SPECIAL TYPE OF WAGON
A BG Bogie open wagon BOXN – HA: It has been designed for carrying increased payload
for bulk movement of Coal and Iron Ore over Indian Railways. The length and width of the
wagon are same as those of existing BOXN wagon except the height, which is 3450 mm
from rail level. There by 225 mm higher than the BOXN.
The Salient Features of BOXN – HA wagon are given below:
i. Length over coupler face 10713mm.
ii. Overall width
3200mm.
iii. Overall Height
3450mm
iv. Tare Weight
23.17 tonnes.
v. Axle Load
22.1 tonnes.
vi. Gross Load
88.40 tonnes.
BOGIE LOW PLATFROM CONTAINER FLATS (BLC):
Bogie container flat wagons have been designed for transportation of 2896mm high
series –I, ISO containers for a gross payload of 61t at an operating speed of 100kmph.
These containers, when loaded on the earlier flat wagon caused infringement to the X –
class MMD, resulting in constraints in their free movement.
In order to ensure that the wagons loaded with 2896mm containers lie within the X
– class MMD, a low platform height of 1009mm has been achieved with the use of hybrid
design of bogie frame and bolster and with the use of smaller diameter wheels (840mm
and the condemning size is 780mm).
The wagons have welded construction and are mounted on two steel bogies. The flats are
formed into units of five wagons, each unit having two - A car at ends and three
intermediate B cars. One end of A car is fitted with CBC to ensure proper coupling with the
locomotive while the other end has slack less drawbar to couple with B cars
empty the barrel and repeat the process till the barrel is free from ammonia.
(b)
CHLORINE TANK WAGONS:
Fill the tank barrel with water and take a specimen of the same in a clean glass
bottle since Chlorine is readily soluble in water. The specimen of water should be
tested for any traces of Chlorine. Any traces of Chlorine in water would have
bleaching effect on colored litmus paper. If Chlorine is detected, empty the barrel
and repeat the process till the barrel is free from Chlorine.
(c)
LPG TANK WAGONS:
A clean bottle filled with water is lowered through the manhole. A string is attached
to the bottom of the bottle before lowering. Tilt the bottle at the bottom of the tank to allow
the water to flow out and gas in the tank to take its place. The bottle should be left in this
position for 5 minutes and withdrawn away from the tank. A lighted match stick should
then be brought near the bottle or applied to the air or gas inside. If their is no flame the
tank is free from injurious gas. In case it gives out flame, the tank should again be steam
cleaned.
NEW WAGONS
S.No.
Stock
1.
BLC/BLCB
2.
BOXNHA
3.
BOXN
4.
BFKN
5.
BFNS
6.
BCCN
7.
BCW
BTPGLN
26. TANK WAGON
Description
Low platform container wagons, light weight, all welded
skeleton design under frame for an optimum tare to payload
ratio, 840mm wheel dia, A&B cars and with AAR CBC on raised
ends of A cars and use of slack less drawbar system on the
inner ends of A cars and on all B cars, tare weight A cars 19.1 t
B cars 18.01 t, pay load 61t. fit to run at 100 km/hr.
Higher Axle load wagon of 22.1t for coal loading. Payload per
rake shall increase to 3783t as against 3411t. in the existing
BOXN wagon Fit for 100 Km/hr. Payload = 23.17t.
Use of carton steel in place of mild steel for manufacturing of
BOXN wagon, in order to reduce the problem of corrosion
substantially.
Air Brake CASNUB bogie container flat wagon owned by
container corporation.
Special wagons for transportation of HR coil, Suitable for
accommodation of various sizes of coils. Adjustable stoppers
have been provided for suitable placement of coil in the groove
and preventing longitudinal shifting of coils. Fit for 100Kmph.
Double Decker Bogie covered wagon for transportation of
automobile cars, Low platform, 840mm wheel dia. Fit for
100Kmph. Axle load = 10.5t,payload = 10t, gross load = 42t, 18
wagons per rack.
IT is privately owned by M/s. Bulk Cement Corporation India
Ltd. Fitted with Air Brake.
Bogie liquefied petroleum gas tank wagon, fitted with Air
Brake.
