2. CARRIAGE DIRECTORATE ‘Recently Completed’ Projects : 2.1 Development of crashworthy design of ICF coach Project ID: 1.3.03.27.03.017.0.0.04.05 Start Date: 01/04/03 Completion Date: 31/12/06 Deliverables/ Benefits : Benefits: In the case of accident 1. No or minimum deformation in passenger occupied areas 2. No climbing of coaches one over the other. 3. Energy absorption in non-passenger areas through controlled collapse 4. Low accelerations (decelerations)- To avoid injuries to occupants Deliverable : 1. FE Models of existing GS and SLR coaches. 2. Component and assembly drawings of the modified design of coaches. 3. Instrumentation and test scheme for cras tests. 4. Development of Crashworthiness Design Centre at RDSO, with necessary software and hardware 5. Training of IR personnel in crash simulation & testing technique. Current Status: 1. On the basis of test results, design of GS coach has been finalized. A list of drawing has been advised to production units for mass manufacturing of crashworthy GS coach in June 2006. 2. Design and drawings of remaining type of ICF coaches except SLR has been issued to Production Units in July 2006. 3. Crashworthy SLR design & drawings have been sent to Pus for series manufacturing in November 2006. An approval for closure of the project has been received from Railway Board vide letter No. 96/MI/7/1 dt. 25.6.2007. 2.2 Fitment of Capsule type Shock Absorber in primary suspension in lieu of conventional dashpot Project ID: 2.5.02.27.03.014.0.0.03.04 Start Date: 01/01/02 Completion Date: 31/03/07 Deliverables/ Benefits : Benefits: i. Saving of expenditure due to replenishment of oil ii. Better riding characteristics iii. Maintenance friendly Deliverable : Spec. of suitable shock absorber. Fitment design in the existing bogie Current Status: 96 GS & SLR type of coaches had been put in service trial by ICF during 2005-06. The feedback and observations reveal the following three problems:- 1. Dropping of the bottom pin due to loosening of the securing circlip and consequent damage to shock absorbers. 2. Excessive wear on acetal guide bush and consequent rubbing of protection tube with lower spring seat. 3. Hit marks on Lower Spring Seat due to over travel of shock absorber caused by excessive loading. The following action have been taken: 1. Circlip arrangement has been replaced by locknut and split pin to prevent the drooping of the bottom pin because of loosening of the circlip. 2. Self-lubricating guide bushes have been developed to deal with the excessive wear on acetal guide bushes caused by lack of lubrication. 3. The problem of overloading has been noticed mainly on services in Northern India and in GS & SLR type coaches. The problem of over travel will be overcome by adopting air springs on GS & SLR coaches and after the trials are successful capsule shock absorber will be provided. Railways have been advised to modify the coaches undergoing service trial to Conventional dashpot oil arrangement where problem of over loading has been experienced. New arrangement of capsule shock absorbers with lock nut and split- pin alongwith self-lubricating guide bushes where the problem of over loading is not there. Pus have been advised to provide the improved arrangement of capsule shock absorbers with lock nut and split-pin alongwith self lubricating guide bushes on 100 coaches each (only on SCN & AC coaches) for extended service trials. In view of issue of final design to Zonal Railways and Pus the project is closed. ‘In-Progress’ Projects : 2.3 High capacity 180 KN air spring for EMU/DMU bogie Project ID: 2.5.04.23.03.035.0.0.12.07 Start Date: 31/03/04 Completion Date: 30/06/08 Deliverables/ Deliverables : Benefits: Development of specifications for higher capacity air springs by RDSO. Procurement of air springs of higher capacity for trial purpose. Manufacture of prototype coaches of EMU and DMU for oscillation trials. Oscillation trials of prototype coaches. Service trials of EMU and DMU coaches provided with these air springs for a minimum of six months followed by joint inspection by RDSO, ICF and Zonal Railway to assess performance. Benefits: Operation of EMUs and DMUs at the standard working pressure of 6Kg/cm2 thereby increasing the service life of air springs and pneumatic equipment as the present practice of raising the feed pipe pressure setting can be discontinued. Further, this provides scope for increase in payload capacity if the need is felt in the future. Current Status: 1. RDSO STR C-K 406 issued in June 2004 for procurement of air springs. Sources advised for procurement to ICF. 2. Prototype HHP DMUs have been manufactured and have completed oscillation trials successfully. 3. Prototype EMUs have been manufactured and dispatched to Central Railway. Oscillation trials are in progress. 