Railway Engineering

Prof. Dr. Padma Bahadur Shahi

1. Introduction Trains move on the steel tracks laid on the ground resulting in heavy expenditure on basic infrastructure. Trains can move at much higher speed than pneumatic type vehicles on modern highways. Steel track can take three to four time heavier axle loads than road. The energy required to haul a unit load through a unit distance by railway is about 16%, in comparison to road transport. Thus rail transport is best suited for carriage of bulk and heavy commodities and large number of passengers on long distances. 2

Historical background
Firstly the wheel path was strengthen by the stone paving along it. And stones are replaced by timber planks. By the passing of time period, the timber baulks were replaced by iron Plates: called as plate ways. Iron plate section was improved: I section iron beam. Tractive power was replaced gradually to mechanical. Invention of steam engine. In 1804 construction of steam locomotive for railways. First public railway in the world: 27th September 1825 in UK In France: 3
1828 railways with horse power

First railways
First railway operation in some countries:
UK: France: Germany: India: Japan: China: 1825 1828 1835 1853 1872 1875

Advantages
Trains move on the steel tracks laid on the ground. Trains can move at much higher speeds than pneumatic tyre vehicles on modern highways. Steel track can take 3-4 times heavier axel load than road. The energy required to haul a unit load through a unit distance by railways is about 16 % in comparison to road transport.

Advantages
Biggest undertaking in the world & employs a sizeable section of society Cheapest mode of transport Less traction to movement No steering required, control to the movement Safe in comparison with road transport Political advantages:
Administration, National unity In wars and emergency situations Human Migration and interaction
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Advantages
Social advantages:
Communication Religious

Economical advantages:
Mobility of goods & passengers During natural calamities High employment of the society Price stability of goods due to the cheap transportation cost Industrial development
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Railway Classification
Broad gauge routes:

Based on the speed criteria railways have been classified into five groups: Group A: speed of 160 kmph or more
New Delhi-Howrah New Delhi Bombay New Delhi- Madras Howrah Bombay

Group B: Sactioned speed is 130 kmph Group C: All sub-urban routes of Calcutta, Bombay and Delhi Group D: All other routes where sectioned speed is 100 kmph Group E: Other routes sections, branch lines where the sanctioned speed is less than 100 kmph.
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Railway Classification
Meter gauge routes:

Q Routes: routes having maximum permissible speed of more than 75 kmph R Routes: Routes having maximum permissible speed of 75 kmph. S Routes: The routes having maximum permissible speed less than 75 kmph

Railway gauges

S/N Type of gauge 1 2 Standard gauge Broad Gauge

Gauge, mm Name of countries 1435 1676 1670 1600 1524 1067 1000 915 672 610 England, USA, Canada, China, Turkey India, Pakistan, Sri Lanka, Brazil, Argentina Spain, Portugal Ireland Russia, Finland Japan, Australia, New Zealand India, France, Argentina, Ireland India, Britain South Africa, India
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3 4 5 6

Broad Gauge Cape gauge Meter Gauge Narrow gauge

Rolling Stock of Railways

Moving part of railways is referred as rolling stock. It includes: Locomotive, Coaches, Wagons and Train Brakes 1. Locomotives

It is the device which converts the energy of fuels into the mechanical energy of motion. Fuel may be coal water, or fuel oil and the conversion may be brought about by steam or electricity. Now electric locomotives are very popular all over the world. Part of Locomotive: Fire box and Boiler: fuel is burnt in fire box and steam is generated in boiler. Proper engine: heat consists of cylinders, pistons and other various moving parts. It converts heat energy of steam into mechanical energy of motion. Frame work: It is mounted on wheels. It has a draw bar which transmits the tractive force to the train. Tender: To store the fuel, a small bogie is attached with the locomotive. 11

Locomotive

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Rolling Stock component

2. Coaches

The compartments which provide accommodation to the passenger in trains are called coaches.

