MAINTENANCE INSTRUCTION FOR REPAIR OF … WMI-001...wmiwmi----001000011001- ---bcnhl doorbcnhl doorbcnhl door- ---201720172017 indian railways maintenance instruction for repair of

WMIWMIWMIWMI----001001001001----BCNHL DOORBCNHL DOORBCNHL DOORBCNHL DOOR----2017201720172017

INDIAN RAILWAYS

MAINTENANCE INSTRUCTION FOR

REPAIR OF DOORS OF BCNHL WAGON

S. No.

Month/Year of issue

Revision/

Amendment

Page No.

Reason for Amendement

01 October 2017 Nil First Issue

Issued By :

Wagon Directorate

Research Designs and Standards Organization

Manak Nagar, Lucknow-226011.


Contents 1. BACKGROUND: ................................................................................................................................ 3

2. TYPES OF DOORS: ............................................................................................................................ 3

A. Two-flap hinge door .................................................................................................................... 3

B. Single sliding door ....................................................................................................................... 3

C. Retrofit table Two -part sliding door .......................................................................................... 3

Table: 1 ................................................................................................................................................ 4

3. Repair Guideline to Door: ............................................................................................................... 7

3.1 Two Flap Hinge Doors: ................................................................................................................ 7

3.2 Single Sliding Door: ..................................................................................................................... 7

3.3 Two part Sliding Door: ................................................................................................................ 8

4. Precaution in Retro fitment of two part sliding door ..................................................................... 8

5. Recommendations: ......................................................................................................................... 9

Annexure-A ....................................................................................................................................... 10


1. BACKGROUND:

Railway Board in reference of minutes of CME conference, held on 17 December 2016 ,

issued letter no 2016/M(N)/951/30 dated 17/01/2017 directed RDSO to review the

issues pertaining to BCNHL door design. Zonal Railways observed that there are various

designs of BCNHL doors running in field and they face a lot of problems in maintaining

them. In view of above, RDSO undertook this study so as to come out with

comprehensive report detailing all aspects of BCNHL door design issue. RDSO personnel

visited Jhansi Workshop, Kota workshop, ROH depot Khan Alampura, Wagon Depot

Madar, Ajmer and CPC yard Kanpur to understand the problems being faced by field

staff in maintenance of various types of BCNHL doors. RDSO has prepared a

report(WDR-001-BCNHL-DOOR-2017), based on field experience and feedback received

over the time from various workshops and Wagon depots. The report has been

examined and approved by Railway Board vide letter No. 2005/M(N)/204/1 Vol. IV

dated:18.09.2017.This wagon maintenance instruction will help field maintenance

personnel in better understanding of various BCNHL Door designs, repair of various type

of doors and precautions to be taken in retro fitment of two part sliding door. This

instruction also standardizes only two designs of BCNHL doors to ease their maintenance

in field.

2. TYPES OF DOORS:

Broadly there are three different types of BCNHL wagon doors.

A. Two-flap hinge door

B. Single sliding door

C. Retrofit table Two -part sliding door

A. Two-flap hinge door

It consists of original door design, Mod-1 design, Mod-2 design and Besco design

door. All variant of Two-part flap door (6-Link or 4-Link with hinge) differ only in

locking arrangement in the same door. Their details are furnished in table no 1.


It consists of TWL design sliding door, Texmaco design Single Piece Sliding Door (SS)

and RDSO design Single Piece Sliding Door (MS). Their details are furnished in table

no 1. The material specification and design of whole structure of BCHNL (Design-D)

and BCHNL (Design-E) are same except those drawings which are concerned with

BMBS. Therefore, single sliding door arrangement can be procured from either WD-

10068-S-16 or WD-11054-S-16 for both type of BCNHL wagon.

C. Retrofit table Two -part sliding door

• Mild steel, 2 Part Sliding Door with top mounted rollers moving in a guide channel

and supported with bottom guide rail. This retrofit able door can be easily fitted on

those wagons which are manufactured with 2-flap hinge door of BCNHL wagons.

