No. MC/LHB/Brake Date: 15.04.2019

Principal Chief Mechanical Engineers,

1. Central Railway, Chhatrapati Shivaji Terminus, Mumbai - 400 001

2. East Coast Railway, Chandrasekharpur, Bhubaneswar - 751 016

3. Eastern Railway, Fairlie Place, Kolkata - 700 001 4. North Central Railway, Allahabad - 211 001

5. Northern Railway, Baroda House, New Delhi - 110 001 6. North Western Railway, Jaipur - 302 006

7. Southern Railway, Park Town, Chennai - 600 003 8. West Central Railway, Jabalpur - 482 008

9. South Central Railway, Rail Nilayam, Secunderabad - 500 071

10. South Western Railway, Hubli - 580 023

11. South Eastern Railway, Garden Reach, Kolkata - 700 043 12. South East Central Railway, Bilaspur - 495 004

13. North Eastern Railway, Gorakhpur - 273 001 14. Integral Coach Factory, Chennai - 600 038

15. Western Railway, Churchgate, Mumbai - 400 020 16. Rail Coach Factory, Hussainpur, Kapurthala, Punjab - 144 602

17. Northeast Frontier Railway, Maligaon, Guwahati - 781 011 18. Modern Coach Factory, Raebareli, Lalganj - 229206

19. East Central Railway, Hajipur - 844 101

20. Konkan Railway Corp. Ltd. Corporate office, Belapur Bhawan, Nawi, Mumbai-400 614

Sub: Consolidated instructions regarding modifications for addressing the problem of Wheel Shelling in LHB Coaches.

Wheel shelling is a serious issue in LHB Coaches. With the sharp increase in population of LHB coaches, the

problem of wheel shelling needs to be addressed on priority. In this connection, RDSO has conducted detailed study to identify the major causes for wheel shelling and published Carriage Research Reports RDSO/CG/CRR-18001 dated 28.03.2018 and RDSO/CG/CRR-18002 dated 27.09.2018. Following major causes have been identified for wheel shelling:

Non-optimal choke sizes of Dump Valves and obstructions in air-brake piping between dump valves and brake cylinders.

Wrong / Loose electrical connections of WSP system.

Jamming of Brake Calipers / Actuators.

Poor design of Junction Box prone to dust/water ingress.

RDSO has issued instructions time to time to Zonal Railways/PUs/OEMs in connection with wheel shelling. Implementation of these instructions have brought about 60-70% reduction in sick marking due to wheel shelling in various depots such as SDAH/ER, LKO/NR, SBC/SWR etc. This letter consolidates all instructions recently issued for the benefit of Zonal Railways and PUs for ease of implementation.

Item wise consolidated list of instructions issued by RDSO (2018-19):

1. Brake Cylinder Pressure

(Ref: RDSO letter no. MC/LHB/Brake dated 20.04.2018 to PCMEs / All Zonal Rlys and PUs)

Zonal Railways / PUs should not resort to alteration in Brake Cylinder pressure of LHB Coaches from the specified value of 3.0+0.1kg/cm2.

Ref: CG-WI-4.2.1-1 Ver.1.0 Page 16 of 38 Issue Date: 23-Mar-2018 Carriage Research report No. RDSO/CG/CRR-18001

Page 16 of 38

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EPBX (0522) 2451200 Fax (0522) 2458500

Government of India-Ministry of Railways

Research Designs & Standards Organisation Lucknow - 226 0 I I

DID (0522) 2450115 DID (0522) 2465310 -"""

No. MC/LHB/Brake Date: 27.09.2018

Principal Chief Mechanical Engineers,

1. Central Railway, Chhatrapati Shivaji Terminus, 2. East Coast Railway, Chandrasekharpur, Mumbai - 400 001 Bhubaneswar - 751 016

3. Eastern Railway, Fairlie Place, Kolkata - 700 001 4. North Central Railway, Allahabad - 211 001

5. Northern Railway, Baroda House, New Delhi - 110001 6. North Western Railway, Jaipur - 302 006

7. Southern Railway, Park Town, Chennai - 600 003 8. West Central Railway, Jabalpur - 482 008

9. South Central Railway, Rail Nilayam, Secunderabad - 10. South Western Railway, Hubli - 580 023 500071

11 . South Eastern Railway, Garden Reach, Kolkata - 700 12. South East Central Railway, Bilaspur - 495 004 043

