WD-01-BVCM-2017

INDIAN RAILWAYS

PARTICULAR SPECIFICATION

FOR

BOGIE BRAKE VAN TYPE `BVCM

BROAD GAUGE

(1676 mm)

Month/Year of Revision /
S.No. Page No. Reason for Amendment
issue Amendment
1. April, 2017 - - First Issue

Issued By

RESEARCH DESIGNS AND STANDARDS ORGANISATION

MINISTRY OF RAILWAYS
MANAK NAGAR
LUCKNOW-226011
INDIA

April, 2017 Price: Rs. ----------- /-

 WD-01-BVCM-2017

CONTENTS

Clause No Description Page No.

1 Scope 3
2 Definitions 3
3 Welding 3-4
4 Testing 4
5 Standard Specifications 4
6 Particular Requirements 4-5
7 Under frame 5
8 Brake van body 5
9 Bogie 5
10 Coupler & Draft gear 5
11 Air brake 5-6
12 Brake gear 6
13 Painting & inscriptions 6
14 Drawings 6-7
15 As Made Drawings, Photographs and 7
Models.
16 Use of Alternatives 7
ANNEXURE
I Method of determination of Tare weight of 8
Brake van.
II Schedule of requirements for Bonded Mineral 9-10
glass Wool insulation for Goods Brake Vans.

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 WD-01-BVCM-2017

INDIAN RAILWAYS
PARTICULAR SPECIFICATION FOR
BROAD GAUGE
BOGIE BRAKE VAN
TYPE BVCM

1. SCOPE

1.1 This Specification covers the requirements for the manufacture and supply of
Broad Gauge Bogie Brake van type BVCM and its variants with particular details
as per relevant drawings of the relevant Brake van outlined in RDSO Index Drg.
No. WD-09107-S-01(latest revision) of the tendered design and General
Standard Specification G-72 (latest revision) issued by R.D.S.O. (Wagon),
Lucknow, which can be had from Director General, RDSO (Wagon), Manak
Nagar, Lucknow-226011. These Brake vans shall be supplied complete in all
respects.

1.2 Cast Steel Bogie, complete together with wheel and axle sets with cartridge roller
bearing mounted adapters along with elastomeric pads thereon, all components
of center pivot assembly and side bearer referred to in clause no-9 with Non
Transition center buffer couplers together with draft gear, yoke, yoke pin, locking
arrangement, striker casting, yoke pin support referred to in Clause 10 and Air
Brake equipment referred to in Clause 11 of this Particular Specification, shall
be fitted with brake vans.

2. DEFINITIONS

2.1 Purchaser means the President of the Republic of India.

2.2 Engineer- means Research Designs & Standards Organization, Ministry of
Railways, Lucknow- 226 011.
2.3 Inspecting Officer means the person, firm or Department nominated by the
Purchaser to inspect the work on his behalf and the deputies of the Inspecting
Officer so nominated.

2.4 Contractor- means the person, firm or company with whom the order for the
supply is placed and shall be deemed to include the Contractors successors
(approved by the Purchaser), representatives, heirs, executors and
administrators as the case may be unless excluded by the terms of Contract.

3. WELDING
3.1 General requirements and comprehensive guidance with regard to edge
preparation, fit up for welding, welding procedure and inspection of welded
joints are contained in relevant clause of General Standard Specification No. G-
72 (Latest Rev), which can be purchased from Director General, RDSO, Manak
Nagar, Lucknow- 226011.

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3.2 Wherever welding is specified or adopted in the manufacture of the Brake van or
in the fabrication of sub-assemblies and components, the manufacturer shall
obtain the approval of his proposed welding procedure and sequence from the
Engineer. This, however, will not, in any way, reduce the Contractors
responsibility for satisfactory execution of the contract in all respects as
stipulated in relevant clause of General Standard Specification No. G-72 (Latest
Revision).

