Maintenance Instruction to Upgrade …

WMI-001-BOXNRHS-UPGRADATION-2020

INDIAN RAILWAYS

Maintenance Instruction to

Upgrade BOXNHS/BOXNHSM1/BOXNR Wagons

to BOXNRHS

For Operation at 100 Kmph

S.No. Month/Year of

issue

Revision/

Amendment

Page No. Reason for

Amendment

01 June 2020 Nil First Issue

Issued By :

Wagon Directorate

Research Designs and Standards Organization

Manak Nagar, Lucknow-226011.


Page 1 of 14

Contents

Preface ..................................................................................................................................................... 2

CONVERSION OF BOXNRHS WAGON .................................................................................................... 3

1.0 Design Data for BOXNRHS Wagon .................................................................................... 3

2.0 Scope of Work: ....................................................................................................................... 7

A. Change in spring group: ................................................................................................... 7

B. Change in Side bearer: ...................................................................................................... 8

C. Change in Friction wedge: ................................................................................................ 9

D. Change in Marking: ......................................................................................................... 10

3.0 Procedure: ............................................................................................................................. 11

4.0 Inspection: ............................................................................................................................. 12

(i) Check sheet for Inspection for Modification Done in BOXNRHS wagon ............... 12

(ii) Check sheet for Inspection of Bogie Parameters of BOXNRHS Wagon ................. 13

5.0 Details of Materials Required for Modifications (Bill of Material): .............................. 14

6.0 Details of Released Materials: ............................................................................................ 14

Annexures:

1. Drawing no WD-12008-S-1

2. Drawing no WX-10046







9. Speed certificate no MW/SPD/BG/BOXNRHS dated 11.09.2019

10. Rly Bd letter no 2020/CEDO/SR/02 dated 30.04.2020


Page 2 of 14

Preface

Presently, there are more than 27 variants of open type freight stocks running all over the

Indian Railways. These wide variations especially in the bogie of these wagons are mainly

due to the fact that these bogies have been evolved with time through various

modifications/improvement made from time to time. Further to meet the increasing demand

of wagon availability and throughput, a necessity was felt to enhance the speed potential and

loading capacity of all wagons.

Therefore, Wagon Directorate of RDSO has undertaken a project to enhance the speed

potential and standardize theses freight stocks.

As such, efforts have been made to develop a common suspension system including side

bearers for the operation of wide variants of wagons.

This particular WMI deals with the guidelines and procedures for the up-gradation of

wagons for operation at high speed. Based on simulation results and detailed oscillation

trials of these wagons, broadly three modifications in bogie suspension arrangement have

been finalized to upgrade the speed of the existing open type wagons:

a. Modifications in the Side Bearer arrangement.

b. Modifications in the Metallic Wedge fitted with CASNUB bogie.

c. Modification in the number of springs of different types in the secondary suspension.

With these modifications, it is now possible to standardize and upgrade the speed of different

variants of open type wagons upto 100kmph in empty and 100 kmph in loaded condition.

These modifications can be planned by POH shops and ROH depots on IR.

This particular WMI covers the detailed work instructions to modify BOXNHS/BOXNHSM1

& BOXNR wagons to BOXNRHS wagons, scope of bill of materials requirements, quality

check and final instructions sheet to be followed by workshops, ROH depots and NTXR

during its third party check.


Page 3 of 14

CONVERSION OF BOXNRHS WAGON

The BOXNHSM1 wagon to RDSO diagram drawing no WD-05084-S-01 is provide with

CASNUB HS bogie and has an axle load of 22.82t. BOXNRHS wagon having 22.9 t axle load

to RDSO diagram drawing no WD-07001-S-02 is rehabilitated version of

BOXNHS/BOXNHSM1 wagon. Only body of these wagons is rehabilitated and the bogie

remains the same. These wagons were earlier not subjected to oscillation trials.

