Reasoned Documents for preparation of STR no. RDSO/2015/CG-05, Rev.00 for FIBA device

STR Clause no.

Clause description M/s KBI’s Comments M/s SIl’s Comments M/s FTIL’s Comments RDSO remark

FOREWORD

This Schedule of Technical Requirements (STR) spells out the schedule of technical requirements of Air Spring Failure Indication Cum Brake Application (FIBA) Device for Air Spring fitted in BG ICF, LHB, Hybrid and double decker mainline coaches having ICF and LHB type bogies.

This Schedule of Technical Requirements is concerned with the Air Spring Failure Indication Cum Brake Application (FIBA) Device and details of the requirements and tests for the Air Spring Failure Indication Cum Brake Application (FIBA) Device.

The specification shall not be altered /modified or reproduced in any form without the written permission of the Director General (Carriage), RDSO, Lucknow.

-------- Noted and agreed Air Spring Failure

Indication Cum Brake Application (FIBA) Device for Air Spring fitted in BG ICF, Hybrid and double decker mainline coaches having ICF type bogies. FTIL Remark: LHB coaches do not have the Air Suspension Control

equipment and hence this standard is not applicable to this coach.

Air springs have been

fitted in BG ICF, LHB, Hybrid and double decker mainline coaches. Hence no change is required.

1. SCOPE:

1.1 This schedule lays down the technical requirements for the design, manufacture and supply of Air Spring Failure Indication Cum Brake Application (FIBA) Device for air spring fitted BG ICF, LHB, Hybrid and Double Decker mainline coaches having ICF and LHB type bogies on Indian Railways. Scope of supply shall generally be as per clause 4 of this Schedule of Technical Requirements (STR). However, if the supplier feels that certain additional items are necessary for improved working performance of the system, he may quote for the same. In any case, purchaser will be at liberty to buy all or part material from the offer.

- Noted and agreed …… Air spring failure

Indication Cum Brake Application (FIBA) Device for Air Spring fitted “BG ICF, Hybrid and Double Decker mainline coaches having ICF type bogies”…… FTIL remark: LHB coaches don’t have

Suspension control equipment and hence this standard is not applicable to this coach and hence LHB type bogies shall be removed

Air springs have been fitted in BG ICF, LHB,

Hybrid and double decker mainline coaches. Hence no change is required.

1.2 Flexible hoses, Isolating Cock, Isolating cock with vent feature for the Air Spring Failure Indication Cum Brake Application (FIBA) Device should be supplied to RDSO’s STR C-K407 (Latest Revision), ABR-02 and

Noted and agreed ……ABR-02 and firm’s

approved drawings by RDSO, Indicator of FIBA device should be

Indicator of FIBA device should be to RDSO STR no. RDSO/2011/CG-04 (Latest Rev.) to be read

firm’s approved drawings by RDSO. Indicator of FIBA device should be to RDSO STR no. RDSO/2011/CG-04 (Latest Rev.) The Air Spring Failure Indication Cum Brake Application (FIBA) Device should be compatible with the other items as described in the above STRs. The purchaser will be at liberty to buy any part or complete item as mentioned above and Air Spring Failure Indication Cum Brake Application (FIBA) Device to this STR from different source of supply.

to RDSO STR no. RDSO/2011CG-04 (Latest Rev.)” wherever applicable”…….

FTIL remark: The referred RDSO spec calls for only the selected items for this requirement and hence the “wherever applicable shall be added

as: Indicator of FIBA device should be as per RDSO STR no. RDSO/2011/CG-04 (Latest Rev.)

2. OPERATING CONDITIONS:

Headline

2.1 The Air Spring Failure Indication Cum Brake Application (FIBA) Device will be fitted in mainline coaches fitted with LHB/ICF bogies having Air suspension in secondary stage.

Noted

Noted …… Air spring failure Indication Cum Brake Application (FIBA) Device will be fitted in mainline coaches fitted

“with ICF bogies”…….. FTIL Remark: LHB coaches don’t have Suspension control equipment and hence this standard is not applicable to this coach

No change is required.

2.2 The Pneumatic suspension system works under two different modes, one in the inflated condition and the other in deflated condition when there is no air cushion and load is directly transferred from the car body to the Emergency rubber spring (bumper).Under deflated condition of the air spring, the maximum permissible operating speed of the coach is restricted on account of inferior riding behavior.

Noted Noted ---

2.3 Compressed air supply to the air spring assemblies shall be maintained through a compressor provided in the Locomotive though Feed Pipe. The Locomotive compressor charges the Feed pipe at 6 Kg/cm² and Brake Pipe at 5 Kg/cm². Provision of air-drying does not exist in some of the compressed air supply system. Pneumatic circuit of Air Spring Failure Indication Cum Brake Application (FIBA) Device system is connected to the Feed pipe. Internal air pressure of air springs may vary from tare to full load.

Noted. Noted ----

2.4 Each coach shall be fitted with four air spring assemblies (two per bogie) and each Air Spring Failure Indication Cum Brake Application (FIBA) Device shall be controlled by an independent levelling valve (4-point control system). Two air springs of the same bogie shall be connected through a duplex check valve set to act at a pressure differential of 1.5 +

0.12 Kg/cm².

Noted. There will be one FIBA per bogie. Each FIBA device will monitor both the air spring of bogie.

Noted and Complied Clause may be modified as under: “Each coach shall be fitted with four air spring assemblies (two per bogie). There will be one FIBA device per bogie. Each FIBA device (consisting 02 valves for sensing each Air spring by the respective valve) will monitor both the air springs of respective bogie. Each Air Spring shall be controlled by an independent levelling valve (4-point control system). Two air springs of the same bogie shall be connected through a duplex check valve set to act at a pressure differential of 1.5 +

0.12

Kg/cm²”

2.5 To meet the requirement of a fool proof arrangement in the suspension design, FIBA device connected with each air spring has been fitted in air spring fitted coaches. FIBA device will send a message to the crew of the train in the event of air spring failure (which will ultimately demand a reduction in the operating speed). An emergency situation is possible due to the likely hood of spring damage, possibility of air supply failure or due to sudden rupture or bursting of bellows of air springs due to any reason.

Noted. Each FIBA device is connected to both the air springs of a bogie. In the event of air spring failure, FIBA device actuate the application of brakes, which will immediately reduce the speed of the train and ultimately cause the train to stop. Indicators of respective failed air spring will turn to red and whistling sound will blow to indicate the location. The train is checked by the engine crew

Noted Clause modified as under: To meet the requirement of a fool proof arrangement in the suspension design, FIBA device connected with each air spring has been fitted in air spring fitted coaches. FIBA device will send a message to the crew of the train in the event of air spring failure (which will ultimately demand a reduction in the operating speed) by way of brake

application and physical indication (Hissing Sound and projection of indicator in affected coach). Failure of Air Spring is possible due to the likely hood of spring damage, possibility of air supply failure or due to sudden rupture or bursting of bellows of air springs due to any reason.

