INDIAN · PDF fileWD-02-BTFLN-2017 (Superseded WD-01-BTFLN-2006) Particular Specification for Bogie POL Tank Wagon Type BTFLN Page 1 of 20 INDIAN

WD-02-BTFLN-2017 (Superseded WD-01-BTFLN-2006)

Particular Specification for Bogie POL Tank Wagon Type BTFLN

Page 1 of 20

INDIAN RAILWAYS

PARTICULAR SPECIFICATION

FOR

BOGIE LIGHT WEIGHT POL TANK WAGON

TYPE ‘BTFLN’

BROAD GAUGE – 1676 mm

ISSUED BY

WAGON DIRECTORATE

RESEARCH DESIGNS AND STANDERDS ORGANISATION MINISTRY OF RAILWAYS

LUCKNOW – 226011

May, 2017 Price: Rs.



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CONTENTS Clause Description Page No. 1. Scope 3 2. Definitions 3 3. General Description of the Wagon 4 4. Welding 4 5. Test Requirements 5 6. Standard Specification 5 7. Use of Alternative 5 8. Particular Requirements 5 9. Testing of Tank barrel, Valves and wagon 11 10. Guarantee 12 11. Painting & Markings 13 12. Inspection 13 13. Dispute regarding Interpretation 13 14. Drawings 14 15. As Made Drawings 14 16. Photographs & Models 14

ANNEXURES I Method of Determining tare weight of wagon II Procedure of Calibration III Nylon 66 Bushes in the Hand Brake Gear of Wagon



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Particular Specification for Broad Gauge

Bogie Light Weight POL Tank Wagon type ‘BTFLN’ Fitted With Bogie Mounted Air Brake System

1. SCOPE 1.1 This specification covers the particular requirements for the manufacture and

supply of Broad Gauge Bogie light weight POL Tank Wagon type ‘BTFLN’ (81.28 t. Gross Load) fitted with bogie mounted air brake system and bogie strictly to relevant drawings outlined in Index Drg. No. RSD-6315-051 (latest alteration) and the requirements of General Standard Specification No. G-72 with latest revision and amendments if any, which can be had from Director General, RDSO, Lucknow-226011. These wagons shall be supplied complete in all respects.

1.2 Bogie, Coupler and Draft Gear as referred to in Clause 8.3 and 8.4 and Air brake

equipment along with pipes and pipe joints as referred to in Clause 8.5 shall be fitted with these wagons.

1.3 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 deviations, 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 specially 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 Contractor.

2. DEFINITIONS 2.1 ‘Purchaser’ means the President of Republic of India. 2.2 ‘Engineers’ means Research, Designs & Standards Organization, Ministry of

Railways, Manak Nagar, Lucknow-226 011 2.3 ‘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.

2.4 ‘Contractor’ means the person, firm or company with which the order for the

supply is placed and shall be deemed to include the Contractor’s successors (approved by the Purchaser), representatives, heirs, executors and administrators, as the case may be unless excluded by the terms of the Contract.

2.5 ‘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.



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3. GENERAL DESCRIPTION OF THE WAGON 3.1 The profile of the wagon infringes with the Maximum Moving Dimensions of 1929,

but remains within the dimensions of ‘X-class’ engine. Structurally, it comprises of a cylindrical tank barrel mounted on under frame. The assembly is rested on a pair of bogies for mobility. The under frame consists of a pair of stub center sill, side sills, bolsters, head stocks, and cradles. The center sill and side sills run from the headstock upto bolster at either end. Between bolsters there is no under frame member except a pair of middle stringers (inverted T-section) welded to the underside of the barrel. This design of under frame results in substantial saving in tare weight.

3.2 The tank barrel is inclined at 1 degree towards the discharge points located at the

bottom of the barrel to facilitate easy flow of POL products. The discharge points are provided with taper plug valves.

3.3 There are two domes on the top of barrel for loading. Each dome carries a filling

pipe, vapour extractor cock, the dip stick guide pipe and hand wheel for operation of the master valve. The barrel carries one safety valve on the top.

3.4 The wagon is fitted with Bogie mounted brake system in which each bogie carries

a brake cylinder which applies tread brake in the bogie through brake beams and push rods. The brake cylinder has a built-in double acting slack adjuster to take up wear in K-type brake shoes and partially wear on wheels.

4. WELDING 4.1 The welding of tank barrel, testing and certification should be strictly as detailed in

Clause No. 8.6. 4.2 Welding of wagon parts other than tank barrel should be strictly as specified in

Clause 8 of General Standard Specification No. G-72 with latest revision and amendments if any.