The suspension of BOXNRHS wagon has been modified as per BOXNHSM2 Wagon. The

BOXNRHS wagon to RDSO Diagram drawing no WD-07001-S-02 was subjected to oscillation

trials and the wagon has exhibited satisfactory riding behavior up-to a speed of 110 kmph in

empty and loaded condition at 22.9 t axle load. Final speed certificate of BOXNRHS wagon at

100 kmph in empty condition and 60kmph in loaded condition at 22.9t axle load has been

issued vide letter no MW/SPD/BG/BOXNRHS dated 11.09.2019. Railway board sanction of

the wagon has also been obtained vide Railway Board letter no 2020/CEDO/SR/02 dated 30-

04-2020.

Based on the above it has been decided that the existing BOXNR wagons having CASNUB-

HS bogies and the BOXNHS & BOXNHSM1 wagon which are proposed to be converted into

BOXNRHS wagon to RDSO specification no WD-16-BOXNR-2010 (Rev.-1) are to be modified

with these instructions. The modification work shall be carried out during the POH/ROH of

the wagon. Railway Board will issue a separate RSP for the above conversion.

1.0 Design Data for BOXNRHS Wagon

Major Design parameters of the BOXNRHS wagons are shown below.

1. CODE BOXNRHS Wagon

2 BOGIE CASNUB 22 HS

3 COMMODITY TO BE LOADED Ore, Coal etc.

4 WAGON BODY DIMENSIONS (mm) :

1 Length over headstocks 9784 mm

2 Length over buffers/coupler faces 10713 mm


Page 4 of 14

3 Inside width 2954 mm

4 Inside height 2127 mm

5 Max. height form R.L. 3408 mm

6 Height of coupler from R.L. (empty with new wheels) 1105 mm

7 Distance between bogie centres 6524 mm

5 BOGIE DIMENSIONS (mm)

1 Bogie width 2780 mm

2 Wheel base 2000 mm

3 Lateral spacing (centre to centre) of elastomeric pads 2260 mm

4 Lateral spacing (centre to centre) of secondary springs 2260 mm

5 Lateral spacing (centre to centre) of side bearers 1474 mm

6 Bogie pivot diameters 325 mm (Bottom Pivot)

315 mm (Top Pivot)

6 WHEEL AXLE DETAILS

1 Axle Load (t) 22.9 t.

2 Wheel dia (mm) New 1000 mm

Condemning 906 mm

3 Distance between journal centres (mm) 2260 mm

4 Tyre Profile Worn wheel profile

(WWP) to R.D.S.O

Drg.No.-WD-88021

5 Wheel & Axle Assembly WD-89025-S/1


Page 5 of 14

7 WEIGHT PARTICULARS (T)

1 Tare weight 21.2 t

2 Gross load 91.6 t

3 Weight of the bogie 5.4 t

8 Spring Details Primary Secondary

1 Type - Helical Spring

2 No. per bogie - 30 (14 outer, 12 inner & 4 snubber)

3 No. of spring nest per bogie - 2 Nos.

4 No. of springs in each nest - 07 outer, 06 inner & 02 snubber

5 Stiffness per spring kg/mm - 27.64(outer), 34.66 (inner),

19.79 (snubber)

6 Stiffness per bogie (Tare) - 466 kg/mm

7 Stiffness per bogie (Gross) - 882 kg/mm

8 Helical Springs

Outer Inner Snubber

(i) Free height (mm) 260 243 293

(ii) Effective No. of coils 5.7 9.0 8.5

(iii) Mean coil dia (mm) 115 70 86

(iv) Wire dia (mm) 22 18 18

(v) Solid height (mm) 149.2 181.8 172.8

9 IMPORTANT CLEARANCES

(i) Between Bolster and bogie frame

a) Vertical(Tare)

(Gross)

71.5 mm (approx.)

114 mm (approx.)

b) Lateral 25 mm (12.5 mm on either side)


Page 6 of 14

(ii) Between adapter and side frame

a) Lateral 16 mm (08 mm on either side)

b) Longitudinal 09 mm (4.5 mm on either side)

c) Crown clearance between axle box

and bogie frame

N.A

d) Side bearer clearances Nil

10 DRAWINGS

1 Diagram WD-07001-S-02

2 Marking Diagram WD-20018-S-01

3 Bogie General Arrangement WD-04038-S/2

4 Side Bearer WD-12008-S/1

5 Centre pivot and side bearer arrangement WD-20024-S-2

6 Suspension Springs WD-92058-S/5

7 Friction Wedge Drg No. WX-10046

8 Leading dimensions and tolerances of

CASNUB HS bogie

WD-92058-S/7

9 Bogie Maintenance Manual G-95

Enclosed:

1. The dimensions given in para 9 above, are shop issue dimensions and are not line

dimension.