13. North Eastern Railway, Gorakhpur - 273 001 14. Integral Coach Factory, Chennai - 600 038 15. Western Railway, Churchgate, Mumbai - 400 020 16. Rail Coach Factory, Hussainpur, Kapurthala,

Punjab - 144 602

17. Northeast Frontier Railway, Maligaon, Guwahati - 781 18. Modern Coach Factory, Raebareli, Lalganj -011 229206

19. East Central Railway, Hajipur-844101 20. Konkan Railway Corp. Ltd. Corporate office, Belapur Bhawan, Nawi, Mumbai-400 614

Sub: Modification in choke sizes of Dump Valves of WSP system in LHB Coaches.

Ref: i). RDSO letter of even no. dated 11.04.2018. ii). Railway Board letter no. 2007/M(C)/137/16 Vol.(XII)Pt. dated 05.04.18.

1. With reference to above, ROSa monitored field trials were conducted to study the effect of dump valve choke sizes on wheel shelling in LHB coaches at coaching depots Lucknow/Northern Railway, Bombay CentrallWestern Railway and Sealdah/Eastern Railway.

2. The observations and results of the trials above are detailed in RDSO's CRR report RDSO/CG/CRR-18002. A copy of the same is enclosed.

3. The actions listed in the report have resulted in substantial reduction in wheel shelling as determined by trials conducted at Sealdah depot of Eastern Railway over a period of 6 months.

4. Zonal Railways and Production Units are advised to take necessary action as detailed in the report to address the problem of wheel sh lIing in LHB coaches.

DA: As above / /'V'1~

(Samir Lohani) Executive Director/Carriage

Copy to: EDME (Chg.), Railway Board, Rail Bhawan, New Delhi-110001 .

Page 7 & 8 of CRR Report RDSO/CG/CRR-18002

Annexure 1

Common defects found that restrict exhaust of air during dumping

1) Obstruction due to poor quality / non-standard nylon washers in flexible hose connecting pipeline from coach body to bogie. Action: Good quality Teflon washers to be used.

Fig 1: Obstruction due to perished washers

Fig 2: Perished Washers

2) End fittings restricting air flow Action: Replace with standard fittings as per Alstom Manual

Fig 3: Excessive joints restricting air flow

Fig 4: Excessive bite joints restricting air flow and also causing leakages

1fmf'ffi'CI'iIT-=m~ ~~m;J~~~~ ~ -226011

EPBX (0522) 2451200 Fax (0522)2458500

No.MC/LHB/Brake

Government of India-Ministry of Railways

Research Designs & Standards Organisation

Lucknow - 226 011

DID (0522) 2450115 010(0522)2465310

MIs Faiveley Transport Rail Technologies India Ltd. 3A, Apparel Park cum Industrial Area, Bhatoli, Baddi, Distt·Solan (H.P)

Sub: Switch over to Self-lubricating non-metallic bushes in LHB Coaches.

Date: 06.09.2018

Ref: i).Your letter no. FTRTILlMKTG/Self-Lubricating Bushes-02 dated 03.09.2018. ii).Railway Board letter no. 2007/M(C)/137/16 Vol.(XII)Pt. dated 05.04.2018.

Presently, M/s FTRTIL is supplying Brake Calipers/Actuators of Axle Mounted Disc Brake system with metallic bushes which need periodic lubrication & attention. Due to use of grease/oil for lubrication in bushes, problem of dust ingress has been noticed which may sometimes result in obstruction in free movement of Brake Calipers/Actuators thus could lead to wheel shelling problem. To overcome this problem RDSO & PU's have advised M/s FTRTIL time & again to switch over to non-metallic self­lubricating bushes (polyamide bushes) which are easy to maintain & may not have problems due to dust accumulation. .

Vide letter at ref (ii) above, Railway Board has also instructed that IIMls FTIL to switch over to polyamide self-lubricating bushes". As such M/s KBIL (other approved vendor) is already supplying their brake system with non-metallic self-lubricating bushes. M/s FTRTIL vide their letter at ref (i) has also conveyed their acceptance to completely switch over to supply Brake Calipers/Actuators of Axle Mounted Disc Brake system with non-metallic self-lubricating bushes (polyamide bushes).

In view of the above, you are hereby advised to switch over to non-metallic self-lubricating bushes (polyamide bushes) for Brake Calipers/Actuators of Axle Mounted Disc Brake system with immediate effect for all future supplies, under intimation to this office.

