File No.

RCF-DSGN0CDE/2/2021-O/o PCME/RCF/KXH
INDIAN RAILWAYS
RAIL COACH FACTORY, KAPURTHALA

No. MD44121

February 17, 2021

Exe. Dir./Stds./Carriage,
RDSO, Manak Nagar,
Lucknow

Sub: Failures in FIBA and Standardization of piping and clamping diagram/layout of piping
for FIBA, Air spring and Air suspension control equipment

Ref:
1. RDSO’s letter no. SV.AS. FIBA dated 27/08/2020, 02/11/2020 & 06/01/2021
2. This office letter of even no. dated 14/12/2020.
3. RDSO’s letter no. SV.EMU RAS/01 dated 11/12/2020, 06/01/2021 & 02/02/2021

Issue concerning to design & operation of FIBA & air suspension at secondary stage of LHB
coaches were highlighted vide letters under ref(1). Comments/Action taken on issues related
to RCF has already been provided vide the letter ref(2).

Further to the earlier actions taken, RCF Design has reviewed the pipelines / hoses for Air
Spring and FIBA systems and have done extensive changes in the layouts and orientation
with a view to improve the reliability of the same.

A brief of the changes done are enclosed.

CAI detailing the modifications has also been prepared. Copy of the same is also enclosed.
Digitally signed by AKHILESH
AKHILESH MISRA MISRA
Date: 2021.02.17 15:14:12 +05'30'
(Akhilesh Misra)
Chief Design Engineer
RCF/KXH
Cell: +91 9779241406
e-Mail: cde.rcf@rcf.railnet.gov.in

Enclosure:

1. Annexure (1)
2. CAI No MD21561 dt 17/02/2021

Copy to:
1. EDME/Coaching/RB
2. CDE/ICF
3. CDE/MCF
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ANNEXURE (1)

1. Issue: Flexible hose pipe between Auxiliary Reservoir & leveling valve
touches with the coach body and has sharp bend

Steel pipe provided on under frame for connecting flexible hose to leveling valve has
been redesigned and shifted towards end of coach. Elbow has been provided on leveling
valve to ensure smooth loop which is not touching with car body and ensures that bend
radius limits for the SAE100 hoses is not compromised.

The following photographs show the old and new designs: -

Old Design New Design

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2. Issue: Piping layout between leveling valve and Dome cum air reservoir of
FIAT bogie’s bolster

Piping layout of this area has been revised resulted into reduction of bulkhead unions
from 04 to 02 nos.

The photographs for old design and modified piping layout between leveling valve &
dome cum air reservoir is given below for ready reference: -

Old Design New Design

Bulkhead union eliminated.

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3. Issue: Failure of ferrule joint of flexible hoses for FIBA

This failure was attributable to the following root causes: -

1. Relative movement between the bolster and the bogie frame which is constantly
moving the hoses.
2. Grazing of flexible hose with steel pipe for connection of leveling valve.

The piping arrangement provided on brake beam of FIAT bogie frame has been shifted
to bogie bolster. Hub flange of underframe and pin bracket of FIAT bogie bolster will work
as a single unit after carrying out body bogie connection. Therefore, this modification will
result into no movement between joints of flexible hoses whose one end is connected to
FIBA piping provided on underframe and other end connected with piping of bogie
bolster.

Steel Pipe connected with leveling valve through flexible hose has also been redesigned
and shifted towards coach end. This shifting resulted into clearance between flexible
hoses and steel pipes. Moreover, loop of flexible hose is become smoothened by
providing additional modified pipe with tee of duplex valve piping which is not touching
to car body pipe.: -

Old Design

Flexible Hose removed Flexible Hose shifted to bolster piping.

Pipe shifted to bogie bolster.

Flexible hose shifted to bogie bolster.

Flexible Hose removed Steel Pipe shifted from bogie to bolster.

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New Design
New clamping bracket Flexible Hoses for FIBA

Flexible Hoses for FIBA

New piping layout shifted from bogie frame to bolster.