2. Copy of drawings given in para 10 above are attached with this WMI. Latest version

of the drawings to be followed during upgradation work.

3. Speed certificate of BOXNRHS wagon

4. Railway Board first sanction for operation of BOXNRHS wagon


Page 7 of 14

2.0 Scope of Work:

The existing BOXNR wagons having CASNUB-HS bogies and the BOXNHS & BOXNHSM1

wagon which are proposed to be converted into BOXNRHS wagon to RDSO specification no

WD-16-BOXNR-2010 (Rev.-1) are to be modified with these instructions. These instructions

are over and above the routine maintenance instructions i.e. yard maintenance, sick line

maintenance, ROH & POH. These routine maintenance shall not be postpone or diluted in

any manner.

A. Change in spring group

B. Change in Side bearer

C. Change in friction wedge

D. Change in Marking

a. On wagon Body

b. On bogie

A. Change in spring group:

Details of spring groups being used in BOXNHS, BOXNHSM1, BOXNR and proposed

BOXNRHS are as follows:

S.No Wagon Bogie Suspension group Remarks

outer Inner snubber

01 BOXNHS CASNUB-

22HS

07 06 02

02 BOXNHSM1

& BOXNR

CASNUB-

22HS

07 07 02


Page 8 of 14

Shall be modified to

01 BOXNRHS CASNUB-

22HS

07 06 02

B. Change in Side bearer:

Details of side bearers being used in BOXNHS, BOXNHSM1, BOXNR and proposed

BOXNRHS is given in following table:

S.No Wagon Bogie Side Bearer Remarks

Type Drawing No

01 BOXNHS CASNUB-

22HS

PU CCSB

AAL-021101

02 BOXNHSM1

& BOXNR


01 BOXNRHS CASNUB-

22HS

Spring

Loaded to

Variant ‘B’ of

Spec. WD-62-

Misc.-17

WD-

12008-S/1

For details see Annexure-I


Page 9 of 14

C. Change in Friction wedge:

Details of friction wedge being used in BOXNHS, BOXNHSM1, BOXNR and proposed

BOXNRHS is given in following table:

S.No Wagon Bogie Friction wedge Remarks

Type Drawing

No

01 BOXNHS CASNUB-

22HS

All Cast

metallic

friction

wedge

SK-77579

02 BOXNHSM1

& BOXNR


01 BOXNRHS CASNUB-

22HS

Friction wedge

with NM liner

(CONTR-02-

MISC-2007, Rev 1)

Drawing

no.

WX-

10046

For details see Annexure-

II


Page 10 of 14

D. Change in Marking:

S.No Wagon Bogie Marking diagram Remarks

Existing Proposed

01 BOXNHS CASNUB-HS WD-80007-S-21 -

02 BOXNHSM1 CASNUB-HS WD-07040-S-05 -

03 BOXNRHS CASNUB-HS - WD-20018-S-1 For details see

Annexure-III

a. Marking shall be done as per new marking diagram no. WD-20018-S-1.

b. Wagon no will remain the same as on existing wagon.

c. The existing transportation code i.e. “ BOXNHS/BOXNHSM1” to be replaced

with New transportation code “BOXNRHS”. The existing BOXNR wagons

with CASNUB-HS bogies will also change to “BOXNRHS” after the

modifications.

d. An additional Zebra strip on each side wall as indicated in marking diagram to

be painted to distinguish the high speed modified wagon with other wagons.

Specification of paint to be used for Zebra marking is given in marking

diagram no. WD-20018-S-1.

e. As the bogies are rolled out during ROH/POH, a special Zebra marking on

each bogie side frame to be painted to ensure fitment of modified bogie in

BOXNRHS wagon. Details and location of marking on bogie are given in

marking diagram no. WD-20018-S-1.

f. Revised colour scheme as detailed in marking diagram shall be ensured.

g. Location of RFID tag to be verified with marking drawing.