4. TESTING

4.1 The Pattern Brake Van shall be tested under tare condition as detailed in
relevant clause of General Standard Specification no. G-72 (Latest Rev.) with
latest amendment. Clearances found between the various members of
underframe and under gear as specified in the relevant drawings of the relevant
Brake van outlined in RDSO Index Drg. No. WD-09107-S-01(latest revision) shall
be measured under tare conditions and submitted to the Engineers through the
Inspecting Officer. In case of Contractors who would take up the manufacture of
this type of brake van for the first time, the tests to be conducted on the Pattern
Brake Van shall be decided in consultation with the Engineers.

5. STANDARD SPECIFICATION

All materials required for manufacture of these Brake van shall conform to the
latest issue of relevant specifications, adopted for railway-use unless otherwise
specified herein.

6. PARTICULAR REQUIREMENT
Construction drawings for wagon indicated in RDSO index drawing No. WD-
09107-S-01(with latest alteration) may include Cold Rolled Formed (CRF) section
of different members of underframe. The cold rolled formed (CRF) section shall
be procured by Railways/Wagon builders only from RDSO approved sources.

The following are the particular requirements in respect of the work required
under this specification.

6.1 MATERIAL FOR CONSTRUCTION:

6.1.1 Underframe members including Details are provided in relevant

Center sill, body stanchions, Body construction drawings mentioned
Brackets, Knees & Gussets. in RDSO index drawing no WD-
6.1.2 Body and Roof Sheets 09107-S-01(with latest alteration)
6.1.3 Floor Plate
6.1.4 Bonded Mineral Glass Wool As per Annexure-II
Thermal Insulation
6.1.5 Bonding material for the application CPRX compound or other
of Thermal Insulation approved adhesive not having
exceeded its recommended self-
life at the time of its application.

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These Brake vans shall be provided with tail lamp brackets, Reflector Indicator
board and LV Boards at both ends.

7. UNDERFRAME
7.1 The under frame shall conform to technical details as per relevant drawings of
the relevant Brake Van outlined in RDSO Index Drg. No. WD-09107-S-01 (latest
revision).

8. BRAKE VAN BODY

8.1 The Brake van Body shall be fabricated as per relevant drawings of the relevant
Brake Van outlined in RDSO Index Drg. No WD-09107-S-01 (latest revision) of
the tendered design. The body design incorporates the use of Bonded Mineral
Wool & Glass Wool for Thermal insulation. The above, should confirm to
technical details as mentioned in Annexure-II.

9. BOGIE

9.1 The Brake van shall be equipped with Cast steel Bogie to Latest RDSO STR
with latest amendments as per relevant drawings of the relevant Brake Van
outlined in RDSO Index Drg. No WD-09107-S-01(latest revision) of the tendered
design.

10. COUPLER AND DRAFT GEAR

10.1 The Brake van shall be equipped with High Tensile Centre Buffer Coupler, High
capacity draft gear & other associated assemblies/ sub-components/ operating/
interfacing equipment to Latest RDSO STR with latest amendments as per
relevant drawings of the relevant Brake Van outlined in RDSO Index Drg. No
WD-09107-S-01(latest revision) of the tendered design.
.

11. AIR BRAKE

11.1 The brake van shall be equipped with air brake equipment to Latest RDSO
Specification with latest amendments as per relevant drawings of the relevant
Brake Van outlined in RDSO Index Drg. No WD-09107-S-01 (latest revision) of
the tendered design.

11.2 Pipes and pipe joints consisting of brake pipe, branch pipes shall be to Latest
RDSO Specification with latest amendments as per relevant drawings of the
relevant Brake Van outlined in RDSO Index Drg. No WD-09107-S-01 (latest
revision) of the tendered design.

11.3 The complete air brake equipment including the pipes and joints shall be fitted on
pattern wagon as per relevant drawings of the relevant wagon outlined in RDSO
Index Drg. No. WD-09107-S-01(latest revision) of the tendered design and
offered to the Engineers' for approval. The Contractor shall be obliged to carry out

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any modification on the layout of the air brake equipment, if found necessary, by
the Engineers'.

