Annual Report 2010-2011
www.rdso.indianrailways.gov.in
COACHING STOCK
RESEARCH, DESIGN & DEVELOPMENT
Manufacture of Prototype Double Decker Coach
MR had announced introduction of AC double decker
coaches on IR in her Budget Speed of 2010-11. For
realizing this vision that the double decker coaches
should match the best in global standards, with fresh
look to interior design and provision of superior
passenger amenities, AC Double Decker
Coacheshaving the following superior design features
weremanufactured at RCF, Kapurthala based on
design developed by RDSO. Shell of the coach is made
of stainless steel and has monocoque design besides
having crashworthiness features:n
Cushioning of seats with fire retardancy features
by use of PU foam to RDSO specification
RDSO/2007/CG-04 with fire barrier cloth to IS
11273 or superior material.
n
Aesthetically appealing superior polycarbonate
luggage racks without interference with normal
passenger movement.
n
Use of polycarbonate windows with roller blinds
like LHB coaches with scratch resistant coating.
n
Use of diffused lighting with LEDs.
n
n
n
n
n
n
n
n
n
n
Use of suitable insulating material like resonaflex
used in LHB coaches along with noise absorption
paint.
Use of metallic finish exterior paint for enhanced
paint life and better aesthetics.
Provision of passenger information system.
Use of automatic odour and hygiene control
systems in toilets.
Use of LED based destination boards to RDSO
specification RDSO/2009/CG-01 (Rev.1).
Provision of modular pantry.
Use of superior toilet fittings as per RDSO
specification RDSO/2008/CG-05 and provision of
dustbin of adequate capacity.
Provision of automatic fire/smoke detection and
alarm system and use of fire retardant coating
and mastic sealing compound.
Use of automatic AC entrance door operating
mechanism.
Use of vestibule door operating mechanism.
Left: Double Decker Coach standing at Saloon Siding of New Delhi Railway Station, Right: Upper Deck
Prototype of the coach was successful in its oscillation
trials on both C&M-I Vol.I& Vol. II standard tracks at a
maximum speed of 180 kmph on Agra-Baad section and
at a maximum speed of 115 kmph on MB-BE section
respectively.
The commercial service is expected to commence in near
future on Board's orders after the issues concerning
clearance of the coach from platform coping as well as
inside curved platforms having being resolved in
validation/ confirmatory trials conducted on HowrahDhanbad section of ER which is the introductory
10
commercial service route of the train.
Fire/Smoke Detection and Alarm System
Railway Board vide letter No. 2006/M(C)/137/10 dated
20.07.2006 directed RDSO to undertake field trial of
fire/smoke detection system. M/s Sidwal Refrigeration,
Faridabad supplied fire/smoke detection and alarm
system was fitted on 18 coaches of Bhuvneshwar
Rajdhani Rajdhani Express rake. The system wasput
under trial for 18 months. All the coaches were
connected through electrical coupler.
Annual Report 2010-2011
Coaching Stock
www.rdso.indianrailways.gov.in
Achievement of 80% Target of Reduction in Fire
Incidences on Trains Given in Corporate Safety Plan
2003-2013 of IR
The Corporate Safety Plan (2003 - 2013) has laid
adequate emphasis on improving the fire safety of trains
by improving fire retardancy properties of coach
furnishing materials. According to Corporate Safety
Plan, fire accidents constitute 2% of total accidents and
account for 2% of total fatalities. Fire accidents and
consequent fatalities was targeted to be reduced by
2002-03
2003-04
2004-05
2005-06
80% with the adoption of fireproof coaches and fire
retardant materials.
RDSO has made a sustained effort in last 2-3
years to reduce fire accidents in coaches and
consequent fatalities. There has been significant
reduction in cases of fire accidents in passenger
coaches since 2007after upgradation of coach
furnishing material. The details of fire accidents
on Indian Railway from 2002-03 onward are given
below:
2006-07
2007-08
2008-09
2009-10
2010-11
From the graph it is evident that a reduction of 87% by 2010 over figure of 2002-03.
It is also evident that cases of fire reduced in last 2-3 years.
Specifications of all coach furnishing material has been
made to UIC norms with respect to following fire
retardancy features:
n
Resistance to spread of flame
n
Deterioration of visibility due to smoke
n
Limiting oxygen index,
n
Toxicity Index
Wheel Shelling
Wheel shelling and spalling are metallurgical
phenomena due to rail wheel interaction, which
happens in all railways systems. The small pieces of
metal continuously brake out of the tread surface at
several places around rim. This requires frequent tyre
turning at small intervals.
