Lok Sabha Question No. 2779 (UNSTARRED), answered on 2025-12-17
Subject: Indigenous Kavach System in Rail Networks
Ministry: RAILWAYS
Asked by: Shri Hasmukhbhai Somabhai Patel, Shri Miteshbhai Rameshbhai Patel

## GOVERNMENT OF INDIA

## MINISTRY OF RAILWAYS

## LOK SABHA UNSTARRED QUESTION NO. 2779 TO BE ANSWERED ON 17.12.2025

## INDIGENOUS KAVACH SYSTEM IN RAIL NETWORKS

## †2779. SHRI MITESHBHAI RAMESHBHAI PATEL: SHRI HASMUKHBHAI SOMABHAI PATEL:

## Will the Minister of RAILWAYS be pleased to state:

- (a) the targeted date for achieving 100 percent implementation of the indigenously developed Kavach (Automatic Train Protection)  system  across  the  major  rail  networks  of  the country;
- (b) the manner  in  which  the Government  is  utilising Al  and predictive  maintenance  tools  to  bring  down  the  number  of signal failures and accidents;
- (c) whether the Government has adopted any new policy mandating  the  use  of  fire retardant materials in all  new passenger coaches and if so, the details thereof; and
- (d) the steps taken/being taken by the Government to expedite the elimination of unmanned level crossings on densely populated routes?

## ANSWER

## MINISTER OF RAILWAYS, INFORMATION & BROADCASTING AND ELECTRONICS & INFORMATION TECHNOLOGY

## (SHRI ASHWINI VAISHNAW)

- (a) Safety is accorded the highest priority on Indian Railways. As a  consequence  of  various  safety  measures  taken  over  the years,  there  has  been  a  steep  decline  in  the  number  of accidents.

Number of Consequential Train Accidents has reduced as shown in the table below:-

| Year                | Consequential Accidents   |
|---------------------|---------------------------|
| 2014-15             | 135                       |
| 2025-26 (till date) | 11 (90% lesser)           |

Another  important  index  showing  improvement  in  safety  in  train operations  is  Consequential  Accidents  Index,  the  details  of  which are as under:-

## Consequential Accident Index:

| Year    | Accident Index    |
|---------|-------------------|
| 2014-15 | 0.11              |
| 2024-25 | 0.03 (73% lesser) |

This index measures number of consequential accidents as a ratio of total running Kilometers of all trains.

## No. of consequential accidents

No. of trains X million kilometers run

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Index =

The various safety measures taken to enhance safety in train operations are as under:-

1. On Indian Railways, the expenditure on Safety related activities has increased over the years as under:-
2. Electrical/Electronic Interlocking Systems with centralized operation  of  points  and  signals  have  been  provided  at  6,657 stations  up  to  30.11.2025  to  reduce  accidents  due  to  human failure.
3. Interlocking  of  Level  Crossing  (LC)  Gates  has  been  provided  at 10,100  Level  Crossing  Gates  up  to  30.11.2025  for  enhancing safety at LC Gates.
4. Complete  Track  Circuiting  of  stations  to  enhance  safety  by verification  of  track  occupancy  by  electrical  means  has  been provided at 6,663 stations up to 30.11.2025.
5. Kavach is a highly technology intensive system, which requires safety  certification  of  highest  order.  Kavach  was  adopted  as  a National ATP system in July 2020. Kavach is provided progressively  in  phased  manner.  Initially,  Kavach  Version  3.2 was  deployed  on  1465  RKm  of  South  Central  Railway  and  80 RKm of North Central Railway. Kavach specification Version 4.0 was  approved  by  RDSO  on  16.07.2024.  After  extensive  and elaborate  trials,  Kavach  Version  4.0  has  been  successfully commissioned on Palwal-Mathura-Kota- Nagda section (633Rkm) on  Delhi-  Mumbai  route  and  on  Howrah-Bardhaman  section (105RKm)  on  Delhi-Howrah  route.  Kavach  implementation  has been  taken  up  in  balance  sections  of  Delhi-Mumbai  and  DelhiHowrah route. Further, Kavach implementation has been taken up  on  15,512  RKm  covering  all  GQ,  GD,  HDN  and  identified sections of Indian Railways.
6. Detailed instructions on issues related with safety of Signalling, e.g. mandatory correspondence check, alteration work protocol,

