Para of uploaded draft spec M/s Knorr-Bremse M/s Escorts M ......Para of uploaded draft spec M/s Knorr-Bremse M/s Escorts M/s FTRTIL JWL-DAKO RDSO Remarks Page 1 of 21 4.2 The supplier

REASONED DOCUMENT ON DRAFT RDSO SPECIFICATION NO.RDSO/CG-18003 FOR AXLE MOUNTED BRAKE SYSTEM WITH EP ASSIST FEATURES FOR 200 KMPH

Para of uploaded draft spec M/s Knorr-Bremse M/s Escorts M/s FTRTIL JWL-DAKO RDSO Remarks

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4.2 The supplier should submit the performance details for the last three years from the user railways for axle mounted brake system with EP Assist feature along with the offer.

This clause should be rewritten as "The supplier should submit the performance details for the last three years from the user railways for axle mounted brake system along with the offer."

User railways do not give performance details of EP Assist feature / system. Hence, this clause may be revised as “The supplier or its principals should submit reference list of supplies of EP Assist system for minimum last three years for coaches along with the offer".

Comments of M/s FT may be accepted and Para may modified as: “The supplier or its principals should submit the performance details (preferably) for the last three years from the user railways, if the same is not providing by them firm must have to submit reference list of supplies for axle mounted brake system with EP Assist feature along with the offer” Comments of M/s Escorts is not acceptable

5.1 For brake system supplied by the contractor, in case of any part of the brake system failing or proving unsatisfactory in service due to defective design, material or workmanship, within 36 months from the date of delivery or 24 months from the date of placing in service whichever is earlier, shall be replaced by the contractor at his own expense. Further, should any design modification be made in any part of the equipment offered, the period of 24 months would commence when the modified part is commissioned in service.

Noted. However the extended warranty shall be only for the modified part/sub assembly but not for the complete brake system.

Comments acceptable and No change needed, as the requirement mentioned is self-explanatory.

5.2 For Distributor valve, the warranty / guarantee period will be 60 months from the date of supply or 48 months from the date of commissioning whichever is earlier for the distributor valve with relay valve. In case a distributor valve with relay valve fails within the warranty, it shall be replaced

Specification calls for "For Distributor valve, the warranty/guarantee period will be 60 months from the date of supply or 48 months from the date of commissioning whichever is earlier for

Not acceptable. Please refer Para 9.0 of C-K209 “The warranty / guarantee period will be 60 months from the date of supply or 48 months from the date of commissioning whichever is earlier for the distributor valve with relay valve. In case a distributor



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by a new distributor valve.

the distributor valve with relay valve with maintenance / overhaul schedule as suggested by OEM (once in 3 Years). For Indian environmental conditions, the overhauling of brake system shall be once in three years as given in our maintenance manual. Please also note this is not applicable for wear parts.

valve with relay valve fails within the warranty, it shall be replaced by a new distributor valve.”

6.1 The offer shall include recommended list of spare parts required for day-to-day maintenance of the brake equipment and spares in the form of kit for the various sub-assemblies for the maintenance at the time of POH. The list shall include the part number, quantity required and price of each component. Spare parts should be procured from OEM only.

As price of each component will vary from time to time, we can provide Spare Part Kit price alone.


7.1 Firm may be required to send his technical expert during the installation and commissioning of their equipment on coach/coaches.

Tender requirement may call for different conditions. Hence, technical expert for Installation and commissioning will be made available depending on the tender condition. The clause may please be added at the end "

Comments of M/s FT may be accepted and Para may modified as: “…..equipment on coach/coaches, as per the consignee requirement”.



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....depending on the tender condition.”

9.0 Scope of supply of Axle mounted Disc brake system with EP assist feature for Alstom-LHB design AC Chair Car (EOG) Coaches fitted with FIAT bogies for operation at 200kmph shall cover the following equipment’s. It is the prerogative of purchaser to procure the system as complete set or in part:

The statement "$ DV with relay valve should have provision of external arrangement for BC pressure adjustment (as per UIC)" should be removed as provision for BC pressure adjustment externally could lead to tampering of set pressure which could further lead to unsafe situation.

For better performance of the system, we strongly recommend the above clause to be changed as ".....the procurement should be done as complete set and not in part". This is also to avoid any performance related issue at system level when using one supplier individual assembly with another supplier assembly.

Comments of M/s Escorts is not acceptable as the existing specification for Axle Mounted Disc Brake system for LHB Coaches i.e. RDSO/2011/CG-04 (Rev.1 with Amendment 1) also have this provision. Comments of M/s FTRTIL is not acceptable as it’s a general term using in all RDSO specifications. No change needed

9.1 & 9.2 • Cables for connecting middle junction

to brake test boxes • Cables for connecting middle junction

to EP assist magnet valves

Cables for connecting middle junction box to brake test boxes & middle junction box to EP assist magnet valves have not been defined by UIC. Balance items for EP Assist are defined by UIC 541-5.

