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In
1993-94 Indian Railways decided to look for a new passenger coach design.
which will suit India's specific need for high speed light weight coaches to run
in Indian Railways within the present infrastructure. Main features of the
specification were the specific railway and track conditions, the specific
environmental conditions in India and the operating speed
of 160 km/h. It was also decided that this design will be
first tried and used in the Rail Coach Factory in Kapurthala (RCF) and
after successful implementation also in the Integral Coach Factory in
Perambur (ICF) at a later stage.
After
a global competition, ALSTOM LHB was selected by Indian Railways and received
the order to design and develop the new generation coach .
Contracts
from Indian Railways
In
1995 , ALSTOM LHB received an order from Indian Railways to
design and develop a new passenger coach . The main targets of the contracts
given are the new coach design for manufacturing a new type of coach in
the factories of Indian Railways and the improvement of the manufacturing
techniques in their factories to make them suitable for the new coach design and
manufacture. This was named IR 20.
For
this purpose, ALSTOM LHB received two contracts which have to be seen as a unit.
The
contract for the supply of „All Metal Light Weight High Speed Coaches for
Broad Gauge“ includes the development, design and manufacture of
These
vehicles are developed in accordance with the specification of Indian Railways.
The
contract for the Transfer of Technology includes the transfer of technology for
design and manufacturing, the training of Indian Railways personnel in the
premises of the manufacturer and the technical assistance at RCF during the
start of production.
Main
features
The
broad gauge vehicle with a length of 23,54 m and a width of 3,24 m results in a
high passenger capacity. The tare weight of the AC 2nd Chair Car was
weighed as 39,5 t.
The
proven bogie based on the EUROFIMA concept is provided by FIAT-SIG. The
automatic centre buffer tight lock coupler of AAR type offer optimum service
conditions and maximum safety.
The
two-and-three seating arrangement in the 2nd class chair car gives a
capacity of 78 seats. The seat are arranged half in moving direction, the other
half against with a table in the centre.
Two
oriental and one western style toilet are provided. In the remaining corner the
central switchboard cabinet is located.
Each
vehicle is equipped with a pantry for storing cold and hot meals which are to be
served to the passengers at their seats.
Design
features of the new passenger coaches
The
design features of the new coaches will be explained on the example of the AC 2nd
Chair Car. BODY
The
shell is a steel lightweight construction made from stainless and low-corrosive
steels. For the underframe IRSM-R41 is used. The frame work and the wall
panelling is made out of ferritic stainless steel DIN 1.4003 and the roof panel
out the austenitic stainless steel DIN 1.4301.
The
isolation of the body provides an efficient heat and sound insulation. The floor
is from makore wood.
THE
INTERIOR
The
AC open saloon chair cars focus on the future vehicle needs in India. The
modular
design represents an innovative concept for long distance passenger
traffic. The main view above (thumbnail) shows the 2 + 3 seating arrangement with
a table in the center, the luminous band in the middle between the air-ducts,
the luggage racks with the integrated reading lamps,
the windows with roller blind and the GRP panels on ceiling and side walls.
The
luggage racks have front parts from
aluminium profiles and side covers from aluminium castings. The safety
glass pane closes the luggage rack completely. The halogen
reading lamps are integrated and are adjusted to each
seat.
The
modular design of the ceiling with 3 mm GRP panels integrates the
lighting arrangement, the AC outlet and the loudspeakers of the public address
system.
The
high comfort seats with in its range infinitely adjustable
reclining back rests are equipped with snack table,
magazine net and bottle holder. The footrest can be fixed in three
positions. The floor is covered with PVC which is glued to the
wooden floor in a kind that water can not penetrate.
The
entrance doors are made of the same steel as the car body shell. They are flush
with the sidewall to
The
door inward opening to the entrance area is covered from inside with a FRP
panel. Above the door is an entrance light. The
entrance steps are closed by a foldable cover. An
inside handhold allows easy entry and exit. An ashtray is also provided.
The
entrance area and the sitting area are separated by the single leaf sliding
passenger room door with automatic closing device.
The door is made of stainless steel and has in the lower half an exhaust air
grill.
In
the gangway between the passenger room door and the entrance is on one side the
pantry and on the other side the storage area. The pantry is closed by a double
leaf sliding door and the storage area by roller shutters.
The
pantry is functionally organised so that the available space is used in an
optimum manner.
TOILET
On
the outside wall of the toilet a waste bin and a fire extinguisher are located.
The fire extinguisher on the power panel end is filled with CO˛, the one on the
other end with water. The toilet doors are of a folding
type to use the available space in an optimum.
On
the one side of the toilet you find the wash basin with water tap and sensor
button, the soap dispenser, the mirror, an ash tray and a waste bin. On the
other side you find the toilet itself, a water tap with mug, a handhold, the
toilet paper holder and the sensor button for the toilet flush. In the AC 2nd class chair car two toilets are of oriental type and one is of western type. The window in the toilet can be opened in the upper half. In Executive class two toilets are western and one toilet is oriental.
AC
EQUIPMENT
In
one corner of the coach the switch board cabinet is provided. The outside is
covered by high pressure laminated walls and doors into which large glass panes
are integrated.
