Global View Workshop

26th-27th March08

Freight Wagon Designs for Indian Railways

By G.C. Budhalakoti
Ex. Dir. Wagon, RDSO

Historical Background
Pre-independence (upto 1947)
25 types of wagons designed by M/s Rendol Palmer in 75 years Axle load was 16.3 t Pay to tare ratio ranging from 1.09 to 2.64

Post-independence (upto 1960)

9 wagon designs developed by various designers from all over the world. Some of the important wagons are BOBS, BWS Axle load max. 22.9 t

Historical Background
Post-independence (upto 1960)
After formation of RDSO in 1957, responsibility of development of design taken by RDSO. First wagon designed by RDSO was BOX wagon in 1960 Between 1960 & 1980 wagons with vacuum brake having UIC bogies were designed by RDSO. In 1980, BOXN wagon with air brake, Casnub bogie. CTRB & CBC was introduced. Since then BOXN and other wagons like BCN, BTPN, etc. having Casnub bogie became workhorse of IR freight transportation. Max. Axle load 20.32 t, Max. speed 100 Kmph

ORIGINATING TONNAGE
(Million Tonnes)

1200 1000 726 800 600 400 200 0 1980-81 1990-91 2000-01 2006-07 2007-08* 2008-09* 318.4 195.9 473.5 850

1100

790

2011-12*

Note:* Estimated

RDSO, Lucknow, INDIA

New Design of Wagons (IR)

Design of 22.9 t A/L - BOXNHL & BCNHL
(wagons under production) Wagon Throughput increase
(in tonnes)

Pay to tare increase from

From To

Additional earning per rake per year

(in Rs. Crores)

From

To
4118

BOXNHL *BCNHL

3369

2.50
(of BOXN)

3.45 3.40

(of BOXN)
2496

(22.25%)
4106

(of BCNA)

(40%)

2.31
(of BCNA)

3.56 Crores 5.64 Crores

* No. of wagons per rake increased from 44 to 58

New Design of Wagons (IR)

Design of 25 t A/L Wagons
Wagon Throughput increase
(in tonnes) From To
4582

Pay to tare increase from

From To

Remarks

Addl. earning per rake per year (in

Rs. Crores)

BOY25 BOXN25 BRN25 BOBRN25 BOBSN25

3686

3.42
(of BOY)

3.76 3.35 3.25 3.10 2.57

Design completed
(no. of wagons per rake increased from 52 to 58)

(of BOY)
3369

(24.3%)
4466

4.88
Crores

2.50
(of BOXN)

Design completed

(of BOXN)
2425

(32.6%)
3210

5.21
Crores

2.45
(of BRN)

Design completed

(of BRN)
3229 (of BOBRN) 3305 (of BOBSN)

(32.3%)
4385

4.31
Crores

2.17
(of BOBRN)

Design completed

5.49
Crores

(35.8%)
4176 (26.4%)

2.01
(of BOBSN)

Design on hand
(no. of wagons per rake increased from 54 to 58)

4.75
Crores

DOUBLE STACK CONTAINER OPERATION ON FLAT WAGONS

Double stack container operation on flat wagons started in March06 Limitation of axle load (20.32 t) & speed (max.75 Kmph), resulting in restriction in container loading Bogie upgraded and Speed certificate for operation at 22 t axle load and speed of 100 Kmph issued in 2007.

Road Railer trains (Development with M/sKPC)

Can be converted into trailer hauled by a truck and into normal wagon Carry white goods, automobiles, manufactured goods, perishables, fragile cargo,part load,etc. Faster turn around time Trials already done on IR Number of wagon per rake- 50 Articulated Bogie, Slackless coupling Kirloskar Pneumatic Co. manufacturing one rake for braking distance trials

ROADRAILER CHASSIS IN ROAD MODE

ROADRAILER CHASSIS IN RAIL MODE

Double Stack Container Train entering in Botad Yard

Flyash Wagon (New traffic)