Page 11 of 14

3.0 Procedure:

a. Place the wagon on Level Track.

b. Measure the Side Bearer Set up height of all the four locations and record.

c. Disconnect brake gear, remove split pin, lock pin and shackle lock etc. of bogie

and lift the wagon body with the help of EOT Crane.

d. Run out the bogies.

e. Lower the car body on the trestles.

f. Lift the bolster and make each spring group of 7 (outer), 6 (inner) and 2 (snubber)

as shown in para 1 (A) of this WMI.

g. Free height of springs in each bogie should be as per para 5.6 of G-95.

h. Remove all old All Cast metallic friction wedge (Drg No- SK-75579) and replace

with new Metallic friction wedge with liner (As per envelope Drg no WX-10046)

to RDSO spec. CONTR-02-MISC-2007 (Rev-1) as shown in para 1(C) of this WMI.

i. Remove P.U. / Metal bonded rubber type side bearer and replace it with variant

‘B’ to RDSO spec. no. WD-62-Misc-17 (drawing no. WD-12008-S-1) as shown in

para 1(B) of this WMI.

j. Remove/Insert shims of suitable size at the body bolster (underframe) at side

bearer locations to achieve proper CCSB assembled height as shown in Centre

pivot side bearer drawing no WD-20024-S-2 .

k. Lower the wagon on the bogies.

l. Check CCSB assembled height at all four locations. Correct, if required, by

inserting/removing shims.

m. Provide split pin, lock pin and shackle lock etc. and fit the brake gear

n. Paint the wagon as per new painting scheme as given in marking diagram no WD-

20018-S-1.


Page 12 of 14

o. Change the marking particulars and provide Zebra strips on both side walls as

well as bogie side frames of the wagon as detailed in para 1(D).

4.0 Inspection:

Wagon shall be inspected after carrying out the modification as per check sheet before

offering to NTXR/ Third party inspector (As per contract requirement)

(i) Check sheet for Inspection for Modification Done in BOXNRHS wagon

S.NO Description Parameter Remark

01 Bogie type CASNUB 22 HS

02 Side bearer Variant ‘B’ (Drg. No.-WD-12008-S/1)

to RDSO Specification no WD-62-

MISC-17

03 Side bearer

setup height

As per Centre pivot side bearer

drawing no WD-20024-S-2 i.e.

128.5±1 mm

04 Friction wedge Friction wedge with Liner to RDSO

Specification no CONTR-02-MISC-

2007 (Rev-1) & Drg no WX-10046

05 Suspension

(Each Group)

Outer spring- 07

Inner spring-06

Snubber spring-02

06 Marking WD-20018-S-01

Wagon Code- BOXNRHS


Page 13 of 14

(ii) Check sheet for Inspection of Bogie Parameters of BOXNRHS Wagon

S.NO Description Required Value Measured

Value

01 Visual inspection of all components for

correctness

No visible defect

02 DPT of side frame and bolster at

critical locations

No crack

03 Trammeling of bogie WD-92058-S-7

04 Lateral Clearances b/w adapter and s/f

jaw

16+6

−1.5 mm (Total)

(8+3

−0.75 mm on either

side)

05 Longitudinal Clearances b/w adapter

and s/f jaw

9+2

−3 mm (Total)

(4.5+1

−1.5 mm on

either side)

06 Lateral clearance between side frame

and bolster

25 ± 3 mm (Total)

(12.5 ± 1.5 mm on

either side)

07 UST of Axles if required as per existing

procedures

No surface and

internal crack


Page 14 of 14

5.0 Details of Materials Required for Modifications (Bill of Material):

Following material is required for the above conversion:

S.No Item

Name

Specification Drawing

No

Quantity

per Bogie

Sources

01 Side bearer RDSO Specification no

WD-62-MISC-17

WD-12008-

S/1

02 Nos Provided in

Vendor

Directory

02 Wedge RDSO Specification no

CONTR-02-MISC-2007

Drg no

WX-10046

04 Nos Provided in

Vendor

Directory

6.0 Details of Released Materials:

Exiting Wagon Item ( Removed

from the existing

Wagon)