Noted and Para modified accordingly.

9.1.11 & 9.2.12 Scope of supply for EP Assist equipments shows “End Junction box to power socket” under Cables for connecting.

End junction box to Power socket is not required, because power supply to the system shall come from loco system. Request to remove "End Junction box to power socket"

Comments acceptable and Para modified accordingly.

9.1 & 9.2 $DV with relay valve should have provision of external arrangement for BC pressure adjustment (as per UIC).

The statement "$ DV with relay valve should have provision of external arrangement for BC pressure adjustment (as per UIC)" should be removed as provision

UIC 540-0, Maximum Brake cylinder pressure by Distributor valve is fixed to 3.8 ± 0.1 bar &doesn't call for BC pressure adjustment etc. As this is IR requirement, request to

Comments of M/s FT may be accepted and Para may modified as: “……BC pressure adjustment (as per IR requirement)” Comments of M/s Escorts is not acceptable



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for BC pressure adjustment externally could lead to tampering of set pressure which could further lead to unsafe situation.

remove "as per UIC".

9.3 The supplier should submit their Distributor Valve used in offered particular axle mounted disc brake system with EP Assist feature for testing in RDSO as per tests mentioned in RDSO specification no. C-K209.

Noted. The EP Assist functionality of DV has not been defined in C-K209. However this is not applicable in our case as our DV with EP assist feature is already working satisfactorily in Tejas rakes, running in the field.

Comments not acceptable. However, decision on the same matter lie within purview of RDSO. No change needed.

10.2 Twin pipe air brake system is provided on IR coaches conforming to specification to 02-ABR-02. A typical piping layout and brake equipment is shown in sketch 85155 Alt.1. Contractor shall confirm suitability of disc brake equipment offered by him for use with this layout.

Noted. In LHB coaches, OD control pipes are used, which are covered by 02-ABR/04-ABR.

The Para is about air brake system not about air brake piping. No change needed.

10.3 The brake equipment shall give a satisfactory maintenance free service (with prescribed OEM’s maintenance schedule) for a period of minimum six years from the date of commission or date of place in service, whichever is later. .

Noted. Clause may be corrected as “The brake equipment shall give a satisfactory trouble free service (with prescribed OEM's maintenance schedule) for a period of minimum six years from the date of commission or date of place in service, whichever is later."

Comments of M/s KB may be accepted and Para may modified as: “The brake equipment shall give a satisfactory trouble free service ….”

10.4 It shall be possible to obtain braking distance not to be more than 1600 meter with axle mounted disc brake on coaches in any of the configurations case at a speed of 200kmph on a straight and level track with loco brakes

Noted. The brake calculations show that braking distance will be less than 1600 meter with EP Assist. However the locomotive should also be equipped with EP Assist Control equipment to operate the EP Assist

Comments acceptable and No change needed.



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in operating condition. equipment on coaches. 10.9 The particular offered new axle mounted disc brake system with EP Assist feature would have to ascertain it’s performance by means of field trial in Indian Railway service condition as per relevant Para 17.0.

Noted. This should be applicable for new entrants. Our EP Assist brake system was tested by RDSO in 2014 in 21 LHB coach rake configuration.

Not acceptable. No change needed

11.4 The axle mounted disc brake system with EP Assist feature shall be of proven design, which has worked successfully in India or International Railway Passenger trains in similar operating conditions. Copies of UIC approval wherever applicable shall be submitted by the firm along with the offer.

Noted. This should be applicable for new entrants. Our EP Assist brake system was tested by RDSO in 2014 in 21 LHB coach rake configuration.

The clause should be rewritten as “The axle mounted disc brake system shall be of proven design, which has worked successfully in India or International Railway Passenger trains in similar operating conditions. Copies of UIC approval wherever applicable shall be submitted by the firm along with the offer."

Comments of M/s KBIL not acceptable. However, decision on the same matter lie within purview of RDSO. Comments of M/s Escorts not acceptable as the subject brake system is highly sophisticated & critical item. No change needed.

11.6 Each Power Car/SLR shall be provided with Flex Ball type parking brakes system which should brake at least one bogie (minimum two axle) having accommodation in Guard’s compartment. Parking Brake system shall be latest Proven Design and shall be capable of holding train on steepest and longest down gradient as indicated in Annexure – I, when applied from two Power Car’s/SLR’s. Firm shall submit detailed calculation in this regard.

Noted. Our offered parking brake system is common with existing LHB (Power Car).

Comments acceptable and No change needed, as the requirement mentioned is self-explanatory & universal for all manufacturers.

