WD-05-BARREL-2011 (Superseded WD-04-BARREL-2001 and WD-01-BARREL-(BMBS)-2009)

INDIAN RAILWAYS
PARTICULAR SPECIFICATION FOR TANK BARREL INCLUDING CRADLES, PLATFORM AND LADDERS OF BOGIE LIQUIFIED PLATFORM GAS TANK WAGON TYPE BTPGLN AND ITS VARIANTS

(BROAD GAUGE)

Issued by: WAGON DIRECTORATE RESEARCH DESIGNS STANDARDS ORGANISATION MANAK NAGAR, LUCKNOW 226 011

March- 2011

PRICE: Rs. 1400/-

WD-05-BARREL-2011 (Superseded WD-04-BARREL-2001 and WD-01-BARREL-(BMBS)-2009)

CONTENTS Clause No. 1 2 3 4 5 6 7 8 Description SCOPE DEFINITIONS LEADING PARTICULARS PARTICULAR REQUIREMENTS GUARANTEE PAINTING AND MARKING DISPUTE REGARDING INTERPRETATION AS MADE DRAWINGS AND PHOTOGRAPHS

ANNEXURES I METHOD OF CERTIFICATION AND TESTING OF DOME FITTINGS.

WD-05-BARREL-2011 (Superseded WD-04-BARREL-2001 and WD-01-BARREL-(BMBS)-2009)

PARTICULAR SPECIFICATION FOR TANK BARRELS OF BOGIE TANK WAGON FOR LIQUIFIED PETROLEUM GAS TYPE BTPGLNAND ITS VARIANTS 1. 1.1 SCOPE: This specification covers the particular requirements of manufacture and supply of the following: Barrel complete with all the welded attachments manholes cover plate and dome. The dome fittings as per relevant drawings of variants outlined in RDSO Index Drg. No. WD-93047-S-50 (latest Alteration) complete with all piping arrangement. Cradle complete. Platform and ladder complete. The assemblies mentioned as Clause 1.1 shall be generally to drawings as per relevant drawings of variants outlined in RDSO Index Drg. No. WD-93047-S-50 (latest Alteration). In addition to the manufacture and supply of barrel and other components as listed as per Clause 1.1 above, the Contractor will also be responsible for the following: Welding the cradles with underframe. Hydrostatic testing of barrel (without fittings) to a test pressure of 22.10 kg / cm2 (313.7 psi). Mounting the barrel on cradles over underframe (supplied by underframe manufacturer) and drilling the barrel attachment rivet holes in position for easy matching and riveting thereon. Installation of tank fittings and conducting necessary tests. Pneumatic testing of barrel with compressed air having a pressure of 15.5 kg / cm2 (220 lbs /sq. inch) after it has been mounted underframe with all the dome fittings in position. Pneumatic test can be carried out by filling the entire volume of barrel with air and the pressure raised in steps slowly to the required value. Alternatively, after hydraulic test, the fittings can be mounted on to the barrel and the barrel drained partially leaving 10 % empty space and pneumatic pressure built up in steps slowly to the required value in the empty space.

1.1.1 1.1.2

1.1.3 1.1.4 1.2

1.3

1.3.1 1.3.2 1.3.3

1.3.4 1.3.5 (a)

(b)

WD-05-BARREL-2011 (Superseded WD-04-BARREL-2001 and WD-01-BARREL-(BMBS)-2009) 1.3.6 1.4 Fitment of platform and ladders. The dome fittings as per relevant drawings of variants outlined in RDSO Index Drg. No. WD-93047-S-50 (latest Alteration) shall be fitted with wagon. The assemblies mentioned at Clause 1.1 shall be fabricated as per relevant drawings of variants outlined in RDSO Index Drg. No. WD-93047-S-50 (latest Alteration). The Contractor shall prepare his own working drawings based on the aforesaid key design drawings and submit them to the Engineers for approval before undertaking construction. The Contractor shall ensure that working drawings submitted for approval of the Engineers are fully in accordance with key design drawings and deviation, if any, are specially pointed out. Approval of the Engineers will only pertain to the design features, important controlling dimensions and the deviations from the design drawings specifically pointed out by the Contractor. Correctness of the details in drawings will not be checked by the Engineers and the responsibility for the same will be that of the Contractor. Alteration number of each drawing is, however, subject to advancement in the course of construction of these wagons and the Contractor shall comply with these amendments in the manufacturing the components. Copies of such amended drawings will be supplied to the Contractor free of cost. The barrel, which is a pressure vessel, should be manufactured, tested and certified in accordance with IS: 2825(with latest revision and amendments) Code for Unfired Pressure Vessel. In addition to testing and certification mentioned in IS: 2825 (with latest revision and amendments) manufacturer is also required to follow the provisions of this particular specification. DEFINITIONS: Purchaser means the party placing the contract for barrel conforming to this Particular Specification. Engineers means Research, Designs & Standards Organisation, Ministry of Railways, Lucknow 226 011. 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.

