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

00 for FIBA device

STR Clause description M/s KBI’s Comments M/s SIl’s Comments M/s FTIL’s Comments RDSO remark
Clause
no.
FOREWORD -------- Noted and agreed Air Spring Failure Air springs have been
This Schedule of Technical Requirements (STR) spells out Indication Cum Brake fitted in BG ICF, LHB,
the schedule of technical requirements of Air Spring Application (FIBA) Hybrid and double decker
Failure Indication Cum Brake Application (FIBA) Device Device for Air Spring mainline coaches.
for Air Spring fitted in BG ICF, LHB, Hybrid and double fitted in BG ICF, Hence no change is
decker mainline coaches having ICF and LHB type bogies. Hybrid and double required.
decker mainline coaches
This Schedule of Technical Requirements is concerned having ICF type bogies.
with the Air Spring Failure Indication Cum Brake
Application (FIBA) Device and details of the requirements FTIL Remark: LHB
and tests for the Air Spring Failure Indication Cum Brake coaches do not have the
Application (FIBA) Device. Air Suspension Control
equipment and hence
The specification shall not be altered /modified or this standard is not
reproduced in any form without the written permission of applicable to this coach.
the Director General (Carriage), RDSO, Lucknow.

1. SCOPE:

1.1 This schedule lays down the technical requirements - Noted and agreed …… Air spring failure Air springs have been
for the design, manufacture and supply of Air Spring Indication Cum Brake fitted in BG ICF, LHB,
Failure Indication Cum Brake Application (FIBA) Application (FIBA) Hybrid and double decker
Device for air spring fitted BG ICF, LHB, Hybrid and Device for Air Spring mainline coaches.
Double Decker mainline coaches having ICF and LHB fitted “BG ICF, Hybrid Hence no change is
type bogies on Indian Railways. Scope of supply and Double Decker required.
shall generally be as per clause 4 of this Schedule of mainline coaches having
Technical Requirements (STR). However, if the ICF type bogies”……
supplier feels that certain additional items are FTIL remark: LHB
necessary for improved working performance of the coaches don’t have
system, he may quote for the same. In any case, Suspension control
purchaser will be at liberty to buy all or part material equipment and hence
from the offer. this standard is not
applicable to this coach
and hence LHB type
bogies shall be removed
1.2 Flexible hoses, Isolating Cock, Isolating cock with Noted and agreed ……ABR-02 and firm’s Indicator of FIBA device
vent feature for the Air Spring Failure Indication Cum approved drawings by should be to RDSO STR
Brake Application (FIBA) Device should be supplied to RDSO, Indicator of no. RDSO/2011/CG-04
RDSO’s STR C-K407 (Latest Revision), ABR-02 and FIBA device should be (Latest Rev.) to be read
 firm’s approved drawings by RDSO. Indicator of FIBA to RDSO STR no. as:
device should be to RDSO STR no. RDSO/2011/CG- RDSO/2011CG-04 Indicator of FIBA device
04 (Latest Rev.) The Air Spring Failure Indication (Latest Rev.)” wherever should be as per RDSO
Cum Brake Application (FIBA) Device should be applicable”……. STR no. RDSO/2011/CG-
compatible with the other items as described in the FTIL remark: The 04 (Latest Rev.)
above STRs. The purchaser will be at liberty to buy referred RDSO spec
any part or complete item as mentioned above and Air calls for only the
Spring Failure Indication Cum Brake Application selected items for this
(FIBA) Device to this STR from different source of requirement and hence
supply. the “wherever
applicable shall be
added
2. OPERATING CONDITIONS: Headline

2.1 The Air Spring Failure Indication Cum Brake Noted …… Air spring failure No change is required.
Application (FIBA) Device will be fitted in mainline Noted Indication Cum Brake
coaches fitted with LHB/ICF bogies having Air Application (FIBA)
suspension in secondary stage. 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
2.2 The Pneumatic suspension system works under two Noted Noted ---
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.
2.3 Compressed air supply to the air spring assemblies Noted. Noted ----
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.
2.4 Each coach shall be fitted with four air spring Noted. There will be one FIBA per Noted and Complied Clause may be
assemblies (two per bogie) and each Air Spring bogie. Each FIBA device will modified as under:
Failure Indication Cum Brake Application (FIBA) monitor both the air spring of “Each coach shall be
Device shall be controlled by an independent levelling bogie. fitted with four air
valve (4-point control system). Two air springs of the spring assemblies (two
same bogie shall be connected through a duplex per bogie). There will
check valve set to act at a pressure differential of 1.5 be one FIBA device per
+ 0.12 Kg/cm². 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 Noted. Each FIBA device is Noted Clause modified as
in the suspension design, FIBA device connected with connected to both the air springs of under:
each air spring has been fitted in air spring fitted a bogie. In the event of air spring To meet the
coaches. FIBA device will send a message to the failure, FIBA device actuate the requirement of a fool
crew of the train in the event of air spring failure application of brakes, which will proof arrangement in
(which will ultimately demand a reduction in the immediately reduce the speed of the suspension design,
operating speed). An emergency situation is possible the train and ultimately cause the FIBA device connected
due to the likely hood of spring damage, possibility of train to stop. Indicators of with each air spring
air supply failure or due to sudden rupture or bursting respective failed air spring will turn has been fitted in air
of bellows of air springs due to any reason. to red and whistling sound will blow spring fitted coaches.
to indicate the location. The train is FIBA device will send a
checked by the engine crew 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 Noted. Noted “whistling sound” is
the application of brakes in the event of air spring replaced with “hissing
failure, which will immediately reduce the speed of the sound”
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.
3. ENVIRONMENTAL CONDITIONS: Headline

