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Vande Bharat Express (Trainset)
Vande Bharat Express
Stock type	Electric Multiple Unit
Manufacturer	Integral Coach Factory, Chennai
Designer	Integral Coach Factory Medha Servo Drives
Assembly	Chennai
Constructed	2018–present
Entered service	2019
Number under construction	115
Number built	VB 1.0: 2 VB 2.0: 71
Formation	8, 16 & 20 car formation
Operators	Indian Railways
Specifications
Car body construction	Spotwelded Stainless Steel, FRP
Train length	192 metres (630 ft) (8 coach) 384 metres (1,260 ft) (16 coach) 480 metres (1,570 ft) (20 coach)
Car length	24,000 millimetres (79 ft) (coupler to coupler)
Width	3,240 millimetres (10.63 ft)
Height	4,140 millimetres (13.58 ft)
Floor height	1,320 millimetres (4.33 ft)
Entry	Automatic sliding foot step
Doors	Automatic Sliding Single Leaf Plug Doors (2 per side per coach)
Wheel diameter	952mm (new) 915mm (half worn) 877mm (fully worn)
Wheelbase	2,700 millimetres (2.7 m)
Maximum speed	180 kilometres per hour (110 mph) (Tested Speed) 160 kilometres per hour (99 mph) (Certified for Commercial Run) 200 kilometres per hour (120 mph) (Upgradable)
Weight	VB 1.0: 1,014.32 tonnes (1,014,320 kg) VB 2.0: 966.72 tonnes (966,720 kg)
Axle load	VB 1.0: 21t VB 2.0: 17t
Traction system	IGBT-VVVF inverter control VB 1.0: Forced Air Cooling Medha MAE675U VB 2.0: Water cooling Medha MAE675UV2
Traction motors	VB 1.0: Medha TME 49-35-4 VB 2.0: Medha TME 49-30-4 Fully-suspended, Self-ventilated, 3-Phase AC Induction Motor
Power output	VB 1.0: 8,128 kW (10,900 hp) (16 coach formation) VB 2.0: 6,720 kW (9,010 hp) (16 coach formation)
Tractive effort	113 kN (per Motor Car)
Transmission	AC-DC-AC 3-Phase electric
Acceleration	0.8 m/s²
Deceleration	FS (EP+ED): 0.8 m/s² FS (Auto Brake): 1.05 m/s² Emergency Brake: 1.15 m/s²
Auxiliaries	Auxiliary Converter Unit (PWM based IGBT converter) for Power Supply
Power supply	Power supplied by Auxiliary Converter Unit in two different voltages: Output-1: 415V 3-Phase AC 50Hz Output-2: 110V DC
HVAC	8TR (x2) RMPUs per coach 2TR RMPU for each driver's cab
Electric system(s)	25 kV 50 Hz AC Overhead line
Current collector(s)	Pantograph Schunk WBL 22.03 (Normal height) OR Faiveley LX2600-VB (Normal height) OR Faiveley LX3600 (High-rise)
Wheels driven	32 powered axles out of total 64 axles (50% powered axles)
Bogies	Bolsterless Bogies; with secondary stage Air Suspension & wheel mounted Disc Brake
Braking system(s)	Air, Regenerative, Electro-pneumatic Knorr Bremse ESRA Evolution Brake Control System Faiveley Brake System
Safety system(s)	TCAS (Kavach), Automatic Fire Detection, Alarm & Suppression system, Disaster Management Lights
Coupling system	Dellner Semi-Permanent Coupler (between coaches) CBC AAR-H Tight-lock coupler (on driving ends)
Headlight type	LED
Track gauge	Indian gauge 1,676 mm (5 ft 6 in) broad gauge

INTRO - VB

Vande Bharat Express is India's first indigenously built Semi- High speed trainset; based on the concept of Multi-unit Distributed Traction powered EMU trainsets; designed for mainline long distance operations.