Classification of tank wagons
Tank wagons form a special class of non-pooled rolling stock. They are classified
according to the product carried by the tank and its design as follows:
a. Tanks as pressure vessels
b. Tanks for corrosive liquids
c. Tanks for petrol and other highly inflammable products
d. Tanks for middle distillates of petroleum and others products.
The Feature of under frame.
The design of the under frame of 4 wheeled and 8 wheeled wagons is generally
similar to that of other IRS wagons except that a pair saddles is provided on the under
frame at each end for mounting the barrel.
The barrel and saddles
The barrel is cylindrical vessel generally fabricated out of low carbon structure steel
to IS 2062 Fe 410 CuW. The barrel is placed longitudinally on the under frame and secured
by means of rivets to the saddle. The saddle is welded on under frame at each end.
The Codes used for different types of tank wagons as follows:
SL. No. Type of Wagon
1
2
3
4
5
6
7.
8.
9.
10.
11.
12.
13.
14.
15.
Code for the Wagon
Ammonia tank
TAL, BTAL, BTALN
Chlorine tank
LCT
Liquefied petroleum gas tank
TLGL, BTPGL, BTPGLN
Sulphuric acid tank
TSA & MBTSA
Petrol tank
TPR/A, MBTPX & MBTPZ
Oil tank
TORX
Heavy oil tank
TORX
Bitumen tank
TBT
Coal tar tank
TR
Petrol tank
TR & MBTP
Oil tank
TO
Oil tank
MBTOX
Caustic soda tank
TCS, BTCS
Hydrochloric acid tank
THA
Molasses tank
TM & MBTM
Various types of barrel mountings and safety fittings and their functions are given below:
SL. No. Mounting/Fittings
Functions
1
Safety valve
The safety valve is provided to prevent building up of
excess pressure inside the barrel. It is fitted on the
barrel either on the diaphragm plate inside the dome or
on a separate opening on the barrel. This is provided on
highly inflammable liquids such as petrol, aviation sprit
etc.
2
Relief valve
It is a spring-loaded valve fitted on the barrel of tanks
for corrosive liquids. Its main function is to release built
up pressure, if it exceeds the working pressure limit.
3
Safety vent
This consists of frangible disc (lead or any approved
Material not affected by lading), which ruptures at
specified pressure. It is an additional safety fitting to
safeguard against the failure of the relief valve. When
the built up pressure exceeds the working pressure of
the relief valve and the latter fails to function for any
reason the frangible disc of this safety vent ruptures to
release the pressure.
4
Compressed air valve It is provided on tank from which the contents are
unloaded by compressed air. Its main function is to
control the rate of discharge by controlling the rate of
air admission.
5
Vapour extractor
Cock
Its function is to extract vapour from the tank while
filling.
6
Master valve
It is a gravity discharge valve fitted with a hand wheel in
The dome for manual operation.
7
Bottom discharge
Valve
BG 4-Wheeler bottom discharge valve are provided
with single bottom discharge valve situated underneath
the master valve while on BG/MG eight wheeler stock
two bottom discharge valves are fitted, one on either
side and connected with the master valve through a “T”
pipe. The main function of the valve is to control the
flow of the contents and also to serve as an additional
safety stop in case the master valve fails or breads. The
bottom discharge valve openings are also provided with
blank flanges to be used with 2mm compressed
asbestos fiber jointing material to serve as further check
on accidental leakage of contents.
The periodicity of POH & ROH of tank wagons as follows:
SL.No.
Type of wagons
For 1st POH
For subsequent POH
1
4 wheeler tank wagons
Except those listed below
Tanks for liquid chlorine
And hydro chloric acid
Tanks for liquid
Ammonia
Tanks for petroleum gas
BPTN
4 years
3-1/2 years
2 years
2 years
2
3
4
5
Codal life of tank wagons is 45 years.
2-1/6 years 2-1/6 years
4 years
6 years
4 years
6 years.
BOGIE CONTAINER FLAT WAGON TYPE BLCA & BLCB
BASIC CHARACTERISTICS AND DIMENSIONS
The Bogie Container Flat Wagons have the following basic
characteristics/leading dimensions.
S.No.
Description
1.
Track Gauge
2.
Estimated Tara Weight
3.
Payload
4.