No

Per

Bogie

Drawing No Remark

BOXNHS

(CC-20.32t)

BOXNHSM1

(CC+6+2)

BOXNHSM1

(CC+8+2)

Outer Spring Nil WD-92058-S/5 Nil

Inner Spring Nil WD-92058-S/5 Nil

Friction

Wedge(FW)

4 SK-77579 Can be used as spare for other

Wagons

Side Bearer

(CCSB)

2 AAL-021101 Can be used as spare for other

Wagons

BOXNHSM1

(CC+2+6)

BOXNHSM1

(CC+8+2)

BOXNR

22.9 T

Outer Spring 2 WD-92058-S/5 Can be used as spare for other

Wagons

Inner Spring Nil WD-92058-S/5 Can be used as spare for other

Wagons

Friction

Wedge(FW)

4 SK-77579 Can be used as spare for other

Wagons

Side Bearer

(CCSB)

2 AAL-021101 Can be used as spare for other

Wagons

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Fax No. 0522-2453916

No. MWSPD/BG/BOXNRHS

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Subl Final speed certificate of Broad Gauge Bogie Open wagon type'BOXNRHS'with maximum axle load of 22.9tfor operation over IndianRailway B.G route.

Broad Gauge Bogie Open Wagon type BOXNRHS to RDSO drawing No.WD-07001-S-02 Alt.-11 with maximum axle load of 22.91is BOXNR wagonfitted with Casnub 22HS bogies. BOXNR wagon (rehabilitated BOXNwagon) was fitted with Casnub 22HS/NLB bogies. To differentiate, theBOXNR wagons fitted with Casnub 22HS bogies are named as BOXNRHSwhile the other wagons fitted with Casnub 22NLB bogies are named asBOXNR wagons with the approval of the Railway Board vide their letter No.201 0/M(N) 1951 123 dated 1 0-05-201 9.

BOXNRHS wagons are being used for transportation of coal, ore etc.BOXNRHS wagons are fitted with Casnub 22HS bogies, high tensile (nontransition) centre buffer coupler, high capacity draft gear and graduatedrelease air brake system. The design parameters and salient features of22.9t axle load BOXNRHS wagon have been shown in RDSO Drg. No.WD-07001-S-02 Alt.-11 & Annexure-|. '

1.0

MW/SPDi BG/BOXNRHS Page 1 of 9

1'1 In order to assess the riding quality and stability behaviour of ,BoXNRHS,wagon (BOXNR fitted with casnu'b 2zHS bogies) in empty and toadedcondition, detailed oscillation trials have oeen conoucted over Mahoba(MBA) - Khajuraho (K-URJ) section of North centrat Raitway. The results ofthe trial are given in RDSo Report no. nosoy2olgtrc/Mr-1612lF Rev.-OAmendment -Nil dated 29-05-201g osciltition triat results indicate that'BOXNRHS, wagon has exhibiteO satistactoiy n sup to a,test speed of 110 kmph in erpty dlocations/stretches as per current revisions of eCriteria Committee', on track maintained to aStandard.

2'0 Based on the design features and details given in Annexure-l andsatisfactory test resurts as indicated i; RDSO n.port no.RDSo/2019/TG/MT-16121F Rev.-0 nmendment -Nit dated 2g-os-2019 andabove, it is certified that 'BoxNRHS'wagon hiving maximum axle toad of22.9tro RDSO Drg. No. wD-07001-s-02 Art.-r i may be permitted to run upto maximum permissibre sp,eed of 100 kmph in empty and 60 kmphloaded condition, subject toirre foilowing .onJitionr,

2.1 Track

2.1.1(i) For roaded condition- Maximum speed up to 60 kmph

The track shail be to a minimum standard of 52Kg (90 urs) rair raid onPSC sleeper with 1540 Nos./Km on 30omm ballast cushion betow the

:i.r.ff; -hich may consist of 150mm crean and the rest in caked up

(ii) For Empty condition-

Maximum speed up to 100 kmphThe track shail be to a minimum standard of 52Kg (g0 urs) rair raid onPSC sleeper with 1540 Nos./Km on 250mm baltast cushion below the