It is jointly designed and manufactured by Integral Coach Factory and Medha Servo Drives (Pvt.) Ltd. at Perambur, Chennai under the Indian government's Make in India initiative. The service was named Vande Bharat Express on 27 January 2019. These trainsets will be replacing premium trains of Indian Railways, like Shatabdi, Rajdhani, Duronto Express etc. in coming days.

Background & History

Indian Railways wanted to introduce trainsets into its service from a long time to replace premium trains like Shatabdi Express; from locomotive hauled coaches to a Semi-high speed trainset. As Indian Railways was searching for suitable manufacturer, from where they could import trainsets, and later manufacture in India after signing a Transfer of Technology Agreement; a Spain based trainset manufacturer Talgo offered Indian Railways to allow them to conduct Speed Trails in India. Ministry of Railways approved the request put by Talgo, as trials were to be funded by Talgo themselves. Talgo brought 9 coaches in April 2016 to India for trials. After extensive trials till September 2016, RDSO gave a Red flag to Talgo; even though the officials were impressed with Talgo's performance, it got rejected for various reasons; major reason being the design of coaches were not feasible for Indian Railways infrastructure.

In 2016 Integral Coach Factory approached Ministry of Railways, with the idea of making a trainset indigenously at par with international standards with already available technology at half the cost compared to that of foreign manufacturers from where the Ministry was seeking to import from. Ministry finally approved the request in April 2017 and manufacturing commenced, and the first prototype was made and rolled out in just 18 months. The unit cost of the first prototype 16 coach trainset was approximately estimated at just ₹100 crore (US$13 million), and it is expected to go down further with subsequent production At the original price, it is estimated to be 40% cheaper than a similar trainset imported from Europe.

As ICF had set deadline for rolling out the first prototype by 2018, they kept the code name of the project as Train-18.

First Generation

Two initial prototype trainsets manufactured by Integral Coach Factory & Medha Servo Drives (Pvt.) Ltd. in between 2017 & 2019, that are already in service are known as the First Generation of Vande Bharat Express trainsets; also known as Train-18.

Design & Development

The core design and dimensions of the coaches are almost similar to that of the LHB coaches. As there was a lack of Bogie and Interior designing experts; ICF hired consultants from Austria and Poland for the same; but made sure that Integral Coach Factory do not loose their Intellectual Property Rights (IPRs) over it. M/s TRAKTIONS SYSTEME AUSTRIA & M/s Medha Servo Drives joint venture worked on designing the Bogie frame and the Traction motor in Hyderabad; while M/s EC ENGINEERING, Poland and Integral Coach Factory worked together in designing the interiors.

For the first two prototype trainsets; Brake System, Automatic Sliding Plug Doors, Seats, Wheels & Axles are the only items which were imported, rest all the components were Made in India by various Original Equipment Manufacturers (OEMs). Wheels & Axles were manufactured by a Czech Republic based company M/s BONATRANS; Brake systems were supplied by Knorr-Bremse, Germany; Automatic Sliding Plug Doors were imported from China and seats were imported from Spain and Italy. The Vande Bharat Express trainset is made up of 80% indigenously manufactured components, while 20% of the parts were imported . The percentage of indigenously manufactured components will increase gradually with subsequent productions.

Trial Run

The first trial run was done on 29 October 2018 in Chennai. An Indian Railways official reported that "some fuses went off" during the trial in Chennai, but that the issue was minor and quickly fixed. The trainset leaved for Delhi on 11th November and arrived on 13th November. Testing commenced along a section of track between Bareilly and Moradabad in Uttar Pradesh on 17 November, but the location was subsequently changed to the stretch of rail between Moradabad and Rampur due to unspecified issues with the initial section of track. The Moradabad–Rampur testing occurred at low speeds ranging from 30–60 km/h (19–37 mph). After the lower-speed testing, the train was moved to a section of track between Kota and Sawai Madhopur to be tested at operating speed. A team of engineers from Research Design and Standards Organisation (RDSO) supervised the testing and was given the go-ahead for the final speed test.

