ACHIEVEMENT OF WAGON DIRECTORATE SINCE 2006

1. Development of 22.9t axle load BOXNHL Wagon

BOXNHL is the first all stainless open wagon of 22.9 t axle load. It was designed by RDSO in year 2006. Railway Board placed orders for procurement of BOXNHL wagons in Nov’07. Prototype approval of six wagon builders was done in 2008-09 and approx. 2000 BOXNHL wagons were manufactured. In the current year (till Feb’10) prototype approval of five more wagon builders, including approval of QAP and Brake Block Force Testing, has been done and 4734 additional wagons have been manufactured.

• Superstructure all stainless steel, for reducing weight and corrosion • Improved quality coupler and draft gears • Lower brake block force with ‘K’ type CBB • Rake throughput increase of 22.25 % over BOXN (20.32 t) and 10.61 % over BOXN (CC+6t) • Additional earning per rake per year of Rs. 3.84 Crores, over BOXN(20.32t) and 2.06 Crores over BOXN(CC+6t)

Upgradation of BOXN Wagon

• BOXN wagon upgraded for 22.9 t axle load (BOXNHL), for transportation of Iron Ore

2. Enhanced axle load

• BCNA wagon upgraded for 22.9t axle load (BCNAHL) • With 22.9 t axle load BCNHL wagons, the rake throughput will increase by (64.51%), in comparison to BCN (20.3 t A/L) wagon. • Additional earning per rake per year of Rs. 7.76 Crores, over BCNA. (CC)

3. Enhanced axle load

• BOY wagon upgraded for 25t axle load (BOY25) • With 25t axle load BOY25 wagons, the rake throughput will increase by (24.30%), in comparison to BOY (20.3 t A/L) wagon. • Additional earning per rake per year of Rs. 4.88 Crores, over BOY. (CC)

4. Special wagon for transportation of rail

• Developed as per requirement of traffic/ engineering department. • Bulk head of swiveling type and lighter in construction. • Load support arm of swiveling type • Fixed roller with roller bearing to eliminate repeated handling of rollers during loading and unloading. • Capable of transporting upto 20 rail length panels, with 48 such panels per wagon.

5. Operation of wagons at 25t axle load wagons

• BOBRN wagon upgraded for 25 t axle load (BOBRNEL), for transportation of Iron Ore • With 25 t axle load BOBRNEL wagons, the rake throughput of Iron Ore will increase by 506 t (13.3%), in

comparison to BOBRN (22.9 t A/L) wagon. • Additional earning per rake per year of Rs. 2.76 Crores, over BOBRN (CC+8t+2t)

6. Enhanced axle load

• Enhanced loading of CC+8t+2t for cement, in the different variants of BCN wagon permitted. • Additional earning per rake per year of Rs. 2.12 Crores, over BCNA. (CC)

7. Double stack

• Axle load and speed of double stack container trains enhanced to 22t (from existing 20.32t) and 100 Kmph in loaded condition (from existing 75 Kmph), respectively by up gradation of the existing design of container wagons • This will permit faster turnaround & higher throughput and thus improve the utilization.

8. Upgraded rehabilitation of existing BOXN wagon

• Design and drawings of Upgraded rehabilitation of existing BOXN wagon at an age between 12-15 years to increase the carrying capacity and to take care of the existing & likely problems due to CC+8+2 t loading issued. Manual for upgraded rehabilitation issued • Throughput increase of 7% over BOXN (CC+6+2) • Carrying capacity for Coal increase by 6.0 t and tare weight reduction by 2.0 t (the wagon can be fully utilized for Coal also with 22.9t axle load) • Additional earning per rake per year of Rs. 1.27 Crores, over BOXN (CC+6+2)

9. Road Railer

• RDSO has developed Road Railer with M/s Kirloskar. • This permits increased flexibility & convenience by providing door-to-door service, while reducing the inter-modal trans-shipment to a minimum. One prototype rake is under manufacturing stage to conduct braking distance trials

10. Cement/Fly Ash wagon (BCFC)

• One rake of the RDSO designed wagon will have a throughput of 3904t for cement & 2842t for fly ash, thereby giving additional carrying capacity of 528t for cement and 239t for Fly Ash in comparison to present cement wagon design of M/s Texmaco • Earning per rake per year of Rs. 21.36 Crores (for cement) & Rs.15.55 Crores (for fly ash). • Tender for procurement of 125 wagons under finalization in Rly. Bd.