2.6 The basic principle in this arrangement is to actuate the application of brakes in the event of air spring failure, which will immediately reduce the speed of the train and ultimately cause the train to stop. Indicators of respective failed air spring will turn to red and whistling sound will blow to indicate the location. The train is checked by the engine crew and after taking necessary action, train is allowed to move in the event of failure of the air spring at prescribed speed.

Noted. Noted “whistling sound” is replaced with “hissing sound”

3. ENVIRONMENTAL CONDITIONS:

Headline

3.1 Air Spring Failure Indication Cum Brake Application (FIBA) Device shall be subjected to following environmental conditions.

Max. Temperature under sun: 60ºC.

Ambient temperature: 0º to 45ºC in shade.

Average relative humidity: 70% to 90%, 100% on

several days.

Rainfall: Fairly heavy, maximum being 200mm in24

hours, typical to the coastal areas.

Atmosphere: Dusty with salt laden air for several

months of the

year.

Noted. Noted Max. Temperature

under sun: 60ºC.

modified as:

Max. Ambient

Temperature under

sun: 60ºC.

3.2 Air Spring Failure Indication Cum Brake Application Noted. Noted and Complied -----------

(FIBA) Device system may also come in contact with the following, during coach maintenance operation:

Chemical products (like cleaning compound of

coach cleaning)

Cotton waste smeared with oil and paint etc.

Disinfectants.

Oils & lubricants used in coach bogies.

4. SCOPE OF SUPPLY: The scope of supply covers the following items: One FIBA device per bogie or 02 FIBA device per coach will be required.

i) For each Air Spring Failure Indication Cum

Brake Application (FIBA) Device:

S.

No.

Item Quantity

1 Air Spring Failure

Indication Cum Brake

Application (FIBA)

Device

1

2 Indicator 2

3 Hose connection 3/4'’

BSPX550 mm with

both end rubber

washers

3

4 Isolating cock (OLP

type) 20mm bore

1

5 Isolating cock 20mm

bore with vent hole

2

Headline Noted. 3+2 may please be replaced by one set.

Noted.

Noted and Complied Quantity “3+2” may be read as “*one set” Following note also to be added with * mark: * One set shall mean total nut bolts/fasteners with locking washer

6 Nut bolts/fasteners

with locking washer

for mounting of FIBA

device and Indicators

3+2

ii) Any other item, which in the view of the supplier is considered essential for operation or enhances the performance of the system, may also be offered.

required for mounting of 01 FIBA device and 02 Indicators for each bogie.

5. PROCEDURE FOR VENDOR REGISTRATION: Headline

5.1 Vendors willing to supply Air Spring Failure Indication Cum Brake Application (FIBA) Device for the use of Indian Railways shall register themselves with Research Designs and Standards Organization, Ministry of Railways, Lucknow-226011 (RDSO) and should be ISO approved.

Noted. Noted and agreed

--------------

5.2 The Vendor shall have a well-documented ‘Internal Quality Assurance System’ to ensure sustained quality of product being manufactured. The Quality Assurance System’ shall generally cover the following:-

Noted. Noted and agreed ----------------

5.2.1 System to ensure that correct raw material is being used.

Noted. Noted and agreed --------------

5.2.2 System to ensure that components having manufacturing defects are identified and destroyed so that such components are not used during assembly of air spring.

Noted. Noted and agreed --------------------

5.2.3 System to ensure that bought out components are strictly as per requirements laid down in the STR / drawing.

Noted. Noted and agreed -------------------

5.2.4 System to maintain strict control of dimensions and workmanship of components and assembled product.

Noted. Noted and agreed --------------------

5.2.5 System to test and establish that the Air Spring Failure Indication Cum Brake Application (FIBA) Device manufactured by the firm meets all the requirements laid down in STR / drawing.

Noted. Noted and agreed ----------------

5.2.6 System of periodical calibration of equipments/gauges to ensure accuracy of product.

Noted. Noted and agreed -----------------

5.2.7 System to ensure cleaning & removal of dust/rust and moisture by dry air.

Noted. Noted and agreed ------------------

5.2.8 System to ensure that Air Spring Failure Indication Cum Brake Application (FIBA) Device is properly packed to meet the requirement of Clause-12 of this

Noted. Noted and agreed --------------------

STR.

5.2.9 System to ensure traceability at least up to guarantee period.

Noted. Noted and agreed -----------------

5.3 Special Conditions: Headline

5.3 a) Air Spring Failure Indication Cum Brake Application (FIBA) Device vendors shall be recognized on the basis of their FIBA design. Company shall have the facilities for designing the Air Spring Failure Indication Cum Brake Application (FIBA) Device and the necessary infrastructure to carry out detailed type tests at their own facility.

Noted. Noted and agreed -----------------------

5.3 b) Since Air Spring Failure Indication Cum Brake Application (FIBA) Device are a safety related air spring failure indication element, in-service trials shall be necessary for each design before full clearance is given for vendor registration as Part-II status for manufacture and supply of FIBA device.

Noted. Noted and agreed ----------------

5.3 c) The Air Spring Failure Indication Cum Brake Application (FIBA) Device of a particular design shall be subjected to field trials on a minimum of ten coach sets for one year on IR’s system for vendor registration as Part-II status for manufacture and supply of FIBA device.

Noted. Type test should be conducted at the time of approval of a product and before granting the clearance for field trials. Trial quantity should be at least one rake and trial period should be 18 months which would be inline with POH of a coach to assess the performance. Similar practice is to be adopted for EMU’s and LHB Brakes.

Noted and agreed Following may be added at end of the clause: “Type test shall be conducted at the time of approval of a product and before granting the clearance for field trials”.

5.3. i In case of any failure during field trials attributable to poor design or material, the field trials shall be repeated.

Noted. Noted and agreed ------------------

5.3. ii After completion of service trial period, a sample of the Air Spring Failure Indication Cum Brake Application (FIBA) Device shall be subjected to the tests laid down at para 10.2.2. In case these values are beyond permissible limits, the air spring design shall be deemed to have failed the service trials.

Noted. The service trials should be repeated.

Noted and agreed Clause may be modified as under: After completion of service trial period, one sample of the Air Spring Failure Indication Cum Brake Application (FIBA) Device shall be subjected to the tests laid down at para 10.2.2. In case these values are beyond

permissible limits, the design of FIBA device shall be deemed to have failed in service trials.

5.3. iii A Vendor shall be considered eligible for upgradation to Part-I status on completing successful supply of a minimum of 500 coach sets of the particular type of FIBA device as per latest ISO guideline of RDSO

Noted. Noted and agreed -------------

5.3. iv A vendor considered eligible for upgradation to Part – I status shall undertake manufacturing facilities and process of manufacturing. At this stage fresh type test shall be essential. The sample Air Spring Failure Indication Cum Brake Application (FIBA) Device shall be picked up by RDSO. Vendor shall arrange the detail type testing of sample Air Spring Failure Indication Cum Brake Application (FIBA) Device at his own cost and type test facilities.

The vendor has to submit the fresh drawing and modified QAP for approval before undertaking in-house manufacture of these components.