During its trials, Train 18 reached speeds of 180 km/h (110 mph), the highest speed any train in India has reached in the trials, and finally got certified and found to be fit for 160 km/h (99 mph) commercial runs by the Commissioner of Railway Safety (CRS) on 12 December 2018, that marked the end of oscillation trials and cleared to get introduced into commercial service. First trainset was put to commercial service on 15th February 2019 as New Delhi - Varanasi Vande Bharat Express. Second trainset was innaugurated as New Delhi - Katra Vande Bharat Express on 5th October 2019.

Rake Formation - VB/ VM/ VS

Traction Equipment Layout

Driving Trailer Coach (DTC)/ Non-Driving Trailer Coach (NDTC): These coaches have Compressor, Battery and Battery Charger units all mounted below the underframe.

Motor Coach (MC): These coaches have Line & Traction Converter and Brake Chopper units mounted below the underframe and the bogies of these coaches are fitted with Traction motors.

Trailer Coach (TC): These coaches have Transformer and Auxiliary Converter fitted below the underframe; whereas Pantograph and VCB fitted on the roof.

Abbreviations:

• DTC- Driving Trailer Coach
• NDTC- Non-Driving Trailer Coach
• TC- Trailer Coach
• MC- Motor Coach
• MC2- Motor Coach with electrical change over switch
• MC3- 180° rotated MC2

Class of Traveling:

• EC- Executive Chair Car (2x2 seats)
• CC- AC Economy Chair Car (3x2 seats)
• UR- UnReserved
• AC1- First AC
• AC2- Second AC
• AC3- Third AC

Rake formation (VB)

Rake Formation of 16 coach VB 1.0

Coach No.	1	2	3	4	5	6	7	8	9	10	11	12	13	14	15	16
Travel Class	CC							EC		CC
Power Configuration	DTC	MC	TC	MC2	NDTC	MC	TC	MC2	NDTC	MC	TC	MC2	MC3	TC	MC	DTC
Basic Power Units	Unit 1				Unit 2				Unit 3				Unit 4
Seating Capacity	44	78	78	78	78	78	78	52	52	78	78	78	78	78	78	44

Rake Formation of 16 coach VB 2.0

Coach No.	1	2	3	4	5	6	7	8	9	10	11	12	13	14	15	16
Travel Class	CC							EC		CC
Power Configuration	DTC	MC	TC	MC2	MC	TC	MC2	NDTC	NDTC	MC2	TC	MC	MC2	TC	MC	DTC
Basic Power Units	Unit 1				Unit 2				Unit 3				Unit 4
Seating Capacity	44	78	78	78	78	78	78	52	52	78	78	78	78	78	78	44

Rake formation (VM)

Rake Formation of 12 coach Vande Metro

Total Seating Capacity= 1150
Total Standing Capacity= 2058
Total Capacity= 3208

Coach No.	1	2	3	4	5	6	7	8	9	10	11	12
Power Configuration	DTC	MC	TC	MC2	NDTC	MC	TC	MC2	MC3	TC	MC	DTC
Basic Power Units	Unit 1				Unit 2				Unit 3
Seating Capacity	57	104	104	104	104	104	104	104	104	104	104	57
Standing Capacity	104	185	185	185	185	185	185	185	185	185	185	104

Second Generation

The Second Generation Vande Bharat Express trainsets are also known as "Train-44" as it took 44 months for ICF to make its 1st prototype. Starting with the 2nd Generation Vande Bharat Express trainsets; it will be now manufactured by Modern Coach Factory, Raebareli and Rail Coach Factory, Kapurthala along with Integral Coach Factory, Chennai

Passenger Variant

First trainset rolled out of ICF on 12th August 2022. The extensive Oscillation Trails were done between Chandigarh - Sanhewal, Kota - Nagda and Delhi - Agra sections. 1st rake commenced commercial service between Mumbai-Gandhinagar on 30th September,2022.

Difference between 1st & 2nd Generation trainsets

Second Generation carried the same exterior design as that of the First Generation, however many under the hood improvements were done to it, as suggested by Research Design and Standards Organisation (RDSO) and Maintenance Depots.Feedbacks from the passengers traveled in the First Generation trainsets were also taken into consideration.