1.5

1.6

1.7

1.8

1.9

2. 2.1

2.2

2.3

WD-05-BARREL-2011 (Superseded WD-04-BARREL-2001 and WD-01-BARREL-(BMBS)-2009)

2.4

Contractor means the person, firm or company on whom the order for supply of barrels conforming to this Particular Specification is placed and shall be deemed to include Contractors successors, and Sub Contractors (approved by the Purchaser), as the case may be, unless excluded by the terms of the Contract. Sub Contractor means the person, firm or company from whom the Contractor may obtain any material or fittings to be used in the manufacture of the above parts.

2.5

3.

LEADING PARTICULARS Leading particulars of the barrel are as per relevant drawings of variants outlined in RDSO Index Drg. No. WD-93047-S-50 (latest Alteration)

4.

PARTICULAR REQUIREMENTS:

4.1 4.1.1

TANK BARREL: MATERIAL: All plates of the tank barrel including manhole cover plate and anchoring T shall be steel as mentioned in relevant drawings of variants outlined in RDSO Index Drg. No. WD-93047-S-50 (latest Alteration).

4.1.2 MANUFACTURE AND WORKMANSHIP: The manufacture and workmanship shall conform to the requirements of Sec. II of IS: 2825 (with latest revision and amendments)Code for Unfired Pressure Vessels (applicable for class I Pressure Vessel). 4.1.3 WELDING OF BARREL: Welding shall conform strictly to the requirements laid down in Sec. II of IS: 2825 (with latest revision and amendments)Code for Unfired Pressure Vessels. Mechanical tests of fusions welded seams shall also conform strictly to the requirements laid down in Sec. II of IS: 2825 (with latest revision and amendments). The electrodes used for welding purposes should have physical properties equivalent to or better than the parent metal.

WD-05-BARREL-2011 (Superseded WD-04-BARREL-2001 and WD-01-BARREL-(BMBS)-2009) 4.1.4 RADIOGRAPHIC EXAMINATION:

4.1.4.1 All fusion welded butt joints shall be examined throughout their entire length by the Xray or Gamma-ray method of radiography, as detailed in Sec. III of IS: 2825 (with latest revision and amendments). 4.1.4.2 After fabrication, tank barrel plates shall be ultrasonically tested as per ASTM A578 Level-B to detect any defect such as lamination etc. Tank barrel not conforming to this test shall be rejected. 4.1.5 NORMALISING OF THE DISHED ENDS: The dished ends after cold forming and before welding with the shell should be normalised as per procedure in order to eliminate the residual stresses generated during cold working, which might affect stresses during welding. 4.1.6 STRESS RELIEVING: The tank is to be stress relieved on completion of the welding of all joints and attachments to the shell and before hydrostatic test is carried out in accordance with the requirements laid down in Sec. II of IS: 2825 (with latest revision and amendments) Code for Unfired Pressure Vessels (applicable for class I Pressure Vessel).

4.1.7

INSPECTION AND TEST OF TANK BARREL: Inspection, test and repairs to all welded joints shall conform to the requirements laid down in Sec. III of IS: 2825(with latest revision and amendments) . In cases where the tank barrel is not mounted on the underframe at the manufactures works and the barrel has to be transported outside the premises of the barrel manufacturers work, the barrel should be subjected to hydraulic test (or pneumatic test) at the barrel manufacture premises and again after its assembly with the underframe to check for any damage to joints during transportation. Where, the tank barrel is mounted on the underframe at the barrel manufacturers works and it is not involved in transportation out side the barrel manufactures premises the hydraulic test (or pneumatic test) of the barrel should be carried out after mounting on the underframe. In case hydraulic tests are conducted it should be ensured that no traces of water are left in the barrel.

WD-05-BARREL-2011 (Superseded WD-04-BARREL-2001 and WD-01-BARREL-(BMBS)-2009) 4.1.8 Tolerances on dimensions of the tank barrel shall be as under: -

1. 2.

3.

4.

5. 6.