3.1 Air Spring Failure Indication Cum Brake Application Noted. Noted Max. Temperature
(FIBA) Device shall be subjected to following
under sun: 60ºC.
environmental conditions.
modified as:
Max. Temperature under sun: 60ºC.
Max. Ambient
Ambient temperature: 0º to 45ºC in shade.
Temperature under
Average relative humidity: 70% to 90%, 100% on
sun: 60ºC.
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.
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: Headline Noted and Complied

The scope of supply covers the following items: Noted. 3+2 may please be
One FIBA device per bogie or 02 FIBA device per replaced by one set.
coach will be required.

i) For each Air Spring Failure Indication Cum

Brake Application (FIBA) Device:
S. Item Quantity
No.

1 Air Spring Failure 1

Indication Cum Brake
Application (FIBA)
Device

2 Indicator 2

3 Hose connection 3/4'’ 3

BSPX550 mm with
both end rubber
washers

4 Isolating cock (OLP 1

type) 20mm bore

5 Isolating cock 20mm 2 Quantity “3+2” may be

bore with vent hole read as “*one set”
Following note also to
be added with * mark:
* One set shall mean
total nut bolts/fasteners
Noted. with locking washer
 6 Nut bolts/fasteners 3+2 required for mounting
with locking washer of 01 FIBA device and
for mounting of FIBA 02 Indicators for each
bogie.
device and Indicators

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.
5. PROCEDURE FOR VENDOR REGISTRATION: Headline
5.1 Vendors willing to supply Air Spring Failure Indication Noted. --------------
Cum Brake Application (FIBA) Device for the use of Noted and agreed
Indian Railways shall register themselves with
Research Designs and Standards Organization,
Ministry of Railways, Lucknow-226011 (RDSO) and
should be ISO approved.
5.2 The Vendor shall have a well-documented ‘Internal Noted. Noted and agreed ----------------
Quality Assurance System’ to ensure sustained
quality of product being manufactured. The Quality
Assurance System’ shall generally cover the
following:-
5.2.1 System to ensure that correct raw material is being Noted. Noted and agreed --------------
used.
5.2.2 System to ensure that components having Noted. Noted and agreed
manufacturing defects are identified and destroyed so --------------------
that such components are not used during assembly
of air spring.
5.2.3 System to ensure that bought out components are Noted. Noted and agreed -------------------
strictly as per requirements laid down in the STR /
drawing.
5.2.4 System to maintain strict control of dimensions and Noted. Noted and agreed --------------------
workmanship of components and assembled product.
5.2.5 System to test and establish that the Air Spring Noted. Noted and agreed ----------------
Failure Indication Cum Brake Application (FIBA)
Device manufactured by the firm meets all the
requirements laid down in STR / drawing.
5.2.6 System of periodical calibration of equipments/gauges Noted. Noted and agreed -----------------
to ensure accuracy of product.
5.2.7 System to ensure cleaning & removal of dust/rust and Noted. Noted and agreed ------------------
moisture by dry air.
5.2.8 System to ensure that Air Spring Failure Indication Noted. Noted and agreed --------------------
Cum Brake Application (FIBA) Device is properly
packed to meet the requirement of Clause-12 of this
 STR.
5.2.9 System to ensure traceability at least up to guarantee Noted. Noted and agreed -----------------
period.
5.3 Special Conditions: Headline
5.3 a) Air Spring Failure Indication Cum Brake Application Noted. Noted and agreed -----------------------
(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.
5.3 b) Since Air Spring Failure Indication Cum Brake Noted. Noted and agreed ----------------
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.
5.3 c) The Air Spring Failure Indication Cum Brake Noted. Type test should be Noted and agreed Following may be
Application (FIBA) Device of a particular design shall conducted at the time of approval added at end of the
be subjected to field trials on a minimum of ten coach of a product and before granting clause:
sets for one year on IR’s system for vendor the clearance for field trials. Trial “Type test shall be
registration as Part-II status for manufacture and quantity should be at least one conducted at the time
supply of FIBA device. rake and trial period should be 18 of approval of a
months which would be inline with product and before
POH of a coach to assess the granting the clearance
performance. Similar practice is to for field trials”.
be adopted for EMU’s and LHB
Brakes.
5.3. i In case of any failure during field trials attributable to Noted. Noted and agreed ------------------
poor design or material, the field trials shall be
repeated.
5.3. ii After completion of service trial period, a sample of Noted. The service trials should be Noted and agreed Clause may be
the Air Spring Failure Indication Cum Brake repeated. modified as under:
Application (FIBA) Device shall be subjected to the After completion of
tests laid down at para 10.2.2. In case these values service trial period, one
are beyond permissible limits, the air spring design sample of the Air
shall be deemed to have failed the service trials. 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 Noted. Noted and agreed -------------
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
5.3. iv A vendor considered eligible for upgradation to Part – Noted. Type test is conducted to Noted and agreed
I status shall undertake manufacturing facilities and assess the suitability of particular
process of manufacturing. At this stage fresh type test design and accelerated
shall be essential. The sample Air Spring Failure performance parameters. Type test
Indication Cum Brake Application (FIBA) Device shall should be conducted at the time of
be picked up by RDSO. Vendor shall arrange the approval before going for field
detail type testing of sample Air Spring Failure trials. The performance of a
Indication Cum Brake Application (FIBA) Device at his particular design is already
own cost and type test facilities. established with field trials of 10
coaches for one year and then
 The vendor has to submit the fresh drawing and further fitment on 500 coaches.
modified QAP for approval before undertaking Type test should be done only
in-house manufacture of these components. when there is a major design
change based on field
For grant of Part – I status after the acceptance of assessment. The clause should be
fresh Type test report by RDSO a minimum of 500 modified accordingly. “a” to be replaced with
coach sets of Air Spring Failure Indication Cum Brake Noted. “and” between
Application (FIBA) Device fitted with indigenous …………………Type
manufactured component as per para. (l) above must test report by
have been supplied by vendor. Air Spring Failure RDSO…………. and
Indication Cum Brake Application (FIBA) Device shall minimum of 500 coach
have been inspected by Carriage (VDG) Directorate, sets ………………
RDSO, Lucknow during service trial.
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 Noted. Noted and agreed -----------------
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.