11.8 Broad dimension & location of sub-equipment of brake panel of LHB

Noted. In order to accommodate the EPZ valve on DV (responsible for EP

Request this clause be implemented only after existing LHB coach

The same may taken as separate project however, it is advised that the Brake Panel should be in line



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Mainline Coaches shall conform to RDSO drawing no.CG-18088.

Assist braking), additional space is required on panel in addition to re-location of Test Fittings and check valves.

Standardization of Brake panel. Hence, this clause be mentioned for reference.

with this drawing, as much as possible. Para is modified accordingly.

12.8 The complete set of drawings in A1/A2 size for each item of particular disc brake equipment which shall contain details regarding material, specification, dimensions, estimated weight, testing parameters, reference to manufacturing/original collaborator’s drawing etc. so as to examine the coach/brake equipment interface.

Noted. Some of the information is proprietary in nature. Hence, they cannot be shared. However, the same can be viewed at our works by authorized RDSO officials if so desired.

Noted and accepted. However, broader details must be covered up in drawing. Para is modified accordingly.

12.16 Thermal calculations of the steel disc with sintered pads at 160kmph, 180kmph, 200kmph and 220kmph.

Noted. Thermal Calculations are done for a max. operating speed of 200kmph.

Comments not acceptable and No change needed, as the designed value is always taken on higher side then the operating one.

13.3 The firm shall submit separate drawings in A1/A2 size for each of the item of brake system containing the necessary details/dimensions as specified. Each drawing shall show sufficiently sectioned view of the particular equipment so that every component of the equipment is identified.

Noted. Only the “General Agreement” shall be submitted for approval.

OGA (Overall General Assembly) Drawings will not contain section views, however drawing will show Adequate dimensions required for installation etc. Hence request to remove section view.

Comments acceptable. Para may modified as: “….Each drawing shall show sufficient dimensions required for installation etc. of the particular equipment so that every component of the equipment is identified”.

13.4 Generic material grade/ specifications for brake system & its associated equipment’s shall be indicated on the relevant OGA drawings of the firm and the firm shall supply copies of translation in English of such specifications/drawings other than Indian Standard Specifications to purchaser/RDSO.

Since material grade and specification is intellectual property of the manufacturer, it may not be possible to indicate in the drawing. However, it will

Noted and accepted. However, broader details must be covered up in drawing.



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be shown to the inspected during inspection. List of generic material will be provided.

13.6 Further changes/modifications in the disc brake equipment may be called for with a view to achieve standardization and interchangeability. Firm shall be obliged to incorporate necessary changes in the design of his equipment for this purpose.

Agreed but requirement to realizable for manufacturer.

Noted and accepted. No change needed

14.3 All parts of brake system shall be given suitable anti-corrosive treatment and painted with two coats of paints with colors as specified by IR before supply (if required).

Friction disc is not coated. However rust prevention oil will be applied over disc for storage purpose. Clause to be changed accordingly.

Comments of M/s FT may be acceptable however; it is to be ensured by the firm that the rust prevention oil providing on disc may not have any safety issue.

17.1

The offered axle mounted disc brake system with EP Assist feature (Internationally approved) shall undergo field trial separately on minimum 18 LHB Mainline Coaches (Preferably in a rake) to check their performance on Indian Railway service conditions for a period of minimum 18 months. The field trials shall be monitored by RDSO or its authorized representative. RDSO at their discretion may increase the trial period.

For supplier who’s offered brake system is internationally approved

The disc brake equipment’s shall be subjected to field trial separately on

For other new Supplier/Manufacturer

Instead of 18 coaches, field trial should be conducted on 16 coaches as in Annexure-I, clause no. 2.1.3, max configuration is 16 nos.

Comments of M/s Escorts is acceptable and Para may modified as: “…..on minimum 16 LHB Mainline Coaches (Preferably in a rake)”



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minimum 18 LHB Mainline Coaches (Preferably in a rake) to check their performance on Indian Railway service conditions for a period of minimum 24 months. The field trials shall be monitored by RDSO or its authorized representative. RDSO at their discretion may increase the trial period.

APPENDIX- A 2.2(iii) Aluminum Distributor Valve (suitably provided with magnet valves for Application and Release during EP Assist operation)

"As per Appendix-A1 of UIC 540" - should not be applicable for the firms who are regular supplier of Distributor valve to IR and hence remarks under 2.2-III should be removed.

DV DAKO CV1nD body is from cast iron.

Para modified accordingly.

(iv) Control Reservoir 6ltr. DV DAKO CV1nD needs for its operation 9ltr. Control reservoir.

M/s DAKO comments are acceptable, Para modified accordingly.

