Industry Overview
The railway wagon manufacturing industry supports the movement of bulk and general goods by providing specialized freight wagons designed for different cargo and operating requirements. Railway wagons are broadly classified according to their undergear and utility, including covered wagons, open wagons, flat wagons, and tank wagons. Covered wagons are closed freight vehicles designed to protect goods such as general merchandise, food grains, and bagged cement from external exposure.
The construction of a covered wagon incorporates side panels and stanchions, end panels and stanchions, roof sheets and carlines, and specialized doors. Modern freight wagon fabrication involves a sequence of operations including cutting, straightening, pressing, welding, component fabrication, assembly, finishing, and testing. Manufacturing also involves critical systems and components such as underframes, centre sills, body structures, CASNUB bogies, centre buffer couplers, and air brake systems.
The report particularly covers the manufacturing process and salient features of the BOXNHL wagon, together with fabrication techniques, welding procedures, quality requirements, finishing, testing, plant layout, market position, and suppliers of raw materials, components, machinery, and plant equipment. Testing procedures include radiography, dye-penetration, compressive strength, water testing, visual inspection, and braking system testing.
Cost Estimation
| Particulars | Details |
|---|---|
| Plant Capacity | 12 Nos/Day |
| Land & Building | Rs. 57.04 Cr |
| Plant & Machinery | Rs. 85.81 Cr |
| Working Capital for 2 Months | Rs. 97.06 Cr |
| Total Capital Investment | Rs. 243.15 Cr |
| Rate of Return | 16% |
| Break Even Point | 65% |
Content Index
- INTRODUCTION
- TYPES OF WAGON
- CONSTRUCTION OF COVERED WAGON
- CLOSED TYPE – BCN, BCNA, BCNAHS, BCNHL
- BCN
- BCNA
- BCNA-HS
- BCCN/BCCNA/BCCNB
- BCCN
- OPEN WAGON
- FLAT WAGON
- CONSTRUCTION OF FLAT WAGON
- FLAT TYPE –
- TANK WAGON
- TANK TYPE –
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- MANUFACTURING PROCESS FOR BOXNHL WAGON
- DESCRIPTION ABOUT BOXHNL WAGON
- DETAILS SALIENT FEATURES OF BOXNHL WAGON
- 3. BOGIE:-
- 4. BRAKE GEAR:-
- 5. RUNNING GEAR:-
- STANDARD FEATURES OF ‘BOXNHL’ WAGON
- (1) UNDER FRAME:
- MAIN PARTS OF UNDERFRAME ARE:-
- (2) CENTER SILL:
- (3) SIDE BODY:
- (4) END BODY:
- (5) DOORS:
- (6) BOGIE:
- BOXHNL WAGON HAS CAS NUB BOGIE
- FIGURE BOGIE GENERAL ARRANGEMENT FOR CASNUB
- FIGURE BOGIE GENERAL ARRANGEMENT CASNUB
- 7. CENTRE BUFFER COUPLER
- ADVANTAGES OF CBC:-
- COUPLER BODY:
- KNUCKLE:
- (8) BRAKE SYSTEM
- AIR BRAKE SYSTEM:
- A) DISTRIBUTOR VALVE:
- B) BRAKE CYLINDER:
- C) CUT OFF ANGLE COCK:
- D) DIRT COLLECTOR:
- E) RESERVOIR:
- F) METAL PIPES AND JOINTS:
- G) SLACK ADJUSTER:
- MAIN STEPS FOR FABRICATION
- MAIN PROCESS
- THE MAIN PROCESS HAS FOLLOWING STEPS ARE GIVEN BELOW
- (1) CUTTING
- (A). GUILLOTINING
- THE FOLLOWING GUILLOTINE CLEARANCE SETTINGS ARE GIVEN FOR GUIDANCE:-
- (B) PLASMA CUTTING
- CUTTING GASES
- (C) ABRASIVE CUT – OFF WHEELS
- (D) ARC-AIR GOUGING
- (E) POWDER CUTTING
- (F) SLITTING
- (G) COLD SAWING
- (H) BLANKING AND PUNCHING
- (I) DRILLING
- (2) STRAGHTENING
- STRAIGHTENING OF IRSM-44:
- (3) PRESSING
- (A) HYDRAULIC PRESS:-
- (B) POWER HAMMER:-
- (C) DROP HAMMER:-
- (4) WELDING
- (A) ARC WELDING:-
- ARC WELDING CIRCUIT:-
- DEFETS OF ARC WELDING:-