5.3. vi The type test shall be witnessed by authorized Noted. Noted and agreed ----------------
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.
5.3. vii In case design of critical component is changed, fresh Noted. Noted and agreed ------------------
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.
5.3. In case, source of any component of Air Spring Noted. Sourcing of component is Noted and agreed It is a safety device
viii Failure Indication Cum Brake Application (FIBA) prerogative of manufacturer. hence the source of
Device is changed or any additional new source is Changing the source doesn’t call component suppliers
introduced, fresh type tests shall be required. The for type testing. Ensuring the needs to be proven
vendor should provide the detailed information of the quality of components from a new one. Therefore this
source changed/ additional source introduced along vendor and compliance to clause is retained as
with the documentary evidences for the record of this guarantee/ warranty obligation is such.
office. Firm shall validate the source in all respects i.e. the responsibility of manufacturer.
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.
6. TECHNICAL REQURIEMENTS: Headline
6.1 General technical requirement: Noted.
 General technical requirement of FIBA device shall be ----------
as under:

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

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.
6.1.2 A device to blow a whistle at a constant sound level Noted. As per our approved Noted and complied Modified as under:
irrespective of the pressure of compressed air in the drawings and product whistling is A device to emit a
bellow after the rupture has taken place. due to discharge of BP from device hissing sound at a
and is consistent in sound level till constant sound level
the discharge 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 Noted. Noted and complied “till either the ruptured
side of the bogie i.e 4 indicators per coach near turn bellow is rectified or the
under and mounted on underframe of the coach to system is isolated”
change colour from green to red till either the ruptured may be replaced with
bellow is rectified or the system is isolated. RDSO’s “till either the ruptured
drawing no. CG-K-10033 of latest revision may be bellow is rectified
referred for space envelop. Pipe diameter from FIBA properly or FIBA device
valve to indicator will be 1/4”. is reset by resetting
key provided on FIBA
device”
6.1.4. An isolating cock of 20 nb inlet and outlet ports to Noted. Isolating cock 10 mm “20 nb” may be
isolate the BP branch pipe connected to each Air bore can be used in replaced with “¾”
Spring failure indication device as per RDSO drawing place of 20mm bore
no.CG K-9132 of latest revision. for the same
operation without
suffering any trouble
of the said system.
6.1.5 It shall have two isolating cocks of 20 nb inlet and Noted. The reset cock is available Noted and complied “20 nb” may be
outlet ports with vent feature for quick discharge of the on FIBA device. Isolating coach replaced with “¾”
air from pipe line of FIBA device to reset the indicator should be used only to isolate and
position as green while isolating the defective air FIBA device. Indicators should not “to reset the indicator
spring system of affected bogie as per RDSO drawing reset automatically until the position as green while
no.CG K-9132 of latest revision. defective air spring is attended. isolating the defective
Therefore the clause should be air spring system of
amended accordingly. affected bogie” may be
deleted”
6.1.6 Noted. Noted and complied ---------
FIBA device shall be mounted on common bracket as
 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 Noted. Noted and complied ---------------
required per coach to indicate the condition of two
sets of adjacent bellows in both the bogies.
6.1.8 The equipment shall sense the rapid discharge of air Noted. Specific limit of air “ beyond the specified
pressure from any of the adjacent air bellows of same pressure is not given limit” may be replaced
bogie and move to apply brake in complete train if the with “ less than 1+0.1
discharge of compressed air from the bellow system Kg/Cm2”
is beyond the specified limit.
6.1.9 In addition to initiating brake in the complete train, it Noted. As per our earlier approval, Noted and complied No change
also shall actuate a hissing sound of 90+5decibel it is the hissing sound of 95+5
intensity with steady pitch to attract the attention of decibel BP discharge.
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.
6.1.10 It shall be possible to fit the FIBA device on the Noted. The fitment of FIBA device Noted and complied Modified as under: It
existing twin pipe graduated release air brake system shall not require any major shall be possible to fit
provided with air suspension system of the vehicle modification on the existing twin the FIBA device on the
without having to make any major modification in pipe graduated release air brake existing twin pipe
piping. system. However pipe connecting graduated release air
the FIBA device will have to be brake system provided
made/ provide by IR. 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 Noted. Noted and complied “The protection
Air Spring failure indication Device monitoring that equipment” shall be
particular bogie with the ruptured bellow alone shall replaced with “FIBA
actuate. The protection equipment in the other bogie device”
and also in the other coaches shall not actuate.
6.1.12 Noted. Noted and complied “Hybrid and ICF
It shall be possible to use the same Air Spring Failure coaches with
Indication Cum Brake Application (FIBA) Device in the pneumatic brake” may
 air brake system and air suspension system of LHB, be modified as “Hybrid
and ICF design
Hybrid and ICF coaches with pneumatic brake.
coaches with
pneumatic brake”
6.1.13 It shall be possible to retrofit the equipment even on Noted. Noted and complied -----------
the existing vehicles having Air suspension if desired.
