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Indian Railways Freight Transportation: Past, Present & Future

anant_s

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Several resources are available on PDF on Indian Railways depicting this multi faceted institute and life line of country. This thread is a small effort in collecting information at one place and see Indian railways and its history of freight transportation, present scenario and what future might be.
i'm tagging a few members here and request them to tag further if they know somebody interested in this subject.
@Chanakya's_Chant @Roybot @Abingdonboy @Rain Man @gslv mk3 @Ankit Kumar 001 @GURU DUTT @SpArK @AUSTERLITZ @nair @AndrewJin @Nihonjin1051

So here it goes

INDIAN RAILWAYS FREIGHT TRANSPORT: PAST, PRESENT & FUTURE
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Along the iron veins that traverse the frame of our country, beat and flow the fiery pulses of its exertion, hotter and faster every hour. All vitality is concentrated through those throbbing arteries into the central cities; the country is passed over like a green sea by narrow bridges, and we are thrown back in continually closer crowds on the city gates.
John Ruskin

In a country as diverse and plural as India, railways is more than a mode of transport. Its the glue that binds us and probably the greatest of all the national institutes. With its humble beginning in 1853 and a track length of around 34 kms, it now is a behemoth with running track length of 90,000 kms, handling more than a billion tons of traffic and in process being one of world's single biggest employer. Did i mention average rate of transporting 1 ton of freight over a kilometers costs Rs. 1.20(less than 2 cents). India today, country's leading news magazines,once mentioned, that if one goes by pure statistics, it would appear that Indian railway exists only to delight trivia buffs.

We begin this story with trade between British India and Rest of the World after Britain took control of administration after First war of independence from East India Company. Britain realized that to keep the country under one rule, it will need to move its troops quickly. it was also dabbling on how to bring the commodities meant for shipment to England to ports quickly. The answer well lied with railways. Unlike in Africa, where tropical rivers provided waterways, India was a dry land and waterway wasn't a solution. There began a journey of setting first rails in country's hinterland connected to ports and in these modest lines lied future of one of the biggest rail networks in the world.
Since British movement of passengers and goods was primarily through sea, several big ports were established in 18th century that grew bigger with time. From the three corners of country namely Calcutta in East, Madras in South and Bombay in West, originated railway lines, that clamoured to reach Delhi. These lines were isolated sections initially but as these progressed, the whole of country was covered eventually, providing a seamless even if rudimentary at times, connectivity. Won't be exaggeration to say, that these lines brought an amazing prosperity to places they connected.

Bombay (now Mumbai)
Opening of Suez canal in 1869 revolutionized the sea trade originating in Asia and more specifically India as it drastically cut down shipping time between the Region and Europe. Mumbai was first beneficiary of this development along with Karachi port. The heavy shipping traffic originating in India led to development of Sasson Dock in 1875 and subsequently followed by Prince's Dock in 1880 and Victoria docks in 1888. More docks and upgradations took place subsequently.
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The major freight originating from the port was Cotton,Food Grains and Cash crops and raw materials including minerals, imports like Heavy machinery also formed bulk of traffic handled.
In order to cater for the growth of traffic, Bombay Port Trust to develop lines that connected to Main lines that originated from Victoria terminus (Present Day's Chhatrapati Shivaji Terminus named after legendary Martha King).
Great Indian Peninsular Railway (GIPR) was one of the first companies in India to lay its rail tracks originating from Bombay (presently Mumbai).
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These lines ran initially upto Thane and later extending to all parts of country. Pune and Kolhapur and later Madras in South, Nagpur and later Calcutta (erstwhile Bengal Nagpur Railways) in East and Itarsi, Bhopal , Delhi and up to Peshawar in North. It must be mentioned here that the entire network consisted of several smaller rail companies that were operating and building new lines as per British administration's Guaranteed Railway System (meaning a fixed return on investment was guaranteed to the builder). These lines allowed quick and reliable mode of transport of prized commodities like Cotton, Food Grain, Tobacco and Jute.
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While all this was happening, Bombay Baroda and Central India (BB&CI) was developing its own network for connecting Bombay to Northern parts of India, serving what is present day states of Gujarat, Rajasthan and further North Uttar Pradesh & Delhi. The Lines ran further North through Punjab (undivided India) upto Peshawar, the last outpost of British India before Afghanistan. However Freight traffic in these lines was not significant, primarily owing to the fact that Colaba Port mainly catered for Passenger Traffic.