There are two provision provided to drain the rain water in two part sliding door

design. A slot is provided on mating plate of one door of two part sliding door and a

rain protection plate (WD-06076-S-15 it-12) is welded with top coping throughout

the length above the door opening. This rain protection plate has been extended


with addition of a plate beyond the side stanchion so that the rain water will flow

outside of the slider channel of door.

• This door may also be retro-fitted with minor modification in body side where TWL

design Single Piece Sliding Door is fitted.

Table: 1 BCNHL wagons are in operations, with the following types of doors, owing to modifications/

design changes based on field experience gained over time:

S.No. Time/

Period of

Introduction

Pictorial View Door Type Fitted

in

Approx

Number

of

Wagons

1 May’2008

ORIGINAL:

6 Hinge Door (SS)

with center locking

from inside.

1000

2

June’2009

MOD-I:

6 Hinge Door (SS)

with center locking

inside & cotters-Long

& Short provided on

door sides.

3065


3

June’2010

MOD-II:

6 Hinge Door (SS)

with center locking

outside & inside

alongwith cotters-

Short provided on

door sides.

3000

4 Aug’2010

BESCO Design 4-

HINGE DOOR:

4 Hinge Door (SS)

with center locking

outside & inside

alongwith cotters-

Short provided on

door sides.

500

5

Sept’2009

TWL Design Sliding

Door:

SS, Single Piece

Sliding Door with

Bottom mounted

rollers.

58


6

July’2010

TEXMACO Design

Sliding Door:

SS Single Piece Sliding

Door with Top

mounted rollers.

300

7

July’2012

RDSO Design Sliding

Door:

MS (micro alloyed)

Single Piece Sliding

Door with Top

mounted rollers

alongwith securing,

rolling & locking

modifications.

11000

8

Jan’2013

Retrofit able 2-Part

Sliding Door:

MS, 2 Part Sliding

Door with top

mounted rollers

moving in a guide

channel. Retrofit able

design for older

BCNHL wagons.

116


3. Repair Guideline to Door:

Door failures have been reported by Zonal Railways on BCNHL wagons & various

corrective actions for the same have been regularly advised. For the purpose of general

guidance, the following are re-iterated, however, it is expected that detailed RDSO

letters/ drgs issued to address the reported door failures along with instructions/

sanctions issued by Rly Bd shall be duly studied/ referred-to by the ZRs/ W’shops to

undertake/ decide on door repairs in BCNHL wagons:

3.1 Two Flap Hinge Doors:

• For BCNHL Wagons manufactured prior to June’2010 and fitted with Door

Design-Original, MOD-I, Railway board has instructed and sanctioned RSP for

retro fitment of these doors by 2-part sliding doors as per RDSO Drg No. WD-

06076-S-13(with latest alteration) & WD-11043-S-01(with latest alteration),

WD-11043-S-02(with latest alteration). Detail procedure and precautions to

be ensured for retro fitment of these doors is given in para-4. It is again

instructed that these door modifications be carried-out (if not already done)

at the earliest .

• In case of other 2-flap hinge type door(Mod-2 and Besco design), if the

under-repair BCNHL wagon is damaged to an extent that the entire door

warrants a replacement, it is instructed that the door be replaced by the

retrofit able two part sliding door as detailed in Drg. No. WD-06076-S-13 &

WD-11043-S-01(with latest alteration) and WD-11043-S-02(with latest

alteration).

3.2 Single Sliding Door:

• Gap between water protection cover pressing and door safety pressing angle

should be as shown in relevant RDSO drawing by straightening the door

safety pressing angle and providing missing/loose fasteners as shown in

enlarged view “B” and “F” of drg no WD-10068-S-15. Picture at item no 14 of

Annexure-A.

• To prevent the derailment of roller from the door top track, 04 no. of door

safety piece (8x18x50 mm) as shown in RDSO drg no WD-10068-S-17 it-2(V)

to be provided in each door. Picture at item no 13 of Annexure-A.

• Safety catch holder, Retaining catch, Retaining catch rivet, shoulder rivet,

cotter etc. should be provided at proper location as shown in drawing

noWD-10068-S-16, S-17,S-18. Picture at item no 15of Annexure-A.

• Proper Gap, as shown in drawing, between Door guard and sole bar to be

maintained to ensure easy sliding of door. Picture at item no 16 of Annexure-

A.