11. Modified BLC wagon Auto car Carrier (BCACM)

• Design developed for modification of Container flat wagons (BLC wagons) for bi-level transportation of auto-cars. Up to 270 Maruti 800 cars may be transported per rake. • Earning per rake per year of Rs. 12.70 Crores • One rake converted by Jagadhari workshop, currently in use.

12. New wagon design for auto car transportation (BCACB)

• Design of the low height bogie was completed in 2007-08 • New design developed for bi-level auto car wagon. Up to 288 Maruti-800 cars may be transported per rake. Provision also exists for transportation of Tall-Boy cars like Wagon-R, Omni, etc. in the lower deck • Earning per rake per year of Rs. 12.88 Crores • Specification and Material Schedule for procurement of these wagons sent to Railway Board.

13. Increase in speed of BOSTHS Wagon

• Speed of BOSTHS wagon in empty condition increased to 100 Kmph • This will permit faster turnaround & higher throughput.

14. Increase in the speed of Wagons

• Speed of BOXNHSM1, BCNAHSM1 & BCNM1 wagons in loaded condition increased from 60 to 75 Kmph at CC+6+2 t loading • This will permit faster turnaround & higher throughput.

15. Modification to the 24 axle Kailash wagon for fitment of CBC

• Unbraked wagon, currently fitted with screw coupling. • Required to be attached with other wagons for movement. • Will help in attachment of this wagon with every other type of wagons for movement 16. Works related to meet current traffic requirements

(i) Increase in the speed of Wagons  Speed of new design 22.9 t axle load stainless wagon type ‘BOXNHL’ has been increased to 75 Kmph in loaded condition. (Rly. Bd. has decided that all BOXNHL wagons will be based in MGS covering MGS-GZB route)  Speed of existing BOXNM1 and BOXNHSM1 has also been increased to 75 Kmph in loaded condition (CC+8+2 t) on MGS-GZB route.  This will help in improving the line capacity on MGS-GZB route which had become a bottleneck in freight operations.  This will help in faster turnaround and increase in freight earning of IR. (ii) Development of BCNHL Wagon

BCNHL is the first all stainless steel covered wagon of 22.9 t axle load. It was designed by RDSO in year 2006. Railway Board placed orders for procurement of 1300 BCNHL wagons in Nov’07. Prototype approval of two wagon builders was done in 2008-09 and approx. 115 BCNHL wagons were manufactured. In the current year (till Feb’10) prototype approval of two more wagon builders, including approval of QAP and Brake Block Force Testing, has been done and 2458 additional wagons have been manufactured.

17. Works r elated to future traffic growth

(i) Design of tank Wagon for LSHS/RFO type BTOH

 Design of bogie tank wagon for LSHS/RFO (residual fuel oil) for replacement of the existing 4-wheeler stock (TOH) has been developed by RDSO.  Design has been made by modification of the existing BTPN wagon with provision of heating coils & suitable accessories like inlet/outlet valve.  The specification & the tentative cost of the wagon have been sent to Rly Bd on 22.12.09  Proposal for manufacturing of three prototype wagons has been submitted to Rly. Bd. for inclusion in RSP 2010-11.  With this design, there will be rake throughput improvement of 44.8%. (with bogie design throughput per rake will be 2491t/rake as against 1720t/rake for the existing 4-wheeler TOH wagons)

(ii) Design Modification and Manufacturing of Prototype of BOXN25M Wagon

 RDSO had designed a 25t axle load BOXN wagon in 2007.  Design of this wagon was modified in April’09 to accommodate new Friendly bogie to be procured from M/s Amsted USA.  Prototype wagon is under manufacturing (expected to be completed by April’10) by GOC workshop , nominated by Rly. Bd., for conducting oscillation trial with track friendly swing motion bogie, being procured with TOT.  BOXN25M wagon will have rake throughput increase of 10 % over BONXHL wagon resulting in additional earning of Rs. 2 Crores per rake per year. (iii) Procurement of Track Fr iendly Bogie with TOT