Calcutta (now Kolkata)
Elsewhere in East, calcutta (presently Kolkata) Port was developing as another major trading hub. While dry docks were established sometime circa 1712 (near old Fort William), in 1870 all the docks were consolidated under one port trust. Owing to its location, Calcutta port commanded a huge hinterland area extending right upto Jammu and Kashmir including Nepal and almost all of Gangetic plains and Eastern India. Today the system is served by two different ports namely Kolkata and Haldia.
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As with Bombay, the large traffic at Kolkata required development of rail network that facilitated movement of goods. The port trust developed its own system that was connected with Eastern and South East Railways that allowed movement from hinterland to port.
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East india Railway company was established in 1845 and it began construction of Calcutta-Delhi rail line. While operations began in 1854 with train running between Howrah and Hooghly, rapid construction of lines running almost parallel to river Ganga, saw completion of entire stretch of railway lines (Barring bridge over river Yamuna at Allahabad). In 1866, with completion of Bridge at Allahabad, Calcutta and Delhi were connected and first Train 1 Down/2 Up (present day 12311/12312 Kalka Mail) ran on these tracks. Calcutta got direct rail connection to Bombay in 1900 with connection of GIPR and BNR lines. The railway station of Nagpur is today a junction of North South (Delhi Chennai) and East West (Mumbai Kolkata) lines.
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One interesting thing about Eastern line was that it passes through Chotta Nagpur Plateau and gangetic plains. In terms of freight in translates to a line criss crossing arguably the most fertile plains in country and a land blessed with abundant mineral resources especially Coal and Iron along with Bauxite. For anyone trying to run rails on this region, it meant constant source of revenue. As we will discuss later, this section is one of the busiest railway sections (presently operating at close to 140% of its saturation level) in country.

Madras (now Chennai)
Present day state of Tamil Nadu was once ruled by powerful dynasties The Pallavas, the Cholas and the Pandyas. this was a period of glory and great economic and social growth and it goes without saying that maritime trade too developed rapidly with trade between countries like Java, Sumatra etc. The city of Madras (now Chennai) had its sea port opened in 1881 and owing to its location, rapidly became one of the biggest ports in Indian (in terms of traffic handled). Today it is second largest seaport in country behind Nhava Sheva port in Mumbai.
the first rail company to be established in this part of the world was Madras Railway in year 1845 and it began operations on Royapuram Arcot line in 1856.
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The line slowly expanded towards bangalore (1864) and it was connected to GIPR lines at Raichur in 1871 thereby connecting Madras with Bombay. As lines expanded further north, a direct connection was established between Delhi and Madras (it came quite late in 1929, as several sections got completed). Madras and calcutta got direct connectivity in 1901 with a major port city of Visakhapatnam (in Andhra pradesh) on the line.

By the time World War I arrived in 1914, all major cities were directly connected to each other through rail and trade flourished and central parts of country was connected to large population centers and ports.
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While it wasn't easy, but it was now possible for a person at any major city to travel to another major city through train. The country truly was united as one for the first time in History.
By the time India gained her independence in 1947, railways had become nation's biggest employer and spinal chord of economy carrying more freight, earning more revenue and exerting more influence than any other national institute.
 
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Electric Traction
Indian railways was one of the first railways in Asia to have adopted electric traction. GIPR electrified its lines for sub-urban traffic back in 1925 between Bombay VT and Kurla. In 1931 meter gauge lines in Madras Tambaram section too were electrified. Incidentally Madras Tambaram Villupuram section was the only electrified meter gauge lines in India.
The voltage adopted for these lines was 1500 Volt Dc and this was in line with development elsewhere in Europe and North America.
GIPR lines had to ascend difficult Sahyadri Mountain range before it enters central India and it has to encounter Bhor ghats (towards pune) and Thull Ghats (towards Nashik). At some places the ruling gradient is as steep as 1 in 37 (in trigonometrical terms that would be Sine(inverse) [1/37] or simply speaking for every 37 meters of travel, you would ascend 1 meter.
These conditions made it an ideal choice to select electric traction as steam locomotives simply weren't powerful enough to tackle these challenges with ever growing freight load.

EF/1 (Later WCG 1)
In 1925, GIPR ordered a batch of 31 locomotives from Vulcan Foundries and Metropolitan Vickers electric company, England. later 10 more were ordered. These locos were rated at 2,600 HP and weighed 123 Tons (there is an interesting trivia later on this value).
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The wheel arrangement was 0-6-6-0 (total 6 axles, connected by rods and couplings, in two pairs of three axles. 2 motors drove each pair of axle and ence total of 4 motors). the locos were designated EF/1 (Electric Freight series 1) and later WCG 1 (W: Broad gauge, C: Continuous or DC voltage, G: Goods service, series 1).These were first examples of Electric locomotives on IR and had an extremely long career with last examples retiring in late 1980s. No more broad gauge locomotives were inducted till after Indian Independence.
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http://www.buritonwheelbarrow.net/IndianRailways/Indian-Railways/i-n7VzxKN/0/XL/WCG1_20048BombayVT6-3-92-XL.jpg

