Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 1 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev.

nil
September, 2015

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS DRAFT

SCHEDULE OF TECHNICAL REQUIREMENTS FOR MANUFACTURE AND

SUPPLY OF FAILURE INDICATION CUM BRAKE APPLICATION
(FIBA) DEVICE

S. Date / Month Revision Reason

No. Of / Page No For Amendment
Issue: Amendment

1 September, 2015 Nil - -

Issued By

Carriage Directorate
Research Design and Standard Organisation
Manak Nagar Lucknow-226011

Price :Rs………./

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 2 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

CONTENTS
Description Page

I FOREWORD … … … … … … … 3
ABBREVIATION … … … … … … … 4

II AIR SPRING FAILURE INDICATION CUM BRAKE APPLICATION (FIBA)

DEVICE ( SECTION – A )
1. Scope … … … … … … …5
2. Operating Conditions … … … … … … …5-6
3. Environmental Conditions … … … … … …6
4. Scope of Supply … … … … … … …6-7
5. Procedure For Vendor Registration … … … … …7-9
6. Technical Requirements … … … … … …9-12
7. Submission of Offer … … … … … … …12-13
8. Guarantee … … … … … … … 13
9. Installation, Commissioning, & Maintenance … … … 14
10. Inspection and Testing … … … … … … …14-16
11. Marking … … … … … … … 16
12. Packing … … … … … … … 16-17
13. Maintenance Manual … … … … … … … 17
14. General … … … … … … … 17

ANNEXURE-A … … … … … … … 18
ANNEXURE-B … … … … … … … 19-22

DRAWINGS
1. SKETCH –Lay out of port of FIBA device… … … 23
2. SKETCH – CG- K9132… … … … … 24
3. SKETCH – CG-K10033… … … … … 25
4. SKETCH – CG-K10031… … … … … 26

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 3 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

FOREWORD

This Schedule of Technical Requirements (STR) spells out the schedule of

technical requirements of Air Spring Failure Indication Cum Brake Application
(FIBA) Device for Air Spring fitted in BG ICF, LHB, Hybrid and double decker
mainline coaches having ICF and LHB type bogies.

This Schedule of Technical Requirements is concerned with the Air Spring

Failure Indication Cum Brake Application (FIBA) Device and details of the
requirements and tests for the Air Spring Failure Indication Cum Brake
Application (FIBA) Device.

The specification shall not be altered /modified or reproduced in any form

without the written permission of the Director General (Carriage), RDSO,
Lucknow.

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 4 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

ABRIVIATIONS

STR Schedule of Technical Requirements

IR Indian Railways
FIBA device Failure Indication Cum Brake Application device

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 5 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

`
SCHEDULE OF TECHNICAL REQUIREMENTS OF AIR SPRING FAILURE
INDICATION CUM BRAKE APPLICATION (FIBA) DEVICE FOR AIR SPRING FITTED
BG ICF, LHB, HYBRID AND DOUBLE DECKER MAINLINE COACHES HAVING ICF
AND LHB TYPE BOGIES.

1. SCOPE:

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

1.2 Flexible hoses, Isolating Cock, Isolating cock with vent feature for the Air Spring Failure
Indication Cum Brake Application (FIBA) Device should be supplied to RDSO’s STR C-
K407 (Latest Revision), ABR-02 and firm’s approved drawings by RDSO. Indicator of
FIBA device should be to RDSO STR no. RDSO/2011/CG-04 (Latest Rev.) The Air
Spring Failure Indication Cum Brake Application (FIBA) Device should be compatible
with the other items as described in the above STRs. The purchaser will be at liberty to
buy any part or complete item as mentioned above and Air Spring Failure Indication
Cum Brake Application (FIBA) Device to this STR from different source of supply.

2. OPERATING CONDITIONS:

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

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

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

2.3 Each coach shall be fitted with four air spring assemblies (two per bogie) and each Air
Spring Failure Indication Cum Brake Application (FIBA) Device shall be controlled by an
independent levelling valve (4-point control system). Two air springs of the same bogie
shall be connected through a duplex check valve set to act at a pressure differential of
1.5 + 0.12 Kg/cm².
Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 6 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

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

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

3. ENVIRONMENTAL CONDITIONS:

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

Max. Temperature under sun : 60ºC.