11.4 Contractor shall proceed with the bulk production of brake van only after the final
approval of fitment and layout of pattern brake van equipment, as mentioned
above.
11.5 During the bulk production of Brake van, the Contractor shall ensure that the
complete air brake equipment is fitted on the Brake van correctly as per the
dimensions shown in the relevant drawing. Special care must be taken with
regard to the clamping arrangement of pipes to under frames besides securing
of clamps with pipe and tack welding of nuts with bolts.

12. BRAKE GEAR

12.1 The Brake van shall be equipped with under frame brake gear in accordance
with the arrangement shown in as per relevant drawings of the relevant wagon
outlined in RDSO Index Drg. No. WD-09107-S-01(latest revision) of the tendered
design. The contractor shall also ensure for correct functioning of the brake
gear components.

12.2 Brake block force shall be checked at the time of prototype testing, with the
necessary facilities, equipments, etc. being provided by the manufacturer. Any
modification required after testing, shall be ensured by the manufacturer.

13. PAINTING AND INSCRIPTIONS

13.1 The surface preparation and Schedule of Painting of Brake Vans shall be as
indicated in relevant clause of General Standard Specification no. G-72 (Latest
Revision).

13.2 The marking on the Brake van shall be as per relevant drawings of the relevant
wagon outlined in RDSO Index Drg. No WD-09107-S-01(latest revision) of the
tendered design.

13.3 The tare weight of the Brake van shall be marked in tonnes up to one decimal
place, as determined by the method detailed in Annexure-I.

13.4 Railway's initials to be marked will be intimated later. The Mechanical code BVCM
shall be stenciled and stamped at the locations shown in Marking Diagram of
detailed in as per relevant drawings of the relevant wagon outlined in RDSO
Index Drg. No. WD-09107-S-01(latest revision) of the tendered design.

14. DRAWINGS
The Brake van shall be manufactured strictly to the relevant RDSO Drgs /
technical details as per relevant drawings of the relevant wagon outlined in
RDSO Index Drg. No. WD-09107-S-01(latest revision) of the tendered design.
The drawings mentioned in the above Index drawing are, subject to advancement

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in course of construction of these wagons and the contractor shall comply with
these amendments in the manufacturing of components. The drawings listed in the
above Index drawing are complete in all respects and any detailing, if necessary,
will be done by the contractor.
15. AS MADE DRAWINGS, PHOTOGRAPHS AND MODELS
15.1 DRAWINGS
In addition, the Contractor shall, also, supply two sets of As Made' Polyster Film
Tracings (50 Micron thick matte) of drawings followed in the manufacture of the
Brake van for the record of purchaser and engineers. These tracings shall
conform to the requirement as detailed in Clause-21 of General Standard
Specification No. G-72 (Latest Revision). The contractor shall incorporate in the
above set of tracings, any deviations, modification and relaxations granted in the
course of manufacture.

The As Made' drawings detailed above shall contain full details of each
component/ assembly/ sub-assembly, inclusive of the material specification, actual
average weight and reference drawings. The general order of the drawings, title
block etc. shall be strictly as indicated in drawing no. SK 67521 with space for IRS
drawings number left blank. The size of the sheet shall be A1 (841 mm x 594 mm)
and the Code of Practice for drawings shall conform to IS Specification No. 696.

15.2 PHOTOGRAPHS

The Contractor shall furnish to the Engineers , at the time of prototype approval, 2
nos. for every order of 100 wagons or part thereof free of cost suitably mounted
color photographs, 600 mm x 450 mm bringing out the salient features as called
for in Clause-21 of General Standard Specification No. G-72 (Latest Revision).

15.3 MODELS

The Contractor shall furnish to the Engineers, at the time of prototype approval, 1
no. for every order of 100 wagons or part thereof free of cost, a 1/16 scale
model made out of steel or acrylic transparent sheet as called for in relevant
Clause of General Standard Specification No. G-72 (Latest Revision).

