No. 04-ABR-2002 (Rev. 01 of Nov.

-2017)

INDIAN RAILWAYS

SPECIFICATION FOR PIPES AND JOINTS FOR

AIR BRAKES FOR FREIGHT AND PASSENGER STOCK OF
INDIAN RAILWAYS.

SPECIFICATION No. 04-ABR-2002 (Rev. 01 of Nov.-2017)

ISSUED BY:

RESEARCH DESIGNS & STANDARDS ORGANISATION

MINISTRY OF RAILWAYS

LUCKNOW - 226011.

November- 2017
 No. 04-ABR-2002 (Rev. 01 of Nov.-2017)

CONTENTS

PART I - GENERAL CONDITIONS

1. FOREWORD

2. DEFINITION

3. PARTICULAR REQUIREMENTS

4. SCOPE

5. SCOPE OF SUPPLY

6. WARRANTY / GUARANTEE

7. AFTER SALES

8. DEVIATIONS

PART II - TECHNICAL REQUIREMENTS

9. PERFORMANCE REQUIREMENTS

10. OTHER REQUIREMENTS

11. MANUFACTURE AND FITMENT

12. INSPECTION

13. INSTALLATION OF PIPES & JOINTS ON VEHICLE

14. PACKING

ANNEXURE A : WELDING PROCEDURE OF JOINING OF STAINLESS STEEL PIPES

OF ASTM - A 312 SCHEDULE-40S GR-TP 304 AND
FLANGES/SOCKETS OF IS: 6911-1992X04 Cr 19 Ni 9 304 SI.
ANNEXURE B : LIST OF DRAWINGS
 No. 04-ABR-2002 (Rev. 01 of Nov.-2017)

SPECIFICATION FOR PIPES AND JOINTS FOR

AIR BRAKES FOR FREIGHT AND PASSENGER STOCK OF
INDIAN RAILWAYS

PART I - GENERAL CONDITIONS

1. FOREWORD

1.1 This specification is issued under the fixed serial 04-ABR. The number after ABR
indicates the year of adoption/revision.

Adopted - 1984
Revised - 1989 , 1991 ,1993, 1994,2002

1.2 In preparing this specification, assistance has been obtained from AAR specification
S-400 and S-402.

2. DEFINITION

2.1 'TENDERER' means firm / company from whom the offer for the supply of Pipes and
Joints for Air Brake equipment is invited.

2.2 'CONTRACTOR ' means the present firm / company on whom the order for the supply
of Pipes and Joints for Air Brake equipment is placed/will be placed.

2.3 'PURCHASER ' means the Indian Railways on behalf of the President of the Republic
of India who are purchasing pipes and Joints for Air Brake equipment.

2.4 `INSPECTING AUTHORITY' means the organisation or its representative nominated by

the Purchaser to inspect Pipes and Joints for Air Brake equipment on his behalf.

2.5 The Research Designs and Standards Organisation, Manak Nagar, Lucknow-226011 is
hereafter referred to RDSO.

2.6 The Indian Railways is hereafter referred to as IR.

2.7 In case the Tenderer needs any clarification in respect of any clause of this
specification or regarding the drawing the Tenderer shall obtain the same from DG
(Wagon)/DG (Carriage), RDSO, for clarification.

3.0 PARTICULAR REQUIREMENTS

3.1 Manufacturers willing to supply pipes and joints for the use of Indian Railways shall
register themselves with RDSO.

3.2 The manufacturer shall have adequate facilities for the manufacture and testing of pipes
and joints conforming to RDSO drawing.
 No. 04-ABR-2002 (Rev. 01 of Nov.-2017)

3.3 The manufacturers 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:-

(i) System to ensure that correct raw material is being used.

(ii) System to ensure that components having manufacturing defects are identified and
destroyed so that such components are not used during assembly of pipes and joints.

(iii) System to ensure that bought-out component are strictly as per requirements laid down
in the specification / drawing.
(iv) System to maintain strict control of dimensions and workmanship of components and
assembled product.

(v) System to test and establish that the pipes and joints manufactured by the firms meets
all the requirements laid down in specification / drawing.

(vi) System of periodical calibration of equipment/ gauges to ensure accuracy of product.

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

(viii) System to ensure that pipes and joints are properly packed to meet the requirement of
para 14 of this specification.

3.4 Rubber items shall be procured from RDSO approved sources only. However, the
manufacturers shall be fully responsible for satisfactory performance of the rubber
items.

