MODERNIZING NARROW GAUGE

COACHES FOR
KALKA-SHIMLA RAILWAY

1
AGENDA

Project
Design Inspiration
01 Authorization & 02
& Approach
Objectives
Proposed
Aspirations &
03 04 Layouts & 3D
Features
Artistic Views
Project Schedule
05 Project Progress 06
& Cost

2
AUTHORIZATION &
OBJECTIVES
Short Term ( Board’s Lt Dated
16.06.2021)
Design & Build a rake of 7 Coaches + 3
spares to completely Transform passenger
experience and comfort and set new
benchmarks.
Some coaches of Panoramic Window and
Vista Dome design give a fillip to tourism

Long Term ( Board’s Lt Dt.

04.06.2021)
Explore and study World Hill Railways
with consultants help to submit report on
Gauges, Rolling Stock Technologies,
Operational parameters, Bogies &
3
Suspension.
 DESIGN INSPIRATIONS: GLACIER EXPRESS
• The Glacier Express (GEX) is a direct train connecting railway
stations of the two major mountain resorts of Zermatt and St. Moritz
via Andermatt in the central Swiss Alps
• Operated by Glacier Express AG, a cooperation jointly owned by the
former operators Matterhorn Gotthard Bahn (MGB) and Rhaetian
Railway (RhB)
Gauge Length Width Height Floor Height
1,000 mm 17,700mm 2,680 mm 3,695 mm 950 mm

• The design concept is a

Panoramic shell

4
 DESIGN INSPIRATIONS: BERNINA EXPRESS

• The Bernina Express is a train connecting Chur (or Davos) in

Switzerland to Poschiavo in Switzerland and Tirano in Italy by
crossing the Swiss Engadin Alps
• Operated by Rhaetian Railway
Gauge Length Width Height Floor Height
1,000 mm 16,450 mm 2,650 mm 3,540 mm 993 mm

• The design concept is a

Panoramic shell

5
 DESIGN APPROACH: VEHICLE DIMENSIONS

• Use Coach length and Inter-Bogie distances RDSO approved KSR NG DHMU design (approval
letter dated 27/02/2021)
• Restrict completely within the existing SOD and MMD of KSR
• Use Existing bogies, Air Brakes and Couplers

Dimensions of Gauge Length Width Height Floor Height

Proposed New Coach Design 762 mm 9,750 mm 2,270 mm 3,050 mm 950 mm
NG DHMU (RDSO Approved design) 762 mm 9,750 mm 2,210 mm 3,050 mm 1,046 mm
ZDM3D Locomotive in use at KSR 762 mm 10,300 mm 2,290 mm 3,200 mm 1,047 mm
Existing Coaches at KSR 762 mm 9,300 mm 2,210 mm 2,290 mm 800 mm
(Approx)

6
DESIGN APPROACH: VEHICLE DIMENSIONS COMPARISON

Top & Side View Compared

MMD Compared
7
 DESIGNED CARRYING CAPACITY

Proposed New Design Existing Design

Class of Coach Capacity (Pax) Class of Coach Capacity (Pax)
AC Executive Chair Car 12 Tourist CT1-CT2 10/12
AC Chair Car 24 Vistadome Tourist 15
Non-AC Chair Car 30 Second Seating 38

Total 10 Coaches with a Rake of 7 Coaches

Class of Coach Quantity for Rake Spare Numbers
AC Executive Chair Car 1 1
AC Chair Car 2 1
Non-AC Chair Car 3 0
Luggage Car 1 1
8
LAYOUT 1: AC EXECUTIVE CHAIR CAR COACH
• Seating Capacity 12 pax.
• Luxury executive chair seats.
• Restaurant type sitting
arrangement with snack table
for each seat.
• Seat Module Pitch of 2522mm
for maximum comfort.
• 3 T Split Unit with Ducting for
air-conditioning of the
complete coach.
• 1 Ergonomic designed FRP
Lavatory module in each
coach
• Mini Pantry, Luggage Bins.
9
LAYOUT 2: AC CHAIR CAR COACH

• Seating Capacity 24 pax

• Modular flip back type
chair seats.
• Seat pitch of 870mm for
comfortable seating
• 3 T Split Unit with Ducting
for air-conditioning of the
complete coach.
• 1 Ergonomic designed FRP
Lavatory module in each
coach.
• Luggage bins & Mini
Pantry
10
LAYOUT 3: NON-AC CHAIR CAR COACH

• Seating Capacity 30 pax

• 2X2 Bench type seats with
cushioned flip back.
• 180 deg modular flip type
sitting arrangement
• Seat pitch of 870mm for
comfortable seating
• 1 FRP Lavatory module for
each coach.
• Luggage space.
• Linear fans inside the duct
for ventilation

