate stresses in different components of a railway track iv Preface to the Second Edition PEDAGOGY The second edition comes with a rich pedagogy that includes the following: Colour photographs for better illustration of the latest machinery and modern 0 methods of track maintenance Chapter-end exercises now include MCQs in addition to theoretical and 0 numerical questions More than 250 illustrations and as many as 300 exercise questions for better 0 comprehension and practice EXTENDED CHAPTER MATERIAL Chapter 1 is completely revised and includes the latest statistical data on various aspects of Indian Railways. The chapter gives details of the Railway Esion 2020 which lays down the ‘goals’ of Indian Railways proposed to be achieved by 2020. Chapter 5 has now additional material on stresses in a railway track. A solved example is included to help the students to calculate bending stress in the track. Chapter 6 provides updated rail specifications as per the latest IRS code. High strength 110 UTS rail sections recently introduced on some important lines on Indian Railways are also explained. Chapter 14 includes details of high-speed turnouts developed on Indian Railways for passenger yards. It also includes details of modern turnouts developed by DMRC. Chapter 17 includes the procedure followed by Indian Railways for distressing of long-welded rails, with and without rail tensors. Chapter 18 now covers the latest developments in track maintenance such as modification in the formula for calculating the gang strength. It also includes the work load of PWI and other field officers. Chapter 20 provides the details of the latest track machines for mechanized track maintenance. Chapter 22 presents the new classification of accidents. The remedial measures to be taken to avoid accidents are also highlighted. Chapter 24 describes the new technology adopted by Indian Railways for design of rolling stock. Chapter 26 explains the new concept of model and world-class stations with state-of-the-art facilities. Chapter 32 explains the concepts of tilting trains and Maglev trains, which are the latest trends in high-speed railways. CONTENT AND STRUCTURE Chapter 1 presents a historical account of railways around the world with special focus on the important features of Indian Railways. It includes a discussion on various undertakings of the Ministry of Railways and highlights the important features of Vision 2020 document. Preface to the Second Edition v Chapter 2 discusses the various gauges adopted by Indian Railways and the problems associated with multi-gauge systems. Chapter 3 explains the factors affecting track alignment. Mountain rails and rack railways are also discussed in this chapter. Chapter 4 describes the different types of engineering surveys required to be undertaken before launching a new railway project as well as the construction of new lines including doubling and gauge conversions. It also includes modern survey techniques for alignment survey for new lines. Chapter 5 presents details of track specifications and structures for different gauges on Indian Railways. It also discusses the forces acting on a track and the stresses generated in track components. The method of evaluating stresses and deflection in the track is explained with the help of illustrative examples. Chapters 6 to 10 describe the various components of a railway track such as rails, sleepers, ballast, formation, and fittings and fastenings. The recent provisions adopted by Indian Railways with respect to these components are also discussed in these chapters. Chapter 11 explains the causes and remedial measures for creep in rails. The method adopted on Indian Railways for field measurement of creep is also described in the chapter. Chapter 12 presents the basic aspects of the geometric design of railway tracks. Chapter 13 discusses the detailed design of horizontal and vertical curves on a railway line. The method adopted by Indian Railways for calculating design speed for a curve and length of horizontal curve in restricted areas is described in detail. Chapters 14 and 15 elaborate on the various types of track junctions and their designs, layouts of turnouts, and the factors affecting speed on turnouts. Chapter 16 discusses rail joints and the methods used for welding rails in India. Recent developments in welding techniques are also included. Chapter 17 describes the theory of long-welded rails and the track specifications for long and short-welded rails. It also includes the procedure followed by Indian Railways for distressing of long-welded rails, with and without rail tensors. Chapter 18 describes the essentials of track maintenance and calendar system of track maintenance being followed by Indian Railways. It provides a detailed discussion on maintenance of rails, sleepers, and ballast. It has conventional type of track maintenance operations as well as the latest developments in track maintenance on Indian Railways. The work load of PWI and other field officers is also discussed. Chapter 19 details the track drainage system, along with the drainage of station platforms, yards, and subsurface drains. Chapter 20 describes the modern methods of track maintenance followed by Indian Railways employing track machines. It presents the details of measured shovel packing (MSP) equipment on Indian Railways. The chapter also describes Directed Track Maintenance (DTM), an annual programme conducted by Indian Railways and its future scope. vi Preface to the Second Edition Chapter 21 elaborates on the methods of track rehabilitation and the renewal of track components. It also discusses some of the new machines used by Indian Railways for track renewal. Estimation of track material for a new track is also included here. Chapter 22 discusses accident and disaster management, which assumes significance because of greater emphasis being placed on safety by Indian Railways. It gives a detailed classification of accidents and the remedial measures to be taken to avoid the accidents are also highlighted. Chapter 23 describes level crossings and the measures taken to prevent accidents at such crossings. Chapter 24 includes the design and maintenance features of locomotives and other rolling stock. It elaborates upon the new technology adopted by Indian Railways for design of rolling stock. Chapter 25 provides details of train resistances and their evaluation. It also defines tractive effort and hauling capacity of locomotives. Chapter 26 includes details of railway stations and yards. Facilities to be provided at station building and platforms are discussed here. Details of special facilities to be provided for model stations and world class stations have also been given. Chapter 27 discusses various types of equipment used in railway stations. It includes foot overbridge, turntables, carriage washing platforms, buffer stops, and other such facilities. Chapter 28 discusses the construction of new railway lines and doubling of railway lines. It also includes civil engineering works of gauge conversion projects. Chapter 29 exclusively discusses suburban railways in metropolitan cities, which is the latest trend in the Indian context, so that this subject is fully appreciated by the readers. It gives details of Delhi Metro and Calcutta Metro Railways. Chapter 30 is devoted to the specialized subject of railway tunnelling, describing the various techniques of construction and maintenance of tunnels in different types of soils. Chapter 31 on signalling and interlocking gives the details of various types of signals, interlocking techniques, and modern developments concerning train control. The chapter also gives details of modern signalling techniques to control railway accidents such as train protection and warning system and anti-collision devices. Chapter 32 discusses the various modernization plans of Indian Railways, covering tracks, locomotives, and rolling stock for high-speed trains, with the aim of widening the readers’ understanding of the scope of railway engineering. The chapter also discusses specification for high-speed railways and some of the new concepts such as tilting trains and Maglev trains. Chapter 33 is exclusively written on dedicated freight corridor, a flagship programme of Indian Railways. It provides a general and technical description of various freight corridor and link projects in India. The new developments on Indian Railways are also discussed in this chapter.