Reasons for wheel shelling
International literature on the problem of wheel shelling
has also been studied. The possible reasons may be as
below:
n
Higher braking force
n
Low Rail-wheel adhesion
n
Ineffective wheel slide protection device
n
Low hardness of wheel
n
Low yield strength of steel
Railways have been reporting the problem of wheel
shelling since the LHB coaches were introduced in
service. RDSO had already taken the following
measures in 2001to overcome the problem of wheel
shelling:
v
Specification R-19/93 Part II for Forged steel
wheel has been revised.
v
Brake cylinder pressure has been reduced to 3.0
kg/cm2 from 3.8 kg/cm2 on Rajdhani coaches.
v
Defining the shelling limits for re-profiling.
v
Instructions for improving maintenance of bogie
& brake system.
The steps taken by RDSO are in line with international
literature.
After these measures, there has been some
improvement in kilometer earning per tyre turning and
corresponding increase in wheel life. But wheel shelling
still continues on LHB coaches.
Self illuminated (LEDs) Backlit type pressure gauge
for brake pipe and feed pipe for use in Guard's
Compartment
RDSO has prepared drawing for self-illuminated (LEDs)
11
Annual Report 2010-2011
Coaching Stock
www.rdso.indianrailways.gov.in
backlit type pressure gauge (100mm) for brake pipe and
feed pipe for use in Guard's Compartment of SLR
coaches. It has the following advantage:
Increased visibility of the pressure reading
n
This will reduce the physical and mental fatigue
n
on guards and results in enhanced safety of train
operation.
A copy of RDSO's drawing No.CG-K10021 & CGK10022 for self-illuminated (LEDs) Backlit type
Pressure Gauge (100 mm) for Brake Pipe and Feed
Pipe respectively and power scheme drawing
No.RDSO/PE/SK/TL/0097-2006 (Rev.0) Alt.2 have
been issued to Railways and PUs.
Modification in Drawing for Brake Gear Bushes
To overcome the problem of premature failure of Brake
Gear Bushes, railways were advised to use self
lubricating polyester resin bushes to specification No.CK605 in critical locations and Generation-3 phenolic
brake gear bushes to specification No. C-K307(Rev.2)
in non-critical locations. East Central Railway was
requested to include brake gear bush item-3 of RDSO
drawing No.SK-98026 in RDSO drawing No.SK-81039
which is used in lever of bogie brake of bogie mounted
brake system.Jagadhari Workshop/NR have also been
requested to include level hanger top position bush for
non BMBC as per drawing SK-81039 Item-4 as critical
location.
Accordingly, RDSO has modified the drawing No.SK81039 and the brake gear bushes used in BMBC and
underframe mounted coaches have been included in
the drawing. The modified drawing No.SK-81039 alt.2
has been issued to all railways and PUs. To make
critical locations more clear for brake gear bushes used
in BMBC and U/F mounted main line coaches,
schematic diagrams indicating critical location has also
been shown in the drawing. The new drawing identifies
the critical and non-critical locations, numbers of bushes
in those locations and the specifications for the brake
gear bushing material to avoid any confusion in the field.
Operating Instructions and Check Points of CBC
Recently IR had a few instances of uncoupling
especially between CBC of Loco and adjacent coach i.e.
WLRRM. Analysis of the cases indicates that
instructions related with CBC operation are needed to
be disseminated to working staff in Railways. It is also
observed that Railways are not recording cases of train
parting properly to enable thorough investigation.
RDSO has prepared a technical booklet containing
operating instructions and check points. It includes:n
Guideline for coupling between coach to coach
and coach to locomotive.
n
Check points to ensure proper coupling.
n
Points to be checked in the event of train parting.
n
Gauges for maintenance.
All the instructions related with operating of CBC issued
12
by RDSO to Railways since introduction of centre buffer
coupler in coaching stock have been complied in the
booklet.
Experience of Railways has also been
considered.
The booklet has been made attractive with pictorial
illustrations and it is expected to prove useful to
Railways specially when CBC equipped coaches are
being introduced in large number in almost all the
Railways.
Development of Panel Mounted Brake System
In 12th CMG meeting held in Nov 2008 at
Guwahati/NFR, it was recommended to develop Panel
Mounted air brake system for LHB Hybrid coaches.
M/s Escorts Ltd., Faridabad has successfully developed
the Panel Mounted Brake System for LHB Hybrid
coaches.
ICF & RCF have been advised to procure each 6 Nos.
brake container modules from M/s Escorts Ltd.,
Faridabad for trial fitment on Hybrid coaches subject to
their successful participation in the tender on
competitive basis. The performance of brake container
Panel Mounted Brake System
module will be monitored for nine month.