Length of barrel measured over +10 mm the centers of the dished ends. - 3 mm Circumferential length. The external Circumference of the complete barrel shall not depart from the calculated circumference based upon nominal inside diameter and the actual thickness by + 0.25 %. Ovality or Out of Roundness. The difference between maximum & minimum diameter at any cross section of the barrel shall be 1% of the nominal internal dia. with a maximum limit of inside diameter+1,250 200 Irregularities in Profile. When checked by 20 degree gauge, the irregularities in profile shall not exceed 3 mm plus 5% of the minimum plate thickness. The maximum value may b increased by 25 % if the length of irregularity does not exceed one quarter of the length of the barrel ring with a maximum of 1,000 mm. Inside diameter of the manhole + 2.0 mm Height of dome + 2.5 mm

4.1.9 CERTIFICATION PERTAINING TO TANK BARREL:

Certification and record pertaining to tank barrel should be as stipulated in sec. III of IS: 2825 (Code for unfired Pressure Vessels). The manufacturer shall furnish a certificate of manufacture and production tests generally in the format given at APPENDIX- M of IS: 2825 (with latest revision and amendments). In addition, the format should include the certification of the provisions of the specification also. The barrel is required to be tested and certified by a reputed Inspecting Agency to be engaged by the Purchaser with the approval of Engineers. The scope of work of the side Inspecting agency is as under: . . . . Certification of material Certification that fabrication of barrel is as per IS: 2825 1969. Certification regarding radiography as per IS: 2825 1969. Certification regarding stress relieving of barrel as per IS: 2825 1969.
7

WD-05-BARREL-2011 (Superseded WD-04-BARREL-2001 and WD-01-BARREL-(BMBS)-2009) . . . . . Certification of hydrostatic and pneumatic tests as called for in this specification. Certification of functioning of all the dome fittings as detailed in Annexure-I. Certification regarding the material and fabrication of the cradle. Certification as to the proper mounting of the barrel on the underframe and riveting thereon. Certification and approval of all the drawings submitted by the manufacturer. Any deviation from design drawings can be approved only with the concurrence of the Engineers.

NOTE: Wherever IS: 2825 1969 is mentioned it should be with latest revision and all up-todate Amendments.

4.1.9 CERTIFICATION PERTAINING TO FULLY ASSEMBLED WAGONS: After receiving the certification papers pertaining to barrel and its mounting over the underframe, Engineers or any other agency approved by the Engineers will finally inspect the wagon and certify the following aspects of the wagon:

i) ii) iii) iv) v) vi)

There is no visual abnormality. The wagon is generally fit to run. All the underframe components are in position and in working. Buffer heights of the wagon are within the prescribed limits. Height of the wagon is within the prescribed limits. The painted surface of the barrel has reasonable reflecting characteristics and the markings are strictly in accordance with marking diagram. TANK CRADLE:

4.2

4.2.1 The Tank cradle shall be as per relevant drawings of variants outlined in RDSO Index Drg. No. WD-93047-S-50 (latest Alteration). All plates used in its construction shall be as per steel mentioned in relevant drawings of variants outlined in RDSO Index Drg. No. WD-93047-S-50 (latest Alteration). 4.2.2 In the fabrication of cradle, general requirements and comprehensive guidance with regard to fit up for welding, welding procedure and inspection of welded joints shall be in accordance with Clause No. 8 of General Standard Specification No. G 72 (with latest revision and amendments) . This however, will not in any way reduce the Contractors responsibility for satisfactory execution of contract in all respects as stipulated in Clause No. 4 of General Standard Specification No. G 72 (with latest revision and amendments) .
8

WD-05-BARREL-2011 (Superseded WD-04-BARREL-2001 and WD-01-BARREL-(BMBS)-2009) 4.3 PLATFORM AND LADDERS: The platform and ladders should conform to relevant drawings of variants outlined in RDSO Index Drg. No. WD-93047-S-50 (latest Alteration). 4.4 PATTERN BARREL AND FINAL ASSEMBLY: Before proceeding with regular production of the barrel one pattern barrel complete with cradles shall be assembled over the underframe as per relevant drawings of variants outlined in RDSO Index Drg. No. WD-93047-S-50 (latest Alteration). Further production shall be proceeded with only after this assembly has been finally inspected and approved by the Engineers. Any modification that may be called for as a result of this inspection will have to be incorporated by the manufacturer in the subsequent production of tank barrel and other components / sub assemblies as mentioned in para 1.1 without asking for any extra cost. 5.0 GUARANTEE: Tank barrels supplied in conformity with this specification shall be guaranteed against defects of workmanship and material for a period of 24 months from the date of dispatch of the tank wagon or for a period of 18 months from the date of their being put into service. 6.0 PAINTING AND MARKING:

6.1 i)

PAINTING Surface preparation of the out side surface of the barrel, cradle, dome and platform should be as per Clause No. 11 of General Standard Specification No. G 72 (with latest revision and amendments) The following paints should be used: Two coats of Zinc Phosphate Primer based Polyurethane (Two Packs) as per RDSO Spec. No. M&C / PCN / 100 / 85 (thickness of each coat 35 microns). OR Two coats of Zinc Phosphate Primer based Epoxy Resin (two packs) as per RDSOs Spec. No. M&C / PCN / 102 / 86 (thickness of each coat 35 microns). Two coats of Paint Finishing based on Polyurethane (two packs) as per RDSOs Spec. No. M&C / PCN / 100 / 85 (thickness of each coat 35 microns). The paint shall be applied by air / air less spray.

ii) a)

b)

iii)

WD-05-BARREL-2011 (Superseded WD-04-BARREL-2001 and WD-01-BARREL-(BMBS)-2009) iv) All the paints for primer and finishing coats should be procured from the same source to ensure compatibility. The color of the barrel, cradle, dome, ladder and platform should be white and a 350 mm wide band to be painted in SINGNAL RED colour No. 537 to IS: 5 all around the barrel and letters on it will be white to IS: 127 as per relevant drawings of variants outlined in RDSO Index Drg. No. WD-93047-S-50 (latest Alteration).

v)

6.2

MARKING: Marking on barrel and Underframe shall be done by the barrel manufacturer as per relevant drawings of variants outlined in RDSO Index Drg. No. WD-93047-S-50 (latest Alteration).

7.0

DISPUTE REGARDING INTERPRETATION: In case of dispute between the manufacture and the owner regarding the interpretation of the Clauses of this specification, the decision of the Engineers will be final and blinding on both the parties.

8.0 8.1

AS MADE DRAWINGS AND PHOTOGRAPHS: AS MADE DRAWINGS: The Contractor shall supply two sets of As Made Polyester film tracing 150 micron thick ( mattel) of drawings followed in the manufacture of the barrels for the record of the Purchaser and Engineers. These tracings shall conform to the requirements as detailed Clause 21 of General Standards Specification No. G-72 (with latest revision and amendments) obtainable or purchase from Director General,RDSO,Lucknow-226011. The Contractor shall incorporate in the above set of tracings, any deviations, modifications and relaxations granted in the course of manufacturer as called for in Clause No. 20 of General Standard Specification No. G 72 (with latest revision and amendments) obtainable on purchase from Director General, RDSO, Lucknow 226 011. The As Made drawings detailed above shall contain full details of each component / sub assembly / assembly, inclusive of the material specification, actual average weight and reference drawing. The general order of the drawings, title block etc. shall be strictly as indicated in Drg. No. SK. 67521 with space for IRS Drawings Number left blank. The size of the sheet shall be A1 (841 mm x 594) and the code of practice for drawing shall conform to IS Specification No. 696.
10

WD-05-BARREL-2011 (Superseded WD-04-BARREL-2001 and WD-01-BARREL-(BMBS)-2009) 8.2 Photographs: Contractor shall furnish two sets of the following negative and photo of the assembled wagon, one set each to the Purchaser and Engineers: 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 Two copies of the coloured negatives. Two copies of the black & white negatives. Three enlarged photographs prints in colour (size 25. 4 cm x 30.5 cm) Three enlarged photographs in black & white (size 25. 4 cm x 30.5 cm) Any other photographs of the wagon as desired by the Purchaser and Engineers.

11

WD-05-BARREL-2011 (Superseded WD-04-BARREL-2001 and WD-01-BARREL-(BMBS)-2009)

ANNEXURE I

METHOD OF CERTIFICATION AND TESTING OF DOME FITTINGS 1.0 SCOPE The fittings as per relevant drawings of variants outlined in RDSO Index Drg. No. WD-93047-S-50 (latest Alteration) or their equivalent are required to be fitted in the dome. All these fittings are proprietary items are covered by guarantee given by the manufacturer. But these fittings may get damaged in transport or storage their working may suffer. It is, therefore, desirable to examine these fittings before they are fitted to the dome. The examination should cover the following fittings: 1.1 1.2 1.3 1.4 1.5 2.0 Safety valve Liquid and Gas Education Valve. Excess Flow Check Valve. Magnetic Gauging Device. Sampling Valve with Excess flow valve check.