For grant of Part – I status after the acceptance of fresh Type test report by RDSO a minimum of 500 coach sets of Air Spring Failure Indication Cum Brake Application (FIBA) Device fitted with indigenous manufactured component as per para. (l) above must have been supplied by vendor. Air Spring Failure Indication Cum Brake Application (FIBA) Device shall have been inspected by Carriage (VDG) Directorate, RDSO, Lucknow during service trial.

Noted. Type test is conducted to assess the suitability of particular design and accelerated performance parameters. Type test should be conducted at the time of approval before going for field trials. The performance of a particular design is already established with field trials of 10 coaches for one year and then further fitment on 500 coaches. Type test should be done only when there is a major design change based on field assessment. The clause should be modified accordingly. Noted.

Noted and agreed “a” to be replaced with “and” between …………………Type test report by RDSO…………. and minimum of 500 coach sets ……………… Air Spring Failure Indication Cum Brake Application (FIBA) Device shall have been inspected by Carriage (VDG) Directorate, RDSO, Lucknow during service trial. To be replaced by Air Spring Failure Indication Cum Brake Application (FIBA) Device shall be inspected by Carriage

(VDG) Directorate, RDSO, Lucknow during service trial.

5.3. v After type tests of a particular design are approved by RDSO, vendors shall ensure that Air Spring Failure Indication Cum Brake Application (FIBA) Device to the particular specification are supplied with components manufactured from the sources as indicated at the time of design approval and used for type testing.

Noted. Noted and agreed -----------------

5.3. vi The type test shall be witnessed by authorized representative of RDSO at the time of design approval of the vendor at their own test facility. Any additional tests if considered necessary shall also be arranged by vendor free of cost. All necessary arrangements for witnessing the type test of Air Spring Failure Indication Cum Brake Application (FIBA) Device at firm’s premises shall be done by the vendor. RDSO reserves the right to witness the type test again if changes in approved design/drawings are carried out which are likely to alter design / performance characteristics of the Air Spring Failure Indication Cum Brake Application (FIBA) Device.

Noted. Noted and agreed ----------------

5.3. vii In case design of critical component is changed, fresh type test and service trial shall be required. However service trials can be dispensed with by RDSO considering the reasons for change and extent of modification.

Noted. Noted and agreed ------------------

5.3. viii

In case, source of any component of Air Spring Failure Indication Cum Brake Application (FIBA) Device is changed or any additional new source is introduced, fresh type tests shall be required. The vendor should provide the detailed information of the source changed/ additional source introduced along with the documentary evidences for the record of this office. Firm shall validate the source in all respects i.e. material, manufacturing process, quality control and inspection & testing etc. to conform to originally approved design and process. Compliance to all obligations including guarantee/warrantee (as per para. 8/Section - A) shall remain the responsibility of vendor.

Noted. Sourcing of component is prerogative of manufacturer. Changing the source doesn’t call for type testing. Ensuring the quality of components from a new vendor and compliance to guarantee/ warranty obligation is the responsibility of manufacturer.

Noted and agreed It is a safety device hence the source of component suppliers needs to be proven one. Therefore this clause is retained as such.

6. TECHNICAL REQURIEMENTS: Headline

6.1 General technical requirement: Noted.

General technical requirement of FIBA device shall be as under:

----------

6.1.1 In no case it shall allow to flow the air supply from

feed pipe or air spring system to brake pipe to avoid

the influence or overcharging in brake pipe.

Noted. Noted and complied ----------

6.1.2 A device to blow a whistle at a constant sound level irrespective of the pressure of compressed air in the

bellow after the rupture has taken place.

Noted. As per our approved drawings and product whistling is due to discharge of BP from device and is consistent in sound level till the discharge

Noted and complied Modified as under: A device to emit a hissing sound at a constant sound level irrespective of the pressure of compressed air in the bellow after the rupture has taken place.

6.1.3 Indication devices/ Indicator, to be fixed one on each side of the bogie i.e 4 indicators per coach near turn under and mounted on underframe of the coach to change colour from green to red till either the ruptured bellow is rectified or the system is isolated. RDSO’s drawing no. CG-K-10033 of latest revision may be referred for space envelop. Pipe diameter from FIBA valve to indicator will be 1/4”.

Noted. Noted and complied “till either the ruptured bellow is rectified or the system is isolated” may be replaced with “till either the ruptured bellow is rectified properly or FIBA device is reset by resetting key provided on FIBA device”

6.1.4. An isolating cock of 20 nb inlet and outlet ports to isolate the BP branch pipe connected to each Air Spring failure indication device as per RDSO drawing no.CG K-9132 of latest revision.

Noted. Isolating cock 10 mm bore can be used in place of 20mm bore for the same operation without suffering any trouble of the said system.

“20 nb” may be replaced with “¾”

6.1.5 It shall have two isolating cocks of 20 nb inlet and outlet ports with vent feature for quick discharge of the air from pipe line of FIBA device to reset the indicator position as green while isolating the defective air spring system of affected bogie as per RDSO drawing no.CG K-9132 of latest revision.

Noted. The reset cock is available on FIBA device. Isolating coach should be used only to isolate FIBA device. Indicators should not reset automatically until the defective air spring is attended. Therefore the clause should be amended accordingly.

Noted and complied “20 nb” may be replaced with “¾”

and “to reset the indicator position as green while isolating the defective air spring system of affected bogie” may be deleted”

6.1.6 FIBA device shall be mounted on common bracket as

Noted. Noted and complied ---------

per RDSO drawing no. CG- K10031 of latest revision.

Pipe diameter from BP to FIBA and FIBA to air

springs shall be ¾”.

6.1.7 Two such equipment sets with four indicators are required per coach to indicate the condition of two sets of adjacent bellows in both the bogies.

Noted. Noted and complied ---------------

6.1.8 The equipment shall sense the rapid discharge of air pressure from any of the adjacent air bellows of same bogie and move to apply brake in complete train if the discharge of compressed air from the bellow system is beyond the specified limit.

Noted. Specific limit of air pressure is not given

“ beyond the specified limit” may be replaced with “ less than 1+0.1 Kg/Cm

2”

6.1.9 In addition to initiating brake in the complete train, it also shall actuate a hissing sound of 90+5decibel intensity with steady pitch to attract the attention of the crew who walks along the train investigating the defect. It shall also not be such as to cause panic to the passengers traveling in the coach. In parallel, the equipment actuates a color change in the side mounted colour indicators from Green to red to quickly catch the eye of the driver. It shall be covered properly by a suitable transparent sheet to protect the same from dust, dirt and water etc.

Noted. As per our earlier approval, it is the hissing sound of 95+5 decibel BP discharge.

Noted and complied No change

6.1.10 It shall be possible to fit the FIBA device on the existing twin pipe graduated release air brake system provided with air suspension system of the vehicle without having to make any major modification in piping.

Noted. The fitment of FIBA device shall not require any major modification on the existing twin pipe graduated release air brake system. However pipe connecting the FIBA device will have to be made/ provide by IR.

Noted and complied Modified as under: It shall be possible to fit the FIBA device on the existing twin pipe graduated release air brake system provided with air suspension system of the vehicle without having to make any major modification in existing piping. The pipeline required for FIBA system shall be laid separately.