4. SCOPE
4.1 This specification covers purchase and acceptance requirements of Pipes and Joints
forming part of Graduated Release compressed Air Brake equipment for use on freight
and passenger stock of Indian Railways.

All the provisions contained in RDSO’s ISO procedures laid down in document No.
QO-D-7.1-11 (latest) (Titled “Vendor – Changes in approved status”) and subsequent
version/ amendments thereof, shall be binding and applicable on the successful
vendor/ vendors in the contracts floated by Railways to maintain quality of products
supplied to Railways.

5. SCOPE OF SUPPLY
5.1 FREIGHT STOCK
5.1.1 The scope of supply of Pipes shall be as follows:

Brake / Feed Pipes : 32 mm nominal dia.

Branch Pipes : 25 / 20 / 15 mm nominal dia.
 No. 04-ABR-2002 (Rev. 01 of Nov.-2017)

5.1.2 The joints shall be flange welded type unless otherwise specifically approved by
RDSO..

5.1.3 Pipes shall be in accordance with air brake layout arrangement drawing mentioned in
RDSO particular specification for the type of freight stock given in contract.

5.2 PASSENGER STOCK

5.2.1 The scope of supply of pipes shall be follows.

Brake / Feed pipes : 25 mm nominal dia

Branch pipes : 20 / 10 mm nominal dia

5.2.2 The joints shall be flange welded type unless otherwise specifically approved by RDSO.

5.2.3 Pipes shall be in accordance with Air brake layout arrangement drawing for the type of
passenger stock specified in the contract.

5.3 In the case of Brake van, scope of supply shall include the following additional items.

Branch Pipes : 20 & 10 mm nominal dia

Pipes for pressure gauge : Flexible hose

6. WARRANTY/GUARANTEE

6.1 The warranty /guarantee period will be 30 months from the date of delivery or 24
months from the date of commissioning whichever is earlier.

7. AFTER SALES

7.1 Contractor shall arrange to supply along with the equipment Maintenance Instructions
for the proper maintenance of pipes and Joints during service. Sufficient number of
copies shall be submitted to enable distribution to the various Depots.

7.2 The Maintenance Instructions shall also indicate list of spares required to be maintained
for Joints giving part number for each item of spare.

8. DEVIATIONS

8.1 In case the offer does not correspond to this specification in any respect a
"DEVIATION STATEMENT" shall be submitted by the Tenderer. This statement shall
clearly give the deviation CLAUSE-WISE with technical reasons for the same alongwith
drgs., if necessary.

8.2 Clauses not covered by the deviation Statement shall be deemed to be acceptable to
the Tenderer in all respects. In case a Deviation Statement is not submitted it would be
taken as the complete specification is acceptable to the Tenderer.
 No. 04-ABR-2002 (Rev. 01 of Nov.-2017)

PART II - TECHNICAL REQUIREMENTS

9. PERFORMANCE REQUIREMENTS

9.1 Pipes and Joints shall be suitable for fitment and operation with Air Brake equipment to
the latest revision of RDSO Specification 02-ABR-2002.

10. OTHER REQUIREMENTS

10.1 PIPES

10.1.1 For Passenger & freight stock (Including BMBS stock)

Brake/Feed & Branch pipe : Stainless steel to ASTM – A 312 Schedule-40S

Gr. TP 304 (seamless).Thickness of pipes to be
governed by IS :1239 (Part-I) Heavy C-Class

Flanges/ fittings for Branch pipes : Stainless steel to IS: 6911-1992X04 Cr 19 Ni 9

304 SI
The pipes should be smooth, inside and outside must be free from defects and must be
provided with parallel threads to IS:554 wherever called for.

10.1.2 Pipes shall be cold bent with the help of bending equipment, but without use of sand
or similar material. Minimum recommended radius of bend are as follows:-

32 mm pipe - 300 mm preferred but not less than 225 mm.

25 mm pipe - 150 mm preferred but not less than 115 mm.
20 mm pipe - 150 mm preferred but not less than 115 mm.
15 mm pipe - 150 mm preferred but not less than 115 mm.
10 mm pipe - 100 mm preferred but not less than 75 mm.