Ambient temperature : 0º to 45ºC in shade.
Average relative humidity : 70% to 90%, 100% on several days.
Rainfall : Fairly heavy, maximum being 200mm in
24 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 (FIBA) Device system may also
come in contact with the following, during coach maintenance operation:

 Chemical products (like cleaning compound of coach cleaning)

 Cotton waste smeared with oil and paint etc.
 Disinfectants.
 Oils & lubricants used in coach bogies.

4. SCOPE OF SUPPLY:

The scope of supply covers the following items:

One FIBA device per bogie or 02 FIBA device per coach will be required.

i) For each Air Spring Failure Indication Cum Brake Application (FIBA) Device:

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 7 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

S. No. Item Quantity

1 Air Spring Failure Indication Cum Brake Application (FIBA) Device 1
2 Indicator 2
3 Hose connection 3/4'’ BSPX550 mm with both end rubber washers 3
4 Isolating cock (OLP type) 20mm bore 1
5 Isolating cock 20mm bore with vent hole 2
6 Nut bolts/fasteners with locking washer for mounting of FIBA 3+2
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:

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

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

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

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

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

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

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

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

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

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

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

5.3 Special Conditions:

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 8 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

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

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

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

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

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

iii) A Vendor shall be considered eligible for upgradation to Part-I status on

completing successful supply of a minimum of 500 coach sets of the particular
type of FIBA device as per latest ISO guideline of RDSO.

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

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

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

v) After type tests of a particular design are approved by RDSO, vendors shall
ensure that Air Spring Failure Indication Cum Brake Application (FIBA) Device to

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 9 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

the particular specification are supplied with components manufactured from the
sources as indicated at the time of design approval and used for type testing.

vi) The type test shall be witnessed by authorized representative of RDSO at the
time of design approval of the vendor at their own test facility.

Any additional tests if considered necessary shall also be arranged by vendor

free of cost. All necessary arrangements for witnessing the type test of Air Spring
Failure Indication Cum Brake Application (FIBA) Device at firm’s premises shall
be done by the vendor. RDSO reserves the right to witness the type test again if
changes in approved design/drawings are carried out which are likely to alter
design / performance characteristics of the Air Spring Failure Indication Cum
Brake Application (FIBA) Device.

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

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

6. TECHNICAL REQURIEMENTS:

6.1 General technical requirement:

General technical requirement of FIBA device shall be as under:

6.1.1 In no case it shall allow to flow the air supply form 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 irrespective of the pressure of
compressed air in the bellow after the rupture has taken place.

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

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 10 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

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

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

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

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

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

6.1.12 It shall be possible to use the same Air Spring Failure Indication Cum Brake Application
(FIBA) Device in the air brake system and air suspension system of LHB, Hybrid and
ICF coaches with pneumatic brake.

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

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 11 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

6.1.14 The FIBA Device shall not need any electrical connections.
6.1.15 Once brake application is initiated by the Air Spring failure indication Device, the brake
application shall remain in effect until the driver or the railway staff has located the defect
on the coach and isolated the system or defect is rectified and system has been re
adjusted for further use.

6.1.16 It shall be possible to reset the brake application by the driver so that the journey can be
resumed at a restricted speed.

6.1.17 However the visual indication shall not be possible to be suppressed unless the
compressed air in the air suspension system of the coach itself is exhausted completely
to atmosphere or discharged through isolating cock with vent feature. Therefore vent
feature may be provided in isolating cock as laid down in drawing no CG - K9132 of
latest revision. FIBA device may also rest manually by providing reset key on FIBA
device.

6.1.18 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 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 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 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 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 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).

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 12 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

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

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

6.2 Space Constraints:

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

6.3 Pneumatic supply connection:

Pneumatic supply connection Air Spring Failure Indication Cum Brake Application (FIBA)
Device shall be as per schematic diagram of RDSO Drawing no. CG-K9132.

6.4 Mounting arrangement:

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

6.5 Other Details:

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

7. SUBMISSION OF OFFER:

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

1) Dimensional drawing of Air Spring Failure Indication Cum Brake Application

(FIBA) Device.

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

4) Whether proposed Air Spring Failure Indication Cum Brake Application (FIBA)
Device is being used by any other rail-road system? If yes, details regarding
quantity, type of stock, max. operating speed, type of service, average annual

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 13 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

running kilometers, life cycle obtained by the user rail-road and maintenance
cycle followed by them shall be furnished.

5) Details of deviation from the STR.