- 1. OVERLAP:-
- 2. UNDERCUT:-
- 3. POROSITY:-
- 4. SPATTER:-
- 5. CRATER:-
- (B) GAS METAL ARC WELDING (GMAW)/MIG:-
- DEFECTS OF MIG WELDING:-
- 1. OVERLAP:-
- 2. UNDERCUT:-
- 3. POROSITY:-
- 4. SPATTER:-
- 5. CRATER:-
- IN A WAGON, VARIOUS PARTS ARE WELDED AS PRESCRIBED FOLLOWING
- WELDING OF IRS M-44
- (A) WELDING PROCESS
- (B) WELD REPAIRS
- (C) POST WELD CLEANING
- (D) MECHANICAL CLEANING
- (E) WELDING PROCEDURE:-
- GENERAL PRECAUTIONS IN WELDING OF STAINLESS STEEL
- WELDABILITY ISSUES:
- PRECAUTIONS DURING WELDING:
- PRECAUTIONS AFTER WELDING:
- QUALITY REQUIREMENTS OF WELDING –
- FABRICATION OF DIFFERENT PARTS
- (1) CENTER SILL
- 3 FINISHED CENTER SILL SET
- Z-SECTION
- CENTER PART OF CENTRE SILL
- END PART OF CENTRE SILL
- FIXTURE OF CENTRE SILL
- (2) UNDERFRAME
- UNDER FRAME STRUCTURE
- (3) BODY END
- BODY END WITH VENTILATOR AND PRESSINGS
- FIXTURE OF BODY END
- (4) BODY SIDE
- BODY SIDE FIXTURE
- BODY SIDE
- (5) DOORS
- DOORS
- (7) BRAKING SYSTEM
- SLACK ADJUSTER
- AUXILIARY RESERVOIR
- DISTRIBUTOR VALVE AND CONTROL BRAKE CYLINDER
- LEVER ASSEMBLY PARTS
- EMPTY LOAD ADJUSTER
- SHOE BRAKES
- BRAKING PROCESS:-
- (6) FINAL ASSEMBLY
- PROCEDURE:-
- A) REMOVAL:-
- B) INSTALLATION:-
- GENERAL DATA:-
- (7) FINISHING (SHOT BLASTING)
- (A) SURFACE PREPARATION
- SHOT BLASTING CHAMBER
- (B) PAINTING OF WAGON BODY AND UNSER FRAME
- FOR STAINLESS STEEL
- PRECAUTIONS TO BE TAKEN IN WORK AREA
- PRECAUTIONS TO BE TAKEN IN STORAGE
- PRECAUTIONS TO BE TAKEN IN STORAGE OF IRS: M 44 STEELS
- (8) TESTING
- (1) RADIOGRAPHY TEST (RT):-
- (2) DI-PENETRATION TEST:-
- (3) COMPRESSIVE STRENGTH TEST:-
- SETUP FOR TEST
- LOAD PROVIDING MACHINE
- (4) WATER TESTING:-
- WATER TESTING UNIT
- (6) VISUAL INSPECTION:-
- (7) BRAKING SYSTEM TEST:-
- PRESSURE GENERATING UNIT
- MARKET POSITION
- FREIGHT CAN SPEED UP ECONOMIC GROWTH
- SUPPLY CONSTRAINTS HIT INDIAN RAILWAYS’ INDUCTION OF FREIGHT WAGONS
- RAILWAY MINISTER SAYS INDIA FACING SHORTAGE OF WAGONS
- INDIAN RAILWAYS INTENDS TO PURCHASE 38,000 WAGONS
- SUPPLY CONSTRAINTS HIT INDIAN RAILWAYS’ INDUCTION OF FREIGHT WAGONS
- RAILWAYS MULLS BUYING NEW WAGONS WORTH RS 9,000 CRORE IN 3 YEARS
- PLANT LAYOUT
- MANUFACTURERS/SUPPLIERS OF RAILWAY WAGON
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF IRS M-44 SS SHEET
- SUPPLIERS OF CRF SECTION
- SUPPLIERS OF COMPLETE CAS NUB BOGIE ASSEMBLY
- SUPPLIERS OF AIR BRAKE ASSEMBLY
- SUPPLIERS OF WELDING ELECTRODES
- SUPPLIERS OF PAINS MATERIALS
- SUPPLIERS OF PLANT AND EQUIPMENTS
- POWER PRESS
- SHEARING MACHINE
- ROLLING MACHINE
- FLYPRESS
- BENDING MACHINE
- MECHANICAL PRESS
- FORGING PRESSES
- FORGING HAMMER
- UNCOILING MACHINE
- SHEET LAVELING MACHINE
- PUNCHING PRESS
- CNC PLASMA CUTTING MACHINE
- MILLING MACHINE
- CNC LATHE MACHINE
- BOARING MACHINE
- POWER HACKSAW
- GRINDING MACHINE
- PROJECTION WELDER
- SEAM WELDING MACHINE
- SPOT WELDING MACHINE
- GAS WELDING EQUIPMENTS
- MIG WELDING MACHINE
- SUPPLIERS OF DRILLING, LATHE,TAPING MACHINES
- EOT CRANE
- POWER TRANSFORMER
- ELECTRICAL PANEL
- ELECTRIC MOTOR
- COOLING TOWER
- EFFULENT TREATMENT PLANT
- AIR POLLUTION CONTROL EQUIPMENTS
- AIR CONDITIONING EQUIPMENTS
- AIR COMPRESSORS
- PLATFORM WEIGHING MACHINE
- MATERIAL HANDLING EQUIPMENTS
- FIRE FIGHTING EQUIPMENTS
- SHOT BLASTING MACHINE
- JIGS AND FIXTURE
- SUBMERSIBLE WATER PUMP
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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