6.1.14 The FIBA Device shall not need any electrical Noted. Noted and complied ---------------
connections.
6.1.15 Once brake application is initiated by the Air Spring Noted. Noted and complied ----------------
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.
6.1.16 Noted. Noted and complied ------------------
It shall be possible to reset the brake application by
the driver so that the journey can be resumed at a
restricted speed.
6.1.17 Noted. To reset the indicators, rest Noted and complied The clause may be
However the visual indication shall not be possible to cock of FIBA device needs to be modified as under:
be suppressed unless the compressed air in the air operated This is as per our However the visual
suspension system of the coach itself is exhausted approved FIBA device. indication shall not be
completely to atmosphere or discharged through possible to be
suppressed
isolating cock with vent feature. Therefore vent automatically either
feature may be provided in isolating cock as laid down without proper
in drawing no CG - K9132 of latest revision. FIBA rectification of the
device may also rest manually by providing reset key deflated air spring or by
resetting the FIBA
on FIBA device. device by resetting key
provided on FIBA
device”
6.1.18 Noted. Noted and complied -----------
The visual indication devices shall stay in actuated
condition at even as low bellow pressure as 0.3
kg/cm2.
6.1.19 It shall not require any special action by the Noted. Noted and complied ------------
maintenance staff to reset the audiovisual indication
to normal condition after repairing/replacing the
defective bellows.
6.1.20 The equipment shall be designed to withstand Noted. Noted and complied -------------------
maximum vibrations as in existing Railway system
without loosing its efficiencies. Complete unit shall be
protected from all possible damages and theft etc. It
 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 Noted. Noted and complied -----------------------
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.
6.1.22 The performance of Air Spring failure indication Noted. Noted and complied ----------------------
Device shall remain unchanged in the air brake
system and air suspension system supplied by any
approved manufacturer.
6.1.23 The specifications for air spring assembly can be Noted. Noted and complied --------------------
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).
6.1.24 Air Spring failure indication Device shall in no way Noted. Noted and complied -------------------
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.
6.1.25 Weight of FIBA device with cover and mounting Noted. Clause to be amended to Noted and complied “16 Kg.” is modified as
bracket shall not excedd16 Kg. read as 17 kg or approx. 16 kg. “16 Kg (approx.).
6.2 Space Constraints: Headline Noted and complied Flexible hoses cannot
Air Spring Failure Indication Cum Brake Application Noted. Mounting hole size is must be avoided without
(FIBA) Device shall be within the space envelope for interchangeability and hence standardization of
shown in RDSO Drawing no. CG-15078 maintained by us. Location of ports 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.
6.3 Pneumatic supply connection: Headline Noted and complied ---------
Pneumatic supply connection of Air Spring Failure Noted.
Indication Cum Brake Application (FIBA) Device shall be as
 per schematic diagram of RDSO Drawing no. CG-
K9132.
6.4 Mounting arrangement: Headline Noted and complied No change is required
Mounting arrangement of Air Spring Failure Indication Noted. Dim 34 to be changed to Noted and complied as the dimension is
Cum Brake Application (FIBA) Device shall be as per RDSO Dim 26 as per RDSO drawing no. kept in consideration of
drawing no. CG-K10031 and drawing no. CG-K10033 shall CG-15078. And also dim 336 strength requirement
be for mounting arrangement of Indicators of Air Spring should be changed to 320. and repairs
Failure Indication Cum Brake Application (FIBA) Device.
6.5 Other Details: Headline SIL design consist of Clause may be
All metal parts of the Air Spring Failure Indication Material of various devices and Valve body in modified as under:
Cum Brake Application (FIBA) Device shall be of manifold plate of our FIBA device Aluminum (anodized) All metal parts of the
corrosion resistant steel duly painted in red. Indicator is aluminum alloy which is suitably with corrosion Air Spring Failure
of FIBA device shall be painted in silver gray clour surface treated i.e. Passivation/ resistant steel box as Indication Cum Brake
(Code K766). However other items of clause 4.1 Anodizing etc. to take care of cover and duly Application (FIBA)
excluding FIBA device and Indicators shall also be corrosion and long service life. painted as per your Device and Indicators
corrosion resistant and shall be painted in red colour. This is in line with similar device in specification. shall be of corrosion
The fasteners shall be of high tensile steel to IS: 2269 use on LHB coaches for last 15 resistant material. FIBA
(ISO 898) and shall be zinc coated. Fasteners/ Nut years. Painting of FIBA device is device and Indicator
bolt shall be strictly of TVS, Unbrako or LPS make not advisable because in due shall be painted/
only. course of service in the field, paint coated in silver gray
may peel-off and may cause clour (Code K766).
malfunctioning of FIBA device. In However other items of
clause 4.1, items at s. no. 345 can clause 4.1 excluding
be painted in red colour. However FIBA device and
the fastener specified in clause 4.1 Indicators shall also be
shall not be painted. The fasteners corrosion resistant and
supplied by us are of stainless shall be painted in red
steel hence no coating is required. 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 1) Noted 2) Noted and agreed ---------------
Indication Cum Brake Application (FIBA) Device.

3) Weight of one Air Spring Failure Indication Cum 3) Noted 3) Noted and agreed ---------------
 Brake Application (FIBA) Device and Indicator
respectively.