AC Traction
After Independence, IR aggressively pursued plans for electrification and it had two choices. First was to continue with 1500 Volt DC traction that it had hostorically and second was to go French way and adopt AC. After World war II, French Engineers pioneered reserach and engineering on 25,000 Volt 50 Hz Ac as supply voltage for electric locomotives. They sucessfully demonstrated that it was possible to run trains at this voltage without disturbing grid stability (Transmission Grid has 3 phases with each phase carrying equal current. If current is drawn from a single phase, it can effect the equal value of current in 3 phases causing instability and in severe cases tripping of Turbine Generators in Power plants that generate power). It was therefore decided in 1957, that all future electric traction would be 25 kV AC only.
Incdentally about the same time when all this was happening, Calcutta region rail lines were electrified at 3000 V Dc, however planners showed remarkable foresight in this sytem and took into consideration that in future, 3000 V DC might not remain in service. So they designed all electric system to be capable of working at 25 kV AC also and when in 1966, changeover occurred, Calcutta region migrated to 25 kV AC relatively simply.

The states of Jharkhand (then South Bihar), Orissa, West Bengal are blessed with amazing amount of minreal wealth that inlcudes Iron ore, Coal, Bauxite among others. All these ores are of great engineering significance and therefore when Soviet Union offered help for setting of steel plants in this region, need for heavy freight arose. This made the lines in the region an Automatic choice for electrification and the first line to be electrified at 25 kV AC was Rajkhasarwan Dongoaposhi in 1960. No prizes for guessing here that the technical help for the system was provided by French Railways (SNCF).

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Chakradharpur division of South Eastern Railways has got the distinction of introducing 25 kV electric traction on Indian Railways. A transformer and a circuit breaker, taken on loan from SNCF, were commissioned at a site near Kendposi. OHE was energized on 25 kV AC from Kendposi to Rajkharswan and the pantograph of loco No.20250 was for the first time raised at Kendposi on 12th December 1959. On 15th December 1959, official inauguration ceremony took place, when a steam special train and an electric loco ran parallel on the 3 Km double track between the feeding post site to Kendposi station. Rajkharswan-Dangoaposi section was officially inaugurated on electric traction on 11th August 1960.
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Today around 24,000 kms or approximately 35% of total network length is electrified in India and except for a small stretch of Harbor lines in Mumbai Sub-urban network everything else in under AC traction. It might be of interest to know that harbor line was the first railway line in India to use DC traction, fittingly enough it will be the last to give up DC traction.
 
AC Freight Electric Locomotives

WAG 1

These were supplied by a consortium of European companies (called 50 cycles European Group) and these were 4 axle, 2 motor (B-B design), 2900 HP locomotives. Close to about 115 locomotives of this class were deployed out of which after initial lot of imports, Chittaranjan Locomotive Works, manufactured them locally.
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WAG 2

These locomotives were supplied by consortium of Japanese companies (Hitachi, Mitsubishi and Toshiba) and had construction similar to WAG 1, with a higher power rating of 3200 HP.
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WAG 3
Only 10 of these locomotives were imported from Henschel, Germany and these had power rating of approximately 3200 HP.

WAG 4
These were supplied by 50 cycles European Group and were the last of B-B design freight locomotives in India. Rated at 3200 HP these locomotives were built by CLW based on ToT from 50 cycles European Group.
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CHAPTER I  GENERAL  30100 Evolution of Electrical Rolling Stock  1 Electrical Concept  1
 
WAG 5
WAG 5 were first indigenously designed and manufactured AC freight locomotives in India, introduced in 1984. This class was designed by RDSO and CLW and were first 6 axle freight locos in India. this was based on extremely reliable WAM 4 class locomotives and were able to cope up with any kind of Traffic, terrain or weather conditions in India.
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Rated at 3850 HP, these locos combined a lot of things India learnt from locomotive imports. WAG 5 had bogies and frame derived from legendary WDM 2 class ALCO diesel locomotives, Alstom or Hitachi and later BHEL motors and ever so reliable Co-Co 6 axle design. Close to about 1200 of these locomotives were manufactured by both CLW and BHEL, Jhansi and significant number of these are still in service.
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WAG 6A, 6B and 6C
In mid 80s, it was getting clear that the locomotives in use with Indian Railways are way too under-powered to tackle the current and projected freight handling scene. WAG 5 as discussed above, although being reliable, at 3850 HP was a moderately powered locomotive at best by world standards. So in 1986-87, Indian Railways decided to purchase as an experimental batch, High Horsepower locomotives from abroad. This resulted in a batch of 18 locos namely WAG A from Sweden and WAG 6B and 6C from Hitachi Japan and all the locos were rated at around 6000 HP mark.
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WAG 6A and 6B, were unique Bo-Bo-Bo design (3 bogies, each having 2 axles and each axles powered by one individual motor). WAG 6C were conventional Co-Co Design. these locos employed a unique thyristor chopper technology with Separate Excitation (or SEPEX).
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Twin WAG 6A units
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WAG 6B (lead loco) with WAG 6C (rear)