6.1.11 When any of the four bellows in a coach ruptures, the Air Spring failure indication Device monitoring that particular bogie with the ruptured bellow alone shall actuate. The protection equipment in the other bogie and also in the other coaches shall not actuate.

Noted. Noted and complied “The protection equipment” shall be replaced with “FIBA device”

6.1.12 It shall be possible to use the same Air Spring Failure

Indication Cum Brake Application (FIBA) Device in the

Noted. Noted and complied “Hybrid and ICF coaches with pneumatic brake” may

air brake system and air suspension system of LHB,

Hybrid and ICF coaches with pneumatic brake.

be modified as “Hybrid and ICF design coaches with pneumatic brake”

6.1.13 It shall be possible to retrofit the equipment even on the existing vehicles having Air suspension if desired.

Noted. Noted and complied -----------

6.1.14 The FIBA Device shall not need any electrical connections.

Noted. Noted and complied ---------------

6.1.15 Once brake application is initiated by the Air Spring failure indication Device, the brake application shall remain in effect until the driver or the railway staff has located the defect on the coach and isolated the system or defect is rectified and system has been re adjusted for further use.

Noted. Noted and complied ----------------

6.1.16 It shall be possible to reset the brake application by

the driver so that the journey can be resumed at a

restricted speed.

Noted. Noted and complied ------------------

6.1.17 However the visual indication shall not be possible to

be suppressed unless the compressed air in the air

suspension system of the coach itself is exhausted

completely to atmosphere or discharged through

isolating cock with vent feature. Therefore vent

feature may be provided in isolating cock as laid down

in drawing no CG - K9132 of latest revision. FIBA

device may also rest manually by providing reset key

on FIBA device.

Noted. To reset the indicators, rest cock of FIBA device needs to be operated This is as per our approved FIBA device.

Noted and complied The clause may be modified as under: However the visual indication shall not be possible to be suppressed automatically either without proper rectification of the deflated air spring or by resetting the FIBA device by resetting key provided on FIBA device”

6.1.18 The visual indication devices shall stay in actuated

condition at even as low bellow pressure as 0.3

kg/cm2.

Noted. Noted and complied -----------

6.1.19 It shall not require any special action by the maintenance staff to reset the audiovisual indication to normal condition after repairing/replacing the defective bellows.

Noted. Noted and complied ------------

6.1.20 The equipment shall be designed to withstand maximum vibrations as in existing Railway system without loosing its efficiencies. Complete unit shall be protected from all possible damages and theft etc. It

Noted. Noted and complied -------------------

shall be as compact and light weight as possible for ease in mounting at the appropriate location.

6.1.21 The equipment shall perform satisfactorily at various bellow pressures from tare to max loaded condition. The design shall be maintenance friendly and if any assistance is required during warrantee/ Guarantee period firm shall facilitate free of cost online health check or personal visit to site as desired by the user.

Noted. Noted and complied -----------------------

6.1.22 The performance of Air Spring failure indication Device shall remain unchanged in the air brake system and air suspension system supplied by any approved manufacturer.

Noted. Noted and complied ----------------------

6.1.23 The specifications for air spring assembly can be referred to in RDSO specification no. CK-106, C K-406, C K-508, C K-509, for air spring control equipments C K-407 and other air brake system/equipments 02-ABR-02, (With Latest amendment).

Noted. Noted and complied --------------------

6.1.24 Air Spring failure indication Device shall in no way interfere /alter the performance of the twin pipe graduated release air brake system and the air spring control system of the coach. Normal braking performance shall not be affected.

Noted. Noted and complied -------------------

6.1.25 Weight of FIBA device with cover and mounting bracket shall not excedd16 Kg.

Noted. Clause to be amended to read as 17 kg or approx. 16 kg.

Noted and complied “16 Kg.” is modified as “16 Kg (approx.).

6.2 Space Constraints: Air Spring Failure Indication Cum Brake Application (FIBA) Device shall be within the space envelope shown in RDSO Drawing no. CG-15078

Headline Noted. Mounting hole size is must for interchangeability and hence maintained by us. Location of ports is design specific, which depends upon the location of devices on the manifold plate. As long as the ports are within space envelop, it should be manufacturers option as there are connected through flexible hose with pipe. Also the internal dimensions such as 22 & 60 of bracket to be amended and left on the discretion of the manufacturer. The RDSO drawing CG-15078 should be updated accordingly.

Noted and complied Flexible hoses cannot be avoided without standardization of ports.

6.3 Pneumatic supply connection: Pneumatic supply connection of Air Spring Failure Indication Cum Brake Application (FIBA) Device shall be as

Headline Noted.

Noted and complied ---------

per schematic diagram of RDSO Drawing no. CG-K9132.

6.4 Mounting arrangement:

Mounting arrangement of Air Spring Failure Indication Cum Brake Application (FIBA) Device shall be as per RDSO drawing no. CG-K10031 and drawing no. CG-K10033 shall be for mounting arrangement of Indicators of Air Spring Failure Indication Cum Brake Application (FIBA) Device.

Headline Noted. Dim 34 to be changed to Dim 26 as per RDSO drawing no. CG-15078. And also dim 336 should be changed to 320.

Noted and complied Noted and complied

No change is required as the dimension is kept in consideration of strength requirement and repairs

6.5 Other Details: All metal parts of the Air Spring Failure Indication Cum Brake Application (FIBA) Device shall be of corrosion resistant steel duly painted in red. Indicator of FIBA device shall be painted in silver gray clour (Code K766). However other items of clause 4.1 excluding FIBA device and Indicators shall also be corrosion resistant and shall be painted in red colour. The fasteners shall be of high tensile steel to IS: 2269 (ISO 898) and shall be zinc coated. Fasteners/ Nut bolt shall be strictly of TVS, Unbrako or LPS make only.

Headline Material of various devices and manifold plate of our FIBA device is aluminum alloy which is suitably surface treated i.e. Passivation/ Anodizing etc. to take care of corrosion and long service life. This is in line with similar device in use on LHB coaches for last 15 years. Painting of FIBA device is not advisable because in due course of service in the field, paint may peel-off and may cause malfunctioning of FIBA device. In clause 4.1, items at s. no. 345 can be painted in red colour. However the fastener specified in clause 4.1 shall not be painted. The fasteners supplied by us are of stainless steel hence no coating is required.

SIL design consist of Valve body in Aluminum (anodized) with corrosion resistant steel box as cover and duly painted as per your specification.

Clause may be modified as under: All metal parts of the Air Spring Failure Indication Cum Brake Application (FIBA) Device and Indicators shall be of corrosion resistant material. FIBA device and Indicator shall be painted/ coated in silver gray clour (Code K766). However other items of clause 4.1 excluding FIBA device and Indicators shall also be corrosion resistant and shall be painted in red colour. The fasteners shall be of high tensile steel to IS: 2269 (ISO 898). Fasteners/ Nut bolt shall be strictly of TVS, Unbrako or LPS make only.

7. SUBMISSION OF OFFER: Headline

7.1 Vendors desirous of seeking approval from RDSO for supply of material as per this STR, shall submit their proposal accompanied by the documents containing the following information to RDSO :-

1) Dimensional drawing of Air Spring Failure Indication Cum Brake Application (FIBA) Device.