DA: Nil

Copy to: For kind information please,

Director/I&LlNDLS/RDSO

~l~h\ . ek Ac arya)

Director/Car iage for Director General/Car iage

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~ - 226 01.1 EP8X {0522} 2451200 Fax (0522) 2458500

No. MC/LHB/Brake

Principal Chief Mechanical Engineers,

1. Integral Coach Factory, Chennai - 600 038

G\.) ·emmcnl of India-Ministry of Railways

Rt:search Dc.signs & Slandanls Organisation LUC KIlOW" 226 Ol1

DID (0522) 2450115 DID (0522) 2465310

2. Rail Coach Factory, Hussainpur, Kapurthala, Punjab -144 602

3. Modern Coach Factory, Raebareli, Lalganj - 229206

Sub: Revised wiring scheme for WSP system of LHB Coaches. Ref: i). Railway Board letter no. 2007/M(C)/137/16 Vol.(XII)Pt. dated 05.04.18.

ii). Railway Board letter no. 2018/M(N)/951/20 dated 31.07.2018 ~ii). RDSO letter of even no. dated 27.09.2018.

Date 30.01 .2019

Vide reference (i) above, Railway Board instructed RDSO to examine the problem of wheel shelling & to study the design of connector of WSP system and suggest ways & means to overcome problem of loosening of connections in LHB coaches.

RDSO examined the matter in detail & issued a brief Carriage Research Report (CRR Report No.RDSO/CG/CRR-18002, vide ref (iii)) to Railways for carrying out the modifications in choke sizes of Dump Valves

. of WSP system, which resulted in substantial reduction in wheel shelling problem in LHB coaches as experienced by Zonal Railways.

Further, at item nO.3.5 of PCME's conference held in July'18 and Railway Board instructed RDSO to develop revised wiring scheme with modified connectors to avoid disconnection/loosening due to vibrations, shocks etc. during train operation or otherwise) for the WSP system. Zonal Railways should carry out modification as soon as the' drawings are issued by RDSO, vide ref (ii) above.

In connection to this, RDSO has developed the revised WSP wiring layout with modified connectors in consultation with LHB brake system suppliers. Successful fitment trial was done at MCF & RCF for the one coach set material (each) with modified WSP wiring, junction box & mil-grade connectors supplied by MIs FTRTIL & MIs KBIL respectively.

The revised WSP wiring & modified junction box layout has following features:

1. IP67 grade Junction Boxes as per RDSO drawing (Drg.No.CG-19005) (copy enclosed).

2. The numbers of Junction Boxes reduced to four from six, to therefore only one Junction Box has all the connections (i.e. Dump Valves, Speed Sensor & Power Panel) per axle.

3. Mil-grade type connectors.

4. Revised wiring layout for WSP system to be as per RDSO drawing (Drg.No.CG-18246) (copy enclosed).

5. The above layouts and drawings are standardized across all type of LHB Coaches.

In view of the above, PU's are requested for implementation of above modifications.

In addition to the above,-Railways have also reported the cases for vandalism, hitting & damage of Junction Boxes; as they were located in lifting & footstep positions of the coach, as such while carrying above modifications, Junction Boxes may be also suitably re-Iocated without affecting the fitment & operation \Ssystem.

This is for kind information & necessary action please. '\ . '.\'~./ DA: As above. L :

(Samir l:ohani) Executive Director (Stds. )/Carriage

Copy to: For kind information please,

EDME (Chg.)/Rail Bhawan, Railway Board New Delhi- 11 0001

"Iffil 1Wf.R - r.r ~ ~ ~ om 'lA'li Ww-i ~ - 226011

EPBX (0522) 2451200 Fax (0522)2458500

Government of India-Ministry of Railways Research Designs & Standards Organisation

Lucknow - 226 011 010(0522)2450115 010(0522)2465310

No. MC/LHB/Bralle Date 27.02.2019

Principal Chief Mechanical Engineers,

1.

3. 5. 7. 9.

11 . 13. 15.

17.

