Freight on IR Transformation through Design Freight The

Freight on IR: Transformation through Design

Freight: The Bread Earner Ø 65% of IR’s Total revenue is generated from Freight. Ø Freight is the only business segment of IR that generates a surplus.

All- Round Design Inputs: Wagons Mild Steel Corten Steel Stainless Steel HSLA Material of Construction Riveted Side Bearers Center Pivot Coupler, Brakes Draft Gear Hot Rolled Sections Cold Formed Sections Fish Bone Structure Design Philosophy Components 4 Wheeler Fabricated UIC CASNUB/ CASNUB HS LWLH Bogie Bearings Plain Brg Roller Brg CTRB

Better Design: Efficient Growth 400. 0 363. 3 378. 0 350. 0 300. 0 226. 2 Tonnage (Coal + Iron Ore) 131. 2 150. 0 100. 0 98. 9 93. 1 97. 5 126. 0 134. 8 50. 0 1200. 0 800. 0 508. 4 600. 0 Revenue(Coal+ Iron Ore) 339. 2 400. 0 Number of Open Wagons 205. 0 200. 0 11 10 - 06 20 05 20 00 - 96 20 95 - 19 91 0. 0 01 98. 9 93. 1 97. 5 126. 0 134. 8 90 - Over the last 20 yrs, while the number of Open wagons have increased by just 35%, the Tonnes Carried (in Open wagons) has increased by 380% & Earning by 1086%!! 1086. 2 1005. 0 1000. 0 19 12 11 - 1 20 10 -1 6 20 05 -0 1 20 00 -0 6 20 95 -9 19 90 -9 1 0. 0 19 Number of Open Wagons 12 160. 7 11 - 200. 0 20 250. 0

Better Design: Efficient 372. 8 Growth 400. 0 350. 0 343. 1 300. 0 250. 0 211. 9 200. 0 150. 0 Number of Covered Wagons 148. 6 100. 0 111. 3 100. 0 51. 3 72. 6 50. 0 Loading of Cement 43. 0 45. 2 46. 3 1000. 0 2 11 -1 20 11 10 - 6 20 05 -0 20 01 00 - 20 96 95 - 19 19 90 - 91 0. 0 902. 1 900. 0 780. 3 800. 0 Number of Covered Wagons 700. 0 600. 0 397. 5 400. 0 280. 7 300. 0 200. 0 163. 6 100. 0 51. 3 43. 0 45. 2 46. 3 72. 6 19 90 -9 19 1 95 -9 20 6 00 -0 20 1 05 -0 20 6 10 -1 20 1 11 -1 2 Over the last 20 yrs, while the number of Covered wagons have in-fact decreased by almost 50%, the Tonnes Carried (in Covered wagons) has increased by 370% & Earning by 900%!! 500. 0 Earnings from Cement

Wagon Design Efficiency: Pay/Tare ratios of Open Wagons BOXN 25 GONDOLA 25 BOXNH L BOXN 3. 46 An 2. 86 BOX 2. 95 2. 25 4. 00 4. 21 increase of 0. 5 in the PAY/TARE ratio, translates to an average additional revenue earning of Rs. 1. 58 lakhs per wagon per year.

Design & Development of 25 T axle load Open Type BOXNS Wagon

Design & Development of 25 T axle load Open Type BOXNS Wagon The design features: 1. Designed with the best ever Pay/Tare ratio of 4. 21. 2. Fish Bone Structure with Side Stanchions integrated with Cross Members. 3. Shorter but Taller Structure Design. 4. No Door Design. 5. Fully Welded Construction. 6. Optimal Material Selection. Cost Effective Design utilizes stainless steel on surfaces in contact with coal but utilizes HSLA carbon steel in underframe.

Design & Development of 25 T axle load Open Type BOXNS Wagon ADVANTAGE 25 T Axle Load – Carrying Capacity Increased by 12. 76%. Resulting, additional 535 MT material overcharge in a 59 Wagons rake in comparison to BOXNHL Rake. • Door-less Design – Low maintenance and higher life-span of the wagon. • Loading – Top Loading. • Discharge System– Unloading with Trippler for Quick & Rapid Discharge. • Body fabricated from Stainless Steel (IRS: M 44): Rust free, better durability, low maintenance. • Under-Frame fabricated from Steel to IS: 2062 E 450 (Fe 570) BR with Cu: This high strength micro alloyed steels have higher yield strength, higher notch toughness, good fatigue properties, excellent weld ability and good formability. • Twin Pipe Air Brake System with Slack Adjuster IRSA: 750: Cost effective & reliable.