2.2 (xii) Pressure switch with mounting assembly (in FP line) (xiii)Auxiliary reservoir – 125ltr. with drain cock (for brake system).

S.No.12 to be deleted. S.No.13 to be updated as "Pressure Switch with mounting assembly on panel(in FP line)”

Comments may be acceptable. Para may modify as: “….mounting assembly on panel (in FP line)”

2.5 The brake container module shall be protected against track stone hitting, dust, rain and salt-water influences.

Dust, rain & salt water influences to be deleted.

Comments may be acceptable. “…dust, rain and salt-water influences” is deleted

2.7 The distributor valve (DV) shall be mounted on the panel through intermediate piece in such a way that it will be possible to replace one type of distributor with another without any difficulty. For this purpose, a DV mounting face similar to the common

Interchangeability of DV's is not possible due to difference in design of EP Assist magnet valve, its connector and its location on DV.

"FT meets the interface mounting as given in RCF Drawing No MI001696 alt-nil, Distributor valve Interference with other makes with surrounding parts has to be

LHB brake system must be a complete assembly and must not be compromised for any component

Para is deleted.



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pipe bracket will have to be provided on the panel. RCF Drawing No. MI001696 alt-nil shall be referred for port holes location on front face of brake control panel and distributor valve. DV isolating cock shall form part of the DV or intermediate piece and shall not be separately mounted on DV.

ascertained by other brake supplier".

interchanged. Distributor valve interchangeability is impossible.

2.11 Test points shall be provided on the brake control panel to measure pressures of brake cylinder, control reservoir, feed pipe and brake pipe.

Test points provided to measure BC, FP, CR & BP.


2.13 The cradle shall be made of stainless steel to AISI 304 with wire-mesh of stainless steel at the bottom. All the critical Isolating cocks at front location in the control panel shall be covered with Stainless Steel (wire-mesh to grade AISI 304) with sliding/hinge door arrangements to prevent their operation by unauthorized persons.

Wire mesh door to be corrected as "sliding door/hinged door".


3.1 All piping of underframe to Brake Control Panel & Air suspension control panel shall be of ferrule type (from reputed sources only like M/s Ermeto-Parker-Germany, M/s Voss-Germay, M/s Waltershield-Germany, M/s Volze Gruppe GmbH & M/s Blange Armaturen-GmbH-Blago).

Please specify the ferrule type as single ferrule tvpe. Imported sources should be made as reference only as currently we are sourcing from local suppliers.

As a part of Make in India program, we do not recommend to import such ferrule fittings which are not technologically challenged. Faiveley Transport procures this type of ferrule fittings from local supplier and used in Indian Railways for many years without any issues from field and hence specific supplier names should be removed.

Para is modified accordingly.



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3.4 If the components included in the scope of delivery of the brake supplier are to be connected with the brake pipes of the car body and/or the bogie, they are to be suitable for ferrule type connections.

Please specify the ferrule type as single ferrule tvpe.

Please refer remarks at Para 3.1.

4.2 Equipment to be supplied shall be free from injurious defects that may impair their strength. The firm shall also ensure that all items are adequately treated and painted (excluding flange faces) to prevent corrosion.

Material and frame of fittings is S.S 304, hence paint not required.

Noted and accepted. No change needed

4.3 All parts of Brake Container Module shall be given suitable anti-corrosive treatment if required, painted with two coats of paints with colors as specified by IR before supply. The surface of light alloy castings shall be anodized.

Statement “The surface of light alloy casting shall be anodized”- To be deleted; as it is already mentioned that suitable anti-corrosion treatment is to be provided.

Noted. However, the mentioned requirement provides better clarity. Hence no change needed.

5.5.2 10% or minimum two numbers Brake container module picked up at random shall be subjected to performance tests as given at clause 6.0

We are carrying out 100% in –house testing of the equipments. Due to increase in lot sizes, sample size of 10% has drastically increased the time taken for 3rdparty inspection. Therefore, it is requested to modify the sample inspection lot from10% to 2%.

Comments not acceptable and No change needed, as the subject item is highly sophisticated & critical in nature.

6.1 Performance Tests

Noted Kindly rename the line as "equivalent volume of 8 nos. brake cylinder of 255mm dia."

Comments acceptable and No change needed, as the requirement mentioned is self-explanatory & provides better clarity.

6.3 The purchaser/inspection Authority may specify any other test to satisfy himself for the performance of the requirements and manufacturer shall assist for conduct of these tests.

Not applicable. No change needed. It’s a general term using in RDSO specifications.



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APPENDIX- B 3.3 Brake Cylinder shall be as per Technical Specification No. 17.501 Part Document 100 version 00 (without hand brake) and as per T.S.17.505 Part Doc 100 version-00 for brake cylinder with mechanical locking (with hand brake).