2.4 Development of air springs for LHB stock Project ID: 3.5.05.28.03.034.0.0.04.08 Start Date: 31/03/05 Completion Date: 31/03/09 Deliverables/ Deliverable : Benefits: 1. Specification of air springs for fitment at the secondary suspension of LHB coaches. 2. Sources of supply for specified air springs. 3. Manufacture of prototypes for oscillation trials. 4. Oscillation trials over Mainline and Rajdhani standard track to establish ride behavior. 5. Service trial for one year to ascertain performance Benefits : 1. Reduction in the great diversity in the number of steel coiled springs presently being used for the LHB coaches particularly due to the manufacture of the indigenous variants. 2. Removing bottlenecks in production of LHB coaches, as an air spring to a single specification shall be provided at the secondary suspension over the entire range of LHB coaches. 3. The problem of low buffer height and vertical uncoupling has been reported on some of the LHB coaches. With the variable stiffness of the Air spring and it’s ability to maintain a constant height irrespective of the load, the severity of these problems shall be reduced to a great extent. Current Status: Extensive simulation studies have been carried out with the entire range of LHB stock, based on which a design of air spring at secondary suspension stage has been evolved. RDSO has developed a specification No. C-K 508 for these air springs, which has already been advised to RCF. RCF has been advised to manufacture three prototype coaches for the purpose of detailed oscillation trials along with three sources for procurement of air springs for LHB coaches by this office letter no. SV.AS.ML dt. 30.11.2005. Orders for procurement of air springs have been placed by RCF and prototype coaches are under manufacture. 2.5 Standardization and upgradation of narrow gauge bogie for 610mm gauge Project ID: 3.3.04.30.03.033.0.0.05.07 Start Date: 01/12/04 Completion Date: 31/03/08 Deliverables/ Deliverable: Benefits: 1. Study of existing design on NG bogies of 610 mm gauge to finalise the modifications required for improvements in passenger comfort 2. Placement of orders based on specifications prepared by RDSO for improved bogies on new coaches. 3. Manufacture of prototype coaches. 4. Oscillation trials of new coaches to assess ride behaviour. 5. Finalisation of improved design by service trials 6. Preparation of specifications for procurement of superior bogie designs through tender process. Benefits: Better ride quality and higher speed potential in Darjeeling Himalayan section trains. Current Status: RDSO specification No K6-N-01 of February 2006 has been prepared for the purpose of procurement of new bogies and advised to NF Railway and Railway Board. In view of the above, Board has been requested to close the project. 2.6 Standardization and upgradation of narrow gauge bogie for 762 mm gauge Project ID: 3.3.04.30.03.032.0.0.05.07 Start Date: 01/10/04 Completion Date: 31/03/08 Deliverables/ Deliverable:- Benefits: Study of existing design on NG bogies to finalise the modifications required for improvements in passenger comfort Placement of orders on identified sources for supply of improved suspension elements Manufacture of prototype coaches by Northern Railway for oscillation trials. Oscillation trials to assess ride behaviour with new/improved suspension elements. Finalization of improved design by service trials. Preparation of specification for procurement of superior bogie designs trough tender process. Benefits:- Improved ride quality and higher speed potential with existing bogies by upgradation of suspension design. Superior design bogies to be procured through tendering for new coaches. Current Status: 1. RDSO has suggested measures to improve riding performance in existing design of bogie. Three suspension elements were identified for this purpose are hourglass type rubber spring for primary suspension, friction damper for the secondary suspension and a roll damper (hydraulic) provided between the carbody and bogie to reduce carbody roll motion. 2. Sources for procurement of improved suspension elements has been advised to Northern Railway. Supply orders have been placed by Northern Railway and material has been received by Kalka workshop. Prototype is under manufacture. 3. As a parallel action, RDSO has made specification for new bogie design (STR K5-B-02 of October 2005). It has been sent to Railway Board for procurement of new bogies for KLK-SML section. 