:ix.ff:: which mav consist of 1o0mm crean and the rest in caked up

Maximum speed up to 60 kmphThe track shail be to a minimum standard of 5 Kg (72 UTS) rair raid onPSC sleeper with 1540 Nos./Km on 250mm tallast cushion below the

:i?tffi which mav consist of 100mm crein and the rest in .rt.o ,p

2'1'2 For track maintained to lower standard than that mentioned above, theChief Engineer shall decide the lower maximum permissible speed on thebasis of maintenance condition. In this connection, Railway Board,s letterdated 19120-10-1966 may be seen. when the chief

that the road be.d is not compacted or there is irprop.,suitabry restrict the maximum permissibre speeddepending upon the local conditions.

MW/SPD/BG/BOXN RHSPage 2 of 9

2.1.3 The welds shall be protected by joggled fish plates as per provisions ofPara 6.4 and Para 8.14 of USFD Manual and Para 6.3 of AT weldingmanual and other policy instructions of Railway Board. The maintenance ofRails and Rail joints shall be ensured as per Para 250 & 251 of IRPWM. In

addition, wherever condition warrants on account of corrosion on rail/weldcollar, wear on rail, cupping of welds etc., necessary precautions shall betaken for fish plating/joggled fish plating.

2.1.4 Zonal Railway shall insure further detailed examination of track as deemedfit, based on the age cum condition, overdue renewal and condition offormation etc. as per provisions of Chapter-lll of IRPWM-2004 regardingpermanent way renewals.

2.1.5 The maximum permissible speed on curves shall be decided on the basis ofthe existing provision of Indian Railway Permanent Way Manual Reprint-2004.

2.2 Bridges

2.2.1 The clearance refers to Bridges "Standard Spans" with standard design ofgirders, slabs, pipe culverts, piers and abutments etc. issued by RDSO forBGML, RBG and MBG-1987 Standard loadings. However, the bearings ofspan 76.2m (clear) designed for BGML standard loading as per RDSO'sdrawing No. BA-11154 shall be strengthened by providing two additionalanchor bolts.

2.2.2 Superstructure & Bearings of "Special Spans' (designed and constructedby Zonal Railways based on site requirements) including all arches andsubstructure of all bridges (all Standard Spans & Special Spans) are to beexamined under the directions of the Chief Bridge Engineer concerned andcertified safe with respect to current Indian Railway Standard Codes withup to-date correction slips.

2.2.3 Other specific restrictions are applicable which are indicated in relevantSpeed Certificates of hauling single/multiple locomotives issued by RDSO.

2.2.4 This clearance is subject to the following parameters of 'BOXNRHS'

wag0n.

. Maximum axle load (empty)

. Maximum axle load (Loaded)- 5.3 1

- 22.9 t. Maximum braking force at Rail level per axle - 10 % of axle load. Maximum C.G height from Rail level (Empty) - 1027 mm. Maximum C.G height from Rail level (Loaded) - 2062 mm

2.2.4.1 For regular operation in empty condition, when bridges will be fully loadedby wagons following restriction shall be applicable:-

(i) In empty condition, there are no speed restrictions on bridges ofBGML/RBG/MBG Loading Standards for proposed speed of 100 kmph.

MW/SPD/BG/BOXN RHS Page 3 of 9

2.2.4.2

(i)

(ii)

(iii)

2.2.5

2.2.6

2.2.7

2.3

2.3.1

2.3.2

2.3.3

For regular operation in loaded condition, when bridges will be fully loadedby wagons, following restrictions shall be applicable:-

All standard spans up to 47.25m(a| effective) of BGML/MBG LoadingStandards shall be restricted to 75 kmph.

standard spans of 63.0m & 78.8m (both effective) of BGML/MBG LoadingStandards shall be restricted to 60 kmph.

All standard spans up to 31.9m (alt effective) of RBG Loading standardsshall be restricted to 75 kmph and span 47.25m (effective) is iestricted to70 kmph.

Standard spans up to 63.0m (effective) of RBG Loading standards shall berestricted to 60 kmph and span 7g,gm (effective) is restiicted to 55 kmph.