11
LAYOUT 4: LUGGAGE CUM POWER CAR COACH

• Seating Capacity 9 pax (Can be

reconfigured to create space for
luggage)
• 2 Tonne luggage capacity
• Partly under slung 62.5 kVA DG
Set
• Under slung mounted 300 AH
battery box
• 415VAC and 110VDC trainlines
ensure no power sources on
passenger coaches
• Separate urinal for crew
• 1 ergonomic designed FRP
lavatory module in each coach
12
 PLANNED SALIENT FEATURES

• Coach Body & Systems

• 415V AC/110V DC EOG system with both engine and batteries located in Luggage Car
• Common shell designs for all classes of the passenger coaches except for luggage Car
• Air brake system of existing design but with brake cylinders on each bogie
• Vista / Panoramic windows in all classes with Board approved exterior colour scheme
• Existing Bogie and coupler,
• Underslung electrics , water tank and bio-tanks
• Interiors
• Noise and vibration proofing, Anti UV coated window glasses , Bio/Vac Toilets, power windows in
upper classes, Darkening Vista glass in Upper classes, Slide window in 2nd class,
• Powered doors , Heating/cooling package AC, Linear concealed fans, Linear LED lights
• Modular seating rail mounted seats with flip backs, restaurant seating with luxury seats for
Executive
• Onboard Mini pantry and Luggage Bins 13
VESTIBULE
• Narrow accordion type
inter-coach gangway

• Allows a clear opening of

510mm

14
MINI PANTRY
• Mini pantry equipped with
• Coffee Machine
• Microwave
• Mini Sink
• Mini refrigerator
• Snack Storage

15
LUGGAGE BINS
• 3 Shelves of different sizes

• For limited baggage space

on first cum first serve
basis

• Remaining larger size

baggage needs to be
checked into the luggage
car

16
SEAT MOUNTING
RAILS
• Aircraft type seat mounting
rails

• Quick mounting for seats

and snack tables

• Provides flexibility to
change layouts to suit
changing demands like air
business

17
 SEAT DESIGNS

• AC Executive Chair Car Luxury • AC Chair Car • Non-AC Chair Car Seating
Seating Seating
• Reversible seating system
• 1 + 1 Facing with snack table • Reversible 2 + 1
• 2+2 seats
• Snack table

18
 NEWLY DESIGNED VRV SPLIT AC SYSTEM

ROOF MOUNTED AC UNIT UNDERSLUNG AC UNIT

COMPRESSOR /
CONDENSOR UNIT

CONDITIONED AIR

• Designed to fit the restricted MMD

• And to lower the CG
19
 NOVEL MODULAR LINEAR FAN UNIT

Farewell to old railway roof fans

• Linear fans designed for use on the non-AC coaches
• Designed to fit the section of AC Duct to use common shell design 20
LAVATORY
• Compact Modular
Lavatory
• 40” x 30”
• Environment friendly
• Bio-digester tank for
zero discharge enroute

• Easy to use and clean

21
DESIGN CONCEPT 01

22
DESIGN CONCEPT -02

23
DESIGN CONCEPT -03

24
DESIGN CONCEPT -04

25
DESIGN CONCEPT -04

26
 PROGRESS MADE SO FAR
Short Term Development of a New Design
• Layouts developed for all classes . To be
submitted for Board’s approval by 30th Jun.
• Mockups under construction for better
understanding of exterior looks
• All material indents by 15th July,
Specifications under preparation.
• Turnkey Tenders for design of interiors and
complete Furnishing by 20th July, Tender
Specifications under preparation.
• Detailed 3 D Shell design in progress. To be
ready with FEA by 30th July 2021
Study of World Hill Railways
• A Project team made functional
• Terms of Reference Prepared and released to
RITES, IRCON & KRCL for submission of the
offers
• Following progress has been made through
RITES:
• Budgetary quote received from M/s
Molinari Rail AG, Switzerland
• Video Conference on 28th June 2021 with
M/s Prose AG, Switzerland
• Communication with M/s DB Engineering
& Consulting GmbH, Germany and M/s
Systra, France is at initial stages
27
A FULLSCALE MOCKUP (2 DESIGNS IN ONE MODEL)

4 windows a side design sidewall 5 Windows a side design sidewall

28
 PROJECTED TIME SCHEDULE AND COST

Short Term Development of a New coach with upgraded superstructure Design

Milestone PDC Estimated Costs ₹ in Crores

LOAs for Furnishing and shell construction 15.10.2021 AC Coaches 1.0
Shell prototype ( inhouse) 15.09.2021 Non-AC Coaches 0.9
Shell Squeeze Testing by RDSO 10.10.2021 Luggage cum Power Car 1.1
Prototype Coach Ready 30.12.2021 Estimated cost of coaches with existing
Prototype oscillation trial by RDSO 31.01.2022 bogies and proposed features with
overheads @ 14-18%
First rake online 31.03.2022

29
30
THANK YOU
WWW. RCF.INDIANRAILWAYS.GOV.IN

GENERAL MANAGER
+91 (1822) 228976 to 79
gm@rcf.railnet.gov.in

RCF
KAPURTHALA