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Rolling Stock component

3. Wagons

To transport goods wagons are used. Types:

Timber wagons Cattle wagons Oil wagons: cylindrical Petrol wagons: Hoper wagons: ballast, minerals, coals Well wagons: bulky articles of excessive height Power wagons: for explosives and chemicals
Refrigerated wagons: milk, fruits, meats and fish

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Rolling Stock Component

4. Train Brakes

To stop moving trains brakes are provided in locomotives. Types:

Hand brakes Steam brakes Continuous automatic brakes

Hand and steam brakes are used to stop locomotives itself only. They can not be used to stop a train moving with a high speed. For the purpose of stopping moving train continuous automatic brakes are used.
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Railway Track
Photos

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Railway track component

Railway track is the permanent way or final track for the movement of trains. The track is the rail road on which trains run. It consists of two parallel rails having a specified distance between them (gauge) and fastened to the sleepers. These sleepers are embedded in the layer of ballast of specified thickness, spread over the formation. Component parts:
Rails Fittings & fastenings Sleepers Ballast Formation

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Functions of the track component

Rails: rails are steel girders over which the train moves and transmit the wheel loads of train to the sleepers below. Sleeper: The sleepers hold the rails in proper position and provide a correct gauge with the help of fittings and fastenings and transfer the train load to the ballast below. Ballast: holds the sleepers in proper positions and provides a uniform level surface. They also provide drainage to the track and transfer train load to the larger area of the formation below. Fittings and fastenings: they provide a grip between rails and sleepers. The rails are fastened with the sleepers by fittings and fastenings. Formation: formation is the base of the railway rack. It gives a level surface where the ballast rests. It takes total loads of the track.
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Requirements of an ideal railway track

Correct gauge Correct alignment Transition curves should be provided Rails should have perfect cross level Gradient should be uniform and as gentle as possible Perfect drainage Minimum friction between rails and wheels. Joints, points & crossings should be designed Track should possess and theft and sabotage qualities Superelevation should be perfectly designed
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Railway Track

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Railway Track

10.82 m
4.725 3.35 m Sleeper Ballast Sleeper Ballast 3.35 m Rail Gauge

Formation

Double Line B. G. Track

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Rail
Functions:

Provide level & continuous surface for the train movement Provide smooth pathway Serve as lateral guide for running wheels Rails bear the stresses developed due to vertical load
Types:

Double headed Bull headed rail Flat footed trail

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Rail sections

Double Headed Rail

Bull Headed Rail

Flat Footed Rail

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Rail cross dimensions and length

Cross section dimensions of a typical 60 kg rail shown in figure. Length og rail depends upon:
The cost of production Difficulties in handling and transport Big expansion joints for longer rail Heavy internal thermal stresses in long rails

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Dimensions
72.33

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16.5

11

150

60 KG Rail Section

172

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Rail length

Country Germany France USA UK India BG track India MG Track

Rail length, m 30 m 23 m 12 m 18 m 13 m 12 m

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Sleepers
Sleepers are transverse support for a railway track to give stiffness to it. Transverse sleepers were introduced on the railway track for the first time in 1853. Functions of sleepers:
holding rails to correct gauge and alignment giving firm and even support to the rails transfer and distribute the axle load from rails acting as an elastic medium between rails and ballast provide insulation for electrified track to provide proper grade, longitudinal and lateral stability
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Sleeper density
Number of sleepers used per rail length is known as sleeper density. Generally one sleeper is used for every one meter length of the rail. It is specified as (N+X) where, N is the length of the rail and X is an mathematical number which depends upon the following factor:
Axle load Type and section of rail Type and strength of sleepers Depth of ballast cushion Nature of the formation

In India the sleeper density on B.G. track is adopted as N+7 or N+4 or, N+3 for M.G. track.
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Sleeper density
Type of sleeper Sleeper density No sleepers per Rails per Km length rail length

B.G Wooden/Metal M.G. Metal/Wooden

N+7 N+4

13+7=20 13+4=17

1538 1308

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Classification of sleepers
Wooden sleepers Cast iron sleepers Steel sleepers Concrete sleepers

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Comparison
Characteristics Wooden sleepers 12-15 83 difficult Low scrap value Steel Sleepers C.I Sleepe rs 40-50 79 easy Higher scrap value than wooden 40-50 87 easy High scrap value Concrete Sleepers 50-60 267 Impossible No scrap value