Gross Weight
5.
Length over Headstock
6. Width over sole bar at centre line of
wagon
7.
Distance between Bogie Centres
8.
Floor height
9.
Height of Centre Buffer Coupler
from Rail Level
10. Height of drawbar system from Rail
Level
11.
Wheel base
12.
Diameter f Wheel (New)/(Fully
Wom)
‘A’ Car
1676 mm
19.10 t
61.00 t
80.10 t
13625 mm
2100 mm
‘B’ Car
1676 mm
18.00 t
61.00 t
79.00 t
12212 mm
2100 mm
9675 mm
1009 mm
1105 mm
8812 mm
1009 mm
-
845 mm
845 mm
2000 mm
840/780
mm
2000 mm
840/780
mm
Salient features at a glance.
Bogie: High speed three piece cast steel bogie.
Floor Height: 1009 mm which is 266 mm less than IRS wagon height.
Axle Load: 20.32 tonne.
Carrying Capacity: 61.0 tonne (two 20’-O” or one 40’O” ISO container
on each wagon).
Maximum operating speed: 100 kmph.
Unit:.Each unit consists of 5 wagons, two “A” Cars at the ends and three
“B’ Cars in the middle.
Rake: Rake consists of 45 wagons in the form of 9units. Length of each
unit — 69 meters approximately.
Coupling: Outer ends of TMA Cars are fitted with standard Centre Buffer
Couplers (CBC)
inner end of A Car and both ends of
B• car are fitted with slack less drawbar.
Brake Beam: Bogie is fitted with sliding type brake beam and brakehead
is the integral part of
blocks are fitted.
brake beam. Compositionbrake
Wheel: Forged wheels and axles are used. Wheel dia New-840mm. Worn
out-780 mm.
Air Brake System: It consists of








Single pipe graduated release
Distributor valve fitted with empty load function
Automatic slack adjuster
Automatic load sensing device
Brake cylinder pressure under tare 2.2 kg/cm2 and under loaded 3.8
kg/cm2
Control reservoir charged to 5 kg/cm2
Auxiliary reservoir charged to 5 kg/cm2
Initial charging of brake pipe at 5 kg/cm2.
Automatic Load Sensing Device (LSD): Two stage empty/ load
braking is controlled by two nos. of change over valves type VTA fitted on
each bogie bolster.
Automatic Twist Locks: Automatic twist locks are provided on the
wagon for securing containers for quick loading and unloading.
Bolster Suspension: Each group of helical spring consists of 7 outer
springs, 6 inner springs and 2 snubber springs.
Spring Loaded Side Bearer Arrangements: It consists of two
helical springs on each side bearer which bear 90% tare load.
SL
No.
01
02
03
Features
BLC
BFKN
BOXK/BOXKH
Wagon Unit
Consist of wagon 2
nos. A-Car = 3 nos.
B-Car
1009 mm
Single wagon
Single wagon
1269 mm
1275 mm
A-Car 13625 mm
13716 mm
12800 mm
B-Car 12212 mm
A-Car 19.10 t
B-Car 18.10 t
20.5 t
19.5 t
61 t
840 mm
Tapered two row
cartridge roller
bearing
100 KMPH
CBC & Slack less
Drawbar
Automatic
61 t
1000 mm
Tapered two row
cartridge roller
bearing
75 KMPH
CBC
48/60 t
1000 mm
Cylindrical roller
bearing
Manual
Two stage
automatic
pneumatically
operated
Spring loaded side
bearer arrangement
Two stage
suspension
45 wagons 90 TEUs
618 Mtrs approx
Manually
leverage
Gide bracket &
Gide block
Manually
leverage
Pubber bondad
Guide steel liner
Single stage
suspension
40 wagons 80
TEUs 587 Mtrs
Single stage
suspension
42 wagons 84
TEUs 576 Mtrs
Platform hight
from R.L.