4) Whether proposed Air Spring Failure Indication Cum 4) Noted 4) Noted and agreed ---------------
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. 5) Noted 5) Noted and agreed ---------------

6) Content of indigenous and imported items in 6) Noted 6) Noted and agreed ---------------
offered Air Spring Failure Indication Cum Brake
Application (FIBA) Device.

7) Expected life cycle in operating and environmental 7) Noted 7) Noted and agreed ---------------
conditions enumerated in clause 2 & 3.

8) A write-up giving broadly the maintenance 8) Noted 8) Noted and agreed ---------------
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 10) Noted 10) Noted and agreed ---------------
Assurance System" being followed for manufacture
of the offered items; and

11) Details of manufacturing and testing facilities 11) Noted 11) Noted and agreed ---------------
available with the manufacturer.
7.2 The information as received above shall be used for Noted Noted and agreed ---------------
preliminary evaluation of the firm's capability in --------------
meeting with the requirements of this STR.
7.3 The firm shall be required to submit a Type Test Noted Noted and agreed ---------------
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.
7.4 The premises of the firm shall be visited by RDSO's Noted Noted and agreed ---------------
officials for on-the-spot assessment of the firm's
 capability after the Type Test Report is accepted by
RDSO.
7.5 RDSO reserves complete right in granting approval or
otherwise to a firm.
8. GUARANTEE:
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.
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.
9. INSTALLATION, COMMISSIONING
MAINTENANCE:
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 ---------------
Headline
Noted. This clause should be read Noted and agreed “emergency spring”
as “Complete Air Spring Failure may be deleted from
Indication cum Brake Application the clause.
(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. The clause should be read Noted and agreed No change is required
as “ In the event of ‘non- as it is already
satisfactorily performance’ of any elaborated in preceding
of the items as indicated above, clause
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.
& Headline Noted and agreed -------
Noted. Noted and agreed ---------
9.2 With every order for supply of the Air Spring Failure Noted. Instead of Compact-Disc, Noted and agreed No change is required
Indication Cum Brake Application (FIBA) Device, the email of the maintenance manual as mailing facility is not
supplier shall have to supply maintenance instructions shall be sent to the concerned available in all depots
in the form of two booklets (hard copy) and one copy Railways.
on Compact Disc (MS-Office compatible).
9.3 Maintenance booklet supplied by the supplier shall Noted and agreed
cover the following aspects in detail: -----------

1) Specification of the Air Spring Failure Indication 1) Noted. 1) Noted. and agreed -----------
Cum Brake Application (FIBA) Device.

2) Working principle based on the actual construction. 2) Noted. 2) Noted and agreed. -----------
-----------
3) Constructional details giving sketches, drawings 3) Noted. 3) Noted. and agreed
and photographs etc. identifying various items and
their part numbers etc. for easy identification.

4) Procedure for dismantling using sequential steps 4) Noted. 4) Noted. and agreed -----------
with the help of sketches.

5) Procedure for assembly, using sequential steps 5) Noted. 5) Noted. and agreed -----------
with the help of sketches.

6) Jigs, tools, other materials and details of special 6) Noted. 6) Noted. and agreed -----------
set-ups etc., necessary for item 4 & 5 above.

7) Testing procedures and facilities required along 7) Noted. 7) Noted. and agreed -----------
with their details.
-----------
8) Details of prevention maintenance kit, required for 8) Noted. 8) Noted. and agreed
periodical preventive maintenance of Air Spring
Failure Indication Cum Brake Application (FIBA) Device
as recommended by the supplier.
-----------
8) Comprehensive details containing legible sectional 8) Noted 8) Noted and agreed
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. 9) Noted 9) Noted and agreed -----------

10) Periodicity for various maintenance activities on 10) Noted 10) Noted and agreed -----------
time and distance basis.
11) Do's and Don'ts for maintenance officials. 11) Noted
10. INSPECTION AND TESTING: Headline
10.1 General requirements: Deadline Noted and agreed
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 1) Noted.
have to arrange for the following and associate with
the same:
2) Noted. -----------
1) Access to all records considered relevant for 1) Noted and agreed.
such activity by inspecting officials.
-----------
2) Questioning of relevant personnel engaged in 3) Noted. 2) Noted and agreed.
production, testing and quality checking activities
etc. or related issues.

3) Testing of few samples of items already 4) Noted. 3) Noted and agreed. -----------
produced by the firm to ascertain the technical
characteristics given in this STR.
5) Noted.
4) Any other check considered necessary by the 4) Noted and agreed. -----------
inspecting party.

5) The inspecting official shall carry out purchase 6) Noted. However RDSO should 5) Noted and agreed -----------
inspection as per inspection check list clarify the statement “Technical
attached at Annexure “B” of this STR. document and type testing etc.,
within the time schedule included
6) The supplier should have credentials of supply of in the purchase order”. 6) Noted and agreed. 6) “Technical
FIBA device and other items as laid down in documentation, and
clause 4 of this STR and will be fully responsible type testing etc.” may
for the delivery of accessories such as Isolating be deleted from the
Cock (OLP Type) 20mm bore, Isolating Cock 7) Noted. For item 3, 4 and 5, RDSO clause10.1.6.
20mm bore with vent hole, Hose Connection and check sheet exist, hence the same
Hardware etc. Technical documentation, and shall be used for purchase inspection
by RDSO/RITES. Item 6 i.e. Nut/Bolts
type testing etc., within the time schedule
& fasteners are standard items and the
included in the purchase order. same are not mentioned in the RDSO 7) Noted and agreed 7) No change is
vendor list. They will be supplied required as the
7) Item no.3, 4, 5 & 6 shall be supplied already against our works test certificate and inspection will be done
inspected by RDSO/RITES as per respective not against RDSO/RITES inspection as per stipulation in
STR. Inspection Certificate of the same shall be 8) Noted. STR
 provided by the firm at the time of inspection of
FIBA device and Indicator.

