Lok Sabha Question No. 146 (STARRED), answered on 2025-07-30
Subject: Implementation of Kavach System
Ministry: RAILWAYS
Asked by: Dr. Shivaji Bandappa Kalge, Shri Bhumare Sandipanrao Asaram

## GOVERNMENT OF INDIA

## MINISTRY OF RAILWAYS

## LOK SABHA STARRED QUESTION NO. 146

## TO BE ANSWERED ON 30.07.2025

## IMPLEMENTATION OF KAVACH SYSTEM

 *146.  SHRI BHUMARE SANDIPANRAO ASARAM: DR. SHIVAJI BANDAPPA KALGE:

Will the Minister of RAILWAYS be pleased to state:

- (a) the various steps taken by the Government to enhance the level of railway passengers safety in the country;
- (b) whether  the  Kavach  System  has  been  implemented  in  all  the zones of Railways as on 30.06.2025;
- (c) if  so,  the  details  thereof  and  if  not,  the  reasons  therefor particularly for Maharashtra;
- (d) the manner in which the Government proposes to implement the Kavach System in the entire country particularly in Maharashtra;
- (e) the  time  likely  to  be  taken/required  for  completion/installation along  with  the  estimated  cost  of  implementation  of  the  said system in the entire country;
- (f) whether  implementation  of  the  said  system  has  started  in Maharashtra and Madhya Pradesh; and
- (g) if so, the details thereof and if not, the reasons therefor?

## ANSWER

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

(SHRI ASHWINI VAISHNAW)

- (a) to (g):    A Statement is laid on the Table of the House.

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STATEMENT REFERRED TO IN REPLY TO PARTS (a) TO (g) OF LOK SABHA  STARRED  QUESTION  NO. 146  TO  BE  ANSWERED  ON 30.07.2025.

(a)  to  (g):  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. Consequential Train Accidents have reduced from 135 in 2014-15 to 31 in 2024-25 as shown in the graph below. The causes of these  accidents  broadly  include  track  defects,  loco/coach  defects, equipment failures, human errors etc.

It may be noted that the Consequential Train Accidents during the  period  2004-14  was  1711  (average  171  per  annum),  which  has declined  to  31  in  2024-25  and  further  to  3  in  2025-26  (upto  June, 2025).

Another  important  index  showing  improved  safety  in  train operations is Accidents Per Million Train Kilometer (APMTKM) which has reduced from 0.11 in 2014-15 to 0.03 in 2024-25, indicating an improvement of approx. 73% during the said period.

The  number  of  consequential  train  accidents  during  the  last five years are depicted in the Graph below.

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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  6,635 stations  up  to  30.06.2025  to  reduce  accident  due  to  human failure.
3. Interlocking of Level Crossing (LC) Gates has been provided at 11,096  level  Crossing  Gates  up  to  30.06.2025  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 6,640 stations up to 30.06.2025.
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.  Kavach  has  already  been deployed  on  1548  RKm  on  South  Central  Railway  and  North Central  Railway.  Presently,  the  work  is  in  progress  on  DelhiMumbai and Delhi-Howrah corridors (approximately 3000 RKm). Track  side  works  on  these  routes  have  been  completed  on about 2200 RKm as on 30.06.2025.
6. Detailed instructions on issues related with safety of Signalling,  e.g.  mandatory  correspondence  check,  alteration work  protocol,  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 approaching  landmarks  like  signals,  level
10. distance  of the 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. Mechanization  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).
18. 17.
19. Patrolling of railway tracks to look out for weld/rail fractures.
18. The use of Thick Web Switches and Weldable CMS Crossing in
21. 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.

| Expenditure on Safety related activities (Rs. in Cr.)   | Expenditure on Safety related activities (Rs. in Cr.)   | Expenditure on Safety related activities (Rs. in Cr.)   | Expenditure on Safety related activities (Rs. in Cr.)   | Expenditure on Safety related activities (Rs. in Cr.)   | Expenditure on Safety related activities (Rs. in Cr.)   |
|---------------------------------------------------------|---------------------------------------------------------|---------------------------------------------------------|---------------------------------------------------------|---------------------------------------------------------|---------------------------------------------------------|
|                                                         | 2013-14 (Act.)                                          | 2022-23 (Act.)                                          | 2023-24 (Act.)                                          | RE 2024-25                                              | BE 2025-26                                              |
| Maintenance of Permanent Way & Works                    | 9,172                                                   | 18,115                                                  | 20,322                                                  | 21,800                                                  | 23,316                                                  |
| Maintenance of Motive Power and Rolling Stock           | 14,796                                                  | 27,086                                                  | 30,864                                                  | 31,540                                                  | 30,666                                                  |
| Maintenance of Machines                                 | 5,406                                                   | 9,828                                                   | 10,772                                                  | 12,112                                                  | 12,880                                                  |
| Road Safety LCs and ROBs/ RUBs                          | 1,986                                                   | 5,347                                                   | 6,662                                                   | 8,184                                                   | 7,706                                                   |
| Track Renewals                                          | 4,985                                                   | 16,326                                                  | 17,850                                                  | 22,669                                                  | 22,800                                                  |
| Bridge Works                                            | 390                                                     | 1,050                                                   | 1,907                                                   | 2,130                                                   | 2,169                                                   |
| Signal & Telecom Works                                  | 905                                                     | 2,456                                                   | 3,751                                                   | 6,006                                                   | 6,800                                                   |
| Workshops Incl. PUs and Misc. expenditure on Safety     | 1,823                                                   | 7,119                                                   | 9,523                                                   | 9,581                                                   | 10,134                                                  |
| Total                                                   | 39,463                                                  | 87,327                                                  | 1,01,651                                                | 1,14,022                                                | 1,16,470                                                |