4.3 Wherever welding is specified or adopted in the manufacture of the wagons or in

the fabrication of sub-assemblies and components, the manufacturer shall submit his proposed welding procedure and sequence to the Inspecting Officer for approval. This, however, will not in any way reduce the Contractor’s responsibility for satisfactory execution of the Contract in all respects as stipulated in “Standard Conditions of Contract for Construction, Supply and Delivery of Underframes and Goods Wagons” as stipulated in Clause 4 of General Standard Specification No.G-72 with latest revision and amendments if any.

5. TEST REQUIREMENTS



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5.1 First wagon to be completed by the Contractor will be treated as Pattern Wagon. Tank barrel to be tested and certified as given in 8.6 and other tests as mentioned in Clause 9.

5.2 The performance of Air Brake equipment for each wagon shall be tested by

means of single car test rig. 6. STANDARD SPECIFICATION

All material required for the manufacture of the wagons shall conform to the latest issue of relevant specifications as adopted by RDSO for Railway use unless otherwise specified herein.

7. USE OF ALTERNATIVES

Certain alternatives, showing different method of manufacture or use of alternative material, which are technically permissible, have been indicated in the relevant drawings outlined in Index Drg. No. RSD-6315-051 (latest alteration). Whenever such alternative use has been permitted, the tenderer must quote separately for the alternatives.

8. PARTICULAR REQUIREMENTS 8.1 Leading Particulars of the BTFLN Wagon are given in relevant drawings outlined

in Index Drg. No RSD-6315-051 (latest alteration). 8.1.1 Barrel Mounting

The details of barrel mountings are given in relevant drawings outlined in Index Drg. No RSD-6315-051 (latest alteration).

8.1.2 BTFLN wagon shall be capable of transporting the products listed in relevant

drawings outlined in Index Drg. No RSD-6315-051 (latest alteration).

8.1.3 Loading and Unloading

Top loading through the filling pipes accommodated in the domes and unloading

through the discharge valves fitted at the bottom of the barrel.

8.2 Material of Construction

The materials of construction of BTFLN wagon are listed in relevant drawings

outlined in Index Drg. No RSD-6315-051 (latest alteration).

8.3 Bogies and Wheels



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The wagon shall be equipped with Cast Steel BG Bogies as per RDSO

Specification with latest revision and amendments as indicated in relevant

drawings outlined in Index Drg. No RSD-6315-051 (latest alteration). This bogie

shall be complete with wheel sets, cartridge bearings, narrow jaw adapters, spring

plank, long travel helical springs, and load proportionate friction damping

arrangement suitable for 20.32 t axle load.

8.4 Draft and Buffing Gear 8.4.1 The BTFLN wagon shall be equipped with High Tensile Centre Buffer Coupler

(Non-Transition CBC) to RDSO Specification with latest revision and amendments as mentioned in relevant drawings outlined in Index Drg. No RSD-6315-051 (latest alteration).

The fitment of coupler, draft gear, striker casting, yoke, yoke pin support and back stop shall conform to relevant drawings outlined in Index Drg. No RSD-6315-051 (latest alteration).

8.4.2 Coupler operating mechanism shall be positioned as shown in relevant drawings

outlined in Index Drg. No RSD-6315-051 (latest alteration).

8.5 Air Brake 8.5.1 The wagon shall be equipped with graduated release air brake equipment to

RDSO Specification with latest revision and amendments in accordance to relevant drawings outlined in Index Drg. No. RSD-6315-051 latest alteration.

8.5.2 The air brake equipment and pipe layout of the wagon shall be in accordance to relevant drawings outlined in Index Drg. No. RSD-6315-051 latest alteration.

8.5.3 The pipes and pipe joints consisting of brake pipe, feed pipe, branch pipes and

pipe joints shall be as specified in RDSO Specification with latest revision and amendment in accordance to relevant drawings outlined in Index Drg. No. RSD-6315-051 latest alteration.

8.5.4 The complete air brake equipment including the pipes and joints shall be fitted on pattern wagon in accordance to relevant drawings outlined in Index Drg. No. RSD-6315-051 latest alteration and offered to the ‘Engineers’ for approval. Before fitment of pipes on wagons, inside of pipes shall be cleaned thoroughly by dry compressed air to remove dirt, dust etc. The Contractor shall be obliged to carry out any modification on the layout of the air brake equipment, if found necessary by the ‘Engineers’.