3) Weight of one Air Spring Failure Indication Cum

1) Noted

3) Noted

2) Noted and agreed

3) Noted and agreed

--------------- ---------------

Brake Application (FIBA) Device and Indicator respectively.

4) Whether proposed Air Spring Failure Indication Cum

Brake Application (FIBA) Device is being used by any

other rail-road system? If yes, details regarding quantity, type of stock, max. operating speed, type of service, average annual running kilometers, life cycle obtained by the user rail-road and maintenance cycle followed by them shall be furnished.

5) Details of deviation from the STR.

6) Content of indigenous and imported items in

offered Air Spring Failure Indication Cum Brake Application (FIBA) Device.

7) Expected life cycle in operating and environmental

conditions enumerated in clause 2 & 3.

8) A write-up giving broadly the maintenance requirements on time/distance basis along with the facilities that would be needed for proper maintenance/upkeep of the offered Air Spring Failure Indication Cum Brake Application (FIBA) Device.

10) A detailed write-up giving the details of "Quality

Assurance System" being followed for manufacture of the offered items; and

11) Details of manufacturing and testing facilities

available with the manufacturer.

4) Noted 5) Noted 6) Noted 7) Noted 8) Noted 10) Noted 11) Noted

4) Noted and agreed 5) Noted and agreed 6) Noted and agreed 7) Noted and agreed 8) Noted and agreed 10) Noted and agreed 11) Noted and agreed

---------------

--------------- --------------- --------------- --------------- --------------- ---------------

7.2 The information as received above shall be used for preliminary evaluation of the firm's capability in meeting with the requirements of this STR.

Noted Noted and agreed --------------- --------------

7.3 The firm shall be required to submit a Type Test Report of a proposed design after the preliminary evaluation carried out as per para 7.2 is found satisfactory. Type Test Report shall be complying with Annexure “A” of this STR.

Noted Noted and agreed --------------- ---------------

7.4 The premises of the firm shall be visited by RDSO's officials for on-the-spot assessment of the firm's

Noted Noted and agreed ---------------

capability after the Type Test Report is accepted by RDSO.

7.5 RDSO reserves complete right in granting approval or otherwise to a firm.

Noted Noted and agreed ---------------

8. GUARANTEE: Headline

8.1 Complete Air Spring Failure Indication Cum Brake Application (FIBA) Device including emergency spring shall be guaranteed for satisfactory performance for a minimum period of 60 months from the date of actual commission in bogies or 72 months from the date of supply. Satisfactory performance for this purpose means that complete Air Spring Failure Indication Cum Brake Application (FIBA) Device or any of its part shall neither show any kind of deterioration which is likely to render it unserviceable nor lose its characteristics as stipulated in this STR, during the guarantee period for reasons attributable to manufacturing/design defects.

Noted. This clause should be read as “Complete Air Spring Failure Indication cum Brake Application (FIBA) device including emergency spring shall be guaranteed for satisfactory performance for a period of 60 months from the date of actual commissioning in bogies or 72 months from the date of supply whichever is earlier.

Noted and agreed “emergency spring” may be deleted from the clause.

8.2 In the event of 'non-satisfactory performance' of any of the items as indicated above, supplier will have to replace the same at his own expense without levying any cost involved in transportation, handling and replacement of such items on the Purchaser.

Noted. The clause should be read as “ In the event of ‘non-satisfactorily performance’ of any of the items as indicated above, supplier will have to replace or repair the same at his own expense without levying any cost involved in the transportation, handling and replacement of such items on the Purchaser”. Further the manufacturer shall replace or repair the FIBA device only when it is established that the failure was caused due to manufacturing, material or design defect.

Noted and agreed No change is required as it is already elaborated in preceding clause

9. INSTALLATION, COMMISSIONING & MAINTENANCE:

Headline Noted and agreed -------

9.1 On placement of order, supplier whose equipment will be purchased for the "First Time" for installation on the coaches, shall have to depute his representative at his own expense to associate with the purchaser in installation and commissioning of the equipment on the first five coaches. He shall also depute his representative during maintenance schedules undertaken on his equipment as per maintenance booklet supplied by him.

Noted. Noted and agreed ---------

9.2 With every order for supply of the Air Spring Failure Indication Cum Brake Application (FIBA) Device, the supplier shall have to supply maintenance instructions in the form of two booklets (hard copy) and one copy on Compact Disc (MS-Office compatible).

Noted. Instead of Compact-Disc, email of the maintenance manual shall be sent to the concerned Railways.

Noted and agreed No change is required as mailing facility is not available in all depots

9.3 Maintenance booklet supplied by the supplier shall cover the following aspects in detail: 1) Specification of the Air Spring Failure Indication

Cum Brake Application (FIBA) Device.

2) Working principle based on the actual construction.

3) Constructional details giving sketches, drawings and photographs etc. identifying various items and their part numbers etc. for easy identification.

4) Procedure for dismantling using sequential steps

with the help of sketches.

5) Procedure for assembly, using sequential steps with the help of sketches.

6) Jigs, tools, other materials and details of special

set-ups etc., necessary for item 4 & 5 above.

7) Testing procedures and facilities required along with their details.

8) Details of prevention maintenance kit, required for

periodical preventive maintenance of Air Spring Failure Indication Cum Brake Application (FIBA) Device as recommended by the supplier.

8) Comprehensive details containing legible sectional

views of defects normally observed or may happen on FIBA device with clear remarks whether the defect is rejectable or non-rejectable.

9) List of other defects and their remedies.

10) Periodicity for various maintenance activities on

time and distance basis. 11) Do's and Don'ts for maintenance officials.

1) Noted.

2) Noted. 3) Noted. 4) Noted. 5) Noted. 6) Noted. 7) Noted. 8) Noted. 8) Noted 9) Noted 10) Noted 11) Noted

Noted and agreed 1) Noted. and agreed

2) Noted and agreed. 3) Noted. and agreed 4) Noted. and agreed 5) Noted. and agreed 6) Noted. and agreed 7) Noted. and agreed 8) Noted. and agreed 8) Noted and agreed 9) Noted and agreed 10) Noted and agreed

-----------

-----------

----------- -----------

-----------

-----------

-----------

-----------

-----------

-----------

-----------

-----------

10. INSPECTION AND TESTING: Headline

10.1 General requirements: During initial approval of a firm by RDSO (Clause 7) and later on when approval has been granted, RDSO for purpose of ensuring quality of purchased product may carry out periodic quality audit, inspection and testing of the equipment at the premises of the manufacturer. Purchase inspection shall be done at the premises of the manufacturer by a representative of the Research Designs and Standards Organization or an agency authorized by RDSO. The supplier shall have to arrange for the following and associate with the same: 1) Access to all records considered relevant for

such activity by inspecting officials.

2) Questioning of relevant personnel engaged in production, testing and quality checking activities etc. or related issues.

3) Testing of few samples of items already

produced by the firm to ascertain the technical characteristics given in this STR.