Reference clause of technical specification should be mentioned for compliance.

The respective clause is deleted, as all TS requirements are covered in other Para’s.

4.3 All parts of Brake Cylinder shall be painted with two coats of paints in grey or black colors or as specified by IR before supply. The surface of light alloy castings shall be anodized.

The surface of light alloy castings shall be anodized - To be deleted; as components are suitably anti-corrosion treated and outer surface is painted.

Painting is applied to calipers and actuators which are done as per specific COC defined process & hence the clause will have to be modified as "Brake cylinder/actuator shall be painted as per principal recommendations before supply".

Comments are acceptable and Para may modified as: “….as specified by IR/ principal recommendations before supply”.

5.1.2.2 Two percent or minimum one brake cylinder shall be dismantled and dimensions and general workmanship of each component checked as per RDSO approved drawings. 5.1.2.3 Ten percent brake cylinder picked up at random shall be subjected to tests as given at clause 6.1 of this specification.

We are carrying out 100% in-house testing of the equipments. Due to increase in lot sizes, sample size of 10% has drastically increased the time taken for 3rdparty inspection. Therefore, it is requested to modify the sample inspection lot from 10% to 2%.

In a single LHB brake system, 8 Nos. of brake cylinders are getting used. As time spent for inspection of 10% of Brake cylinders are more, Request to modify the clause as "Two percent or 2 Nos. of brake cylinder picked up at random shall be subjected to tests as given at clause 6.1 of this specification"

Comments are partially acceptable and Para may modified as: In Para 5.1.2 the lot size changes from ‘50Nos.’ to ‘100Nos.’

APPENDIX- C 2.7 Stainless steel pins with bushes, which will have long life as well as non-metallic self-lubricating property to be

Noted. Bushes should be of self-lubricating material.

Steel bushes and Pins or non-metallic self-lubricating Bushes and steel pins can be used

As per OEM design.

Para is modified accordingly.



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used in brake calipers. in Brake calipers for long life.

3.2 Brake caliper assembly shall be suitable for fitting UIC type 200x2cm2 sintered brake pads of thickness 30 mm.

The brake caliper assembly fitted in Tejas rake are fitted with flexible sintered pads of 30mm thickness. The same may be revised in this clause.

There is no such word ‘flexible’ being used in respective UIC. Moreover, thickness of Brake Pads changes to ‘30mm (min.)’.

5.2.2 10% or minimum five numbers Brake Caliper Assembly picked up at random shall be subjected to tests as given at clause 6.0.


In a single LHB brake system, 8Nos. of brake caliper assemblies are getting used. As time spent for inspection of 10% of Brake caliper assemblies are more, Request to modify the clause as "Two percent or 2Nos. of numbers Brake Caliper Assembly picked up at random shall be subjected to tests as given at clause 6.0.

Comments are partially acceptable and Para may modified as: In Para 5.2 the lot size changes from ‘50Nos.’ to ‘100Nos.’

APPENDIX- D 3.2 After having satisfied about the quality standards, 10% of each lot of 100 Passenger Emergency Brake Valve and Passenger Emergency Alarm Pull Box shall be tested as per procedure given in clause 4.



4.1.2 Now exhaust the outlet portion through PEAPB or Isolating cock, the air should start escaping through the large orifice (at least 19mm diameter) provided on the valve. The pressure should not fall below 2Kg/cm2 (+0/-0.5 Kg/cm2) and remains at that level thereafter.

Stabilization pressure in brake pipe will be 2±0.2 Kg/cm2. When BP is dropped to 3.4 Kg/cm2, Brake cylinder pressure will reach maximum value 3.8±0.1 Kg/cm2

and hence stabilization

Comments acceptable. Para may modified as “…2Kg/cm2 (+0/-0.2 Kg/cm2) ……”



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pressure (2 +0/-0.5) doesn't have effect on brake application in the coach.

APPENDIX- E 2.1 The emergency brake accelerator valve should be one of the types mentioned in Appendix-L of UIC 541-1 OR (copy of UIC approval certificate for the same has to be submitted).

This clause should not be applicable for firms already supplying Emergency brake accelerator valve to IR and hence this clause to be removed.

Brake pipe accelerator DAKO Z2 meets UIC 541-1, but is not certified and mentioned in Appendix – L of UIC 541-1 OR.

Comments of both the firms were not acceptable and No change needed, as the subject item is highly sophisticated & critical in nature.

4.1.2 After having satisfied about the quality standards, 10% of each lot of 100 Brake Accelerator Valve shall be tested as per procedure given in Clause 5.



5.1.1 The emergency brake accelerator valve is tested on the test bench. Charge the valve to a pressure of 10kg/cm2. There should not be any leakage in vent hole if checked with soap water.