| Expenditure/Budget on Safety related activities (Rs. in Cr.)   | Expenditure/Budget on Safety related activities (Rs. in Cr.)   | Expenditure/Budget on Safety related activities (Rs. in Cr.)   | Expenditure/Budget on Safety related activities (Rs. in Cr.)   | Expenditure/Budget on Safety related activities (Rs. in Cr.)   |
|----------------------------------------------------------------|----------------------------------------------------------------|----------------------------------------------------------------|----------------------------------------------------------------|----------------------------------------------------------------|
| 2013-14                                                        | 2022-23                                                        | 2023-24                                                        | 2024-25                                                        | 2025-26                                                        |
| (Act.)                                                         | (Act.)                                                         | (Act.)                                                         |                                                                |                                                                |
| 39,463                                                         | 87,327                                                         | 1,01,651                                                       | 1,14,022                                                       | 1,16,470                                                       |

- preparation of completion drawing, etc. have been issued.
7. System of disconnection and reconnection for S&T equipment as per protocol has been re-emphasized.
8. All  locomotives  are  equipped  with  Vigilance  Control  Devices (VCD) to improve alertness of Loco Pilots.
9. Retro-reflective sigma boards are provided on the mast which is located  two  OHE  masts  prior  to  the signals in electrified territories  to  alert  the  crew  about  the  signal  ahead  when visibility is low due to foggy weather.
10. A GPS based Fog Safety Device (FSD) is provided to loco pilots in fog  affected  areas  which  enables  loco  pilots  to  know  the distance of the approaching landmarks like signals, level crossing gates, etc.
11. Modern track structure consisting of 60kg, 90 Ultimate Tensile Strength (UTS) rails, Prestressed Concrete Sleeper (PSC) Normal/Wide  base  sleepers  with  elastic  fastening,  fan  shaped layout turnout on PSC sleepers, Steel Channel/H-beam Sleepers on  girder  bridges  is  used  while  carrying  out  primary  track renewals.
12. Mechanisation  of  track  laying  activity  through  use  of  track machines like PQRS, TRT, T-28 etc. to reduce human errors.
13. Maximizing supply of 130m/260m long rail panels for increasing progress of rail renewal and avoiding welding of joints, thereby improving safety.
14. Ultrasonic Flaw Detection (USFD) testing of rails to detect flaws and timely removal of defective rails.
15. Laying  of  longer  rails,  minimizing  the  use  of  Alumino  Thermic Welding and adoption of better welding technology for rails i.e., Flash Butt Welding.
16. Monitoring  of  track  geometry  by  OMS  (Oscillation  Monitoring System) and TRC (Track Recording Cars).
- 17.
- Patrolling of railway tracks to look out for weld/rail fractures.
18. The use of Thick Web Switches and Weldable CMS Crossing in
- turnout renewal works.
19. Inspections  at  regular  intervals  are  carried  out  to  monitor  and educate staff for observance of safe practices.
20. Web based online monitoring system of track assets viz. Track database and decision support system has been adopted to

- decide rationalized maintenance requirement and optimize inputs.
21. Detailed instructions on issues related with safety of Track, e.g. integrated block, corridor block, worksite safety,  monsoon precautions, etc. have been issued.
22. Preventive maintenance of railway assets (Coaches & Wagons) is undertaken to ensure safe train operations.
23. Replacement  of  conventional  ICF  design  coaches  with  LHB design coaches is being done.
24. All  unmanned  level  crossings  (UMLCs)  on  Broad  Gauge  (BG) route have been eliminated by January 2019.
25. Safety of Railway Bridges is ensured through regular inspection of Bridges. The requirement of repair/rehabilitation of Bridges is taken  up  based  upon  the  conditions  assessed  during  these inspections.
26. Indian Railways  has  displayed Statutory 'Fire Notices' for widespread  passenger  information  in  all  coaches.  Fire  posters are provided in every coach  so as to educate  and alert passengers  regarding  various  Do's  and  Don'ts  to  prevent  fire. These include messages regarding not carrying any inflammable material, explosives, prohibition of smoking inside the coaches, penalties etc.
27. Production  Units  are  providing  Fire  detection  and  suppression system in newly manufactured Power Cars and Pantry Cars, Fire and  Smoke  detection  system  in  newly  manufactured  coaches. Progressive  fitment  of  the  same  in  existing  coaches  is  also underway by Zonal Railways in a phased manner.
28. Regular counselling and training of staff is undertaken.
29. Concept  of  Rolling  Block  introduced  in  Indian  Railways  (Open Lines) General Rules vide Gazette notification dated 30.11.2023, wherein  work of  integrated  maintenance/  repair/replacement  of assets is planned up to 52 weeks in advance on rolling basis and executed as per plan.

