India's most congested city, Bengaluru, faces train set supply crisis

Also, read: Tech hub Bengaluru ranks 6th most congested city globally in 2023: TomTom report

Similarly, two corridors of the city's long-pending suburban rail project (Benniganahalli to Chikkabanavara, 25 km, and Heelalige to Rajanukunte, 46.8 km) are expected to be completed in two years. However, there is no clarity on the induction of trains as the rolling stock tender is yet to be finalised.

South Western Railway (SWR) is also facing a rake shortage, preventing it from operating additional MEMU or mainline electric multiple unit trains, especially on routes connecting Whitefield and Hosur during peak hours.

BMRCL officials said that the tender was awarded to CRRC in February 2020 to deliver 216 new coaches for the Yellow, Purple and Green Lines within 173 weeks. "CRRC had committed to manufacturing 204 of the 216 coaches at its plant in Sri City, Andhra Pradesh, and even conducted a groundbreaking ceremony in 2021.  India’s decision to scale back business relations with China amid geopolitical tensions affected CRRC’s capacity to fulfill the 75% local production mandate under the Make in India initiative. Later, they partnered with TRSL," said a BMRCL official.

“CRRC quoted Rs 1,578 crore for the 216 coaches, which was the lowest bid compared to BEML’s Rs 1,996 crore, Bombardier’s Rs 1,801 crore and Alstom’s Rs 2,052 crore,” the official added.

The delays are attributed to factors such as Covid-19, foreign direct investment policies, restrictions on trade deals with China and delay in issuing visas to CRRC engineers.

Asked if coaches from other metro corporations could be used, the official explained: "Metro systems have different viaduct, tunnel and track dimensions as well as signalling systems. For example, Bengaluru Metro uses a third rail (for power), while many others use OHE (overhead equipment), making it impossible to rent trains from other metro systems."

An industrial source said, "Unlike foreign rolling stock manufacturers, BEML doesn't have its own propulsion system and is dependent on foreign vendors for supply."

He added that another mistake BMRCL is making is awarding the rolling stock and signalling contracts to different contractors. "A lot of time is wasted in finalising the interface between the rolling stock and signalling. Cities like Bhopal, Indore, Kanpur and Agra, avoided this mistake by bundling signalling and rolling stock together for faster rollout".

Bengaluru was India's most congested city in 2023, ranking sixth globally, according to the TomTom Traffic Index.

Yellow Line delayed

BMRCL sources said that the unavailability of trains is delaying passenger operations of the Yellow Line. Currently, BMRCL has only a six-coach prototype train, which was manufactured by CRRC and delivered in February 2024. The Lucknow-based Research, Design and Standards Organisation (RDSO) under the railway ministry has been conducting oscillation and emergency braking distance trials on Yellow Line since September 9. BMRCL needs at least five train sets to commence operations on Yellow Line with a 20-minute headway. Officials are expecting the first train from TRSL by November 15, with another set expected by December. A phased operational plan, with three trains stopping only at major stations, is being drawn up to begin services in December 2024 or January 2025. However, if this is not feasible, the launch could be pushed to the second quarter of 2025.

Also read: Major stations first: Bengaluru Metro scrambles with plan B for Electronics City line due to train crunch

Overcrowded coaches

Bengaluru Metro’s Purple Line (43 km from Challaghatta to Whitefield) and Green Line (30.5 km from Nagasandra to Silk Institute) are now overcrowded due to low frequency of services. Experts say that one train per kilometre is necessary to maintain a 3–4-minute frequency, but 73-km Bengaluru Metro network only has 57 trains. BMRCL officials said that TRSL will begin delivering 126 DTG (distance-to-go signalling system) coaches (21 six-coach trains) from June 2025, after completing deliveries of 14 CBTC (communications-based train control)  train sets for the Yellow Line. While the DTG prototype train was supposed to reach Bengaluru from China by September 2024, it has yet to arrive. Testing of the DTG prototype train will also be challenging due to the limited four-hour night slots available on the operational Purple and Green Lines.

Also read: Bengaluru Metro's Whitefield line chokes after return-to-office mandates, more trains only next year

Train shortage likely to hit Pink and Blue Lines

Bengaluru Metro’s two under-construction corridors, Pink Line (Kalena Agrahara to Nagawara) and Blue Line (Outer Ring Road to Kempegowda International Airport), are likely to face delays due to the shortage of trains. BMRCL had planned to open the Pink Line in phases: the 7.5 km elevated section from Kalena Agrahara (Gottigere) to Tavarekere (Swagath Cross) by September 2025, and the 13.8 km underground section from Dairy Circle to Nagawara by June 2026. Similarly, the KR Pura-Ibbalur section of the Blue Line was scheduled for opening in 2025.

However, sources are sceptical. In August 2023, BMRCL awarded a Rs 3,177-crore contract to BEML to supply 318 coaches (53 six-car trains) for both lines. BEML commenced prototype train manufacturing in August 2024 but is reliant on Mitsubishi Electric (Melco), Japan, for propulsion systems for Blue and Pink Line trains. Melco is expected to deliver the first propulsion equipment to BEML only by October 2025. "The first train expected by December 2025 and BEML requires an additional 4-5 months after the prototype rollout to deliver 10 trains to begin passenger service" said a source. This means that passenger operations on both lines are expected to begin only after May 2026.

Also read: BEML receives Rs 3,177 crore rolling stock order from Bengaluru Metro

Suburban rail project delayed

In June 2022, Prime Minister Narendra Modi said that Bengaluru's long-pending suburban rail project (four corridors spanning 148 km), which had been delayed for 40 years, would be completed in 40 months, by October 2025.

Civil work has commenced on two corridors—Benniganahalli to Chikkabanavara (25 km) and Heelalige to Rajanukunte (46.8 km)—with a target of December 2026. However, tenders for train sets are yet to be finalised.

K-RIDE, a special purpose vehicle executing the project, plans to induct 264 coaches, comprising 80 trains of three cars each and four trains of six cars each. It will take two to three years for rolling stock manufacturers to supply the required trains.

Also read: Two Bengaluru suburban rail corridors to be ready by Dec 2026: Railways MoS V Somanna

"Three firms—BEML, BHEL and CAF—participated in the RFQ (request for qualification) under the PPP (public-private partnership) model. However, no bids were received, even after the deadline was extended to August 22, 2024. There were no takers for the lease model, so we have now proposed purchasing the rolling stock under a 50:50 cost-sharing model between Karnataka government and ministry of railways. The procurement of coaches should be completed at least six months before the scheduled launch date,” said a K-RIDE official.

SWR faces MEMU rake shortage

SWR should be able to operate more MEMU trains between Bengaluru Cantonment and Whitefield, especially during peak hours, as automatic signalling is in place on this route. SWR is unable to add trains due to a shortage of MEMU rakes, despite demands to increase MEMU services on routes such as Hosur, Tumakuru, Hassan, and Whitefield/Marikuppam during peak hours. Bengaluru Divisional railway manager Yogesh Mohan said: “There is a shortage of MEMU rakes. We have sought additional MEMU trains from the Railway Board. On the Bengaluru Cantonment-Whitefield section, quadrupling work is progressing and already, line capacity utilisation is above 100 percent. On the Hosur route, doubling work is progressing.”

Also read: Bengaluru suburban rail expansion plans to satellite towns stalled as South Western Railway raises red flags