10.1.3 Pipes must be tested after bending and before installation for free passage with a ball
of following dia.

32 mm pipe - 28 mm ball
25 mm pipe - 22 mm ball
20 mm pipe - 16 mm ball
15 mm pipe - 11 mm ball
10 mm pipe - 8.5 mm ball

10.1.4 Before despatch, pipe alongwith joint must be given the following treatment:

i) The pipe should be slightly hammered to loosen the rust and scale.

ii ) After descaling , pipe must be blown with dry compressed air to ensure complete
cleaning of rust and scale.
 No. 04-ABR-2002 (Rev. 01 of Nov.-2017)
iii ) Immediately after cleaning, the pipes shall be covered with air tight protection caps at
both the ends.

iv ) Before the dispatch ,the pipes along with joints for freight stock should be painted
from outside with one coat of red lead paint ready mixed to IS Specification 102.Two
coats of red oxide zinc chromate primer to IS:2074 is also acceptable as an alternative
subject to before the painting, all surfaces shall be cleaned by grit blasting or
mechanical brushing. For passenger stock, the pipe alongwith joints should be given 2
coats of zinc rich epoxy paint to specification BS:4652 after all the surfaces have been
cleaned and grit biased.
NOTE : Inside of pipes as well as joint faces of the flange must not be painted.

10.2. JOINTS
10.2.1 Joints shall conform to the latest revision of RDSO drawings mentioned in Annexure
`B' of this specification unless otherwise specified. The drawings can be obtained from
DG (Wagon)/DG (Carriage), RDSO,Lucknow-226011 on payment.

11. MANUFACTURE AND FITMENT

11.1 Pipes and Joints shall be suitable for fitment on wagons / passenger stock in
accordance with the Air Brake Equipment layout drawings indicated in the Particular
Specifications for the wagons / passenger stock for which air brake equipment is to be
supplied.

11.2 Contractor shall ensure that all components of equipment are manufactured by and
procured from approved / registered sources only .

11.3 Welding of joints to pipes shall be in accordance with the procedure given in
Annexure – A for stainless steel pipes.

11.4 Contractor shall also ensure that Pipes with Joints are painted (excluding flange faces)
according to colour specified.

11.5 Air Brake Equipment along with Pipes and Joints shall be first fitted on a pattern
wagon/passenger stock. Contractor shall be obliged to incorporate necessary
changes in the layout and piping, if found necessary during the inspection and testing
of pattern wagon/passenger stock. The relevant RDSO drawings of piping layout and
fitment of air brake equipment shall be revised before series production is
commenced.

11.6 At the time of assembly no bending or readjustment of pipes shall be done to suit the
fitment by means of hammering, bending or heating by Gas. The correct profile of
pipes and bends shall be achieved by adjustment of bending equipments and fixtures
only.

11.7 Bulk manufacture of pipes and joints by Contractor shall commence only after the
pattern wagon / passenger stock is inspected and passed by the Inspecting Authority.
 No. 04-ABR-2002 (Rev. 01 of Nov.-2017)

12. INSPECTION
12.1 Pipes and Joints to be supplied by Contractor shall be inspected and accepted by the
Inspecting Authority.

12.2 Contractor shall submit a list of items:

(i) That will be manufactured by Contractor himself.

(ii) That will be procured from Sub-contractors and their details.

12.3 20% samples of the above shall be thoroughly checked by the Inspecting Authority
for dimensional accuracy, material composition, workmanship and performance
before permission is granted to the Contractor for manufacture.

12.4 For rubber items, if any, Contractor shall arrange to send samples of each item to
RDSO/LKO for check and approval. Subsequently contractors shall procure and
supply the rubber items only from approved firms.

12.5 After permission is granted for manufacture as mentioned in clause 12.3 and 12.4
purchase inspection shall be undertaken. The inspecting authority shall carryout audit
checks to verify that pipes and joints are being manufactured strictly to well
documented 'Quality Assurance Programme` as specified in para 3.3 of this
specification and welding is being done as per procedure given in Annexure-A of this
specification. The inspecting authority then carryout following test / checks.

12.5.1 10% Pipes joints shall be checked for dimensional accuracy.

12.5.2 Verification of manufacturer record to confirm that correct material has been used.

12.5.3 5% Pipes with flange shall be tested for leakages at 10 kg/cm2 air pressure. If a single
case of leakage was found whole lot shall be rejected. However manufacturers can
re-offer the lot after rectification of defects. In this case 20% pipes and joints shall be
inspected. A single case of leakage shall be sufficient to reject the lot.

12.5.4 The inspecting authority then make checks to see that pipes & joints has been
cleaned properly to meet the requirement of para 10.1.4 of this specification. It shall
also be ensure that packing requirement as given at para 14 has been met. 5%
packing of pipes shall be opened to make visual inspection for dust / rust inside the
pipes.

12.6 Pipes and Joints alongwith other air brake equipment as fitted on the wagon /
passenger stock shall be tested for its performance. Contractor shall be responsible
for proper functioning of the Pipes and Joints as per procedure laid down.