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:-

| SN   | Item                                    | 2004-05 to 2013-14           | 2014-15 to 2024-25 (till March 25)   | 2014-25 Vs. 2004-14          |
|------|-----------------------------------------|------------------------------|--------------------------------------|------------------------------|
|      | 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               | 288 times                    |
| 5.   | Thick Web Switches (Nos.)               | Nil                          | 28,301 Nos.                          |                              |
|      | 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 |
| 1.   | New Track KM added (Track km)                               | 14,985 Nos.                             | 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: 8948                    | 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                      |

Further,  Indian  Railways  has  also  gone  for  implementation  of advance technology system 'Kavach' as an Automatic Train Protection (ATP) system.

- i. 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).
- ii. 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.
- iii. 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. iv.
5. Kavach was adopted as National ATP system in July 2020.
- v. Implementation of Kavach  System  involves following Key Activities:
- a. Installation  of  Station  Kavach  at  each  and  every  station, block section.
8. b.
9. Installation of RFID Tags throughout the track length.
10. c.
11. d.
12. Installation of telecom Towers throughout the section.
13. Laying of Optical Fibre Cable along the track.
- e. Provision  of  Loco  Kavach  on  each  and  every  Locomotive running on Indian Railways.
- vi. Based on  deployment of Kavach version 3.2 on  1465 RKm on south  central  Railway,  a  lot  of  experience  was  gained.  Using that further improvements were made. Finally, Kavach specification version 4.0 was approved by RDSO on 16.07.2024.
- vii. 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.
- viii. 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.
- ix. After extensive and elaborate trials in 324 kms of Mathura-Kota section  for  advance  version  of  Kavach  4.0,  the  section  is approved by Independent Safety Assessor (ISA) and the section is ready for commissioning. This is also the first section to be approved by ISA for Kavach version 4.0.
- x. Progress  of  Key  items  comprising  Kavach  system  on  Indian Railways upto 14.07.25 is as under:-
- xi. Next phase of Kavach implementation is planned as under:-
- a. Project for equipping 10,000 Locomotives has been finalized. 69 number of loco sheds have been prepared for equipping with Kavach.
- b. Bids  for  track  side  Works  of  Kavach  for  approximately 15,000 RKm have been invited covering all GQ, GD, HDN and identified sections of Indian Railways, out of which works of 14847 RKm have been awarded.
- xii. The sections mentioned above also includes the railway routes in  states  of  Maharashtra  &  Madhya  Pradesh  as  summarised below:
- xiii. Specialized training programmes on Kavach are being conducted at centralized training institutes of Indian Railways
25. to impart training to all concerned officials. By now more than 30,000 technicians, operators and engineers have been trained on Kavach technology. Courses have been designed in collaboration with IRISET.
- xiv. The cost for provision of Track Side including Station equipment  of  Kavach  is  approximately  Rs.  50  Lakhs/Km  and cost  for  provision  of  Kavach  equipment  on  locomotives  is approximately Rs. 80 Lakh/Loco.
- xv. The funds utilized on Kavach works so far up to June'25 is Rs. 2015 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.

| SN   | Items                                | Progress   |
|------|--------------------------------------|------------|
| i.   | Laying of Optical Fibre Cable        | 5856 Km    |
| ii.  | Installation of Telecom Towers       | 619 Nos.   |
| iii. | Provision of Kavach at Stations      | 708 Nos.   |
| iv.  | Provision of Kavach in Loco          | 1107 Locos |
| v.   | Installation of Track side equipment | 4001 Rkm   |

| State          | Railway Routes                                                                                                                                                                                                 |   Route Km |
|----------------|----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------|------------|
| Maharashtra    | Mumbai-Pune, Mumbai-Bhusawal Including Mumbai Area, Igatpuri-Badnera-Nagpur- Narkher, Balharshah, Lonavla-Pune-Daund- Baramati, Ankai-Pune-Miraj-Kolhapur, Kurdwadi-Latur, Purna-Akola, Including branch lines |       3856 |
| Madhya Pradesh | Narker-Jujharpur, Amla-Parasia-Chindwara, Wagoda-Khandwa, Dhaulpur-Agasod, Itarsi- Bina, Ratlam-Jawad, Nagda-Bhopal                                                                                            |       1219 |

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