Brake pipe accelerator DAKO Z2 is able to withstand 10 bar for a short term but limiting mechanism will start exhausting of control chamber at pressure level 8+0, 2 bar.

Comments acceptable and No change needed, as the Para requirement is only to check for leakage test as high pressure i.e. 10kg/cm2.

APPENDIX- F 2.1 The WSP Unit & its respective equipment’s are in accordance with UIC

Addition to the clause: Alternatively, Indian firms who has got

Comments not acceptable and No change needed, as the subject item is highly sophisticated & critical in



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leaflet 541-05 and WSPs accepted in international traffic for vehicles built after 01.01.2004 as per Appendix F of UIC 541-05 must be offered to IR. It must have UIC approval & certificate for the same should have to be submitted.

approval from RDSO as per spec. RDSO/2016/CG-05 dated July, 2017, are also eligible to supply WSP along with AMDBS-200KMPH.

nature.

2.6 The WSP Unit shall have Additional output lines for attachment of speedometer, vacuum toilet system and door sub-systems.

Noted. WSP System provides signal to vacuum toilet system and door subsystem. However, there is no provision for speedometer. The clause may kindly be read as "The WSP Unit shall have Additional output lines for attachment of vacuum toilet system and door sub-systems.

Comments may be acceptable and Para may modified as: “…….for attachment of vacuum toilet system and door sub-systems”

3.1.2 Connector (1 Pc.)

"Connector (1 Set)". In WSP unit more than 1 Pc. Connector is used, hence to be considered as 1 Set.

Comments may be acceptable and Para may modified as: “Connector (1 Set)”

3.1.4 Mil grade type Connector Plug (4 Pc)

Noted. Currently not part of our scope of supply. However, can be provided on request.

Standard connectors (4Pcs.) as recommended by principals should be used for Speed sensors.

Comments not acceptable and No change needed, as the subject item is to be updated as per latest RDSO instructions.

3.1.8 Housing (4Pcs.)

Remove the Housing (4Pcs.) from the requirement as they are not used

Comments may be acceptable and Para is deleted

3.6 The microprocessor wheel slide protection shall have additional module for kilometer performance. So that total kilometer earned by the coach (WSP unit) can be recorded and it can be correlated with the Error Code.

Noted. Kilometers earned will be automatically stored and can be view. However error codes are not linked to Kilometers earned.




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3.8 WSP software should have suitable user friendly interface and should store at least the following data w.r.t. time and date for minimum period of three months. WSP software to be provided free of cost against purchase order to the user Railway and fault data can be downloaded to any Windows laptop/computer using USB cables a) Error code b) Dump valve activation date & time;

Axle number and reference speed/speed of all four axles.

Noted. Data can be downloaded to any computer or laptop by using Ethernet Cable. Hence clause may be updated as "using USB/Ethernet cable". WSP software is licensed software hence can be provided to designated shed only once. Please amend the clause accordingly.

"WSP software should have suitable user-friendly interface and should store at least the following data w.r.t. time and date. WSP software to be provided free of cost against purchase order to the user Railway and fault data can be downloaded to any Windows laptop/computer using RS232 or USB cables. If RS232 connector is used, suitable cable to connect RS232 to USB should be supplied" a) Error code b) Dump valve activation date & time; Axle number and reference speed/speed of all four axles. In WSP software, all data shall store in memory based on memory capacity. It will store in 'First in – Last out' format, we cannot define period for data storage as it depends on the number of fault events that occurs as these events may happen within the period of 3 months also. In WSP software, the

Comments may be acceptable and Para may modified as: “……following data w.r.t. time and date for minimum period of two to three months. WSP software to be provided free of cost against purchase order to the user Railway and fault data can be downloaded to any Windows laptop/computer using RS232 or USB cables. If RS232connector is used, suitable cable to connect RS232 to USB should be supplied by the firm…….”



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fault can be downloaded using RS232 cable. As in general the preferred way of communication is through serial port based on its stability of transferring/receiving data when compared with USB type.

3.13 Permissible insulation test voltage of 1500 VAC and 50 Hz for one minute.

The clause should be re written as "Speed sensor should be preferably Current or Voltage based type". The clause "Protection on all input and output against reverse polarity and short circuit connection" should be rewritten as "Protection on all input and output against reverse polarity and short circuit connection to the extent possible”.

"Permissible insulation test voltage of 500V AC and 50 Hz for one minute".

All characteristics of Speed Sensor would be as per OEM design.

Comments of M/s Escorts & M/s DAKO are not acceptable. Comments of M/s FTRTIL are partially acceptable and Para may modified as “……750 VAC and 50 Hz……”

4.1.1.1 All materials selected must withstand these external influences during their lifetime without any restrictions on their function and safety.