 Existing Casnub bogie has constraints of: high lateral forces at higher speed, maintenance intensive and axle load limited to 22.9 t.  To overcome these problems, tender for procurement of track friendly with TOT was floated by Rly. Bd. in year 2007. LOA for design, manufacturing and supply of such bogies (called Swing Motion Bogie) was issued in Oct’08 by Rly. Bd.  Contract Agreement with M/s Amsted, USA for TOT against the said tender was signed in Aug’09.  Same bogie can be used for 25t and 32.5 tonnes axle load by change of suspension springs  Speed potential of 110 KMPH at 25 tonnes as well as 32.5 tonnes axle load  Less lateral force [at 25 t a/l, maximum lateral force (at Rail-wheel level) of 4 t at 125 KMPH against present lateral force of 7 tonnes at 70 KMPH (22.82 t a/l)]

(iv) Design of 25t axle load Container Wagon ‘BLC25’

Design of 25 t axle load container , BLC25, proposed to be utilized for the oscillation trial with the Swing Motion Bogie has been completed. Manufacturing drawings have also been prepared. This wagon will have a standard floor height of 1270 mm, based on which the Double Stack Container trials will be conducted.

As per Rly Bd’s directives all required documents (Specification, manufacturing drawings and uncommon material with BLC) of BLC25 were sent to GOC workshop by e-mail on 07.09.2009 and in hard copy on 09.09.2009 for manufacturing of prototype. Manufacturing of the superstructure of the wagon has since been completed by GOC workshop in Jan’10. Wagon shall be made ready for Oscillation trial after receiving the Swing Motion Bogie.

(v) New Design of using Casnub Bogie

The existing brake van (BVZI) is having ICF trolley with spring combination different from coaches. Difficulty in maintenance of these brake vans (BVZI) is being faced in wagon depots and yards. Mainly, following problems are being faced:-

 Breakage of centre pivot  Uncommon spares required for maintenance  Requirement of Sch. ‘C’ repair to ICF trolley  Requirement of Dashpot oiling  Requirement of attention to Roller bearing Keeping in view the above problems, a new design of brake van using Casnub HS bogie with modified suspension (2 snubber & 5 outer springs) has been developed. The elastomeric pad of higher longitudinal/lateral stiffness meeting RDSO’s spec. No.WD-32.Misc.99 (Rev.3) has been used in the bogie. The NUCARS simulation results suggest satisfactory riding characteristics upto 110 kmph.

The proposal of this new design of Brake Van has been submitted to Rly. Bd. vide this office letter no. MW/BVZI dated 30/10/2009 for approval and nomination of one workshop to make prototype brake van so that oscillation trial can be organized before regular manufacture of this brake van. Prototype wagons under manufacturing by JMP workshop, nominated by Rly. Bd. PDC, March’10.

(vi) Design of BG Bogie 28 -Axle ‘T hreaded Beam’ Special Wagon:

Design for BG Bogie 28-Axle ‘Threaded Beam’ Special Wagon has been completed. This wagon is for

transportation of 660 MW turbo generator stator weighing 296 t for BHEL, Haridwar. This is special wagon provided with a 380 mm hydraulic lateral shifting arrangement for the “threaded Beam”, to permit the shifting of the consignment at curves to permit adequate clearances. It is an unbraked wagon, like the existing 24- axle wagon, & the brake power is provided by braked wagons attached to the front & rear of this wagon. It has been provided with transition type CBC & air brake piping. Tare weight of the wagon will be 186.1t.

(vii) Preparation of drawings and cost estimate for Conversion of BCX wagons into air brake with Casnub HS bogie:-

To meet the shortfall of covered wagons and also utilize the remaining life of existing covered vacuum brake eight wheeler stock, drawings and cost estimate for conversion of BCX wagons into air brake with Casnub HS bogie have been prepared and submitted to Rly. Bd. vide this office letter no. MW/BCX dated 07/10/2009.