Recently designed transportation of flyash Special features are:-

wagon

for

bulk

Pay to tare ratio 2.14 for Flyash (3.02 for Cement ) No. of wagons/rake 58 Stainless steel (IRSM 44) underframe & body Rake throughput of 2732 t Can carry cement-rake throughput 3875 t Axle load 22.9 t max. with Cement

Autocar Wagons
Dedicated wagon for transportation of autocars
New Design Bi-Level Autocar Wagon type BCACB Features
- Can carry upto 294 autocars. - New bogie design with lower wheel dia (760-700 mm) - Provision of hydraulic cushioning devices

Status: Design completed

New Design Tri-Level Autocar Wagon type BCACT -Features

- Can carry upto 444 autocars - Can run only on Double stack ISO container routes (i.e. presently JaipurPipavav) - Provision of various types of cars in three decks

Status: PDC of design May, 2008.

Diagram of Bi-level Autocar Wagon Type BCACB

Diagram of Tri-level Autocar Wagon Type BCACT

Ro-Ro Under Wire

With the new bogie of 700 mm wheel dia of Autocar wagon, it is now possible to run Ro-Ro services under wire. RDSO has also undertaken the design of such Ro-Ro wagon.

Dedicated Freight Corridor

Following two new corridors dedicated to freight traffic movement are being constructed: Eastern CorridorMain traffic- Coal & Ores

Western CorridorMain traffic- Containers

Axle Load

32.5 t (Final target) 25 t (Starting)

Amritsar

Nagal Dam Chandigarh

Dedicated Freight Corridor Ludhiana-Son Nagar with Extensions to Durgapur/Bokaro/Tatanagar

Legend:

Ludhiana
Bhatinda

Panipat

DFC (EASTERN)
Ambla Saharanpur Meerut Hapur
Harduaganj

Main Route

Feeder Route

Khurja

Tundla Kanpur
Unchahar

Mughal Sarai
Paricha

Allahabad

Son Nagar
Gomoh Asansol

Katni

Durgapur Tata Nagar Bondamunda

P R O P O S E D F R E I G H T C O R R ID O R (W E S T E R N )

L U D H IA N A L E G E N D :M A IN R O U T E F EE D E R RO U TE H IS S A R D ELH I

R EW A RI J A IPU R J O D H PU R LUNI M A R W A R JN . P H U L ERA T U N D LA AGRA

G ANDHI DHAM M u n d ra P o rt

P A L A N PU R M EH SA N A

K A N D LA P o rt R A JK O T

A H M ED A BA D V IR A M -G A M V ADODARA H a z ira SURAT

OKHA

P IP A V A V

V A L SA D

V A SA I R O A D M UM BAI

D IV A T hal M u m b a i P o rt

Approved MMD for DFC

MMD for Feeder Routes of DFC (under consideration)

Future Wagons for DFC/IR (25 t A/L)

Possible throughput on existing length of Wagons

25t axle load

Type of Wagon Commodity Payload (in tonnes) & Pay to tare ratio
84 (5.0) 82 (4.5) 84 (5.0) 80 (4.0)

Throughput increase/ rake (in tonnes) & % improvement

1504 (44.6) 1527 (47.2) 1186 (32.2) 2141 (85.9)

Additional earning per rake per year

(in Rs. Crores)

BOXN BOBRN BOY Covered

Coal Coal Iron Ore Bagged commodity

7.15 Crores 7.26 Crores 6.47 Crores 10.33 Crores

Future Wagons for DFC/IR (32.5 t A/L)

Possible throughput on existing length of Wagons

32.5 t axle load

Type of Wagon Commodity Payload (in tonnes) & Pay to tare ratio
108 (5.0)

Throughput increase/ rake (in tonnes) & % improvement

2896 (85.9)

Additional earning per rake per year

(in Rs. Crores)

BOXN

Coal

13.76 Crores 13.87 Crores 14.06 Crores 17.04 Crores

BOBRN

Coal

106 (4.5)

2919 (90.4)

BOY

Iron Ore

108 (5.0)

2578 (69.9)

Covered

Bagged commodity

104 (4.0)

3536 (141.6)