CARRIAGE WORKSHOP

SOUTH CENTRAL RAILWAY

LALLAGUDA, SECUNDERABAD

AN INTERNSHIP REPORT

ON

STUDY OF LHB AIR BRAKE & EP BRAKE SYSTEM

SUBMITTED BY
S.PRANEET KUMAR 16B81A03B4
G.HANOCK BABU 16B81A0352

CVR COLLEGE OF ENGINEERING

(UGC Autonomous Institution)
Affiliated to JNTU Hyderabad
Vastunagar, Mangalpalli (V), Ibrahimpatnam (M),
Ranga Reddy (Dist.), Hyderabad – 501510, Telangana State
 ACKNOWLEDGEMENT

With the deep sense of gratitude and thankfulness, we acknowledge the

instructions and supervision, support and effective cooperation given by the
following people whose guidance has supported the effort which led to the
successful completion of this work.

We express our sincere gratitude to Dr. M. VENKATA RAMANA, head of the

department of Mechanical Engineering Department, CVR College of Engineering,
Mangalpally for permitting us to undertake the Internship at Railway Carriage
Workshop, Lallaguda.

We express our sincere gratitude to Shri. PRASHANT KUMAR, Production

Engineer, Carriage Workshop, Lallaguda, who allotted us into this Internship.

We express our sincere gratitude to Smt. C. SIRISHA, Chief Instructor, Basic

Training Centre, Carriage workshop, Lallaguda, who allowed us into this
Internship.

We also express our gratitude to one and all for instant support and rendered
help in completing this Internship.
 CONTENTS
 Complete study of LHB Air Brake System with circuit diagram.
 DV (Distributor Valve) overhauling and testing.
 WSP (Wheel Slide Protection) System in LHB Coaches.
 POH Procedure and components of LHB Air Brake System.
 Study the working principle of EP Brake System with circuit diagram.
 POH Procedure & components of EP Brake System.
 LHB COACH BRAKE SYSTEM (FTIL Type)

1.0 Introduction

The Axle Mounted Disc Brake System of the recent Alstom-LHB design
Mainline Passenger Stock for Indian Railways from the layout shown in IR
drg no. SK 85155 duly incorporating changes to meet the requirement of
the Alstom-LHB specification is shown in air brake schematic drawing No.
A2 040 0210 and A2 040 0209.

This air brake schematic is for AC-NON AC (FOG)/ACCN (SG) Coaches and
Power Car and SLR coaches respectively.
The brake system meets various conditions in the specification laid down
by RDSO Indian Railway.
The brake system equipment provided on the Alstom-LHB coach comes on
the broad classification as under:

\a) Brake Frame control equipment

b) Brake Control equipment in the system layout
c) Disc Brake Equipment on the bogie
d) Wheel Slide Protection equipment (device)

The basic system of Twin Pipe graduated release air brake conforming to RDSO
specification no. 02-ABR-94 & 04-ABR-94 with 25 mm bore dia of BP / FP at 5.0
& 6.0 kg/cm2 operating pressure respectively in use on Passenger Coaches on
IR however is retained. Another set of FP & BP branch pipes are also provided
in each Coach on the either side of Central Draw Bar with BP, FP End Cocks and
Hose Couplings to provide straight connections of Hose Coupling sets during
the reversal and attachment of the Coaches to the formation.
The details of sophistication additionally provided on LHB Coach brake system
are as under:
A Brake Panel with an Aluminium Slab manifold accommodates the Critical
Valves of t he brake system. This provision protects the Valves from the
vulnerability of impact damages from ballast / flying debris during train
operations, eliminate substantial piping work and facilitate maintenance by
unit replacement. It also contains test points for checking the pressures of BP,
AR, DV, BC and CR outputs at one location itself.

The C3W lP DV incorporates additionally Relay Valve which ensure consistent

application and release timings of Brake Cylinder irrespective of the volumes
at all times.

A Brake Pipe Accelerator Valve with an Isolating Cock is connected to the

Brake Pipe of the
vehicle that provides rapid venting of the Brake Pipe Air. It comes to action
during brake applications whenever the BP pressure is exhausted at an
emergency rate and does not get activated during normal braking function up
to full service position of the Driver’s Brake Valve.

Five Passenger Emergency Valves are provided inside the Coach of Chair Car
to enable a passenger for operation towards stopping the train in case of an
emergency. These Valves are connected to a single exhaust Valve that opens
the Brake Pipe line to atmosphere whenever any of the Passenger Emergency
Valve is operated. The passenger emergency alarm valves are provided
limited switches and LED indication lamps to locate the particular valve which