• Care needs to be taken to ensure that the correct/ recommended material of

construction of door/ its components is used in repair of the door/ its

assemblies.

• In case Texmaco design single sliding door (SS) warrants complete

replacement owing to damages then RDSO design single sliding door (MS) to

be used as replacement.


3.3 Two part Sliding Door:

• If doors are found jammed, the fitment of transfer balls at bottom of doors to

be checked for proper fitment. The doors should be fitted with 05 nos

transfer balls on each part.

• Replacement of rollers can be done only after cutting of one nearest side

stanchion of one side of door.

• Any missing latching and locking component to be provided as per RDSO

drawing.

4. Precaution in Retro fitment of two part sliding door

• Remove the old hinge type door.

• Check the side wall near door portion for straightness. If found bulged, the side walls

should be straitened by use of turn buckle or any other suitable method. Now the

side wall to be strengthened by providing horizontal and vertical stiffeners as per

RDSO drawing no. WD-06076-S-13 Alt-5 to prevent the bulging of side wall and to

avoid water ingress due to gap in between side wall and door. Ensure maintenance

of clearance in between door and side wall in range of 17 mm.

• Slider channel to be welded with top coping as shown in enlarged view at-‘Y’ of

Drawing no-WD-11043-S-01(with latest alteration).

• The guide rail to be fitted with sole bar ensuring the alignment of door.

• Slider Channel and door assembly to be fabricated as per drawing no WD-11043-S-01

& S-02(with latest alteration). Alignment of the slider channel with the door frame

and guide rail to be done such that the both end of door fully overlap top to bottom

after closing. (Section-PP overlap on section-OO in full height of door as shown in

Drg. no WD-11043-S-02) (with latest alteration)

• 12 mm wide slot must be ensured throughout the length on the inside portion of

lapped door (As shown Section-OO of Drg WD-11043-S-02(with latest alteration).

Picture at item no-9 of Annexure-A.

• The size of transfer ball must be ensured as shown in item no-22 of Drg WD-11043-S-

01(with latest alteration). The transfer ball should be procured from the approved

manufacturer of RDSO as shown in drawing.

• The transfer ball is to be fitted on the inside bottom plate of door (As shown section-

NN of WD-11043-S-02(with latest alteration) for ease of sliding of door with guide

rail. The fitment of guide rail must be such that the transfer balls are in proper

contact with guide rail. The correct fitment of transfer ball is shown as enlarged view

at-‘Z’ in Drg.No.-WD-11043-S-01(with latest alteration). Picture at item no-3, 7 of

Annexure-A.

• The guide rail fabrication with angle must be ensured as shown in section-CC of WD-

11043-S-02(with latest alteration). Picture at item no-1 of Annexure-A.

• The angle for guide rail (WD-11043-S-02(with latest alteration), item no-14) should

be in one piece and 85 mm wide slot to be cut only on top flange at six locations on

equal distance.

• Supporting plate for guide rail angle (WD-11043-S-01(with latest alteration), item no-

28) to be carefully welded with sole bar so that this plate could provide the strength

to guide rail angle.


• Stiffener plate (WD-11043-S-02(with latest alteration) item no.-8 & 10) to be welded

at proper location so that the door movement can be ensured up to required

distance and door can be closed with proper alignment and tight overlapping.

• The barrel bolt hold bracket (WD-11043-S-01(with latest alteration), item no-24) to

be welded from both side (outside and inside) with sole-bar at right location so that

the door can be locked at right location maintaining the alignment and tight

overlapping of door. This would also ensure proper strength of bracket.

5. Recommendations:

• RDSO has standardized all available 8 variants of doors into two types of doors i.e.

single sliding door (MS) and two part sliding door.

• All types of 2 flap hinge doors (Original, Mod-1, Mod-2, TWL design single sliding

and Besco design) may be replaced by two part sliding door. They will have to be

done on condition basis whenever complete door warrants replacement.

• Texmaco design single sliding door (SS) may be converted into RDSO design single

sliding door (MS). They will have to be done on condition basis whenever complete

door warrants replacement.

• All new BCNHL wagons, to be manufactured from now onwards, to be fitted with

two part sliding door.