Major changes in the Second Generation compared to its First Generation are:

• Seats were changed to pushback reclining type compared to slide-forward type reclining.
• Time to attain speed of 160 kmph is now reduced to 140 seconds, compared to 180 seconds earlier.
• The residual acceleration at 160 kmph will be 0.1 m/second as against 0.05 m/second.
• Four emergency windows were added in every coach.
• Kavach (TCAS), a SIL-4 certified indigenously developed train protection system; is provided to avoid collisions and prevent SPAD.
• Underslung electrical equipment can now withstand floods upto a height of 650 mm as of 400 mm earlier.
• VVVF compressors with Photo catalytic UV lamps were added to RMPU unit for germ free supply of air without voltage fluctuation caused by Neutral sections.
• Two 32 inches infotainment screens are given instead of four 24 inches screens in each coach.
• Coach Control Management System (CCMS) with 18 inch touch screen display are provided for monitoring the air-conditioning, communication and feedback to control centre/maintenance staff through GSM/GPRS.
• The 2nd Generation trainsets are now having four platform side cameras including rear view cameras outside the coach instead of two in the 1st Generation trainsets.
• SIL-2 certified Fire detection system based on an aerosol fire suppression system in all coaches are provided in place of a smoke detection system in the earlier generation trainsets.
• Two signal exchange lights were installed on the coaches for exchange of signals with the wayside stations.
• As there were frequent cases of filter choking of Auxiliary Converters & Traction Motors in 1st Generation trainsets; a separate ventilation duct with a bigger filter mesh is being provided on the sidewall and oil cooled Traction Converters are being used.
• The driver-guard communication comes with a voice recording facility now.
• There will also be Class 3 and 4 surge arrestors for electrical safety as against Class 2 and 3 surge arrestors earlier.
• Four emergency lights are provided in each coach for powering lights in case all electricity connections fail. The earlier generation trainsets did not have any emergency lights.
• The 2nd Generation trainsets has a battery backup of 3 hours compare to 1 hour earlier, for emergency systems. Lithium Iron Phosphate batteries are used and charged by 415 V AC current. In 1st Generation batteries were charged by DC current.
• Train Control & Management System (TCMS) is now SIL-2 certified, with two displays in each cab.
• Gigabit comfort network for Passenger Information System (PIS) and CCTV. CCTVs can record in 25fps.
• 415 V synchronized Auxiliary Converter is provided for 100% power availability incase of failure of Auxiliary converter, equivalent to one basic unit in place of one Auxiliary converter failure in 1st Generation trainsets.
• Ester oil (ClassK) and ClassH with enamel insulation for Transformer is used.
• Overall weight of 16 car trainset is reduced by 33.68 tons compared to its 1st Generation.

VB Variants (Family)

Sleaper Variant

Unlike in the previous two generations of Vande Bharat Express trainsets, in which there were only seats for daytime travel, suitable for 6-8 hours journey; The Third Generation will be having sleeping berths, having AC-1, AC-2 and AC-3 tier coaches for long distance overnight journey. However the carbody will be made of Stainless Steel; and the overall exterior design and features will be similar to that of its 2nd Generation trainsets. Indian Railways has already released tender for manufacturing of 200 3rd Generation Vande Bharat Express trainsets, and is expected to roll out first trainset by the end of 2024.

HS-SPART Variant

RCF is developing a High Speed Self Propelled Accident Relief Train (HS-SPART) on Vande Bharat platform. It will consist of 4 coaches, having one Medical Van, two Tool Vans and one for Staffs & Supervisors. It will have dual modes for traction power Electric & Diesel with either of two working at a time having maximum operating speed of 160 kmph on Electric and 140 kmph on Diesel mode. It will feature two underslung mounted diesel engines each having 750HP. It will have seat/berth capacity for carrying 25 crew members and 10 medical ward berths in Medical Van. There will be a 1 ton capacity EOT Jib crane for easy material handing in both tool vans.