Central Railway, Chhatrapati Shivaji Terminus, Mumbai - 2. East Coast Railway, Chandrasekharpur, Bhubaneswar -400001 751 016 Eastern Railway, Fairlie Place, Kolkata - 700 001 4. North Central Railway, Allahabad - 211 001 Northern Railway, Baroda House, New Delhi - 110 001 6. North Western Railway. Jaipur - 302 006 Southern Railway, Parik Town, Chennai - 600 003 8. West Central Railway, Jabaipur - 482 008 South Central Railway, Rail Nilayam, Secunderabad - 500 10. South Western Railway, Hubli - 580 023 071 South Eastern Railway, Garden Reach, Koikata - 700 043 12. South East Central Railway, Bilaspur - 495 004 North Eastern Railway, Gorakhpur - 273 001 14. Western Railway, Churchgate, Mumbai - 400 020 Northeast Frontier Railway, Maligaon, Guwahati - 781 011 16. East Central Railway, Hajipur - 844 101

Konkan Railway Corp. Ltd. Corporate office, Belapur Bhawan, Nawi, Mumbai-400 614

Sub: Revised wiring scheme for WSP system of LHB Coaches.

Ref: i) . Railway Board letter no. 2007/M(C)/137/16 Vol.(XII)Pt. dated 05.04.18. ii). Railway Board letter no. 2018/M(N)/951/20 dated 31.07.2018 iii). ROSO letter of even no. dated 27.09.2018.

Vide reference (i) above, Railway Board instructed RDSO to examine the problem of wheel shelling & to study the design of connector of WSP system and suggest ways & means to overcome problem of loosening of connections in LHB coaches.

RDSO has examined the matter in detail & issued a brief Carriage Research Report (CRR Report NO.RDSO/CG/CRR-18002, vide ref (iii)) to Railways for carrying out the modifications in choke sizes of Dump Valves of WSP system, which resulted in substantial reduction in wheel shelling problern in LHB coaches as reported by Zonal Railways.

Further, at item nO.3.5 of PCME's conference held in July'18 and Railway Board instructed RDSO to develop revised wiring scheme with modified connectors to avoid disconnection/loosening due to vibrations, shocks etc. during train operation or otherwise) for the WSP system. Zonal Railways should carry out modification as soon as the drawings are issued by ROSO, vide ref (ii) above.

In connection to this, RDSO has developed the revised WSP wiring layout with modified connectors in consultation with LHB brake system suppliers. Successful filment trial was done at MCF/RBL & RCF/KXH for the one coach set material (each) with modified WSP wiring, junction box & mil-grade connectors supplied by Mis FTRTIL & MIs KBIL respectively.

The revised WSP wiring & modified junction box layout has following features:

1. IP67 grade Junction Boxes as per ROSO drawing (Org.No.CG-19005 Alt 1) (copy enclosed).

2. The numbers of Junction Boxes reduced to four from six, to therefore only one Junction Box has all the connections (i.e. Dump Valves, Speed Sensor & Power Panel) per axle.

3. Mil-grade type connectors. 4. Revised wiring layout for WSP system to be as per ROSO drawing (Org.No.CG-18246 AltO) (copy enclosed).

5. The above layouts and drawings are standardized across all type of LHB Coaches.

In view of the above, Railways are requested for implementation of above modifications.

This is for kind information & necessary action please.

DA: As above.

Copy to: For kind information please,

EDME (Chg.), Railway Board, Rail Bhawan, New Delhi-110001

a -~"J.1 ';')..·\~ (Vi~O Director/Carriage

for Director General/Carriage

CONNECTOR (TO TRAIN)

CONNECTOR (FROM DUMP

VALVE)

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NOTE; 1. ENCLOSURE COLOUR: RAL 7001 SILVER GnEY (INDICATIVE) 2.JUNCTlo.'4 BOX SHOULD SE IP67 CER TIfiED. 3,LOCATlON or SPEED SENSOR CONNECTOR IS INDICATIVE AND

MAY VARY DEPEND:NG ON LOCATION OF FITMENT OF J/S &: AVAILASIUTY OF SPACE THERE AND AXLE LOCATION

·UYPE OF CONN::CTORS &: 1l'E1R PiNS SHOWN IS INOICATIVE 5.CONNECTORS SHOULD BE POSiTlvtLY SECURED AGAINST VANDAliSM 6.FOR FURTHER DETA.LS. PLEASE REFER OEM'S Rose APFROVED

ORAI'MoIes

MODIFIED JUNCTION BOX

CG- 1900 5

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B.G ' ," on I""r-I e.G 18246 ~i"':'J' IDATE : l""' ~'-J