4) Any other check considered necessary by the

inspecting party.

5) The inspecting official shall carry out purchase inspection as per inspection check list attached at Annexure “B” of this STR.

6) The supplier should have credentials of supply of

FIBA device and other items as laid down in clause 4 of this STR and will be fully responsible for the delivery of accessories such as Isolating Cock (OLP Type) 20mm bore, Isolating Cock 20mm bore with vent hole, Hose Connection and Hardware etc. Technical documentation, and type testing etc., within the time schedule included in the purchase order.

7) Item no.3, 4, 5 & 6 shall be supplied already

inspected by RDSO/RITES as per respective STR. Inspection Certificate of the same shall be

Deadline 1) Noted. 2) Noted. 3) Noted. 4) Noted. 5) Noted. 6) Noted. However RDSO should clarify the statement “Technical document and type testing etc., within the time schedule included in the purchase order”. 7) Noted. For item 3, 4 and 5, RDSO check sheet exist, hence the same shall be used for purchase inspection

by RDSO/RITES. Item 6 i.e. Nut/Bolts & fasteners are standard items and the same are not mentioned in the RDSO

vendor list. They will be supplied against our works test certificate and not against RDSO/RITES inspection

8) Noted.

Noted and agreed 1) Noted and agreed. 2) Noted and agreed. 3) Noted and agreed. 4) Noted and agreed. 5) Noted and agreed 6) Noted and agreed. 7) Noted and agreed

-----------

-----------

-----------

-----------

-----------

-----------

----------- 6) “Technical documentation, and type testing etc.” may be deleted from the clause10.1.6.

7) No change is required as the inspection will be done as per stipulation in STR

provided by the firm at the time of inspection of FIBA device and Indicator.

8) The supplier shall be fully responsible for

successful running of the system.

9) The performance of equipment should be equally good for tare and loaded condition.

9) Noted.

8) Noted and agreed. 9) Noted and agreed.

8)------------ 9)-------------

10.2 Inspection and testing of Air Spring Failure Indication Cum Brake Application (FIBA) Device:

Noted.

10.2.1 Dimensional check:

ITEM REFERENCE

DOCUMENTS

Air Spring Failure

Indication Cum

Brake

Application

(FIBA) Device

As per Firm’s

assembly drawing

approved by RDSO,

Clause 1 of

ANNEXURE-B &

technical requirements

of clause 6 of this

STR.

Indicator of

FIBA device

Hose

Connection

RDSO drg no. K1054

& STR C-K407 (latest

rev.)

Isolating Cock

(OLP Type)

20mm bore

RDSO sketch 97002 &

STR C-K407 (latest

rev.)

Isolating Cock

20mm bore

with vent hole

RDSO drawing no. 02

610 0871

Noted. Noted. Noted. Noted. Noted. Noted. However the RDSO drawing no. 026100871 is not clear. We understand the correct drg. no. is SK-98013.

Noted and agreed RDSO drawing no. 02 610 0871 is modified as RDSO drawing no. SK-98013

10.2.2 Functional test of the FIBA device:

Functional test of FIBA device shall be carried out as per ANNEXURE- B of this STR. Functional testing of Indicators of FIBA device shall also be carried out as per clause 4 of ANNEXURE-B. Leak test of Air Spring Failure Indication Cum Brake Application (FIBA) Device shall be carried out as follows- - Install the Air Spring Failure Indication Cum

Brake Application (FIBA) Device at test bench. - Gradually raise the air pressure to 2 kg/cm

2 and

thoroughly check the air leakage from FIBA device with the help of liquid soap solution.

- Gradually raise the air pressure to 10 kg/cm2

- There should be no leakage from any joint, port or FIBA device. Repeat the same procedure for leakage testing of Indicator.

Noted. Noted. Noted. Noted. Noted. Noted. Noted.

Noted and complied

--------------------- ----------------------- ------------------------ ---------------------- ---------------------- ------------------- --------------------

10.3 10% samples of the lot or a minimum 10 samples shall be picked up randomly for dimensional & other specified inspections as given in clause 9.2 of this STR.

Noted. Sample size is too large. As per the standard RDSO inspection guidelines, 2% or minimum 02 nos. per lot should be the sample size. Reference to clause 9.2 should be corrected. There should be a standard guideline for sampling size.

Noted and agreed.

9.2 may be read as 10.2.2 10% is reasonable, hence no change is required

10.4 For other specified inspections a given in clause 9.2 of this STR, samples shall be picked up randomly as under:

Lot size upto 10 25 50 75 100

No of samples 2 3 4 5 6

For lot sizes more than 100, 6% of the samples shall be picked up randomly for the above inspections.

Noted. The referred 9.2 doesn’t pertain to inspection. For FIBA device 10% is a large sample size. It should be amended to 2% or minimum 02 nos.

Noted and agreed 9.2 may be read as 10.2.2

10.5 In case any picked up sample fails, manufacturer/supplier shall re-offer, rectifying the defects. However, in such cases, double the quantity of samples shall be picked up and shall be checked for dimension and other specified testing. In case any one sample fails again, the entire lot shall be rejected.

Noted. Noted and agreed

11. MARKING: Every item of the Air Spring Failure Indication Cum Brake Application (FIBA) Device shall be legibly

Headline Noted. Noted. In our case we are making

Noted and agreed No change

marked to indicate the following: 1) Manufacturer's initials. 2) Month and year of manufacture. 3) Identification marks, i.e. Part Number, Batch

Number, etc.

week & year.

12. PACKING: The Air Spring Failure Indication Cum Brake Application (FIBA) Device shall be suitably packed along with its loose parts and exposed threaded portion, to protect against any damage that may occur during transit and handling. The threaded and other ports of the FIBA device shall be suitably covered with a plastic/rubber cap to prevent ingress of dust or foreign material in the FIBA device and Indicator.

Headline Noted.

Noted and agreed

13. MAINTENANCE MANUAL: The supplier shall provide at least one copy free of cost for each consignment, a detailed maintenance manual for maintenance and overhaul purpose.

Headline Noted. Please refer our comments to clause no.9.2

Noted and agreed No change

14. GENERAL: Headline

14.1 RDSO may draw samples for quality check to test any property mentioned in this specification at it’s discretion. The vendor shall arrange testing of these samples at a reputed outside laboratory as decided between RDSO and the vendor. The testing charges should be borne by the vendor.

Noted. The costs for testing the samples picked up by RDSO at random, other than during purchase inspection, shall be borne by RDSO/IR.

Noted and agreed No change is required. Such testing will be only on complaining quality of product or random examination for which supplier has to bear the cost.

14.2 Additional information if required may be obtained from the office of the Director General (Carriage), RDSO, Manak Nagar, Lucknow – 226011.

Noted. Noted and agreed

REQUIREMENTS OF TYPE TEST REPORT Annexure – A

The type test report of Air Spring Failure Indication Cum Brake Application (FIBA) Device shall consist of the following, clearly represented by graphs as well as in tabulation forms, with detailed test procedures and their results: -

Noted. Noted and agreed

1) MATERIAL TESTS Headline.