12.7 Inspecting Authority may deviate from the agreed procedure if and when found
necessary to re-assure that the material is being furnished in accordance with these
specification. In this regard, Contractor shall not be entitled to object on any ground
 No. 04-ABR-2002 (Rev. 01 of Nov.-2017)
whatsoever on the nature and procedure of testing that may be followed by the
Inspecting Authority.

13. INSTALLATIION OF PIPES & JOINTS ON VEHICLE

13.1 Before the fitment of pipes and joints on vehicle all the protection caps shall be
removed from the pipes. Inside of the pipes shall be blown with dry compressed air to
ensure that no foreign matter is entrapped inside and also to remove condensate.

13.2 Pipes which are badly corroded shall not be fitted. Such pipes shall be returned to the
manufacturers for replacement free of cost.

13.3. After the installation of pipes and joints the exterior shall be painted with Mid
Brunswick Green paint to ISC No. 226 of IS:5-2007 ready mixed paint to IS:119 for
Brake pipe and ready mixed white finish paint to IS:127 for Feed pipe.

14. PACKING

14.1 The Contractor, before actual supply, shall ensure that all outer ports and exposed
threaded portions of pipes and joints are suitably covered with air tight protection caps
to prevent ingress of foreign matter, formation of moisture and damage to threads
during handling and storage. The protection caps should be fitted in such a manner
that they should not come out during transit, storing and handling.

14.2 Contractor shall also ensure that pipes and joints are adequately packed before
despatch to prevent damage in handling and storage

.
 No. 04-ABR-2002 (Rev. 01 of Nov.-2017)
Annexure - A

Welding Procedure of Joining of Stainless steel pipes of ASTM-A 312 Schedule-40S GR

TP304 and flanges/sockets of IS: 6911-1992X04 Cr 19 Ni 9 304 SI. (A) Prior to welding
i. The area about 15 mm each side from the weld zone shall properly be cleaned.
ii. The weld area shall be free from dust, grease, oil dirt, paint etc. For this solvent
cleaning may be used.
iii. Stainless steel wire brushes should only be used to remove tenacious layer of
chromium oxide formed for better strength of joint.

(B) During welding

i. Connect the electrode with positive terminal (DC+) of welding equipment when
welding with DC.
ii. Use 70,OCV welding transformer while welding with AC.
iii. Keep the welding current on lower side (as possible) of the range as recommended
by the manufacturer of the electrode.
iv. Maintain short arc as possible to minimize the loss of alloying elements.
v. Use smaller diameter of electrodes to minimize heat input hence minimizes distortion.
vi. Put strenger beads. Weaving shall not be more than two times of the diameter of
electrode used.
vii. Each run shall properly be de-slaged by using S.S brushes & chisels.
viii. Job is not required to be preheated.
ix. For cutting of stainless steels plasma cutting or machining shall be used.

(C) Welding Consumables

i. MMAW electrodes approved under IRS class M1 as per M-28-02 shall be used.
ii. The diameter of MMAW electrodes shall be 2.5 mm/3.15mm/4.0mm depending upon
the thickness of the plate/job.
iii. Re-dry the electrodes to about 150°c for at least one hour or as recommended by the
manufacturer.
iv. MIG/MAG welding filler wires approved under IRS Class VI as per M-46-03 shall also
be used. The diameter of wires shall preferably be 1.2 mm/0.8 mm.

(D) After welding

i. The stainless steels are rust & corrosion resistant only when their surfaces are in
polished conditions. It is therefore necessary to finish the S.S joints by grinding and
subsequent polishing for maximum corrosion resistance.
ii. The weld reinforcement of S.S welds must be grinded.
iii. The stainless steels have got less heat conductivity, hence during grinding; grinder
shall not be strayed at one location for long time to avoid overheating.
 No. 04-ABR-2002 (Rev. 01 of Nov.-2017)

Annexure - B

LIST OF DRAWINGS

S.NO. DESCRIPTION DRG. NO. ALT. NO.

1. Flange welded joint WD-83062-S-06 3 or latest

2. Flange welded joint WD-83062-S-07 5 or latest

(Pipe to equipment)

3. Tee Flange WD-94056-S-01 Nil or latest

4. Flange welded joint SK- 85187 4 or latest

(Pipe to pipe)

5. Tee flanges for Air Brake Passenger SK--96074 2 or latest

Coaches.

NOTE: The drawings can be obtained from DG (Wagon)/ DG (Carriage), RDSO, Lucknow -
226011 on payment.