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

7) Expected life cycle in operating and environmental conditions enumerated in

clause 2 & 3.

8) A write-up giving broadly the maintenance requirements on time/distance basis

along with the facilities that would be needed for proper maintenance/upkeep of
the offered Air Spring Failure Indication Cum Brake Application (FIBA) Device.

10) A detailed write-up giving the details of "Quality Assurance System" being
followed for manufacture of the offered items; and

11) Details of manufacturing and testing facilities available with the manufacturer.

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

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

7.4 The premises of the firm shall be visited by RDSO's 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 reas ons
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.

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 14 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

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.

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

9.3 Maintenance booklet supplied by the supplier shall cover the following aspects in detail:

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

2) Working principle based on the actual construction.

3) Constructional details giving sketches, drawings and photographs etc. identifying

various items and their part numbers etc. for easy identification.

4) Procedure for dismantling using sequential steps with the help of sketches.

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

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

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

8) Details of prevention maintenance kit, required for periodical preventive

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

8) Comprehensive details containing legible sectional views of defects normally

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

9) List of other defects and their remedies.

10) Periodicity for various maintenance activities on time and distance basis.

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

10. INSPECTION AND TESTING:

10.1 General requirements:

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 15 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

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

1) Access to all records considered relevant for such activity by inspecting officials.

2) Questioning of relevant personnel engaged in production, testing and quality checking

activities etc. or related issues.

3) Testing of few samples of items already produced by the firm to ascertain the
technical characteristics given in this STR.

4) Any other check considered necessary by the inspecting party.

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

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

7) Item no.3, 4, 5 & 6 shall be supplied already inspected by RDSO/RITES as per

respective STR. Inspection Certificate of the same shall be provided by the firm at the
time of inspection of FIBA device and Indicator.

8) The supplier shall be fully responsible for successful running of the system.

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

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

10.2.1 Dimensional check:

ITEM REFERENCE DOCUMENTS

Air Spring Failure Indication Cum Brake
Application (FIBA) Device
Indicator of FIBA device
Hose Connection
Isolating Cock (OLP Type) 20mm bore
Isolating Cock 20mm bore with vent hole
As per Firm’s assembly drawing approved
by RDSO, Clause 1 of ANNEXURE-B &
technical requirements of clause 6 of this
STR.
RDSO drg no. K1054 & STR C-K407
(latest rev.)
RDSO sketch 97002 & STR C-K407
(latest rev.)
RDSO drawing no. 02 610 0871

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 16 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

10.2.2 Functional test of the FIBA device:

Functional test of FIBA device shall be carried out as per ANNEXURE- B of this STR.
Functional testing of Indicators of FIBA device shall also be carried out as per clause 4
of ANNEXURE-B.

Leak test of Air Spring Failure Indication Cum Brake Application (FIBA) Device shall be
carried out as follows-

- Install the Air Spring Failure Indication Cum Brake Application (FIBA) Device at
test bench.
- Gradually raise the air pressure to 2 kg/cm 2 and thoroughly check the air leakage
from FIBA device with the help of liquid soap solution.
- Gradually raise the air pressure to 10 kg/cm 2

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

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

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

Lot size upto 10 25 50 75 100

No of samples 2 3 4 5 6

For lot sizes more than 100, 6% of the samples shall be picked up randomly for the
above inspections.
10.5 In case any picked up sample fails, manufacturer/supplier shall re-offer, rectifying the
defects. However, in such cases, double the quantity of samples shall be picked up and
shall be checked for dimension and other specified testing. In case any one sample fails
again, the entire lot shall be rejected.

11. MARKING:

Every item of the Air Spring Failure Indication Cum Brake Application (FIBA) Device
shall be legibly marked to indicate the following:

1) Manufacturer's initials.
2) Month and year of manufacture.
3) Identification marks, i.e. Part Number, Batch Number, etc.