8) The supplier shall be fully responsible for 8) Noted and agreed.

successful running of the system.

9) The performance of equipment should be 9) Noted. 9) Noted and agreed.

equally good for tare and loaded condition. 8)------------

9)-------------

10.2 Inspection and testing of Air Spring Failure Indication Noted.

Cum Brake Application (FIBA) Device:
10.2.1 Dimensional check: Noted. Noted and agreed

ITEM REFERENCE Noted.

DOCUMENTS

Air Spring Failure As per Firm’s

Noted.
Indication Cum assembly drawing
Brake approved by RDSO,
Application Clause 1 of
(FIBA) Device ANNEXURE-B &
technical requirements
Indicator of of clause 6 of this
FIBA device STR.

Hose RDSO drg no. K1054 Noted.

Connection & STR C-K407 (latest
rev.)

Isolating Cock RDSO sketch 97002 &

(OLP Type) STR C-K407 (latest Noted.
20mm bore rev.)

Isolating Cock RDSO drawing no. 02 RDSO drawing no. 02

20mm bore 610 0871 Noted. However the RDSO 610 0871 is modified
with vent hole drawing no. 026100871 is not as RDSO drawing no.
clear. We understand the correct SK-98013
drg. no. is SK-98013.
10.2.2 Functional test of the FIBA device: Noted. Noted and complied ---------------------

Functional test of FIBA device shall be carried out as Noted. -----------------------

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 Noted.
Application (FIBA) Device shall be carried out as ------------------------
follows-
- Install the Air Spring Failure Indication Cum Noted. ----------------------
Brake Application (FIBA) Device at test bench.
- Gradually raise the air pressure to 2 kg/cm 2 and Noted. ----------------------
thoroughly check the air leakage from FIBA
device with the help of liquid soap solution.
- Gradually raise the air pressure to 10 kg/cm 2 Noted. -------------------
- There should be no leakage from any joint, port Noted. --------------------
or FIBA device. Repeat the same procedure for
leakage testing of Indicator.
10.3 10% samples of the lot or a minimum 10 samples Noted. Sample size is too large. As Noted and agreed. 9.2 may be read as
shall be picked up randomly for dimensional & other per the standard RDSO inspection 10.2.2
specified inspections as given in clause 9.2 of this guidelines, 2% or minimum 02 nos. 10% is reasonable,
STR. per lot should be the sample size. hence no change is
Reference to clause 9.2 should be required
corrected. There should be a
standard guideline for sampling
size.
10.4 For other specified inspections a given in clause 9.2 Noted. The referred 9.2 doesn’t Noted and agreed 9.2 may be read as
of this STR, samples shall be picked up randomly as pertain to inspection. For FIBA 10.2.2
under: device 10% is a large sample size.
Lot size upto 10 25 50 75 100 It should be amended to 2% or
minimum 02 nos.
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.
10.5 In case any picked up sample fails, Noted. Noted and agreed
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.
11. MARKING: Headline Noted and agreed No change
Every item of the Air Spring Failure Indication Cum Noted.
Brake Application (FIBA) Device shall be legibly Noted. In our case we are making
 marked to indicate the following: week & year.
1) Manufacturer's initials.
2) Month and year of manufacture.
3) Identification marks, i.e. Part Number, Batch
Number, etc.
12. PACKING: Headline Noted and agreed
The Air Spring Failure Indication Cum Brake Noted.
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.
13. MAINTENANCE MANUAL: Headline Noted and agreed No change
The supplier shall provide at least one copy free of Noted. Please refer our comments
cost for each consignment, a detailed maintenance to clause no.9.2
manual for maintenance and overhaul purpose.
14. GENERAL: Headline
14.1 RDSO may draw samples for quality check to test any Noted. The costs for testing the Noted and agreed No change is required.
property mentioned in this specification at it’s samples picked up by RDSO at Such testing will be
discretion. The vendor shall arrange testing of these random, other than during only on complaining
samples at a reputed outside laboratory as decided purchase inspection, shall be quality of product or
between RDSO and the vendor. The testing charges borne by RDSO/IR. random examination
should be borne by the vendor. for which supplier has
to bear the cost.