[IRFCA] New CLW locos and other pictures
These locos were employed in Andhra Pradesh on what are country's most difficult heavy haul Broad gauge line of kirandul-kottalvalasa dealing with Iron ore freight brought to Visakhapatnam port. As destiny would have it, these locos did not have a very successful life, not owing to technology but how the decision to purchase them was conceived.
RDSO during those days was working on a heavy haul freight locos and that resulted in WAG 7 in 1992. So anymore plans of WAG 6 fleet augmentation were ditched and these 18 odd locos remained only members of their family. Another thing that led to all this was advent of Gate Turn off (GTO) thyristor 3 phase loco technology and that meant DC motor locos will not have much of a chance in future.
 
WAG 7
In early 90s, need for a reliable high Horsepower electric locomotive was troubling IR. To this RDSO came up with a design employing Tap Changer DC motor technology based Hitachi HS 15250 motors, rated at 5000 HP. These locos turned out to be thumping success and are in production till date. As up to now, close to about 2000 such locos have been produced by CLW and BHEL. This apparently is the last of DC motor Tap changer locomotive on IR.
The weight of this loco is 123 Tons (remember that trivia i mentioned in WCG 1), the weight of first and last DC motor locos are identical only to be separated by catenary voltage, horsepower and offcourse 65 years.
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WAG 9
In 1995, India signed a contract with then ADTRANZ group (now Bombardier) to supply high speed passenger and high horsepower freight locomotives based on 3 phase GTO traction technology. The deal included supply of assembled and semi finished locomotives along with transfer of Technology. This resulted in WAP 5 (Bo-Bo) passenger loco and what certainly is future of Freight hauling on electric traction, WAG 9.
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WAG 9 is a 6 axle (Co-Co) locomotive rated at continuous 6000 HP and can pull standard 4500 Ton freight train quite on their own on almost all terrains in India.
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These are now being manufactured by CLW and some pieces are assembled by Electric locomotive Workshops at Bhusawal.
 
Wow!!! What a thread.... For a railfan like me.... this straight away went to my bookmarks :tup:
@anant_s Really sad that thw WAG6 are getting decomissioned...

Recent e-locos list shows only a handful remains active :(
More coming up!
The reality is far more cruel. these are getting cannibalized for want of spares. Vizag shed is now being allocated WAG 9H to meet the requirements of KK and other freight traffic. But yes its really sad the way WAG 6 class is treated.
 
More coming up!
The reality is far more cruel. these are getting cannibalized for want of spares. Vizag shed is now being allocated WAG 9H to meet the requirements of KK and other freight traffic. But yes its really sad the way WAG 6 class is treated.

Soon the WCAM2ps will also meet the same fate.... Once hauling Rajdhani trains on Mumbai WR, these days are getting converted into WAG5s and are used as bankers on CR
 
Soon the WCAM2ps will also meet the same fate.... Once hauling Rajdhani trains on Mumbai WR, these days are getting converted into WAG5s and are used as bankers on CR
True.
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And unfortunately the same seems to be happening with WCAM 3, which are now getting same uniform as WAG 7.
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With mumbai Central railway region under full AC traction now and Pune Daund line electrification in full swing (there is a new Electric loco shed coming up at Daund), there is little use of these bi-voltage locos, and i'm afraid bankers might be the only use left for these erstwhile rulers of Bhor and Thull Ghat
 
:p:
Zameen par hain.
Aur wahin rahen to achcha.

I hope it becomes some sort of useful reference section to all those who are interested in IR.
@gslv mk3 : i'm counting on your contributions to the thread.
Railways is the entity that has touched and influenced the Indian-ism then any other organization or entity..
 
Nice thread, thanks for tagging me.
@anant_s Any news about that Delhi-Agra semi-high speed train service? In official operation now?
That will be a very ideal transport method for tourists in golden triangle region.
 
Nice thread, thanks for tagging me.
@anant_s Any news about that Delhi-Agra semi-high speed train service? In official operation now?
That will be a very ideal transport method for tourists in golden triangle region.
cheers mate!
well the official world is that they'll start regular service in November this year. clearance based on oscillation tests have been given by Safety commissioner, however some concerns remain regarding unfenced part of tracks.
apart from the HST, there are plans for a new airport to serve tourists coming to Agra. the existing one is an Airforce base and hence limited and poor air connectivity.
 
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