The  details of the Safety related works  related to better maintenance practices, Technological improvements, better infrastructure  and  rolling  stock  etc.  undertaken  by  Railways  are tabulated below:-

| S. No.                                  | Item                                                      | 2004-05 to 2013-14                      | 2014-15 to 2024-25                      | 2014-25 Vs. 2004-14                     |
|-----------------------------------------|-----------------------------------------------------------|-----------------------------------------|-----------------------------------------|-----------------------------------------|
| Technological Improvements              | Technological Improvements                                | Technological Improvements              | Technological Improvements              | Technological Improvements              |
| 1.                                      | Use of high-quality rails (60 Kg) (Km)                    | 57,450 Km                               | 1.43 Lakh Km                            | More than 2 times                       |
| 2.                                      | Longer Rail Panels (260m) (Km)                            | 9,917 Km                                | 77,522 Km                               | Nearly 8 times                          |
| 3.                                      | Electronic Interlocking (Stations)                        | 837 Stations                            | 3,691 Stations                          | More than 4 times                       |
| 4.                                      | Fog Pass Safety Devices (Nos.)                            | As on 31.03.14: 90 Nos.                 | As on 31.03.25: 25,939 Nos.             | 288 times                               |
| 5.                                      | Thick Web Switches (Nos.)                                 | Nil                                     | 28,301 Nos.                             |                                         |
| Better Maintenance Practices            | Better Maintenance Practices                              | Better Maintenance Practices            | Better Maintenance Practices            | Better Maintenance Practices            |
| 1.                                      | Primary Rail Renewal (Track Km)                           | 32,260 Km                               | 49,941 Km                               | 1.5 times                               |
| 2.                                      | USFD (Ultra Sonic Flaw detection) Testing of Welds (Nos.) | 79.43 Lakh                              | 2 Crore                                 | More than 2 times                       |
| 3.                                      | Weld failures (Nos.)                                      | In 2013- 14: 3699 Nos.                  | In 2024-25: 370 Nos.                    | 90 % reduction                          |
| 4.                                      | Rail fractures (Nos.)                                     | In 2013- 14: 2548 Nos.                  | In 2024-25: 289 Nos.                    | More than 88% reduction                 |
| Better Infrastructure and Rolling Stock | Better Infrastructure and Rolling Stock                   | Better Infrastructure and Rolling Stock | Better Infrastructure and Rolling Stock | Better Infrastructure and Rolling Stock |
| 1.                                      | New Track KM added (Track Km)                             | 14,985 Km                               | 34,428 Km                               | More than 2 times                       |
| 2.                                      | Flyovers (RoBs)/Underpasses (RUBs) (Nos.)                 | 4,148 Nos.                              | 13,808 Nos.                             | More than 3 times                       |

|   3. | Unmanned Level crossings (Nos.) on BG   | As on 31.03.14: 8,948   | As on 31.03.24:Nil (All eliminated by 31.01.19)   | Removed            |
|------|-----------------------------------------|-------------------------|---------------------------------------------------|--------------------|
|    4 | Manufacture of LHB Coaches (Nos.)       | 2,337 Nos.              | 42,677                                            | More than 18 times |