Setting up of Longitudinal Simulation Facility for
Optimization of Draft Gear Characteristics of
Coupling Arrangement
In a comprehensive study done by RDSO on problem of
longitudinal jerks in CBC equipped passenger coaches, it
was recommended to set up a longitudinal simulation
facility at RDSO. A global tender has been advertised on
for engaging international expert in this field. The
estimated cost of the work is Rs.1,98,45,000/-.
The facility is also expected to reduce a large number of
coupler force and emergency brake trials. These field
trials can be reduced with test results obtained through
simulations.
METRO PROJECTS
Bangalore Metro Project
MoU between RDSO and BMRCL was signed in July
2010 for technical clearance and issue of speed
certificate. A payment of Rs. 3.3 crorewas received
from BMRCL.
Annual Report 2010-2011
Coaching Stock
www.rdso.indianrailways.gov.in
Provisional speed certificate for a maximum operational
speed of 55 Kmph has been issued by RDSO. The
operational speed has subsequently been increased to
75 kmph vide amendment to the speed certificate.
Delhi Airport Metro
Oscillation trials of Delhi airport metro has been
completed. On the basis of the trial, speed certificate for
a maximum operating speed for 120 kmphhas been
issued for Dwarka Sector 21 to DhaulaKuan. For the
section from Dwarka 21 to New Delhi station,
confirmatory oscillograph car run (COCR) of the metro
coaches has to be carried out. The CMRS sanction is
awaited for conducting the COCR.
Improvements in Coach Interiors
Expression of Interest for Upgradation of Sub-systems
for Rail Coach Interiors has been called for through
open advertisement. The improvements in coach
interiors are envisaged by way of material upgradation,
ergonomic design, colour scheme etc. so that the
interior of IR coaches are state- of art assimilating the
best national and international practices and materials.
Design options have been invited for the following subsystems :a Flooring
f
b Paneling
g Sealing
c Partition frame
h Lavatory
d Seats and berths
i
binding on GS and SLR coaches is also reported.
RDSO in-association with M/s Knorr Bremse has
developed 203 mm bogie mounted brake cylinder with
double acting slack adjustment. Double Acting Bogie
Mounted Brake Cylinder automatically adjusts the
constant piston stroke by pay-in and pay-out during
each brake application & release. This will have the
following benefits:
n
Reduction in maintenance effort by C&W crew
n
Reduction in brake binding cases on GS & SLR
coaches
n
Reduction in uneven wear of brake blocks
Air circulation system
Luminaries and lighting
e Windows
The design shall be finalized based on the feedback and
cost benefit analysis for each option.
Development of High Capacity Milk Tanker
RDSO in association with RITES is developing high
capacity milk tanker. Followings are its salient features:n
Total capacity of 50,000 Kl which is 10,000 Kl
higher than the present milk tanker.
n
EMU bogie, 20.3 t axle load.
n
Use of Poly Urethane Foam insulation. With this
insulation, temp. rise in milk will be less than one
degrees in 72 Hrs. without any refrigeration.
n
Length of tanker less than 11 meters.
n
Use of transition couplers for flexibility in
operation.
Conceptual drawings and broad parameters have been
frozen and advised to M/s RITES. This project is
appropriately timed to upgrade aging stock of existing
VVNs.
Development of Double Acting Bogie Mounted
Brake Cylinder
Railways have reported that the piston stroke of 203 mm
size BMBC on ICF coaches gets reduced up to 20 mm
from the pre-set value of 32 mm in every trip. This
necessitates readjustment of piston stroke in each trip
by the maintenance staff. Sometimes, frequent brake
The prototype has been successfully tested at Test
bench for desired objectives. Northern Railway has
been advised to conduct field trial of the prototype on
one GS & one SLR coach vide letter No.MC/APB/BMBC
dated 21.09.2010
Modification in AAR `H' type CBC Design to Provide
Secondary Anti-Creep Mechanism
To prevent uncoupling of CBCs on run, different
Railways have adopted their own modification schemes
in the design of CBC. To uniform the design all over the
Indian Railways, RDSO has prepared a modification
scheme vide sketch no. CG10077 to provide secondary
anti-creep mechanism.
In the modification, an
additional rib has been provided on the lock lift lever to
ensure that the latter does not move unintentionally.
The lock lift lever moves only when it is operated through
manual uncoupling rod. The modification retains all the
advantages of coupler being automatic. The
improvement has been advised to all the Railways.