Wagon length
over head stock
04
Tare
05
06
07
Payload
Wheel Dia
Type of bearing
08
09
Speed
Coupling
10
Twist lock
11
Empty/Load
divice
12
Side bearer
arrangement
Suspension
13
14
Rake carrying
capacity/Rake
75 KMPH
CBC
15
16
length
Brake system
Brake cylinder
pressure
Air brake
3.8 kg/cm.sq loaded
Air brake
-
Vaccum brake
-
2.2 kg/cm.sq empty
Comparison of CASNUB-22-NLB and Container Bogie Type
LCCF2O(C) with
respect to similar and dissimilar features.
S.
N.
Description
Centre Pivot Height
from rail level
Maximum height of
side frame
2
fromrail level
1
Bottom of side frame
from rail level
Height of side bearer
4 top from rail level
3
5 Wheel dia
CASNUB-22-NLB
Container
Bogle
Type
LCCF20(C) - 96
932 mm
715mm
851 mm
786mm
165mm
149mm
921 mm
772mm
1000-925 mm
6 Side frame design
Cast steel design suitable for
narrow jaw adapter
7 Bolster Design
Cast steel design- separate type
centre pivot straight bottom.
401780
mm
Cast steel
design
suitable for
wide jaw
adapter
Cast steel
design
integral fiat
type centre
pivot
8
Design of centre
pivots
9 Centre pivot liner
10 Side bearer
11 Load bearing coil
12 Snubber springs
Bottom
pivot
integral
with
bolster, flat
Separate pivots. IRS spherical type,
type top
assembled by rivets
pivot
separate
bolted to
underframe
.
Manganes
e steel
liners
conforming
No liner is provided
to1RS-R65-78 are
provided at
bottom and
vertical
Friction
type with
Rubber type in a cast steel
coil springs
housing.
in a cast
steel
housing.
l4outer and
12 inner
12 outer and 8 springs inner
springs.
Material
Material
IS:3195 60 Si7
IS:3195
Gr.60S17
4 Snubber
4 Snubber springs Material lS:3195
spring
Gr. 60 S17
Material
15:31 95
13 Brake shoe
Conventional brake shoe Material
cast Iron.
14 Adapters
Narrow adapter.
Gr50
CrMoV4
Nonmetallic
brake
shoe.
Jaw Wide
jaw
adapter.
SIMILARITY









Wheel base
Journal centres
Spring plank
plate
Centre pivot bolt
Wedge design.:
:
:
:
:
2000 mm
2260 mm
Pressed plate design from 12 mm
Similar design.
Similar
Cartridge bearing
:
Standard AAR Cartridge bearing
tyoperoller bearing ClassE.
Side frame key
:
Similar design.
Bogie brake gear
:
Similar design in case of bogies
with CBC end but anextra equalizing lever has been provided in
U-shape toconnect under frame bracket with 2 nos. Of end pull
rods.
Elastomeric pads
:
Similar.
. BOGIE LOW PLATFORM CONTAINER FLATS (BLC)
Bogie container flat wagons have been designed for transportation of 2896 mm
high Series-I, ISO containers for a gross payload of 61t at an operating speed of 100
km/h. These containers, when loaded on the earlier flat wagon caused infringement to
the X-class MMD, resulting in constraints in their free movement.
In order to ensure that the wagons loaded with 2896 mm containers lie within
the X- class MMD, a low platform height of 1009 mm has been achieved with the use
of hybrid design of bogie frame and bolster and with the use of smaller diameter
wheels (840mm).
The wagons have all welded construction and are mounted on two cast steel
bogies. The flats are formed into units of five wagons, each unit having two “A” car at
ends and three intermediate “B” cars. One end of “A” car is fitted with centre buffer
WAGON MAINTENANCE MANUAL
CHAPTER 11 – SPECIAL TYPE OF WAGONS Ver. 2.0
Page 9 of 10
couplers to ensure proper coupling with the locomotive while the other end has
slackless draw bar to couple with “B” cars. “B” cars are coupled together and to “A”
cars by slackless drawbars.
The length of A car is 1362 mm while the length of B car is 12212 mm. The
coupler of A car for attaching to loco or other stock is at 1105mm. The coupler in the
B car at both ends is at 845 mm from rail level. The wagons are equipped with Air
Brake. The diameter of new wheel is 840 mm and the condemning size is 780 mm.
Fig 11.1
TABLE 11.3 NEW WAGONS
S.No. Stock Description
1. BLCA/BLCB