16. USE OF ALTERNATIVES

Some of the drawings detailed in as per relevant drawings of the relevant wagon
outlined in RDSO Index Drg. No. WD-09107-S-01(latest revision) pertaining to
the tendered design could include alternative material/ alternative mode of
manufacturing. Wherever such alternates have been mentioned/ permitted, the
tenderer must quote separately for the alternatives.

***

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ANNEXURE-I

METHOD OF DETERMINING THE TARE WEIGHT OF BRAKE VAN

All Contractors (whether equipped with Weigh Bridge or not in their works)
will arrange to weigh each Brake van of identical design and mark individual tare
weight on them by actual weighment.

Tare weight of the wagons shall also be intimated to the Engineers duly certified by
the Inspecting Officer.

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ANNEXURE-II

Schedule of requirements for Bonded Mineral glass Wool insulation for Goods
Brake Vans

The materials shall have a nominal thickness of 25mm and shall generally
conform to requirements of GroupI of IS Specification 8183 (Specification for
bonded mineral wool for thermal insulation) and the following additional
requirements:-

1 (a) Bonded Mineral Wool

The bulk density of the material shall be 48 kg / cu m or 40 kg / cu m or as

specified by the purchaser and shall not vary more than 15% of the value
specified when tested as per Clause 3.2.1 of IS : 8183 . The material with upper
limit of bulk density of 48 kg / m + 15 % (i.e. 55kg / m ) shall be considered to lie
within Group 1 also.

(b) Bonded Glass Wool

The bulk density of the material shall either be 24 kg/cu m or16 kg/cu m or as
specified by the purchaser and shall not vary more than 15% of the specified
value when tested as per Clause 3.2.1 of IS : 8183.

2. The thermal conductivity of the material ( K- value ) shall not exceed 0.49m
W/cm/0 C ( 0.042k cal /m / h/ 0 C ) for a mean temperature of 50 0 C.
3. It must be suitable for application on steel sheets or other surfaces with suitable
adhesive and shall firmly adhere to the surface on which it is applied.

4. The insulation must be guaranteed for the above performance for a minimum
period of one year from the date of putting the brake vans into service.

5. The materials shall satisfy all optional requirements given under Clauses 3.10.1 to
3.10.7 of Specification No. IS: 8183

6. The materials shall in addition pass the jolting test described below:

6.1 Apparatus for jolting test :

The apparatus consists of a steel frame with a slot to accommodate the test panel
of size 41 x 32 cm. The Provision is made for raising the frame work through a
height of 25 mm and dropping freely on two rubber blocks with an approximate
frequency of 4 cycles per second. The shape of the cam shall be such that it
supports the frame with the panel right through. In the last 2mm stroke, a mild
shock is given to the panel by making the panel compress against the rubber
blocks.

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6.2 Test procedure

300 x 300 mm square pieces of sample from the supply are to be tested on the
panel plate on which the entire system of painting for the roof has already been
painted. For bonding for the insulation material CPRX compound or any other
approved adhesive may be used. Sufficient flash time may be given after the
application of the adhesive before the insulation material is pasted on. The test
panel shall not show any lamination and should withstand one lakh jolts in the
jolting machine. The material should not also exhibit friability.

7. Inner surface preparation of inner and outer panels. (Side, end & roof).

a. Clean thoroughly the inside surface of the inner and outer panels. ( Side,
end & roof ) with emery cloth or wire brush to remove the rust, mill scale
etc.

b. Apply two coats of red oxide zinc chrome primer to IS : 2074.

c. Apply three coats of Bituminous emulsions to IRS Specification No. P 30

or four coats of Bituminous Anti Corrosive paints to IRS Specification No.
P 29.

8. Fixing of Glass Wool

After the above paint coats are dry, affix the glass wool insulation firmly with
CPRX compound or any other suitable adhesive.

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