Track on bridges and approaches of BGML span 7g.gm (effective) shail bestrengthened or modified in such a way so as to allow for dispersion oflongitudinal force as per clause 2.8.3.2 of IRS Bridge Rules. In cases wheredispersion can not be allowed as per clause 2.9.3.2 such as due toprovision of sEJ in bridges etc., the bridge superstructure includingbearings and sub-structure shall be checked for longitudinal force withoutdispersion and certified safe by the chief Bridge Engineer concerned.

Location of bridges on which speed restrictions are imposed shall benotified by the Zonal Railways and incorporated in the working timetable sothat all operating staff is aware of the instructions

The above clause have been arrived considering bridges are in physicallysound condition. In case the bridges are not in satisfactory physicalcondition, necessary speed restriction to be imposed by concern chiefBridge Engineer of the Zonal Railway.

The directives of RDSO for operation of cc+g+21, axle load 22.g2tcommunicated vide RDSO letter no. CBS/Golden/Q/Strength dated 21/27-07-2009 shall also be followed.

Signalling

Provisions of GR, sR, sEM & all extant instructions issued from time totime shall be complied with.

While running through a station, speed of the train shall be restricted to themaximum permissible speed as per standard of interlocking provided at thestation.

on the sections where EBD of more than 1 km is to be catered for, seconddistant signal or automatic signalling shall be available failing which suitablespeed restrictions is to be imposed.

(v)

(v)

MW/SPD/BG/BOXNRHS Page 4 of 9

2.3.4

2.3.5

2.3.6

2.3.7

2.3.8

2.3.9

ln the normal single phase 25KV AC electrified section where electriclocomotive is used, provision given in Para 22.6,22.7,22.8,22.9 & 22.10 ofSEM Pt.ll regarding maximum permissible length of track circuits, signal

feed, maximum permissible length for operation of point motor, use of block

instruments and use of track circuits such as DC Track circuit/AFTC shall

be complied by the Railway.

All level crossing gates within station limit shall be manned and interlocked

with station signals. All manned level crossing gates outside station limit

shall be interlocked depending on the classification of the level crossing.

Suitable communication shall be provided in the locomotive and guards van

for communication between loco pilot, guard and adjacent station master.

It is necessary to provide meansiarrangements to put back the home signal

and last stop signal to its "ON" position immediately after passage of the

train.

The condonation regarding infringements in schedule of dimensions, if any,

shall be obtained in accordance with local conditions, before initiating theoperation.

Precaution for Automatic signalling system working:

For running through the train at a station, the last stop signal shall not betaken "OFF" at the station unless:

The sections up to the station in advance is clear, and

At the station in advance, the route of the train is clear, correctly set andlocked for reception of train.

All manned level crossing gates in a stretch of block sections referred toabove are closed to road traffic and locked.

a)

b)

c)

2.3.10 Precautions for Absolute block system working:

For running through the train at a station, the signals shall not be taken'OFF' at the station unless:

a) The section up to the station in advance is clear and the station in advancehas confirmed that it has obtained permission to approach from the nextstation.

b) At the station in advance, the route for the run through of the train via main, line is clear, correctly set and locked.

c) All manned level crossing gates in a stretch of two block sections referredto above are closed to road traffic and locked.


2.4 Roiling Stock

2'4'1 Before initiating the operation, PCME of the concerned onal Railway shallarrange to certify the track wort'tiness and safety of th rolling stocks. Heshall also ensure the proper maintenance of the rolling stock.

2'4'2 Brakes of the rake of the wagons shall be in good working order during theoperation

2.5 Traction Installation

2'5'1 In 25 kV AC traction area, the CEE of the Railway shall have to ensure thatheight of Co clearances as stipulatedo! Chapte Traction ,,schedule

off 1676mm G ,with latest Addendum &Slips is not owed to ensure its safe

running.

2'5.2 al En Concerestri basisional he fiel

n.

2'5'3 When the Wagon is being moved, it shall be ensured that all the protrudingparts are withdrawn and suitably locked, so that during the run there is nopossibility of any infringement occurring to the standard movingdimensions.