12. PACKING:

The Air Spring Failure Indication Cum Brake Application (FIBA) Device shall be suitably
packed along with its loose parts and exposed threaded portion, to protect against any
damage that may occur during transit and handling. The threaded and other ports of the

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 17 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

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:

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

14. GENERAL:

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

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

*****************

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 18 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

Annexure – A
REQUIREMENTS OF TYPE TEST REPORT

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

1) MATERIAL TESTS

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

2) ENDURANCE TEST OF AIR SPRING FAILURE INDICATION CUM BRAKE

APPLICATION (FIBA) DEVICE:

a) The endurance test is conducted to assess suitability of the Air Spring Failure
Indication Cum Brake Application (FIBA) Device provided at secondary stage
suspension in coach bogie by simulating service condition.

b) FIBA device shall be tested for 1000 actuation cycle for each valve. Actuation
pressure of both side FIBA valves shall be recorded continuously for first 100 cycles
and afterward at every 10th cycles for each Valve. Actuation pressure of FIBA valves
shall be within specified limit.

c) The test on Air Spring Failure Indication Cum Brake Application (FIBA) Device shall
be conducted only when the results of functionality test are obtained and found
satisfactory.

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

4) Any other test felt necessary by the manufacturer.

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

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

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

************

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 19 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

ANNEXURE - B
CHECKLIST FOR INSPECTION OF AIR SPRING FAILURE INDICATION CUM BRAKE
APPLICATION DEVICE
As per inspection and testing Clause no.10.0

1. Dimensional Check (10% of the Lot Qty.)

S. no. Particulars Unit Specified Observed Remarks

Sample No.
1. Length of FIBA Device mm As per
approved
2. Height of FIBA Device mm
drawing
3. Thickness of FIBA Device mm
without bkt.
4. Thickness of FIBA Device with mm
bkt.
5. Port diameter BP 3/4”BSPP
and thread: B1 3/4”BSPP
B2 3/4”BSPP
IND ¼” BSPP
6. Mounting bkt hole pitch of FIBA mm 134+1
device

7. Dia of mounting Hole 1 mm 18+0.5

bkt. Holes
Hole 2 mm 18+0.5
8. Weight of FIBA valve with bkt Kg As per
approved
drawing
9. Height of indicator mm As per
Indicator Drawing not received

approved
10. Width of indicator mm
drawing
11. Thickness of indicator mm
12. Total Height of indicator mm
13. Inlet port dia of indicator mm 1/4" BSPP
14. Weight of indicator Kg As per
approved
drawing

2. Leak Test of Air Spring: As per Clause 9.2.2 of section A.

************

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 20 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

3. Functional test of FIBA device:

S . No. Test and testing procedure S tandard Results of FIBA device sample obtained
S. No……... S. No……... S. No……...

M fg dt…… M fg dt…… M fg dt……

1. Initial Charging:
i) Ensure that all Isolating cocks and ---------
cut of angle cocks in supply line
should be in open condition. Other
end cut of angle cocks and drain
cocks provided on test bench
should be in closed position.
ii) Charge the FP line at 6.0 Kg/Cm2 FP= 6 + 0.1 Kg/Cm2
and BP line at 5.0 Kg/Cm2 . BP= 5 + 0.1 Kg/Cm2

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

3. Pressure tightness test: i) No leakage in FIBA device

Charge FP and BP upto 10.0 Kg/Cm2.
4. Insensitivity test:
Drop the air pressure of one air spring
side by 0.5 Kg/Cm2 in 10 seconds with
the help of the respective choke/drain
cock. Repeat the process for other side
air spring.
5. A) Functional Test at 2.0 Kg/Cm2
(Tare Pressure)
i. Charge the FP at 2.0 Kg/Cm2 Pressure
and BP at 5.0 Kg/Cm2.
ii. Open the ½” drain cock to drain the
air pressure of one side air spring/40L
auxiliary reservoir.
Repeat the process for other side air
spring.
Valve
ii) FIBA device should not
operate.
iii) No damage in FIBA device
or circuit.
i) No response and no exhaust
of air from the exhaust port.
ii) Indicators do not turn red.
i) Pressure in respective gauge
start falling & FIBA device
actuate when respective gauge
pressure becomes less than
1+0.1 Kg/Cm2.
ii)BP pressure starts venting
gradually and settles at 3.4
Kg/Cm2 approx.

iii)Both indicators should be red.

iv) Whistling/ Hissing sound of

90+ 5db should blow.