(viii) Preparation of drawings of BOXNHL & BCNHL wagons for conversion to twin pipe air brake system: -

To take advantage of twin pipe air brake system, drawing of BOXNHL & BCNHL wagons for conversion to twin pipe air brake system have been prepared. Wagon Builders have been asked to manufacture these wagons with twin pipe air brake system. Two Zonal Railways (ECR & SCR) have also been asked to take action for retrofitment of twin pipe air brake system in these wagons.

(ix) Design of Ro -Ro Wagon for Universal Operation

 New Design of a flat wagon for carrying trucks type “BTRO” has been developed  Can be used for transporting 25 t GWT, 3-axle trucks, under wire  Will ply in those sections which have non-platform lines throughout the route  Will help in attracting new traffic  Will help in substantial fuel saving, Rs. 5 Crores per rake per year  Procurement of three Prototype wagons has been proposed in RSP 2010-11 (x) Devel opment of Cement/Fly Ash wagon (BCFC)

 In 2007-08, RDSO had designed a wagon for transportation of cement/flyash in bulk  P.O. for procurement of 125 such wagons was placed by Rly. Bd. in April’09.  QAP and WPS for manufacturing of this wagon were approved in the current year.  Prototype wagon is under manufacturing (expected to be completed by April’10) by the firm.  One rake of the RDSO designed wagon will have a throughput of 3904t for cement & 2842t for fly ash, thereby giving additional carrying capacity of 528t for cement and 239t for Fly Ash in comparison to present cement wagon design of M/s Texmaco  Will help in attracting new traffic  Earning per rake per year of Rs. 21.36 Crores (for cement) & Rs.15.55 Crores (for fly ash). (xi) Design of 25t axle load iron ore hopper wagon:

 BOBRN wagons are designed for transportation of coal & have door operating mechanism suitable for aggregate materials. But, it is being used for transportation of iron ore fines, during which Railways have reported cases of dropping of iron ore fines on the railway track.

 As per para 77 (vii) of Hon’ble MR’s budget speech, requirement of “special wagons for iron ore” has been emphasized. In pursuant to this, bottom discharge wagons catering to iron ore traffic is proposed to be developed.

 During discussions, M/s TISCO indicated their preference for bottom/side discharge wagons, as compared to BOXN/BOY variants, chiefly due to lesser unloading time & for the reasons that rake integrity is maintained & wagon tippler is not required.

 Hence, a preliminary study has been conducted on the feasibility of designing a 25 t axle load iron ore hopper wagon. The new design will have a modified door operating mechanism to prevent leakage of iron ore fines. Materials used in the wagon fabrications will be stainless steel & high tensile steel for wagon body & wagon under-frame, respectively.

 Comparative assessment of the proposed design is as under :-

BOBS MK. -II Proposal 1 with Proposal 2 with S.No. Item No. with 25t axle 9.33 t/m TLD 10.86 t/m TLD load

1 Axle Load(t) 25t 25t 25t

2 Gross Load(t) 100t 100t 100t

3 TLD(t/m) 7.9 t/m 9.33t/m 10.86/m

4 Tare weight(t) 30.4t 21t 21t

5 Pay load(t) 69.6t 79t 79t

6 Pay Load/Tare ratio 2.29 3.76 3.76

7 No. of wagons per rake(nos.) 53 58 68

8 Throughput per rake(t) 3689t 4582t 5372t

% throughput improvement in proposed 9 - 24.2% 45.6% design over BOBS MK.-II

 Decision has been sought from Railway Board over the adoption of one of the above proposals. After receiving clearance from Rly. Bd., detailed design work of the wagon will be undertaken. Prototype for manufacturing of three prototype wagons has been submitted for inclusion in RSP 2010-11.

18. Other Important Works done

(i) Conversion of BOXN Wagon into MBOXN for departmental use

 Drawings prepared for conversion of unloadable BOXN wagon into MBOXN wagon for departmental use.

 The carrying capacity de -rated from 58t to 39.47t, keeping in view the age of BOXN wagons.  Will help in movement of departmental traffic (ii) Issue of Revised Drawing of Seal Wear Ring of M/s NEI

Problem of grooving of axle journals fitted with M/s NEI make bearings was reported by the Zonal Railways. On investigation, it was found that grooving is taking place due to less contact length and less interference of the seal wear ring of M/s NEI make, as compared to that of M/s Timken. This issue was discussed in 6 th WMG meeting and it was decided that RDSO will arrange to issue revised drawing of seal wear ring of M/s NEI make with increased contact length and interference.