14.2 Additional information if required may be obtained Noted. Noted and agreed
from the office of the Director General (Carriage),
RDSO, Manak Nagar, Lucknow – 226011.
REQUIREMENTS OF TYPE TEST REPORT Annexure – A
The type test report of Air Spring Failure Indication Noted. Noted and agreed
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: -
1) MATERIAL TESTS Headline.
Material test report (supported by standard test Noted. Noted and agreed
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.
2) ENDURANCE TEST OF AIR SPRING FAILURE Headline. Noted and agreed
INDICATION CUM BRAKE
APPLICATION (FIBA) DEVICE:
a) The endurance test is conducted to assess a) Noted. Noted and agreed
suitability of the Air Spring Failure Indication Cum
Brake Application (FIBA) Device provided at secondary
stage suspension in coach bogie by simulating service b) Noted. Noted and agreed
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 Noted and agreed
cycles and afterward at every 10th cycles for each c) Noted.
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.
3) Burst pressure test of FIBA device shall be done after Noted. There is no burst test for Instead of Burst “Burst pressure test”
endurance test, as per para 2 of Annexure- “A” of this FIBA device. Clause to be Pressure Test, it will may be replaced with
STR. suitable amended. be better to check “High Pressure test”
Pressure tightness
test at 10 Kg/cm2 as
per annexure B.
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 Noted. Noted and agreed
of registration after first time acceptance of a particular
design of Air Spring Failure Indication Cum Brake
Application (FIBA) Device.
6) Leak test of Air Spring Failure Indication Cum Brake Noted. Noted and agreed
Application (FIBA) Device as detailed at para 10.2.2 of
this STR.
7) Tolerance in different dimensions of Air Spring Failure Noted. IS:2102 (Part-I) pertains to Noted and agreed Clause 14.2. 7) may
Indication Cum Brake Application (FIBA) Device should tolerances on machined parts be modified as under:
be as per IS 2102 (Part -I) and mentioned in Type Test only and doesn’t cover the Tolerance in different
Report and drawing. tolerances on rubber parts, dimensions of Air
springs, casting and assembly Spring Failure
Indication Cum Brake
dimensions. Clause should be
Application (FIBA)
amended accordingly. Device for machined
parts should be as per
IS 2102 (Part -I).
However for other
components
 manufactured by
different process
respective IS to be
followed duly
mentioned in Type Test
Report and respective
drawings.

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.
Particulars Unit Specified Observed Remarks Headline.
no.

Sample No. Headline.

1 Length of FIBA Device mm As per Noted.
2 Height of FIBA Device mm approved Noted.
Thickness of FIBA Device
3 mm drawing Noted.
without bkt.
Thickness of FIBA Device with
4 mm Noted.
bkt.
BP ¾” BSPP
Port diameter
and thread: B1 ¾” BSPP
5 Noted.
B2 ¾” BSPP
IND ¼” BSPP
6 Mounting bkt hole pitch of FIBA mm 134±1 Noted.
 Device
Hole 1 mm 18±0.5 Noted. As per RDSO
Hole 2 mm 18±0.5 drawing CG-K10031, there rd
Dia of mounting 3 Hole added at
7 are three mounting holes of
bkt. Holes Hole 3 s. no. 7
dia. 18 mm and the same
(if mm 18±0.5
is provided by us.
available)
As per
8 Weight of FIBA valve with bkt Kg approved Noted.
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.

As per
14 Weight of indicator Kg approved Noted.
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 Noted. Clause 9.2 is not pertaining Noted and agreed Clause 9.2.2 may be read as
FIBA device: to testing of FIBA device, may 10.2.2
kindly be corrected.

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

Results of FIBA
device sample
S. Test and testing obtained
Standard Noted.
No. procedure S. No. S. No.
Mfg dt Mfg dt

Initial Charging:
i) Ensure that all Noted. We are using
Isolating cocks and cut only isolating cocks
of angle cocks in supply on the Test Benches.
line should be in open There are no cut-off
condition. Other end cut angle cocks/end cut
--------- Cut of angle cock
1 of angle cocks and drain of angle cocks.
FP= 6 + 0.1 Kg/Cm2 may be deleted
cocks provided on test As per earlier test
BP= 5 + 0.1 Kg/Cm2
bench should be in proforma, tolerance
closed position. on FP/BP pressure is
ii) Charge the FP line at ±0.1 Kg/cm2.
6.0 Kg/Cm2 and BP line
at 5.0 Kg/Cm2.
Leak Test:
Check for any leakage in
FIBA device & pipe lines.
No leakage is permitted
2 in FIBA device and Leak test within limit. Noted.
through its joint. Total
leakage in system
should not be more than
0.2 Kg/Cm2 in 60 sec.
i) No leakage in FIBA device
“Pressure tightness
Valve i) Noted.
High Pressure test: test” replaced with
ii) FIBA device should not ii) Noted.
3 Charge FP and BP upto Noted and agreed “High pressure
operate. iii) Noted.
10.0 Kg/Cm2. test”
iii) No damage in FIBA device or
circuit.
 Insensitivity test:
Drop the air pressure of
one air spring side by 0.5
i) Noted
Kg/Cm2 in 10 seconds i) No response and no exhaust
.
4 with the help of the of air from the exhaust port. Noted and agreed
ii) Noted
respective choke/drain ii) Indicators do not turn red.
.
cock. Repeat the
process for other side air
spring.
i)Pressure in respective gauge
A) Functional Test at 2.0 start falling & FIBA device i) Noted. As per
Kg/Cm2 (Tare Pressure) actuate when respective gauge our approved test
i. Charge the FP at 2.0 pressure becomes less than plan and earlier
Kg/Cm2 Pressure and BP 1+0.1 Kg/Cm2. test proforma,
at 5.0 Kg/Cm2. tolerance on
ii. Open the ½” drain cock to pressure setting
ii)BP pressure starts venting for FIBA device
drain the air pressure of gradually and settles at 3.4 is1 ±0.1 Kg/cm2.
one side air spring/40L Kg/Cm2 approx. ii) Noted.
auxiliary reservoir.
iii) Noted.
Repeat the process for iii)Both indicators should be red. Noted. Tolerance
other side air spring. should be 90±5 dB.
“whistling sound” is
Hissing sound of 90+ 5db should deleted
blow.
i) Noted.
i) BP pressure exhaust, through ii) Noted.
BP Isolation: (Brake
FIBA device exhaust port stops iii) Noted. The “whistling sound” is
release and
and BP pressure rises to 5 clause (iii) should be deleted and
suppression of whistle)
Kg/Cm2. modified as “Both replaced with
Close the Isolating cock
ii)Whistling/Hissing sound stops. indicators show red” hissing sound
provided before FIBA
iii) Both indicators show to meet the
device in BP line.
red/green. requirement stated in
clause 6.1.17.