2.7 Development of classical design NG coach with roller bearings and air brakes Project ID: 3.1.05.30.03.030.0.0.09.07 Start Date: 06/09/05 Completion Date: 31/12/07 Deliverables/ Deliverable: Specification Benefits: Benefits: Improved safety Lightweight structure Improved ambience and aesthetic interiors Modern amenities Current Status: Specifications have been sent to Board on 30-11-05 for KSR and on 07-04- 06 for DHR for procurement action. The specifications for DHR have been revised and sent to Board on December 2006. Coaches for DHR are under manufacture at Kurduwadi workshop. In view of the above, Board has been requested to close the project. 2.8 Development of new NG coach with panoramic windows Project ID: 3.1.05.30.03.029.0.0.09.07 Start Date: 06/09/05 Completion Date: 31/12/08 Deliverables/ Deliverables : Specification Benefits: Benefits : Improved safety Lightweight structure Improved ambience and aesthetic interiors Modern amenities Current Status: Revised specification for tourist coaches for DHR alongwith layouts has been finalised on the basis of heritage dtes. comments for operating speed of 50kmph and issued to Board on 4.12.07 2.9 Setting up of fire test lab Project ID: 1.1.06.27.03.028.0.0.12.08 Start Date: 01/01/06 Completion Date: 31/12/09 Deliverables/ Deliverables : Feasibility study, Technical specification for the fire testing Benefits: equipments, Process for fire testing, Specification for fire retardant coach furnishing material, Development of fire retardant material, Improvement in fire safety of coaches. Benefits : Fire test facilities will help in development in fire worthiness of coaches. Fire accidents and consequent fatalities will be reduced by 80% by adoption of fireproof coaches and fire retardant material in the existing coaches. The value of human lives saved and the improvement in the corporate image of Indian Railways in public cannot be assessed in terms of money. The fire testing lab developed can also provide its services to the industry manufacturing the coach furnishing materials, textile industry and building material industry for testing their materials, thereby, earning revenue. Current Status: A proposal for setting up of fire testing laboratory was presented to GCM, which has directed to review it in the same meeting. Project has been reviewed and only consultancy part of it being taken up first. The project has been sanctioned under DG’s power after finance vetting. After detailed estimate vetting, global tender has been invited. Tender has been opened on 15.1.2008. Briefing note is under preparation. 2.10 Development of Soft side buffers for CBC equipped coaching stock Project ID: 3.1.06.27.03.027.0.0.12.06 Start Date: 19/01/06 Completion Date: 31/03/08 Deliverables/ Deliverables : Benefits: Design and spec of soft side buffers compatible with IR coaching CBCs and operating pattern. Development of prototypes and field trials on one rake. Benefits : Will pave way for complete switch to CBCs with its associated benefits. Current Status: Use of soft side buffers with CBC to reduce the effect of longitudinal jerks taken up as a fresh project. the indigenous developed soft side buffers has been put on one rake of Tamil Nadu Express. Soft buffers for LHB coach had been developed. The supply to RCF is expected by Feb 2008. The buffers will be put on trials on newly manufactured coaches. 2.11 Development of crashworthy design of LHB type coaches Project ID: 1.5.06.28.03.024.0.0.06.07 Start Date: 16/03/06 Completion Date: 15/10/08 Deliverables/ Deliverable : Crashworthy design of LHB Type GS coach. Benefits: Benefits : In the case of accident No or minimum deformation in passenger occupied areas No climbing of coaches one over the other. Energy absorption in non-passenger areas through controlled collapse Low decelerations to avoid injuries to occupants Current Status: Development of FEM model, crashworthy behavior of existing design through computer simulation completed, design optimization is under progress. A crashworthy design of LHB coach has been developed. 2.12 Development of Fire Retardant Coaches Project ID: 1.3.04.27.03.022.0.0.03.06 Start Date: 01/03/04 Completion Date: 30/12/08 Deliverables/ Deliverables : Development of fire retardant materials for coach Benefits: construction and furnishing. Benefits : Prevent loss of human lives due to fire accidents. Saving Railway assets from accidental fires Current Status: All specifications of coach furnishing materials including UIC vestibule have been issued. 