The matter was discussed with M/s NEI and the revised drawing has been issued. Future supply of seal wear ring shall be done by the firm as per the revised drawing. This will prevent rejection of axles on account of grooving of journal by seal wear ring.

(iii) Modification in the body bolster of Brake van (BVZI):

Zonal Railways have been reporting problem of breakage of body bolster joint in eight wheeler Brake van (BVZI). To overcome this problem, design of body bolster of Brake van (BVZI) has been modified by RDSO. The modified design does not require the use of intermediate piece (body bracket) between centre pivot pin and body bolster. New drawings (Drg. No. WD-1/33-S-01 and WD-1/33-S-02) have been prepared by RDSO for this purpose.

(iv) Following initiatives have been taken for the benefit of Zonal Railways:

 “Wagon Diagram Book” for 8 wheeler wagons has been updated & prepared in entirely new format. This diagram book is having following information: (i) General arrangement drawing along-with important dimensions (ii) Speed Certificate No. & date (iii) Important features of wagon (iv) Important design data of wagon (v) Available photograph of the wagon This diagram book has also been uploaded on Wagon Directorate’s home page at RDSO’s website

(www.rdso.gov.in/wagon/diagram_book/index.html).

 Speed Certificate of wagons, normally required by Zonal Railways for CRS clearance, have been uploaded on RDSO’s website (www.rdso.gov.in/wagon/speed_certificate/index.html).

(v) Preparation of Pamphlet of Main Wagon Fleet of Indian Railways

At present, many types of wagons are in operation. Also, there are variants of wagons in which overloading has been permitted. Hence, at field level there was lot of confusion regarding difference in various types of wagons. To overcome this problem, one pamphlet ‘Main Wagon Fleet of Indian Railways’ has been published by Wagon Directorate. This pamphlet gives brief description of various types of wagons, difference in variants of wagons and respective permissible speeds.

This will be helpful in educating the field staff about various types of wagons and their variants in operation. A

copy of the pamphlet is enclosed.

(vi) Finalization of specification of critical items of D.O.M. in BOBRN wagons & associated Infrastructure facilities

Failure analysis of D.O.M. components indicate failure of six main items i.e. door hinge, adjustable bushing, bronze bush, bearing housing, eye bolt and square shaft. On further investigation by wagon directorate & M&C directorate, it was found that almost all the failures are due to either material or manufacturing defect.

In this regard it was observed that none of these items were covered by RDSO inspection. Also, there are no RDSO approved vendors for these items. Hence, to ensure quality, STR for these items & associated infrastructure facilities have been finalized. QA (Mech.) has included these items in the purview of RDSO inspected items.

Now, vendors for these items will be developed accordingly and inspection will be done by RDSO. With these measures, it is expected that the failures would come down.

(vii) Modification in the Centre Sill of BTPN Wagons:

Jhansi workshop had reported cracks in center sill, near bottom plate of body bolster, in 21 BTPN wagons. After investigation and analysis of this problem, a drawing No. WD-08097-S-01 has been issued for modifying the existing BTPN wagons. Also, drawing of the BTPN wagon has been altered to take care of this problem in future manufacturing.

Crack in Flange of Centre Sill of BTPN Drawing No. WD-08097-S-01

(viii) Meeting on BOXNHL Wagons: -

To review the performance and get first hand information about problems in BOXNHL wagons, two meeting, on 5th May’09 and 28 th Oct’09 on BOXNHL wagons were held at MGS. These meetings were attended by representative of all the Wagon Builders, Wagon and QA dte of RDSO, Lock Bolt Manufacturers, Bearing Manufacturers (in 2 nd Meeting) and user Railways including of traffic deptt. of MGS(in 2 nd Meeting). Representatives of WCR and SECR were also called in the second meeting in view of the Railway Board’s decision to base BOXNHL wagons at NKJ and Bhilai in near future.