2.6 General

2'6'1 All the permanent and temporary speed restrictions inforce and those thatmay be imposed from time to time due to track, bridges, curves, signalingand interl.ocking etc shall be obse ved.

2'6'2 For movement of wagon on any private or assisted siding for loading orunloading tl9 consignments, the Chief Engineer of colncerned ZonalRailway shall be referred to.

2'6'3 The profile of 'BOXNRHS' wagon does not infringe to clauses of Chapter lV(A) of Indian Railway Schedulb of Dimensions B.G revised 2004.

2'6'4 The heap of loading shall not exceed the diagram No. 1D of Indian RailwaySchedule of Dimensions BG Revised, 2004.

2'6'5 USFD testing shall be carried out at a frequency, one grade higher than thespecified frequency in the USFD manual. On dection with Gl\ll'T more than60' the existing stipulated frequency of once in one and a half month as per, USFD Manual may be continued.

MWSPD/BGIBOXN RHS Page 5 of 9

gdr{tD: (i) Drg. No. WD-07001-S-02 Alt.-11(ii) Annexure-l -Salient Features of 'BOXNRHS'(iii) Annexure-ll (List of referred documents)-in a pact Disc enclosed.

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Annexure-l

Principle dimension of RollingStock

(Diagram drawing ne. yyp-[J[g(€{2Art.-11). Length over Couplers/Buffers = 10713 mm. Bogie centre distance = 6524 mm

' Wheel Base = 2000 mm' Axle load (loaded) = 22.g t. Axle load (Empty) = 5.3 t

Details of Bogie and wfreel

having 14 outer, 12 inner and 04snubber springs.. 1000 mm diameter wheels set toDrg.no. WD-8902S-S-01 and

fication no. R-19/93 pt-1.

. Casnub 22HS04038-5-02 w

Details of Brake system Underframe mounted CTaOuEGO ReleaseAir Brake system to RDSO SpecificationNo. 02 ABR-02

Details of Coupler and buffer . EIF NT-Coupler to RDSO SpecficationNo. WD-708D-10

O Specification1BD-15.

schedules and standards(safety limits) to be foilowedin respect of safety items.

Periodic maintenance . Bogie maintenance manuEl no. G€5. For wheel &axle ref. para2.g ofchapter-2 of tRCA part-ilt additition_1973. Air Brake Maintenance Manual no.G-97.. Coupler Maintenance Manual no. G_76(for Workshop staff). Coupler Maintenance Manual no.G-80(for Line sta

MWSPD/BG/BOXNRHSPage 8 of 9

Annexure-ll

(List of documents referred in speed certificate ot 22.9t BOXNRHS wagon. Thecopy of these documents available in the CD enclosed with the speed

certificate)(i) RDSO Drg WD-04038-S-02 for Bogie General Arrangement(ii) RDSO Drg.no WD-07001-S-02 Wagon Diagram(iii) Wheel Spec. no. R-19/93 Pt.1(iv) Para 2.8 of chapter 2 of IRCA Part lll | 1973(v) Air Brake Spec. No. 02-ABR-02(vi) Air Brake Maintenance Manual No. G-97(vii) EIF NT.CBC Spec. No. WD-708D-10(viii) E/F NT.CBC Spec. No. Instruction & Maintenance Manual of CBC.

(a) G-80 (For workshop staff;(b) G-76 (For line staffl)

(ix) Draft Gear Spec. No. 49-BD-08/ WD-718D-15(x) Bogie Maintenance Manual No. G-95(xi) Railway Board's letter No.65A/VDO/SR/26 dated 19120.10.1966(xii) Indian Railways Permanent Way Manual reprint-2004(xiii) USFD manual, Revised 2012(xiv) Maximum moving profile of 1D (EDOIT-2202)oI IRSOD, revised 2004.(xv) RDSO Report no. RDSO/2019/TG/MT-16121F Rev.-0 Amendment -Nil

dated 29-05-2019(xvi) Railway Board's letter No 2010/M(N)951123 dated 10.05.2019(xvii) RDSO letter no. CBS/Golden/Q/Strength dated 21127-07-2009


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