2.13 Development of environment friendly Toilet Discharge System in coaches Project ID: 7.3.05.27.03.023.0.0.12.08 Start Date: 01/08/05 Completion Date: 31/12/08 Deliverables/ Deliverables : Benefits: Development & design of the proposed toilet system for adoption on new & existing coaches. Manufacture and testing of prototype. Benefits : Discharge on track and in station will be eliminated. Water will be recycled to be used for toilet flushing. Possibility of corrosion due to effluents is eliminated. Current Status: A project to develop an environment friendly toilet system is going on along with IIT/K. The model being developed by IIT/K is based on separation of solid and liquid matter, suitable treatment of liquid using membrane technology, recycling the liquid for flushing and retention of solid residue till the end of journey where it will be evacuated and converted to manure. The first prototype is under fabrication and is likely to be put on a coach for service trial by March 2008 end. The coach will be put on 2623/24 Chennai Thiruvananthapuram Mail for field trials. During the trial the evacuation will be arranged by the industry partner using a mobile evacuation system. As a parallel action the specifications for biological toilets were also made by RDSO and sent to Board in May 2005. Order for 80 Biological Toilets have been placed on M/s. Aikon Technologies, Faridabad who have tied up with Microphor, USA. The first prototype has been provided on a WGACCN coach no. NR 6149C in Prayagraj express since 17.05.2007 and has now been placed in AP Express 2723/2724 by N. Rly. All the 80 toilets have now been provided on a new rake from RCF and put in service on NDLS- Rewa express 2427/2428. Vacuum toilet specifications were finalized in November 2006. Board floated a global tender for design, development, manufacture, supply, installation, commissioning, maintenance and operation of the Vacuum Toilet System in Coaching Stock on IR. Technical scrutiny of the offers received has been done and sent to Board on 20.2.07. 2.14 Air Springs for main line ICF bogies Project ID: 3.5.04.27.03.007.0.0.11.07 Start Date: 24/05/04 Completion Date: 30/04/08 Deliverables/ Benefits : Benefits: 1. Much superior ride comfort as predicted by simulations. Particularly notable improvement in lateral ride quality. 2. Overcoming problems of low buffer height due to constant height of air spring. 3. Overcoming problems associated with overloading on GS coaches. Deliverable : Design of suspension proven by oscillation and service trials with a single variant of air spring for the entire range of ICF type stock. Current Status: 1. RDSO has successfully conducted oscillation trials of mainline ICF coach of EOG type. Two such coaches – one power car and one AC chair car are presently undergoing service trial over Southern Railway: 2. For the SG variants of mainline ICF coaches, One GS coach has been successfully subjected to oscillation trial over mainline standard track. Trials on Rajdhani standard track shall be carried out shortly. RCF has been instructed to manufacture one 3-tier AC SG prototype coach for oscillation trial, which is in progress. 3. Extensive simulation studies have been carried out with the entire range of LHB stock, based on which a single air spring at secondary suspension stage has been designed and RDSO’s Specification CK – 508 developed. RCF had been advised to manufacture three prototype coaches for detailed oscillation trail along with source of procurement of air springs. Orders for procurement of air spring has been placed and one coach set had already been received at RCF. Prototype coaches are under manufacture at RCF. 4. On the instructions from Railway board, RCF has manufactured on AC 3 tier SG coach with LHB shell and ICF bogie provided with air springs. This coach has successfully completed oscillation trials. Preparations for oscillation trials of future variants are being made at RDSO. Board has instructed RCF to manufacture one GS coach with this configuration for oscillation trials. 2.15 Fitment of Centre Buffer Coupler on ICF coaches Project ID: 1.3.00.27.03.003.0.0.12.02 Start Date: 20/01/00 Completion Date: 31/03/09 Deliverables/ Benefits : Benefits: 1. Enhanced safety of passengers. 2. Reduction in maintenance costs. 3. Increased passenger earnings due to haulage of longer trains. Deliverable : Design and specifications of CBC for coaching stock Current Status: 1. Key, drawings, Squeeze Test Scheme, etc. sent to ICF. 2. Specification for procurement of CBCs prepared. 3. CBC Tender finalized and supply received. 4. The CBC specification has been revised in view of service experience gained so far. 5. On advise from Railway Board, the project was continued to dealwith problem of longitudinal jerk. 6. Use of soft side buffers with CBC to reduce the effect of longitudinal jerks taken up as a fresh project. the indigenous developed soft side buffers has been put on one rake of Tamil Nadu Express. Soft buffers for LHB coach had been developed. The supply to RCF is expected by Feb. 2008. The buffers will be put on trials on newly manufactured coaches. 7. A new design of draft gear offered by M/s Dellner, Sweeden is also being evaluated. RCF has placed an order for 60 nos on m/s Dellner. DP 31.12.2007, extended by 6 months.