Cleaning of PVC Flooring to RDSO Specification
RDSO/2006/CG-12 (Rev.1)
At present flooring to spec. RDSO/2006/CG-12 (Rev.1)
is being used in Coaches. Performance of the flooring
has been reported satisfactory except the Railways are
finding difficulty in its cleaning. The issue was taken up
with manufacturers of PVC flooring. Manufacturers in
collaboration with M/s Poly-Beek India Pvt. Ltd.,
13
Annual Report 2010-2011
Coaching Stock
www.rdso.indianrailways.gov.in
Gurgaon and M/s Doan Rajkamal, Mumbai have
developed cleaning agent for the flooring and rexene.
This product was tested in New Delhi Coach Care
Center of Northern Railway and was found to be
encouraging in cleaning of PVC flooring and rexene.
Railways have been requested to try out the solution for
cleaning of PVC flooring and stained on rexene on 2-3
coaches for checking the adequacy of the cleaning
solution in their conditions.
Based on feedback regarding the performance of the
cleaning solution on the railways, instructions for use of
cleaning agent for periodic intensive cleaning will be
issued.
Development of Alternative Design of AC Double
Decker Coach
During trial of double decker coaches on ER, grazing
marks were noticed on side wall at a few locations.
These grazing marks took place on account of
inadequate clearance on platform as per SOD. This
called for review of double decker coach width
considering existing maintenance. Accordingly, an
alternative design no. CG-10115 of AC double decker
coach having coach width of 3050 mm below
platformlevelwas developed thereby generating more
clearance from platform as well as providing more
space from inside by adopting differential width of lower
and upper decks.
Dispensation for conducting oscillation trial for 3050 mm
width double decker coach has been received from
CCRS while the condonation of infringement of
dimensions is expected soon from Railway Board.
IRDD Mark-II Shell
14
Annual Report 2010-2011
Coaching Stock
www.rdso.indianrailways.gov.in
RDSO has submitted a detailed report on "Development
of Alternative Shell Design IRDD Mark-II for AC Double
Decker Coach". The report is based on extensive
simulation studies conducted on IRDD Mark-II shell at
RDSO for its structural strength. The design is validated
through FE analysis under various loading conditions as
prescribed in UIC 566 standards. The report also
covers manufacturability aspect of the design.
Corrosion Repair Procedure of Head Stock
Railways had reported a few instances of coach parting
cases from head stock area. This called for review of
corrosions repair practices being followed by
workshops. The need for review was also impressed
upon during CWMs' conference at Board. Accordingly,
carriage directorate undertook review of repair practices
and revised the procedures. Such procedure detailing
precautions to be taken during welding and painting of
assembly, post repair, has been issued to Railways.
Adoption of Brake Gear Bushes for Coaching Stock
Due to unsatisfactory performance of phenolic bushes,
Railways were advised to use self-lubricating polyester
resin brake gear bushes only at critical locations and
Gen-3 phenolic bushes to be used in non-critical
locations. In addition, high performance polyamide
(HPPA) brake gear bushes were recommended for trial
at non critical locations. As per the trial report of these
bushes at non critical locations, the performance was
found encouraging.
Based on the trials and Railway Board's approval, all
railways have been advised to take following action,
n
The procurement of phenolic brake gear bushes
to RDSO Spec. No. C-K307 should be
discontinued with immediate effect. However,
Railway shall continue to use the phenolic brake
gear bushes available in stock and also those
received against warranty replacements.
All the new procurement for bushes shall be as
per the revised 2 kit system i.e. HPPA brake gear
bushes to RDSO/2009/CG-17 for non-critical
location and self-lubricating polyester resin
based composite brake gear bushes to RDSO
spec. C-K605 for critical locations.
n
HPPA brake gear bushes to be fitted on 200
coaches each on major Railways and PU's for
trials in all locations, this will be reviewed after 912 months, in view of experience gained on HPPA
brake gear bushes.
Introduction of New Types of Rolling Stocks in
Important Train services.
During the month, RDSO has issued speed
certificates for non-AC chair car (EOG) LHB variant
coaches and revised speed certificate of AC double
decker coach. These speed certificates of the new
rolling stocks are based on extensive special trials like
dust and noise measurement in non-AC coaches,
validation trials of AC double decker coach for issues
related with platform clearances etc. The speed
certificates have paved the way for introduction of
these new types of rolling stocks in important train
services.
RDSO had earlier proposed for condonation of nonAC chair car (EOG) LHB variant coaches to Railway
Board through CCRS.
The proposal has been
accepted by Board. Also, a proposal for dispensation
of oscillation trials of this coach was accepted by
CCRS and thus speed certificates could be issued in
time.
Instructions for Corrosion Repairs
Instructions for corrosion repairs of ICF/RCF built BG
coaches to specification RDSO/2011/CG-CMI-01 have
been issued to all Railways. This specification
supersedes earlier specification C-7602 (Rev.1).
n
15