Material test report (supported by standard test specifications). Material test of FIBA device including rubber part shall be carried out in ISO and NABL approved lab for confirmation of properties of materials as per approved QAP and drawings of the firm. Testing shall be done as per ASTM/IS/EN/UIC standard.

Noted. Noted and agreed

2) ENDURANCE TEST OF AIR SPRING FAILURE INDICATION CUM BRAKE APPLICATION (FIBA) DEVICE:

Headline. Noted and agreed

a) The endurance test is conducted to assess suitability of the Air Spring Failure Indication Cum Brake Application (FIBA) Device provided at secondary stage suspension in coach bogie by simulating service condition. b) FIBA device shall be tested for 1000 actuation cycle for each valve. Actuation pressure of both side FIBA valves shall be recorded continuously for first 100 cycles and afterward at every 10th cycles for each Valve. Actuation pressure of FIBA valves shall be within specified limit. c) The test on Air Spring Failure Indication Cum Brake Application (FIBA) Device shall be conducted only when the results of functionality test are obtained and found satisfactory.

a) Noted.

b) Noted.

c) Noted.

Noted and agreed Noted and agreed Noted and agreed

3) Burst pressure test of FIBA device shall be done after endurance test, as per para 2 of Annexure- “A” of this STR.

Noted. There is no burst test for

FIBA device. Clause to be

suitable amended.

Instead of Burst Pressure Test, it will be better to check Pressure tightness test at 10 Kg/cm

2 as

per annexure B.

“Burst pressure test” may be replaced with “High Pressure test”

4) Any other test felt necessary by the manufacturer. Noted. Noted and agreed

5) The type test should be repeated at the time of renewal of registration after first time acceptance of a particular design of Air Spring Failure Indication Cum Brake Application (FIBA) Device.

Noted. Noted and agreed

6) Leak test of Air Spring Failure Indication Cum Brake Application (FIBA) Device as detailed at para 10.2.2 of this STR.

Noted. Noted and agreed

7) Tolerance in different dimensions of Air Spring Failure Indication Cum Brake Application (FIBA) Device should be as per IS 2102 (Part -I) and mentioned in Type Test Report and drawing.

Noted. IS:2102 (Part-I) pertains to

tolerances on machined parts

only and doesn’t cover the

tolerances on rubber parts,

springs, casting and assembly

dimensions. Clause should be

amended accordingly.

Noted and agreed Clause 14.2. 7) may be modified as under: Tolerance in different dimensions of Air Spring Failure Indication Cum Brake Application (FIBA) Device for machined parts should be as per IS 2102 (Part -I). However for other components

ANNEXURE – B CHECKLIST FOR INSPECTION OF AIR SPRING FAILURE INDICATION CUM BRAKE APPLICATION DEVICE

As per inspection and testing Clause no.10.0

M/s KBI’s Comments M/s SIl’s Comments M/s FTIL’s Comments

1. Dimensional Check (10% of the Lot Qty.) Noted. Kindly refer our comments to clause 10.3. Noted and agreed

M/s KBI’s Comments M/s SIl’s Comments M/s FTIL’s

Comments

S. no.

Particulars Unit Specified Observed Remarks Headline.

Sample No. Headline.

1 Length of FIBA Device mm As per Noted.

2 Height of FIBA Device mm approved Noted.

3 Thickness of FIBA Device without bkt.

mm drawing Noted.

4 Thickness of FIBA Device with bkt.

mm Noted.

5

Port diameter and thread:

BP ¾” BSPP

Noted. B1 ¾” BSPP

B2 ¾” BSPP

IND ¼” BSPP

6 Mounting bkt hole pitch of FIBA mm 134±1 Noted.

manufactured by different process respective IS to be followed duly mentioned in Type Test Report and respective drawings.

Device

7 Dia of mounting bkt. Holes

Hole 1 mm 18±0.5 Noted. As per RDSO drawing CG-K10031, there are three mounting holes of dia. 18 mm and the same is provided by us.

3rd

Hole added at s. no. 7

Hole 2 mm 18±0.5

Hole 3 (if available)

mm 18±0.5

8 Weight of FIBA valve with bkt Kg

As per

Noted. approved

drawing

9 Height of indicator mm As per Noted.

10 Width of indicator mm approved Noted.

11 Thickness of indicator mm drawing Noted.

12 Total Height of indicator mm Noted.

13 Inlet port dia of indicator mm mm Noted.

14 Weight of indicator Kg

As per

Noted. approved

drawing

M/s KBI’s Comments M/s SIl’s Comments M/s FTIL’s Comments

2. Leak Test of Air Spring: As

per Clause 9.2.2 of section A.

Noted. Clause should be read

as “Leak test of FIBA” instead of

“Leak test of Air Spring”.

Noted and agreed Clause should be read as “Leak test of FIBA device” instead of “Leak test of Air Spring”.

Clause 9.2.2 may be read as 10.2.2

M/s KBI’s Comments M/s SIl’s Comments M/s FTIL’s Comments

3. Functional test of

FIBA device:

Noted. Clause 9.2 is not pertaining

to testing of FIBA device, may

kindly be corrected.

Noted and agreed

Clause 9.2.2 may be read as

10.2.2

M/s KBI’s Comments M/s SIl’s Comments M/s FTIL’s Comments

S. No.

Test and testing procedure

Standard

Results of FIBA device sample obtained

Noted.

S. No. Mfg dt

S. No. Mfg dt

1

Initial Charging: i) Ensure that all Isolating cocks and cut of angle cocks in supply line should be in open condition. Other end cut of angle cocks and drain cocks provided on test bench should be in closed position. ii) Charge the FP line at 6.0 Kg/Cm2 and BP line at 5.0 Kg/Cm2.

--------- FP= 6 + 0.1 Kg/Cm2 BP= 5 + 0.1 Kg/Cm2

Noted. We are using only isolating cocks on the Test Benches. There are no cut-off angle cocks/end cut of angle cocks. As per earlier test proforma, tolerance on FP/BP pressure is ±0.1 Kg/cm2.

Cut of angle cock may be deleted

2

Leak Test: Check for any leakage in FIBA device & pipe lines. No leakage is permitted in FIBA device and through its joint. Total leakage in system should not be more than 0.2 Kg/Cm2 in 60 sec.

Leak test within limit.

Noted.

3 High Pressure test: Charge FP and BP upto 10.0 Kg/Cm2.

i) No leakage in FIBA device Valve ii) FIBA device should not operate. iii) No damage in FIBA device or circuit.

i) Noted. ii) Noted. iii) Noted.

Noted and agreed

“Pressure tightness test” replaced with “High pressure test”

4

Insensitivity test: Drop the air pressure of one air spring side by 0.5 Kg/Cm

2 in 10 seconds

with the help of the respective choke/drain cock. Repeat the process for other side air spring.

i) No response and no exhaust of air from the exhaust port. ii) Indicators do not turn red.

i) Noted.

ii) Noted.

Noted and agreed

A) Functional Test at 2.0

Kg/Cm2 (Tare Pressure) i. Charge the FP at 2.0

Kg/Cm2 Pressure and BP at 5.0 Kg/Cm2.

ii. Open the ½” drain cock to drain the air pressure of one side air spring/40L auxiliary reservoir.