## Implementation of Kavach

1. Kavach is an indigenously developed Automatic Train Protection (ATP)  system.  Kavach  is  a  highly  technology  intensive  system, which requires safety certification of highest order (SIL-4).
2. Kavach aids the Loco Pilot in running of trains within specified speed  limits  by  automatic  application  of  brakes  in  case  Loco Pilot fails to do so and also helps the trains to run safely during inclement weather.
3. The  first  field  trials  on  the  passenger  trains  were  started  in February 2016. Based on the experience gained and Independent Safety Assessment of the system by Independent Safety Assessor (ISA), three firms were approved in 2018-19, for supply of Kavach Ver 3.2.
4. Kavach was adopted as National ATP system in July 2020.
5. Implementation of Kavach System involves following Key Activities:
- i. Installation of Station Kavach at each and every station, block section.
- ii. Installation of RFID Tags throughout the track length.
- iii. Installation of telecom Towers throughout the section.
- iv. Laying of Optical Fibre Cable along the track.
- v. Provision  of  Loco  Kavach  on  each  and  every  Locomotive running on Indian Railways.
6. Based  on  deployment  of  Kavach  version  3.2  on  1465  RKm  on South Central Railway and experience gained, further improvements were made. Finally, Kavach specification version 4.0 was approved by RDSO on 16.07.2024.

7. Kavach version 4.0 covers all the major features required for the diverse railway network. This is a significant milestone in safety for  Indian  Railways.  Within  a  short  period,  IR  has  developed, tested and started deploying Automatic Train Protection System.
8. Major  improvement  in  Version  4.0  includes  increased  Location Accuracy,  Improved  Information  of  Signal  Aspects  in  bigger yards,  Station  to  Station  Kavach  interface  on  OFC  and  Direct Interface to existing Electronic Interlocking System. With these improvements, Kavach Ver.4.0. is planned for large scale deployment over Indian Railways.
9. After extensive and elaborate trials, Kavach Version 4.0 has been successfully commissioned on 738 Route km  on Palwal -Mathura- Nagda section (633 Rkm) on Delhi - Mumbai route and Howrah-Bardhaman  section  (105    Rkm)  Delhi  -  Howrah  route. Kavach implementation has been taken up in balance sections of Delhi - Mumbai & Delhi - Howrah corridors.
10. Progress  of  key  items  of  Kavach  on  High  density  routes including Delhi- Mumbai & Delhi- Howrah corridors are as under:
11. Further, track side Kavach implementation work has been taken up  on  15,512  RKm  covering  all  GQ,  GD,  HDN  and  identified sections of Indian Railways.
12. Bids have been invited for equipping another 9,069 locomotives with Kavach version 4.0. Kavach is being provided progressively in a phased manner in locomotives.

| SN   | Item                                 | Progress   |
|------|--------------------------------------|------------|
| i    | Laying of Optical Fibre Cable        | 7129 Km    |
| ii   | Installation of Telecom Towers       | 860 nos    |
| iii  | Station Data Centre                  | 767 Stns   |
| iv   | Installation of Track side equipment | 5672 RKm   |
| v    | Provision of Kavach on Locos         | 4,154      |

13. Specialized training programmes on Kavach are being conducted at centralized training institutes of Indian Railways to impart  training  to  all  concerned  officials.  By  now  more  than 40,000 technicians, operators and engineers have been trained on  Kavach  technology.  This  includes  33,000  Loco  Pilots  & Assistant Loco Pilots. Courses have been designed in collaboration with IRISET.
14. The  funds  utilized  on  Kavach  works  so  far  up  to  Oct'25  is  Rs. 2,354.36 Crores. The allocation of funds during the year 2025-26 is Rs. 1673.19 Crores. Requisite funds are made available as per the progress of works.
3. (b):  Technological  improvements  in  Indian  Railways  (IR)  are  a continuous  process.  Some  of  the  Artificial  Intelligence  based predictive maintenance applications are as follows:
- i.  Pilot  initiatives  involving  AI-driven  predictive  maintenance  of Signalling  system  is  being  undertaken  over  Indian  Railways  at some of the stations to evaluate its efficacy. Measurable outcome includes Standard Failure and Prediction Logics and Alerts mechanism to be derived from trial results at these stations.
- ii.  Artificial  Intelligence  (AI)  enabled  Intrusion  Detection  System (IDS)  using  Distributed  Acoustic  System  (DAS)  for  detecting presence of elephants on Railway tracks is implemented in 141 RKms  section  on  NF  Railway  and  further  tenders  have  been awarded for 981 RKms section of Indian Railways. The system is designed to generate alerts for  loco  pilots,  station  masters  and Control  Room  about  the  movement  of  elephants  in  proximity  of railway tracks, for taking timely preventive action.
- iii. 1) IR has adopted advanced/improved technologies like Online Monitoring  of  Rolling  Stock  System  (OMRS),  Wheel  Impact Load Detector (WILD) for predictive maintenance of Rolling stock.
- 2) A Memorandum of Understanding has been signed between IR  and  Dedicated  Freight  Corridor  Corporation  of  India Limited  (DFCCIL)  in  July  2025  for  induction  of  wayside Machine Vision based Inspection System (MVIS). This is an AI/ML driven system for detecting hanging parts or missing components in moving trains.

