Upgradation of M/s KBIPL and

M/s Escorts design BMBS)

Escorts design BMBS-

• Number of wagons with Escorts design BMBS~ 40,000

• Problem related to breakage at pivot point- reported in
April’ 23. Sample received and sent for testing in
May,23
• VC held with zonal railways on 20.06.2023.
• Meeting with M/s Escorts on 07.07.2023
• Metallurgy and chemical analysis report of failed bell
crank lever received on 11.07.2023.
• Instructions issued on 04.08.2023
 Issues in M/s Escorts design BMBS
Description Corrective action
• Failure due to oblong hole
• By using the suitable size
pin and checking the bell
crank lever as directed in
the OEM maintenance
manual, the failure can be
controlled
Breakage of bell crank lever
at cross section
Corrective action
• 6 mm radius is provided at the
change in cross section.
• Procedure of Heat treatment of bell
crank at the area of welding of the
pin in order to address the issue of
martensitic development.
Opening of adjuster spindle Corrective action
• Tack welding on the leader nut
casing and barrel pipe of the
cylinder.
• A permanent locking arrangement
under design by firm

Welding failure of safety chain
bracket
Corrective action
A proper lap joint be made instead of
butt joint in order to have higher
strength of the weld, as shown in
figure below. Work instructions
issued

Butt joint Lap joint

Failure of U clamp for safety
chain on brake cylinder
Safety strap U clamp
Corrective action
Provision of safety strap on cylinder
head to avoid requirement of welding
for safety bracket clamp
Grazing marks on spring
plank/push rod Corrective action
• Check condition of brake beam end piece
and bogie pocket liner areas
• Ensure availability of brake beam end
piece liners
Infringement of APD Corrective action
Work instructions issued for proper
fitment of APD
Improvements in check sheet for inspection
1. Sample size for dimension check increased from 2% to 5%
per lot.
2. Dimension checks added for more parameters of bell
crank lever (thickness )
3. Destructive testing added for checking physical properties
of lever.
4. Microstructure checking of HAZ near pivot point
5. Heat treatment record verified for 100% levers
6. Chemical properties verified by means of checking ITR
7. DPT of welded area done for 100 % levers.
8. Verification of identification marks for improved lever
Improved bell crank lever

• Colour coding- Blue

• Orange colour
fluorescent tape
• SR stamp after marking
Tentative plan submitted by M/s Escorts
Supply schedule for Aug 2023- Wagon Sets

Details 01st -05th 07th -12th 14th -19th 21st -26th 28th -31st Total

Bell Planned - 200 300 500 500 1500

Crank
Lever

Actuals 100 65 as on
23.08.23

August onwards -2500 wagon sets per month.

Solution proposed by Knorr Bremse-
1. Brake Cylinder
 Brake cylinder size increased from11” from 10”.
 Longer bearing cup to increase piston over stroke capacity.
 Higher ram spring force to increase payout capability.
 Slack adjusting spring force increased for robustness.
2.Beams – Addition of Beam stops on Beams to
centralize the beams during dynamic condition
 Upgradation Action plan-
• Intimated vide Railway board dated 08/08/2023
• Upgradation of existing brake cylinders supplied by M/s
KBIPL in ~ 69566 wagons (~ 139132 brake cylinders) on free
of cost basis. If more wagons found, same shall also be
covered
• Only removal and fitment of brake system under scope of
railways.
• Before pick up for upgradation by M/s KBIPL, existing
cylinders to be jointly inspected by representatives of IR and
firm.
• Supply of beam stops and fixtures to be done by firm.
• Warranty cover for a period of 72 months.
Time lines for completion of upgradation
Year Q1 Q2 Q3 Q4 Total
(Wagons)

2023 -- -- 2,000 6,000 8,000

2024 6,500 7,000 7,500 7,500 28,500

2025 7,500 7,500 7,500 7,500 30,000

2026 *3066 -- -- -- 3,066

*by Feb'26 Total 69,566

• Firm to submit BG totalling Rs 1080 crore valid for three years before
withdrawal of letter dated 20.09.022.
• Firm to submit BG of Rs 432 cr valid for three and half years before
release of BG of 217 cr. To be released provided no resolved issues of
BMBS in 69566 wagons.
Sl No. No. of KBIPL 10” brake BG amount Condition
cylinders upgraded to 11” released Rs cr
(wagon sets)

A 36000 559 Satisfactory field performance in

9000 wagons and no unresolved
issue in remaining 27000 wagons

B 14000 217 No unresolved issues in 50,000

wagons

C 14000 217 No unresolved issues in 64000

wagons. Receipt of fifth BG of 432 cr.

D 5566 87 No resolved issues in 69,566 wagons

Total 69566 1080
• M/s KBIPL to share design of upgraded BMBS with two licensees
(M/s Medha and M/s Prag) for upgradation of ~26530 wagons (~
53,060 wagons).
• Performance of first 9000 upgraded wagons shall be monitored
jointly by IR and M/s KBIPL till one year from date of fitment in
9000th wagon.
THANK YOU