Design & Development of 25 T axle load Open Type BOXNS Wagon Special Structural Features

Special Structural Features

NEW LWLH 25 T BOGIE FOR BOXNS WAGON

BEARING: AAR Standard Cartridge Taper Roller Bearing [ 6 ½“ X 9“ ] Class ‘K’ WHEEL & AXLE : 840 MM Dia Wheel on Tread and 25 T Axle

25 T OPEN WAGON DESIGNS: Design Parameter BOXNEL BOXN 25 Design A GONDOLA 25 BOXN 25 M Design B Max Axle load 25 25 Body Design jointly by RDSO-ARI, No Door Design, Fish Bone Structure, Micro alloyed underframe & SS interiors Complete Design by RDSO, No Door Design, Fish Bone Structure, Micro alloyed underframe & SS interiors Major Design Features Complete Design by by RDSO, 4 Doors, SS MS Underframe & Body Bogie used CASNUB NLC Amsted SMB Optimized weight LWLH Speed (L/E) kmph 45/60 To be ascertained 75 /100(proposed) 9. 596 x 2. 99 x 2. 43 9. 784 x 3. 135 x 2. 3 L x H x W (m) 9. 784 x 2. 95 x 1. 95 9. 784 x 2. 957 x 2. 33 Tare weight (T) 23. 1 22. 58 20 T 19. 2 Pay Load(T) 76. 9 77. 42 80 T 80. 8 T Pay/tare 3. 33 3. 43 4. 00 4. 21 No. of Wagons/ Rake 59 59 Throughput/ Rake (T) 4537 4567 4720 T 4767 T

Creating Revenues where none Existed • Innovative, 2 Tier , Cost-effective Design enabling transport of 318 cars of all types- Compact to SUV per rake. • NO capital investment in rakes by IR. • Rakes have clocked 1 lakh kms & 8000 cars already transported within 1 year of service. Extremely satisfied, thankful customer. BCACBM: The Autocar Wagon

Autocar Wagon BCACBM : Exterior BCACBM: Autocar Wagon BCACBM interior : Lower deck With movable middle deck

Coal 42% Raw Mat for Pig Iron &Steel Plant Finishedexcept Iron Steel Ore 6% 2% 78. 74 66. 67 80. 00 49. 94 60. 00 37. 40 40. 00 re 18. 53 O n C on ta i ne rs il O al er M liz rti Fe gr a in s s t od en e C or n- em Fo sh ni Fi Iro nt la & l l oa C el P Pi g Iro n or St e at f M 31. 72 ep t. I ro 0. 00 aw 31. 24 20. 31 20. 00 R A Strategic transportation shift, that could make cement transport captive for IR is to encourage bulk transport of cement/ related products Percent of Total with Rail 79. 87 in er For a bulk commodity like Cement, IR has just 50% of the transport share & cement (despite freight rates same as coal) comprises under 10% of IR’s freight earning. Clinker Wagons. St ee Cement 9% Iron-ore 11% 3. Bulk Commodity - Cement, Flyash & ed Foodgrains 7% Earnings of IR(2011 -12) ex c Other Freight Commodities Containers 7% Mineral Oil 5% 5% Fertilizers 6%

Creating Revenues where none Existed Loose Cement, Flyash & Clinker: A rake of Cement earns as much as a rake of Coal for IR & IR has only 49% of the Cement transportation market of India. New Wagons-BCFC, have been introduced with an aim to bring a strategic shift in cement transportation- from bagged to bulk (loose). Bulk Cement transport would create captive customers for IR.

Bulk Commodity Wagons: An Array of Designs Wagon Type (Designed by) BCCW (CIMMCO) BCFC Design A (RDSO) BCFC Design B (RDSO) Bulk Cement (T) Flyash(T) Clinker(T) 3380 2720 Cannot Carry 3904 2842 Cannot Carry 4007. 8 2900 Cannot Carry 3949 2785 3967 3405 Cannot Carry 3886 BCFC Design C (RDSO) BCFC Design D (RDSO) BCBK (RDSO-RITES) Remarks Some rakes invested by ACC (Currently under operations) 2 rakes under operations Best In Class for Bulk Cement Throughput ONLY design that can carry ALL 3 commodities Best In Class for Clinker Throughput Best In Class for Flyash Throughput

Creating Revenues where none Existed BLC: The Container Wagon • IR had NO share of the container business till 2010. • Development of BLC wagons opened the container freight business for IR. • In 2013 -14, IR earned over Rs. 4000 Cr by transporting Containers & ferrying over 43. 5 m. T of Freight in Container alone. • With new design of 25 T axle load Container Wagons, RDSO is ready for the future of this lucrative segment.

Development of 25 tons axle load container wagon Ø Ø On request of CONCOR, RDSO has designed 25 tons axle load capacity broad gauge bogie container flat wagon type BLC 25. The new container Flat Wagon has 17. 4 % & 24. 6 % increase in rake throughput vis-à-vis existing BLCM and BLC wagons. The design has better curve negotiability and capable to transport tank containers besides dry box containers. Prototype wagons is under manufacture at GOC Railway workshop.