• The correct fitment of two part sliding door and single sliding door may be ensured

as detailed in Annexure A.

• Zonal Railways to ensure correct retro fitment of two part sliding door by preparing

check sheets based on precautions mentioned in para 4.


Annexure-A

Common fitment errors noticed during field observations in retro fitment of

two-part sliding door and Single sliding Door.

A. Two part sliding door

S.No. Error Noticed Correct Fitment as per drawing

1

Incorrect dimension of angle (50X50X6mm) for

guide rail. Due to excess dimension of angle,

this angle rubs with fixed structures

Guide rail fabrication with angle of size

(50X30X6mm) must be ensured as shown in

section-CC of WD-11043-S-02

2

Due to Incorrect dimension and Position of

guide rail angle (50X50X6mm), this angle

infringes with fixed structure.


3

Wrong fitting of transfer ball, it should be in

proper contact with guide rail

4

One rib(WD-11043-S-01 item-23) is fitted with

each horizontal flange of guide rail angle

Two rib(WD-11043-S-01 item-23) to be weld

with each horizontal flange of guide rail angle

5

The location and dimension of Bkt. for barrel

bolt are not found welded as per RDSO drg. no

WD-11043-S-01

Guide Bkt. for barrel bolt to be fitted

according to drg. no WD-11043-S-01



6

An additional plate was found welded with

barrel bolt hold bkt(WD-11043-S-01 it-24) in

level of floor plate. This would cause ingress of

rain water from bottom side of door.

The additional plate is not provided in RDSO

drawing. However, it can be welded at bottom

face of barrel bolt hold bkt(WD-11043-S-01 it-

24)to provide the strength of barrel bolt hold

bkt(WD-11043-S-01 it-24).

7

Transfer ball are fitted in blind hole. Due to such

error of fitment, the projection of ball are more.

The transfer ball to be fitted on the inside

bottom plate of door(As shown section-NN of

WD-11043-S-02) for ease of sliding of door

with guide rail.

8

The welding area of Hasp locking pin Bkt(WD-

11043-S-01 item-14) is less and due to poor

welding quality, this bkt. found missing

Hasp locking pin Bkt(WD-11043-S-01 item-14)

to be welding according to this photograph.


S.N

Error Noticed Correct Fitment as per drawing

9

Slots are not provided. The slot will prevent the

rain water to flow inside the wagon.

12 mm wide slot must be ensured in

throughout length on the inside lapped door

(shown Section-OO of WD-11043-S-02).

10

The doors are misaligned and door part are not

properly mate on each other. Due to such

defect, water will ingress into the wagon.

The barrel bolt hold bracket (WD-11043-S-01,

it-24) to be welded from both side (outside

and inside) with sole-bar at right location .

11

Stitch welding of door way side sill

pressing(WD-06076-S-13 it-18) with door link

bracket frame(WD-06076-S-13 it-16) instead of

continuous fillet welding

Door way side sill pressing(WD-06076-S-13 it-

18) with door link bracket frame(WD-06076-S-

13 it-16) to be done continuous welding as per

Section-GG


12

Excessice Gap between door and side wall

Normal Gap between Door and Side wall



13

Door safety piece are missing.

v

WD-10068-S-17 Item no-2(V) To prevent the derailment of door the Door

safety piece are provided, it must be weld as

per drawing



14

Excess gap found between door top

pressing(WD-10068-S-17, item-02) and Door

safety angle pressing(WD-10068-S-15,item-16).

This gap shall be filled by fitment of suitable

thickness of plate.

15

Missing Safety catch holder, Retaining catch,

Retaining catch rivet, shoulder rivet, cotter etc

Safety catch holder, Retaining catch, Retaining

catch rivet, shoulder rivet,cotter etc. to be

provided at proper location as per drg noWD-

10068-S-16, S-17,S-18.

16

Door Guard is rubbing with sole bar.

Door Guard(WD-10068-S-17 item-6) to be

welded as per drawing.

Documents

MAINTENANCE INSTRUCTION FOR REPAIR OF … WMI-001...wmiwmi----001000011001- ---bcnhl doorbcnhl doorbcnhl door- ---201720172017 indian railways maintenance instruction for repair of