Service life, yrs. Weight, kg for B.G track Gauge adjustment Scrap value

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Ballast
It is the layer of broken stone or gravel or any other material placed under and around the sleepers to distribute the load from sleepers to the formation and for providing drainage as well as lateral and longitudinal stability to track.
Functions

Suitable foundation for sleepers Transfer and distribute load from sleeper to larger area of formation Increases elasticity and resilience of the track for getting good riding comfort Lateral and longitudinal stability Provide effective drainage Protects top surface of the formation 34

Ballast Types
Broken stone: it is best to be used as ballast. The size of the ballast is generally is 40 to 50 mm. At points and crossing 25 mm size may be used. Gravel ballast: it is cheaper Cinder or coal ash: Sand ballast: coarse sand is cheap if available locally. Moorum ballast: it is the decomposed laterite rocks. Brick ballast: 35

Minimum depth of Ballast cushion

The dispersion of load can be assumed at 45 degree to the vertical. In order to ensure that the lines of dispersion of load do not overlap each other, the thickness or depth of the ballast should be enough.

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Depth of the ballast Cushion

Spacing sleeperwidth D= 2
635 254 381 254

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Depth of Ballast Cushion

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Minimum width of ballast section:

To provide lateral stability to the track, the width of the ballast section should be sufficient. It should be extended by 30 cm on BG track and 23 cm on MG track beyond the edge of sleepers. This ballast is known as shoulder ballast. The ballast under the sleeper is known as ballast cushion, ballast outside the sleeper is known as shoulder and in between the sleeper is called crib ballast
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Test for ballast

Abrasion Test: aggregate abrasion value should not be more than 30% Aggregate Impact Test: Aggregate Impact Value should not be more than 20%. Flakiness Index: If the least dimension of a aggregate is less than 60% of its mean dimension, then it is known as flaky particle. Flakiness Index is the percentage by weight of particles whose least dimension (i.e. thickness) is less than 60 % 0f their mean dimension. It should not be less than 50%

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Track Fittings & Fastening

Rail Joints

It is weakest part of rail. In order to provide provision for expansion and contraction of rails due to variation in temperature, certain gap is provided at each joint. The joint causes severe blows to the passenger due to moving of wheels over this gap.

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Joint Types
a) according to the position of joints:
square joints staggered joints

Squared Joint

Staggered Joint

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Joint Types
b) According to the position of sleepers
Suspended joint Supported joint

Supported Jont

Suspended Joint

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Fastening of Rails
The devices used to connect rails and sleepers together to form the track are known as fastenings. Fish plates, bolts, Chairs, keys and bearing plates are the devices for fastening the rails. Fish Plates: are used to hold two rails together in horizontal as well as in vertical planes. At each joint a pair of fish plate is used. Holes are drilled through the plates and the web of rails. Rails are jointed by tightening fish bolts with the help of nuts. 43

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Fittings for wooden sleepers

Spikes: The device used to hold the rails to the wooden sleepers are known as spikes. Types of spikes: Dog spikes, Round spikes, screw spikes, elastic spikes.

Dog Spike

Round spikes

Screw Spikes

Elastic Spike

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Slide chair type fitting

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Elastic fitting: Pandrol Clip

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Concrete sleeper Fitting: Pandrol Rail clip

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Materials Requirement per Km of railway track

Quantities of different materials required to lay one Km track can be calculate as follows: a) No. of rails per Km length = (1000x2)/rail length = For BG Track 60 kg rail and 13 m length of rail recommended: No. of rails per km length = (2x100)/13=154 b) Weight of rail per km length = 154x13x60 = 120120 kg. c)No. of sleepers per km length = (No. of rails per km)/2 x (sleeper density) On BG track sleeper density = 13 + 7 = 20 No. sleepers per km track = (154/2)x20 = 1540nos c) No of fish plates per one km of track length = no of rails per km x2 = 154x2 = 308 nos d) No. of fish bolts = 4x no of rails per km = 4x154 = 616 nos. e) No of bearing plates = 2 x No of sleepers per km length = 2x 1540 = 3080 nos. f) No of labours required to lay one km of track (with 8 hour shift) = total tonnage + 20%

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