- 3) A Memorandum of Understanding has been signed between IR  and  Delhi  Metro  Rail  Corporation  to  induct  Automatic Wheel Profile  Measurement  System  (AWPMS).  The  AWPMS allows  for  automatic  non-contact  measurement  of  train wheel  profile  ensuring  real-time  measurement  of  wheel
2. geometry and wear.
3. (c):  The  inherent  design  of  rolling  stock  is  done  keeping  in  mind various safety provisions. Further modification and up-gradation of  coaches to enhance fire safety is a continuous and ongoing process on Indian Railways (IR). Following measures have been taken for safety including fire safety in coaches:
- i. Provision of Minimum two Fire Extinguishers in all coaches over Indian Railways.
- ii. Fire  Detection & Suppression System has been provided in fire prone areas of Power cars and Pantry cars.
- iii. Fire  and  smoke  Detection  system  has  been  provided  in coaches as per extant guidelines.
- iv. Water mist type fire suppression system is being provided on pantry cars and power cars in phased manner.
- v. Provision of emergency windows in coaches for evacuation in case of fire.
- vi. Use  of  Fire-retardant  material  as  per  global  fire-retardant norms in coaches for seats/berths, panels, flooring, insulation, toilets etc for improved fire safety.
- vii. Use of fire retardant E-beam cable in coaches.
- viii. Use  of  different  level  of  protection  in  the  form  of  fuses, Miniature Circuit breaker (MCBs) and Motor protection Circuit Breakers (MPCBs) in the electrical circuits to prevent the damage from electrical faults/surges.
- ix. Provision of Aerosol based  fire suppression system  in
13. electrical cabinets.
- x. Further, up-gradation of material in line with global standards is regularly being carried out with fitment of new generation material in Amrit Bharat & Vande Bharat Sleeper trains.
- xi. Display of "Fire Notices" for widespread information in all

coaches  to  inform  and  alert  passengers  regarding  various 'Do's' and 'Don'ts' to prevent fire. These include messages regarding not to carry any inflammable material, explosives, prohibition of smoking inside the coaches and penalties etc.

- xii. Prohibition of flame based cooking in coaches.

Regular maintenance of various fire safety equipments/components  as  per  the  prescribed  periodicity is  carried  out  by  the  designated  officials  at  Depots/Sheds for ensuring their proper upkeep.

- (d):   All unmanned level crossings (UMLCs) on running lines of Broad Guage  (BG)  network  of  Indian  Railway  including  high  density sections have been eliminated by 2019.

Elimination of  manned level crossings (MLCs) is a continuous and dynamic process of Indian Railway. Such works are taken up  on  the  basis  of  its  impact  on  safety  in  train  operations, mobility of trains & impact for road users and feasibility etc.

MLCs are eliminated either by providing Road Over Bridges/Road Under Bridges    (ROBs/ RUBs) in lieu of LCs or through  direct  closure  (for  low  traffic  LCs)  or  by  diversion  of road  traffic  to  nearby  ROB/RUB/LC  depending  upon  the  site conditions.

Nos. of ROBs/ RUBs constructed on Indian Railways during the period 2004-14 vis a vis 2014-25 (Oct'25) is as under:

| Period   | ROBs/ RUBs constructed   |
|----------|--------------------------|
| 2004-14  | 4,148 Nos.               |
| 2014-25  | 13,653 Nos.              |

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