In these meetings, special features of BOXNHL wagons, problems being faced in BOXNHL wagons and their

remedial action, settlement of pending warranty claims, feedback about the modifications done in the wagon and status of preparedness of Railways for maintenance of BOXNHL wagons were discussed. Discussion and decision taken in the meeting have been informed to all concerned vide this office letter no. MW/BOXNHL-FP dated 08/05/2009 & letter no. MW/BOXNHL-FP dated 05/11/2009. Implementation of decisions taken in the meeting will help in improving the reliability of the BOXNHL wagons.

(ix) Seminar on ‘New Wagon Designs and Related Issues of Maintenance’

A Seminar on ‘New Wagon Designs and Related Issues of Maintenance’ was organized in RDSO/Lucknow on 5 th June’09. The seminar was attended by CRSEs/Sr. DMEs of all the Zonal Railways. Following topics were covered in the Seminar:-

a) Variants of existing wagons in operation

b) New Wagon Design being manufactured

c) Problem of door operating mechanism in BOBRN wagons

d) Process of Cold Rolled Formed Sections

e) Bogie Mounted Brake System being introduced in Wagons

f) Problems in Wagon maintenance being faced by the Zonal Railways

(x) Meeting of Technology Development Group for CBC:

Technology Development Group (TDG) for suggesting improvements in coupler manufacturing was formed in year 2006. Third meeting of TDG was held in RDSO on 26 th June’09. In the meeting, the problems being faced by Zonal Rlys on account of coupler defects and analysis of Railway wise and Vendor wise reported coupler failure for last two years were presented. In the meeting decisions were taken to revise the existing specifications of coupler, in view of recent additions done by AAR, and to review the current manufacturing process of coupler.

(xi) Quality Audit Report of Bearing Ove rhauling

As desired by Railway Board, Quality Audit of Bearing Overhauling section of Jagadhari and Kharagapur was carried out by a team of Director Standards Wagon-III/RDSO and Director I&L/RDSO. Both the workshops have been advised for taking necessary action to make up the deficiencies noticed during Quality Audit. Complete report of the Quality Audit has been submitted to Railway Board vide this office letter no. MW/CTRB/D dated 01/05/2009.

(xii) Quality Audit of New Bongaigaon Workshop

As per directives of Railway Board, Quality Audit of wheel axle assembly and ultrasonic testing of axles at New Bongaigaon Workshop was conducted by Director wagon and ARO/M&C. Report of the Quality Audit has been sent to CME/NF Railway with copy to Rly. Bd.

(xiii) Meeting on ‘Maintenance of Wheels, Axles and Bearings’:

A meeting on maintenance of ‘Wheels, Axles and Bearings’ was organized in RDSO/Lucknow on 22 nd Jan’10. The meeting was attended by upto SG/JAG officers of all the Zonal Railways. Following items were discussed in the meeting:-

a) Phasing out and examination of sprag hole wheels and related issues b) Examination of wheels of Container Wagons (BLCA/B) supplied by M/s SMR Bals c) Important points to be taken care in UST of Axles d) Attention to be given in maintenance of Bearings in Open Line and Workshops e) Need to phase out Backing Ring and Seal Wear Ring with vent holes f) System of reporting of online bearing failures and bearing rejection during overhauling g) Action taken by Zonal Railways to comply with the deficiencies noticed during Quality Audit of bearing overhauling by RDSO, M/s Timken and M/s NEI h) Feedback on performance of BOXNR wagon Presentation on maintenance of bearings was also given by M/s NEI and M/s Timken. All the participants were made specially aware of the need to pay special attention to maintenance of bearings in yards, depots and workshops, in view of the increasing trend of on line failures of bearings.

(xiv) Introduction of Additional Intermediate Profile for Wagon Wheels:

 Till recently, there were three intermediate profiles of wagon wheels, having flange thickness of 25, 22 & 20mm. Still, due to restriction on number of intermediate flange thickness, extra turning of wheel tread had to be done, in some cases.

 To overcome this constraint, six additional intermediate wheel profiles have been introduced and circulated to all the Zonal Railways. Now, total nine intermediate wheel profiles are available which will help in reducing the material removal from wheel tread to bare minimum and thereby resulting in increased wheel life.