Methods of Inspecting and Certification for individual dome fittings is explained as follows:SAFETY VALVE Midland/A3225 OR Chandra & Co. Drg. No.CC-SV-01 95/01 OR Arieckal Industries Drg. No. -V-AI-003. It should Generally be examined to see that: . . . . . . . All components are intact. All its components are cleaned and there is no dirt, grit or rust anywhere. All seals and components made of synthetic material are in good condition that is, they have not aged / deteriorated due to any reason. The valve seating is perfectly cleaned and there is no dirt or grit between valve spindle and seating. Follower slides properly in spring guide and properly lubricated. Stem slides properly in the top guide. Both the surfaces be properly lubricated. When subjected to an air / gas pressure of 15.85 kg. / cm sq. (225 1bs / sq. inch) the valve should start to discharge. The tolerance allowed is + 5 lbs / sq. inch. The valve should be vapor tight at 80 % of the start to discharge pressure.

2.1

2.1.1

12

WD-05-BARREL-2011 (Superseded WD-04-BARREL-2001 and WD-01-BARREL-(BMBS)-2009)

2.2

LIQUID & GAS EDUCATION VALVE Midland/A724 OR Chandra & Co. Drg. No. CC/ED/95/01 OR Arieckal Industries Drg. No. V-A1-001 Valve should generally be examined for any deficient part or any injury to any of its components. Its opening and closing should be smooth. When subjected to an air / gas pressure of 15. 85 kg. / cm sq. (225 lbs / sq. inch) it should not show any leakage from either the body or the opening. EXCESS FLOW CHECK VALVE MIDLAND / A 134 W Or Chandra & Co. Drg. No. CC/EX/95/01 Or Arieckal Industries Drg. No. V-A3-001 These valves are fitted under the liquid vapor education valves and can be checked only after being fitted under the manhole cover plate. Before fitting under manhole cover plate these valve should be: . . . Cleaned for any rust or grit. The slug should slide smoothly in the body without any obstruction. The valve body should be fitted by welding to the manhole cover plate in perfectly vertical position.

2.2.1

2.2.2 2.2.3

2.3

2.3.1

2.3.2

After valve has been welded to the cover plate it should be subjected to an air / gas pressure of 15.85 kg. / cm sq. (225 lbs / sq. inch). Education valve should then be progressively opened to the atmosphere. When the air flow becomes quicker the slug should move up and reduce the flow of air through the Eduction Valve. The Eduction valve should be closed at this juncture. After sometime the float should be heard falling by its own weight. The eduction valve may again be opened and it should discharge air / gas again. This operation be repeated twice and if the closing and opening is smooth the excess flow check valve should be deemed as operating.

13

WD-05-BARREL-2011 (Superseded WD-04-BARREL-2001 and WD-01-BARREL-(BMBS)-2009) 2.4 MAGNETIC GAUGING DEVICE MIDLAND / B 612 Or Chandra & Co. Drg. No. CC/MLG/0195-0 Or Arieckal Industries Drg. No. ML A2-003 The device should generally be inspected to see that: . . . . . . The body of the magnetic gauge is square with the cover plate. Stainless steel spherical float is not damaged or punctured. Red washer of the float is on the top side. Gauging Rod is straight and is not bent anywhere. The permanent magnet in the rod is active. All welding work is proper.

2.4.1

2.4.2 For checking its functional working the float (alongwith rod and other components) should be placed in a drum with a certain level of water. The level of water be raised by pouring more water. The float should rise with the water level and also the rod indicating the rise of level. When the rod lifts with addition of water the device is deemed as operating. 2.5 SAMPLING VALVE WITH EXCESS FLOW CHECK VALVE MIDLAND / A 254 AND MIDLAND / A 111. Or Chandra & Co. Drg. No. CC/2175/100 and CC/CV/95-03 Or Arieckal Industries Drg. No. V-A2-001 and V-A4-001 .

The valve should be thoroughly examined for any deficiency. It should be subjected to an air / gas pressure of 15.85 kg. / cm sq. (225 lbs / sq. inch). The valve should be progressively opened to the atmosphere. After sometime when the discharge becomes quicker it should automatically reduce the rate of discharge. This operation should be repeated twice or thrice and if the reduction in discharge rate is automatic then it should e deemed as operating. 3.0 The pressure testing of all the fittings be done after the same have been fitted over / above the manhole cover plate with all the internal pipes in position by bolting the whole assembly over a chamber of sufficient capacity can be pressurized with air / gas

14