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0
BP Isolation: (Brake release and
suppression of whistle)
Close the Isolating cock provided
before FIBA device in BP line.
S uppression of Indicator:
Close the both isolating cocks with
vent feature or pull the resetting keys
provided on FIBA device.
B) Functional Test at 5.0 Kg/Cm2:
i. Charge the FP at 5.0 Kg/Cm2 Pressure
and BP at 5.0 Kg/Cm2.
ii. Open the ½” drain cock to drain the
air pressure of one side air spring/40L
auxiliary reservoir.
Repeat the process for other side air
spring.
BP Isolation: (Brake release and
suppression of whistle)
Close the Isolating cock provided
before FIBA device in BP line.
S uppression of Indicator:
Close the both isolating cocks with
vent feature or pull the resetting keys
provided on FIBA device.
C) Functional Test at 6.0 Kg/Cm2:
i. Charge the FP at 6.0 Kg/Cm2 Pressure
and BP at 5.0 Kg/Cm2.
ii. Open the ½” drain cock to drain the
air pressure of one side air spring/40L
auxiliary reservoir.
Repeat the process for other side air
spring
Signature
Name & Prepared By:
Designation Ratnaker Tiwari/ SSE/Design
Page 21 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015
i) BP pressure exhaust, through
FIBA device exhaust port
stops and BP pressure rises to
5 Kg/Cm2.
ii) Whistling/Hissing sound stops.
iii) Both indicators show red/green.
Both indicators of same bogie
should turn to green from red.
Indicators of other bogie should
remain show green.
i) Pressure in respective gauge
start falling & FIBA device
actuate when respective gauge
pressure becomes less than
1+0.1 Kg/Cm2.
ii)BP pressure starts venting
gradually and settles at 3.4
Kg/Cm2 approx.
iii)Both indicators should be red.
iv) Whistling/ Hissing sound of
90+ 5db should blow.
i) BP pressure exhaust, through
FIBA device exhaust port stops
and BP pressure rises to 5
Kg/Cm2.
ii)Whistling/Hissing sound stops.
iii)Both indicators show
red/green.
Both indicators of same bogie
should turn to green from red.
Indicators of other bogie should
remain show green.
i) Pressure in respective gauge
start falling & FIBA device
actuate when respective gauge
pressure becomes less than
1+0.1 Kg/Cm2.
ii)BP pressure starts venting
gradually and settles at 3.4
Kg/Cm2 approx.
iii)Both indicators should be red.
iv) Whistling/ Hissing sound of
90+ 5db should blow.
Checked By: Approved By:
S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 22 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

BP Isolation: (Brake release and i) BP pressure exhaust, through

suppression of whistle) FIBA device exhaust port stops
Close the Isolating cock provided and BP pressure rises to 5
before FIBA device in BP line. Kg/Cm2.
ii) Whistling/Hissing sound stops.
iii) Both indicators show red/green.
S uppression of Indicator:
Close the both isolating cocks with vent Both indicators of same bogie
feature or pull the resetting keys should turn to green from red.
provided on FIBA device. Indicators of other bogie should
remain show green.
6. Brake Pipe Variation Test: i) FIBA device should not
Drop Brake Pipe pressure from 5.0 actuate.
Kg/Cm2 to zero.
ii) FP line pressure should not
drop.

iii)Both indicators should show

green.

iv) No whistling/Hissing sound.

7. Charging Behaviour test:
Charge BP prior to FP and observe the FIBA device should not actuate
actuation behaviour of FIBA Device if
actuated.

8. Resetting behaviour test:

i) Charge the system at 5.0 Kg/Cm2 FIBA device should not reset
pressure . automatically
ii) Drop FP line pressure and actuate
the respective FIBA Device.
iii) Close the drain cock and raise FP
line pressure of FIBA Device to
again5.0 Kg/Cm2 .

4. Testing of Indicator:

i) Leakage test:
Apply a pressure of 10 Kg/Cm 2. There should not be any leakage if checked with soap
water.

ii) Functionality Test:

a) Apply a pressure of 0.5 to 0.6 Kg/Cm 2. Red colours should appear in window of
Indicator.
b) Now release the pressure to 0 Kg/Cm 2. green colours should appear in window of
Indicator.
c) Piston of indicator should move smoothly and piston should not be sticky. Indicator
shall be air tight and water resistant.

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 23 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 24 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 25 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG
 Ref: CG-WI-4.2.1-1 Ver. 1.0 Page 26 of 26 Date / Month of issue: RDSO/2015/CG-05, Rev. nil
September, 2015

Signature
Name & Prepared By: Checked By: Approved By:
Designation Ratnaker Tiwari/ SSE/Design S. S. Raypa/DD/VDG Mohd. Saquib /Dir./VDG