Repeat the process for

other side air spring.

i)Pressure in respective gauge start falling & FIBA device actuate when respective gauge pressure becomes less than 1+0.1 Kg/Cm2.

ii)BP pressure starts venting gradually and settles at 3.4 Kg/Cm2 approx.

iii) Both indicators should be red.

Hissing sound of 90+ 5db should blow.

i) Noted. As per

our approved test plan and earlier test proforma, tolerance on pressure setting for FIBA device is1 ±0.1 Kg/cm2.

ii) Noted. iii) Noted. Noted. Tolerance should be 90±5 dB.

“whistling sound” is deleted

BP Isolation: (Brake release and suppression of whistle) Close the Isolating cock provided before FIBA device in BP line.

i) BP pressure exhaust, through FIBA device exhaust port stops and BP pressure rises to 5 Kg/Cm2. ii)Whistling/Hissing sound stops. iii) Both indicators show red/green.

i) Noted. ii) Noted. iii) Noted. The

clause (iii) should be modified as “Both indicators show red” to meet the requirement stated in clause 6.1.17.

“whistling sound” is deleted and replaced with hissing sound

Suppression of Indicator:

Both indicators of same bogie should turn to green from red.

Noted. However feature is there but during testing of FIBA

“same bogie” may be replaced with the FIBA device”

Close the both isolating cocks with vent feature or pull the resetting keys provided on FIBA device.

Indicators of other bogie should remain show green.

device on test bench there is no provision for 2

nd bogie. Hence

“Indication of other bogie should remain show green” to be applicable only in case of testing on actual coach.

Indicators of other bogie should remain show green. May be deleted

B) Functional Test at 6.0 Kg/Cm2:

iii. Charge the FP at 6.0 Kg/Cm2 Pressure and BP at 5.0 Kg/Cm2.

iv. Open the ½” drain cock to drain the air pressure of one side air spring/40L auxiliary reservoir.

Repeat the process for other side air spring

i)Pressure in respective gauge start falling & FIBA device actuate when respective gauge pressure becomes less than 1+0.1 Kg/Cm2.

ii)BP pressure starts venting gradually and settles at 3.4 Kg/Cm2 approx.

iii) Both indicators should be red.

iv)Whistling/ Hissing sound of 90+ 5db should blow.

i) Noted. As per our approved test plan and earlier test proforma, tolerance on pressure setting for FIBA device is1 ±0.1 Kg/cm2.

ii) Noted iii) Noted iv) Tolerance

should be 90±5 db.

“whistling sound” is deleted and/or replaced by “hissing sound”

BP Isolation: (Brake release and suppression of whistle)

i) BP pressure exhaust, through

i) Noted.

Whistle is replaced with hissing sound

Close the Isolating cock provided before FIBA device in BP line.

FIBA device exhaust port stops and BP pressure rises to 5 Kg/Cm2.

ii) Noted.

ii) Whistling / Hissing sound stops.

iii) Clause should be read as “Both Indicators should be remaining red”. Indicators shouldn’t reset automatically until the defective Air Spring is attended. Therefore the clause should be amended accordingly.

“whistling sound” is deleted and/or replaced by “hissing sound”

iii) Both indicators show red/green.

Modified as “Both indicators should show red”

Suppression of Indicator:

.Both indicators of same bogie should turn to green from red Indicators of other bogie should remain show green.

Noted. However feature is there but during testing of FIBA device on test bench there is no provision for 2

nd bogie. Hence

“Indication of other bogie should remain show green” to be applicable only in case of testing on actual coach.

Indicators of other bogie should remain show green. May be deleted

Close the both isolating cocks with vent feature or pull the resetting keys provided on FIBA device.

6

Brake Pipe Variation Test:

i) FIBA device should not actuate.

i) Noted.

Drop Brake Pipe pressure from 5.0 Kg/Cm2 to zero.

ii) FP line pressure should not drop.

ii) Noted.

Noted and agreed

iii) Both indicators should show green.

iii) Noted.

iv) No whistling/Hissing sound. iv) Noted

.

“whistling sound” is deleted

7

Charging Behaviour test:

FIBA device should not actuate

Noted. Noted and agreed Charge BP prior to FP and observe the actuation behaviour of FIBA Device if actuated.

8

Resetting behaviour test:

FIBA device should not reset

i) Noted.

i) Charge the system at 5.0 Kg/Cm2 pressure.

automatically ii) Noted

.

ii) Drop FP line pressure and actuate the respective FIBA Device.

iii) Noted

.

iii) Close the drain cock and raise FP line pressure of FIBA Device to again5.0 Kg/Cm2.

Clause

no.

Clause description M/s KBI’s Comments M/s SIl’s Comments M/s FTIL’s Comments

4. Testing of Indicator: Noted.

i Leakage test: Noted. Noted and agreed

Apply a pressure of 10 Kg/Cm2. There

should not be any leakage if checked with

soap water.

Noted.

ii Functionality Test: Noted. Noted and complied

a)Apply a pressure of 0.5 to 0.6 Kg/Cm2. Red colours should appear in window of Indicator. Movement of Piston of Indicator shall be smooth and steady.

Noted. Noted and complied

b) Now release the pressure to 0 Kg/Cm2. green colours should appear in window of Indicator.

Noted. Noted and complied

c) Piston of indicator should move smoothly and piston should not be sticky. Indicator shall be air tight and water resistant.

Noted. Noted and complied

Clause description M/s KBI’s Comments

M/s SIl’s

Comments

M/s FTIL’s

Comments

Noted. Mounting holes size is must for

interchangeability and hence maintained

by us. Location of ports is design specific,

which depends upon the location of

devices on the manifold plate. As long as

the ports are within space envelop, it

should be left to be decided by individual

manufacturer as these are connected

through flexible hose with the pipe. Also

the internal dimensions such as 22 & 60

of bracket to be left the discussion of

individual manufacturer. The RDSO

drawing CG-15078 should be updated

accordingly.

In case RDSO wants to be standardized

the location of inlet ports of FIBA device,

it is advisable RDSO drawing no. CG-

15078 should be amended as per our

approved drawing no. C149523 alt.02. As

KBI is the only manufacturer which have

completed their installation and field trial

successfully as per IR.

No change. We may use

steel pipe in future as is

used in Air Dryer system

of Locos. Hence fixing

port location is a must

requirement from

manufacturing and

maintenance point of

view.

Clause description M/s KBI’s

Comments

M/s SIl’s

Comments

M/s FTIL’s

Comments

Noted. 02 nos.

Isolating cock

with vent (ICV)

per bogie has to

be provided in the

line from Bellows

to FIBA device,

needs to be

mentioned in

legends.

No change

Clause description M/s KBI’s

Comments

M/s SIl’s Comments M/s FTIL’s

Comments

Noted.

Clause description M/s KBI’s Comments M/s SIl’s Comments M/s FTIL’s Comments

Noted. Dim. 34 should

be changed to Dim. 26

as per RDSO drawing

CG-15078. Also dim.

336 should be changed

to 320.

No change