Climate condition according to CSN EN 50155.


4.1.2.1 Due to the climatic conditions defined above, protection against corrosion as well as an anticorrosive design and material selection are of special importance for the parts and components of the WSP Unit and must be realized accordingly. All WSP

Noted. All the items of WSP system are adequately protected against corrosion with suitable surface treatment to provide long service life. Hence painting is not required. The clause may be deleted as not relevant to WSP.

As per OEM Design.

Comments may be partially acceptable and No change needed, as the mentioned requirement provides better clarity & manufacturers must have to comply.



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components to be arranged in the vehicle’s underframe are to be painted completely. The following coats of paint have been provided (colours may change). • Anticorrosive primer beige-red RAL

3012, epoxy metal primer with hardener approved by DBI, layer thickness 60 µm.

• Intermediate coat: sand yellow RAL 1002, PUR priming paint with normal hardener, layer thickness 60 µm.

• Top coat quartz grey RAL 7039, PUR varnish paint with normal hardener, layer thickness 60 µm.

4.1.2.2 Before painting, the inspection addresses with the company labels are to be covered. Bolts, slide surfaces, threaded spindles, valves, etc. are not to be painted. If necessary, the inner walls of the WSP Unit components are to be molatened with corrosion protection oil.

Noted. All the items of WSP system are adequately protected against corrosion with suitable surface treatment to provide long service life. Hence painting is not required. The clause may be deleted as not relevant to WSP.

As per OEM Design.

Comments may be partially acceptable and No change needed, as the mentioned requirement provides better clarity & manufacturers must have to comply.

4.1.5.1 The coaches manufactured by Indian Railways are designated for a service life of 35 years. The WSP Unit is to be developed and designed accordingly. The supplier should specify the recommended maintenance schedules/practices clearly to achieve the desired life.

The clause should be rewritten as "The coaches manufactured by Indian Railway are designed for a service life of 35 years. The WSP unit is to be designed accordingly. The supplier should specify the maintenance schedules/practices clearly to achieve the desired life of 10 years."

Comments not acceptable and No change needed, as the subject item is highly sophisticated & critical in nature & the mentioned requirement provides better clarity.



Page 18 of 21

5.1 The following documentations for the development and design of the WSP Unit are to be prepared by the supplier: • A set of drawings consisting of

drawings and parts lists, including block diagrams, pneumatic flow charts and wiring schemes, list of operating subassemblies etc. (for documentation of electrical and pneumatic components).

• A description of the WSP Unit incl. the description of diagnostics

• An operation and maintenance manual

• A list of spare parts.

This are intellectual property of OEM, cannot be hand over. However, outline drawing and manual already provided.

Comments are partially acceptable and No change needed, compliance is must.

APPENDIX- G 2.3 Two additional indicators will be required for checking the connectivity of EP system.

Noted. These are electrical indications and from part of Appendix-G. Hence should be deleted from here.

Comments may review as the same is not understandable.

3.1.2 After having satisfied about the quality standards, 10% of each lot of 100 brake indicators shall be tested as per procedure given in clause 4.

Noted. We are carrying out 100% in house testing of the equipments. Due to increase in lot sizes, sample size of 10% has drastically increased the time taken for 3rd party inspection. Therefore, it is requested to modify the sample inspection lot from 10 % to 2%.


APPENDIX- H 1.1 EP Assist Brake System should be approved by UIC so as to meet the latest provision of relevant UIC specification for “Passenger Train” application. The proposed EP Assist System when used along with this basic system shall enable performance of the

Noted. The text should be changed as “EP Assist brake System should confirm to UIC”.

The clause should be re written as "EP Assist Brake System should be as per UIC so as to meet the latest provision of relevant UIC specification for "passenger Train"

UIC does not approve EP Assist system. No such approval can be submitted by FT to any customer. FT can only supply an EP Assist system following the prescriptions of UIC.

Our system complying UIC but not approved.

Comments may be acceptable and Para may modified as: “EP Assist Brake System must be in accordance with UIC………”



Page 19 of 21

whole system in conformity of relevant UIC specification.

application. The proposed EP Assist System when used along with this basic system enables performance of the whole system in conformity of relevant UIC specification".

Hence the specification may be modified as "EP Assist Brake System should be accordance to UIC to meet the latest provision of relevant UIC specification for "Passenger Train" application. The proposed EP Assist System when used along with this basic system shall enable performance of the whole system in conformity of relevant UIC specification"

1.2 Design of EP Assist System shall permit the fitment of disc brakes, braking and WSP system in the brake system.

Noted. “Without affecting the functionality of the existing brake system”, should be added.