Noted. However “same bogie” may

Suppression of Both indicators of same bogie
feature is there but be replaced with
Indicator: should turn to green from red.
during testing of FIBA the FIBA device”
 device on test bench Indicators of other
there is no provision bogie should
for 2nd bogie. Hence remain show green.
Close the both isolating
“Indication of other May be deleted
cocks with vent feature Indicators of other bogie should
bogie should remain
or pull the resetting keys remain show green.
show green” to be
provided on FIBA device.
applicable only in
case of testing on
actual coach.
i)Pressure in respective gauge
B) Functional Test at start falling & FIBA device
i) Noted. As
6.0 Kg/Cm2: actuate when respective gauge per our approved test
iii. Charge the FP at 6.0 pressure becomes less than plan and earlier test
2
Kg/Cm2 Pressure and BP 1+0.1 Kg/Cm . proforma, tolerance
at 5.0 Kg/Cm2. “whistling
ii)BP pressure starts venting on pressure setting
iv. Open the ½” drain cock to sound” is deleted
gradually and settles at 3.4 for FIBA device is1
and/or replaced by
drain the air pressure of 2
Kg/Cm approx. ±0.1 Kg/cm2.
“hissing sound”
one side air spring/40L ii) Noted
auxiliary reservoir. iii)Both indicators should be red. iii) Noted
Repeat the process for iv)Whistling/ Hissing sound of 90+ iv) Tolerance
other side air spring should be 90±5 db.
5db should blow.

BP Isolation: (Brake
i) Noted Whistle is replaced
release and i) BP pressure exhaust, through
. with hissing sound
suppression of whistle)

Close the Isolating cock FIBA device exhaust port stops

ii) Noted
provided before FIBA and BP pressure rises to 5
.
device in BP line. Kg/Cm2.
 iii) Clause
should be read as
“Both Indicators
should be remaining
red”. Indicators “whistling sound” is
ii) Whistling / Hissing sound shouldn’t reset deleted and/or
stops. automatically until the replaced by “hissing
defective Air Spring is sound”
attended. Therefore
the clause should be
amended
accordingly.

Modified as “Both
iii) Both indicators show
indicators should
red/green.
show red”
Noted. However
Suppression of feature is there but
Indicator: during testing of FIBA
device on test bench
.Both indicators of same bogie
there is no provision Indicators of other
should turn to green from red
for 2nd bogie. Hence bogie should
Close the both isolating “Indication of other remain show green.
cocks with vent feature Indicators of other bogie should
bogie should remain May be deleted
or pull the resetting keys remain show green.
show green” to be
provided on FIBA device. applicable only in
case of testing on
actual coach.

Brake Pipe Variation i) FIBA device should not i) Noted

Test: actuate. .

Drop Brake Pipe

ii) FP line pressure should not ii) Noted
6 pressure from 5.0 Noted and agreed
drop. .
Kg/Cm2 to zero.
iii) Both indicators should show iii) Noted
green. .

iv) Noted “whistling sound” is

iv) No whistling/Hissing sound.
. deleted
 Charging Behaviour
test:

7 Charge BP prior to FP FIBA device should not actuate Noted. Noted and agreed
and observe the
actuation behaviour of
FIBA Device if actuated.

Resetting behaviour i) Noted

FIBA device should not reset
test: .

i) Charge the system at ii) Noted

automatically
5.0 Kg/Cm2 pressure. .
8 ii) Drop FP line pressure
iii) Noted
and actuate the
.
respective FIBA Device.
iii) Close the drain cock
and raise FP line
pressure of FIBA Device
to again5.0 Kg/Cm2.

Clause Clause description M/s KBI’s Comments M/s SIl’s Comments M/s FTIL’s Comments
no.

4. Testing of Indicator: Noted.

i Leakage test: Noted. Noted and agreed

Apply a pressure of 10 Kg/Cm2. There Noted.

should not be any leakage if checked with
soap water.
ii Functionality Test: Noted. Noted and complied

a)Apply a pressure of 0.5 to 0.6 Kg/Cm2. Noted. Noted and complied

Red colours should appear in window of
Indicator. Movement of Piston of Indicator
shall be smooth and steady.
b) Now release the pressure to 0 Kg/Cm2. Noted. Noted and complied
green colours should appear in window of
Indicator.
c) Piston of indicator should move smoothly Noted. Noted and complied
and piston should not be sticky. Indicator
shall be air tight and water resistant.

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

Comments Comments
Noted. Mounting holes size is must for No change. We may use
interchangeability and hence maintained steel pipe in future as is
by us. Location of ports is design specific, used in Air Dryer system
which depends upon the location of of Locos. Hence fixing
devices on the manifold plate. As long as port location is a must
the ports are within space envelop, it requirement from
should be left to be decided by individual manufacturing and
manufacturer as these are connected maintenance point of
through flexible hose with the pipe. Also view.
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.
Clause description M/s KBI’s M/s SIl’s M/s FTIL’s
Comments Comments Comments

Noted. 02 nos. No change

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

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

Noted. Dim. 34 should No change

be changed to Dim. 26
as per RDSO drawing
CG-15078. Also dim.
336 should be changed
to 320.