Creating Revenues where none Existed • IR had negligible share of the finished steel business till development of Steel Coil wagons. • Development of BFNS & BRN 22. 9 wagons tapped the finished steel products freight business for IR. • In 2013 -14, IR earned over Rs. 4600 Cr by transporting Finished Iron & Steel Products & ferrying over 27. 8 m. T of Freight in this segment alone. • With new design of BFNS Wagons, with increased throughput by 68%, RDSO is ready for the future of this lucrative segment.

Development of Shorter length Flat wagon for transportation of steel coil (BFNS 22. 9) A new design of a dedicated 22. 9 T Axle load Bogie flat Wagon for transportation of Steel coils has been developed by RDSO. Ø The new Shorter length Flat Wagon has 68% Improvement in rake throughput against existing BFNS wagon (3944 tons v/s 2344 tons). Ø Patent application has been filed by RDSO for this design with office of controller general of patents. Ø Prototype manufacturing is completed at works of M/S Texmaco, Kolkata. Ø

Development of Shorter length Flat wagon for transportation of steel coil Salient Features: Easy Loadability � Lashing and Securing of coils � Lower Turn-round Time: � High Reliability � Anti Skid mats � Amenability to versatile covering arrangements �

Creating Revenues where none Existed • IR, currently, has a dismal share (1828 crore-2013 -14) in a 1. 4 lakh crore Parcel traffic market in India !! A market share of 1. 3% • The Parcel Traffic has stayed stagnant & not grown in last decade. • Although the earning is 1828 Cr, Parcel is a Net LOSS making segment on IR. • The NEW BCPV (High Capacity Freight Parcel Van) would redefine this scenario. INDIAN RAILWAYS FREIGHT PARCEL VAN: Breakthrough Design by RDSO

Key Design Features: � Designed using CASNUB Bogies, to operate as Freight stock. � Speed Potential of 100 kmph. � Highlights: �Optimized wagon dimensions for maximizing volumetric capacity(LHB length, BCNHL profile). �Design wagon interior arrangement for strapping/ securing. �Door Arrangement & Design. �CBC (for larger No. of wagons/ rake). �Cost-Effective selection of Material of Construction. �Specially Designed, Extra Wide, Two-Part Sliding Door. Provisions of 2 Doors per Van (One on each Side). [Door opening of 2. 5 m (W) x 2. 10 (Ht). Present van-ICF- has a door opening of 1. 397 m (W) x 1. 868 m(Ht)] �Interior Lighting operable at terminals. �Possible Development of Refrigerated Variant.

28 Axle Special purpose Wagon � Designed by Wagon Directorate of RDSO to carry 660 MW Generator with max load of 296 Tons. � Unique design feature : Combination of 4 bogies of 4 axle type and 4 bogies of 3 axle type. � Tare Weight : 186 T, Gross Weight 482 T (heaviest on Indian Railways) � Length : 52. 54 m (Longest Wagon on IR) � First Consignment has been successfully transported by BHEL Haridwar in April 2015 from Hardwar to Bara for power plants. Another 5 consignments are ready for transport to various parts of country.

Designed for transportation of heavy plant and machinery like power plant equipment mainly used by BHEL.

Design of Salt Wagon As desired by PMO, RDSO designed two types of special wagon for transportation of salt. One is Open type BOXNHL (Design E) and another is Covered type BCNHL (Design F). OPEN TYPE BOXNHL (DESIGN E) WAGON WITH SLIDING TARPAULIN ROOF MFD. BY M/s. BESCO LTD. (WAGON DIV. ) COVERED TYPE BCNHL (DESIGN F) WAGON WITH SLIDING FRP ROOF OPERATED BY HAND WHEEL MFD. BY M/s. TEXMACO LTD.

Design of Salt Wagon ROPE OPERATED SLIDING ARRANGEMENT OF TARPAULIN ROOF IN OPEN WAGON HAND WHEEL OPERATED SLIDING ARRANGEMENT OF FRP ROOF IN COVERED WAGON.

Bull-Dozer Wagon Ø Ø Ø Bulldozers are part of machinery available in many accident relief trains. Presently these bulldozers are loaded on a well wagon and run as ODC at 40 KMPH. On request of NC Railway, A new type of special design of well wagon for movement of Bulldozer at full speed potential has been developed by RDSO with following salient features: High operational speed potential upto 100 kmph. Within IRSOD: No ODC restriction Usage of special steel girders. Provided with twin pipe, BMBS and completely new design of hand brake arrangement.

Coming Shortly……. . • 25 T Covered Wagon. • 25 T Hopper Wagon. • Tilt Bed Wagon for Wide Plates. • Wagons for Missile Transport. • Eo. TT. • Hollow Axle. • High Speed Operations. • Indigenous Draft Gear. We would continue to strive for more efficient, more productive & more profitable Freight solutions for Indian Railways.

What we need to look into for freight attraction �Change of scheme of rake loading to piecemeal loading. �RORO truck carrying with attachment of coach for driver. �Resolving BCNHL issues with customer requirment. �Allowing salt wagons for loading of cement, fertiliser and salt making it multipurpose.

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