After opening the
switch board cabinet doors all electrical control equipment located centrally
here can easily be accessed. The equipment is fixed to different layers which
can be opened one after the other.
The
air conditioning system comprises 2 roof-mounted compact
units located one at each coach end. The 2 units
are controlled by one microprocessor located in the switchboard cabinet
to ensure a proper functioning of both units together. The operating voltage of
the unit is 3 phase, 415 V, 50 Hz.
Each
unit has 2 refrigerant circuits with hermetic refrigerant compressors,
condensers with Cu pipes and Al fins, evaporators and condenser fans.
The
fresh air is coming in via the air inlet of the AC unit. The conditioned air is
transported in heat insulated aluminium ducts mounted below the roof and
distributed via the perforated ceiling into the passenger room. The return air
is flowing back via openings above the compartment door to the AC unit. The
entrance area, toilets and pantry are connected to the exhaust air system. The vestibule is of UIC rubber type. The vestibule door is a double leaf stainless steel sliding door. On the left side the socket of the local 415 V supply is located.
COUPLERS The automatic center buffer coupler of AAR tight lock type at the coach end has a support frame which is providing an anti-climbing protection. The coupler can be opened from the side by a lever. The design allows the use of screw coupler instead of center buffer coupler. Therefore a fixing plate for buffers is also provided. The inter-vehicle coupler for the supply of the 750 V from the generator car is located below the under-frame. Due to the moving situation 4 brake hoses are to be used at the coach end which are brought to two hoses behind the coupler.
WATER
SUPPLY AND DISPOSAL
The
two connected fresh water tanks with a total capacity of 1370 lit for the 3
toilets are made of stainless steel. The water level is indicated on one tank on
each side. The filling can be made from both sides by one filler for both tanks.
Three
intermediate water tanks, each with a capacity of 30 lit, made out of stainless
steel are located above the toilets. Two centrifugal pumps located in a
stainless steel casing at the under frame are supplying the water to the tanks.
One of the 415 V pumps is always working, the other is standby. After each
switch off the other pump will work.
Below each toilet a 40 lit waste water tank is provided in which the toilet waste is collected when the coach is standing. It will be opened with a pneumatically operated sliding valve when a defined speed is reached. The junction box for the inter-vehicle coupler is visible.
POWER
SUPPLY A 60 kVA transformer with copper winding is transforming the power given by the generator car from 750 V to 415 V.
BRAKES All brake control equipment is centrally located in a brake container. A main brake pressure reservoir of 125 lit and a service pressure reservoir of 75 lit are provided.
BOGIES
The
FIAT-SIG bogie is a welded H frame type based on
the Eurofima bogie. The wheel base is 2560 mm, the
wheel diameter new 915 mm and at maximum wear 845 mm. Main features of the bogie
are primary suspension with articulated arms and coil
springs, secondary suspension of integral flexicoil type with coil springs and
rubber pads on top and bottom, anti-roll bar, vertical and transverse shock
absorbers and anti-hunting dampers. For braking on each axle two disc brakes
with 640 mm diameter, brake cylinders and automatic slack adjuster are provided.
Benefits
of the new coach technology
The
new coaches and their technology will give benefits in different areas.
As
benefits for the passengers can be named the
improved
ride comfort, the comfortable seats
with infinitely adjustable back rest, the
good
appearance of the side wall
where
no screws are visible, the improved air duct design for
better
air flow and cooling,
the
big
sized windows with functional roller blinds
which give good visibility,
the
luggage racks with integrated lamps for all seats,
the anti drumming feature and
sound
insulation which reduce noise,
the
functional
toilets for oriental and western style which allow easy cleaning
and the optimised design of the
pantry
with the functional trolley.
As
benefits for the safety of travel can be named the modern design of vestibule
for inter car connection, the
anti-climbing
feature
to prevent climbing of coaches in case of collision, the
improved
brake system with wheel slide protection and electro pneumatic brake features
and the use of fire code for materials following state of art practices.
As
system benefits can be named the coach length increased by ~ 2 m which gives
extra
carrying capacity
(AC chair car carries 78 passengers against 67 in existing design), the
coach
weight reduced
for lower hauling costs (AC chair car weight brought down by around 7 t), the
ease of manufacture by suitable material selection and design, the use of
anti-corrosive
materials
to
give better corrosion protection and the
toilets
designed for discharge at predetermined speeds
to
help station cleanliness. Also can be named the improved availability by
longer
intervals between maintenance schedules
and
the
enhanced
maintenance friendliness
through easy accessibility and exchangeability of wearing parts, entrance doors
which are flush with the side wall for automatic car washing, the functional
switch board cabinet with centrally located and
easily
accessible electrical equipment,
the
closed
roof mounted air conditioning units
eliminating incidences of water dripping into the coach and the
glued
PVC floor
which allows no floor damage through water seepage
Delivery
to Indian Railways
The first 3 coaches
were delivered from Germany in the beginning of year 2000 and were
unloaded in Calcutta on DIVISIONS & WORKSHOPS Divisions : Sealdah Howrah Asansol Maldah Workshops : Jamalpur Liluah Kanchrapara Some of the Divisional Pages are UNDER CONSTRUCTION. TO SITE MAP
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allow easy car-washing. Two handholds and three fixed steps are provided to
enter the coach.