Comments may be acceptable and Para may modified as: “Design of EP Assist System shall permit the fitment of disc brakes and WSP system in the brake system, without affecting the functionality of the existing brake system”.

1.4.1 Electro-pneumatic module with application and release magnet valves. The equipment to be fitted on coaches shall perform satisfactorily in the voltage range of 48V to 137V DC. Supplier will include protection against sudden variation in voltage like surge in EP assisted brake system devices design itself.

FTRTlL make EP valve will work from 50V DC only and hence the range of voltage may please be changed to 50 V DC to 137 V DC.

Agreed but voltage variation rated voltage - 30% + 25% will applying.

Comments may be acceptable and Para may modified as: “…..48V to 137V DC (with permissible voltage variation of +30%)......”

1.4.2 Cable for running application, return application, release and common lines

Noted. The clause should be amended as “9/11 core UIC approved cable as

Comments may be acceptable and Para may modified as: “9/11 core UIC approved cable as



Page 20 of 21

in the coaches. per UIC-541-1 should be used between the junction boxes and inter coach connections.

per UIC-541-1 should be used between the junction boxes and inter coach connections.”

1.4.3 Cable for connection of electro-pneumatic magnetic valves.

Noted. The clause may be amended as “Cable for connection of electro pneumatic magnet valves on DV and middle junction box to brake test box with indicator”.

Comments may be acceptable and Para may modified as: “Cable for connection of electro pneumatic magnet valves on DV and middle junction box to brake test box with indicator”.

1.4.4 Brake test box to be provided both sides of each coach as per UIC guidelines to check proper functionality of EP Assist features.

Noted. The clause may be amended as “Brake test box to be provided on both sides of the coach as per UIC guidelines for testing of EP assist feature in the rake.

Comments may be acceptable and Para may modified as: “Brake test box to be provided on both sides of the coach as per UIC guidelines for testing of EP assist feature in the rake.”

2.3 Parking brake system shall give satisfactory performance under wet condition also as well as shall have holding capability even after continuous braking for prolonged time during downhill travel.

Parking brake system shall give satisfactory performance under 1 in 250 gradients.

Comments not acceptable and No change needed. Compliance as per specified requirement in Annexure-I is must.

3.1 &3.3 Broad specification of the discs shall be as per RDSO drawing no. CG-15066 (Alt.-Nil) and material of the offered brake disc as Steel.

Broad specification of the discs shall be as per RDSO drawing no. CG-15066 (Alt.-Nil) or Principals own design with material of brake disc as Steel.

Para may reworded as: “Broad specification of the Brake Disc shall be as per RDSO drawing no. CG-15066 (Alt.-Nil) with material as Cast Steel.”

3.10 Flexible Sintered pads should be such that they can be fitted on any make of discs to obtain friction characteristics as per UIC 541-3-OR.

Flexible sintered pad is specific to competition, which can be made more generic by removing the word" flexible".

Comments may be acceptable & Para may modified as: “Sintered pads should be such that they can…….”

3.11 Each side brake pads shall be in two halves of 200 cm2 each.

"Each side brake pads shall be in two halves of 140 cm square each (approx.)"

Comments not acceptable. However, Para may reword for better clarity as “….in two halves with surface area of 200cm2 each.”



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Sintered pad area is calculated only for pad friction surface in contact with disc.

This is as per UIC-541-3.

3.12 Sinter element of between 17-25mm thickness shall be preferred, wear limit shall be specifically be mentioned.

FTRTIL pad thickness will be 30 mm and hence the clause is to be modified as "Sinter element of between 17-30 mm thickness shall be preferred"

Comments may be acceptable & Para may modified as: "Sinter element of between 17-30 mm thickness shall be preferred….."

APPENDIX- I 7.5 If the components included in the scope of delivery of the brake supplier are to be connected with the brake pipes of the carbody and/or the bogie, they are to be suitable for ferrule connections (from M/s Ermeto-Parker-Germany, M/s Voss-Germay, M/s Waltershield-Germany, M/s VolzeGruppe GmbH & M/s BlangeArmaturen-GmbH-Blago). Ferrule connections type B are used (Ferrule are made of stainless steel, screwed connections are made of galvanised steel, the carbody pipes are made of stainless steel).

As a part of Make in India program, we do not recommend to import such ferrule fittings which are not technologically challenged. Faiveley Transport procures this type of ferrule fittings from local supplier and used in Indian Railways for many years without any issues from field and hence specific suppliers should be removed.

Please refer remarks at Para 3.1 of Appendix-A

Documents

Para of uploaded draft spec M/s Knorr-Bremse M/s Escorts M ......Para of uploaded draft spec M/s Knorr-Bremse M/s Escorts M/s FTRTIL JWL-DAKO RDSO Remarks Page 1 of 21 4.2 The supplier