New Clamping bracket with New pipe provided for smooth

‘C’ type clamping loop of flexible hose.
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STEEL PIPE FOR CONNECTING FLEXIBLE HOSE PIPE TO LEVELLING VALVE

PLUMBING PIPES TO BE SHIFTED UPWARD ON PP END

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CLOSER VIEW OF SHIFTED STEEL PIPE TOWARDS COACH END

CLOSER VIEW OF FLEXIBLE PIPES CONNECTED WITH FIBA PIPING OF

UNDERFRAME

CLEARANCE FROM STEEL PIPE TO BE CONNECTED TO LEVELING VALVE

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4. Issue: Design of Protection cover for installation lever

Protection cover design advised by ICF vide letter no. MD/SS/LHB/103B dated
18.01.2021 has been examined and found that mounting of this protection cover is not
matching with the existing mounting arrangement provided on underframe.

Initially, RCF has revised the protection cover drawing by rounding off the lower end.
Further, revised design of protection cover has been developed and slot has been
provided in this cover to adjust the cover to protect the leveling valve and bending at
ends increased the covering area from ballast hitting. Corners has been rounded off and
Notching has been provided at ends for proper vision of control rod of leveling valve.

The photographs for same is as under:

New Design
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5. Issue: Layout for piping and clamping of air spring, FIBA and ASCE (Air
suspension control equipment

It was instructed to issue layout of piping & clamping of air spring, FIBA & ASCE after
consulting with other PUs. MCF and ICF was requested to provide the layout of LHB
coaches currently being manufactured by them vide letter no. MD23151 dated
12.01.2021.

ICF has provided the layout being followed by them vide letter no. MD/SS/LHB/103B
dated 18.01.2021. ICF has advised that following standardized design has been used
for air spring, FIBA and ASCE: -

1. On Bogie: Drawing no. LGS/EOG/ASR-3.2-009 for all LHB AC & Non-AC coaches.

2. On Underframe: Drawing no. LWSCWAC/EOG/ASR-3-5-001 for LHB AC and

NON-AC area and Drawing NO. LSLRD-3-5-007 for LWLRRM and LSLRD
coaches. ICF has advised that above layouts have been used due to balancing and
space constraints.

RCF is using following standardized piping layout for air spring, FIBA & ASCE: -

1. On Bogie: Drawing no. LW 36189 for all LHB AC & Non-AC coaches except
LSLRD & LWLRRM to drawing no. LD36437 & LP36307 alt ’nil’ respectively.

2. On Underframe: Drawing no. LW36002 is being used for LHB AC & Non-AC
coaches except LWLRRM, LVPH, LHB GS and LSLRD coach.

The piping layout for LVPH, LWLRRM, LHB GS and LSLRD coaches is uncommon as
layout of these coaches is different due to differences in location of lavatory, doors,
electrical equipment, bio-tanks, fuel tanks, water tanks etc. Underslung items are to be
re-located to achieve specified balancing of the coaches.

Comments on comparison of RCF layout with ICF layout is mentioned in the table below.

SN Type of RCF’s ICF’s layout Comparison comments

coach layout
1. LHB AC LW36002 LWSCWAC/EOG/ASR- Same as ICF layout
& Non- 3-5-001
AC
coaches
2. LWLRRM LP36003 Two fuel tanks are in middle
portion and other equipment kept
same as per original LPC coach to
LSLRD-3-5-007 maintain balancing recd. Under
ToT.
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SN Type of RCF’s ICF’s layout Comparison comments

coach layout
3. LSLRD LR36016 150 litters Auxiliary reservoir in
RCF & ICF coaches is different.
This reservoir was provided at end
due to non-availability of space at
middle (Four doors, divyangjan
lavatory in middle) and to maintain
coach balancing etc.
4. LHB GS LG36126 LWSCWAC/EOG/ASR- 150 litters Auxiliary reservoir in
3-5-001 RCF & ICF coaches is different.
This air reservoir was provided
between middle door in RCF’s
layout to achieve specified
balancing.