8.5.5 Contractor shall proceed with the bulk production of pipe and joints only after the

final approval of the layout of complete air brake equipment, on the pattern wagon.



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8.5.6 During the bulk production of wagons, Contractor shall ensure that the complete air brake equipment is fitted on the wagon correctly as per the dimensions shown in the layout drawing. Special care must be taken with regard to the clamping of pipes.

8.5.7 The wagon shall be fitted with hand brake gear arrangement in accordance to

relevant drawings outlined in Index Drg. No. RSD-6315-051 latest alteration. The Contractor shall also ensure correct functioning of the brake gear components in conjunction with air brake equipment. Only Nylon 66 bushes in lieu of steel bushes wherever indicated in the drawing of Hand Brake Arrangement to be provided as per details given in Annexure-III.

8.5.8 The wagon shall be fitted with side operated screw type hand brake as indicated

in relevant drawings outlined in Index Drg. No. RSD-6315-051 latest alteration. 8.6 Tank Barrel 8.6.1 Tank barrel shall be of seven-course construction in accordance to relevant

drawings outlined in Index Drg. No. RSD-6315-051 latest alteration. Any deviation should have the prior approval of the ‘Engineers’.

8.6.2 Circumferential and longitudinal seams as shown in relevant drawings outlined in

Index Drg. No. RSD-6315-051 latest alteration shall be done by automatic submerged arc welding.

8.6.3 Manufacture and Workmanship: The manufacture and workmanship shall

conform to the requirements of Section II of IS: 2825 (Code for Unfired Pressure Vessels) to latest revision and amendments.

8.6.4 Welding of Barrel: Welding shall conform strictly to the requirements laid down in

Section II of IS: 2825 (Code for Unfired Pressure Vessels) with latest revision and amendments. Mechanical tests of fusions, welded seams shall also conform strictly to the requirements laid down in Section III of IS: 2825 to latest revision and amendments. The electrodes used for welding purposes should have physical properties equivalent to or better than the parent metal.

8.6.5 Inspection & Test of Tank Barrel: Inspection, test and repairs to all welded

joints shall conform to the requirements laid down in Section II of IS: 2825 to latest revision and amendments. In case, the tank barrel and the underframe are manufactured in the same place the tank barrel after placement on the underframe and being anchored shall be subjected to hydraulic test. In case, the tank barrel is manufactured away from the shop making the under frame and the tank has to be transported, the barrel shall be first hydraulically tested at the barrel manufacturer’s premises. A second hydraulic test shall be carried out after assembly of the barrel with the under fame.



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8.6.6 The procedure and sequence of welding and assembly of barrel should have the prior approval of the ‘Engineers’.

8.6.7 Dished ends having any sign of crack shall be rejected. Repair by welding on the

dished ends are not permissible. 8.6.8 Certification pertaining to Tank Barrel: Certification and record pertaining to

tank barrel should be as stipulated in Section III of IS: 2825 (latest revision and amendments). The manufacturer shall furnish a certificate of manufacture and production tests generally in the format given at Annexure-II of IS: 2825. In addition, the format should include the certification of the provisions of this specification also. The barrel shall be tested & certified by the Inspecting Officer. The scope of work of the Inspecting Officer is as under:

Certification of material. Certification that fabrication of barrel is as per IS: 2825. Certification of hydrostatic & air tests as called for in this specification. Certification of functioning of all the dome fittings. Certification as to the proper mounting of the barrel on the underframe. Certification & approval of the drawings submitted by the manufacturer. Any

deviation from design drawings can be approved only with the concurrence of the ‘Engineers’.

8.6.9 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 wagons:

There is no visual abnormality. The wagon is generally fit to run. All the underframe components are in position and in working order. 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 &

the markings are strictly in accordance with the marking diagram. 8.6.10 Welds inside the barrel shall be ground flush after welding. 8.6.11 All valves and mountings shall be procured by the contractor and subjected to

bench test separately before fitment. 8.6.12 The barrel shall be fitted with the following valves and accessories:

2 Nos. of 100 mm dia filling pipe with its attachments to relevant drawings outlined in Index Drg. No. RSD-6315-051 latest alteration.

2 Nos. of 25 mm dia dip reading pipe with its attachments to relevant drawings outlined in Index Drg. No. RSD-6315-051 latest alteration.



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2 Nos. of vapour extractor cocks to relevant drawings outlined in Index Drg. No. RSD-6315-051 latest alteration.

1 No. safety valve to relevant drawings outlined in Index Drg. No. RSD-6315-051 latest alteration.

2 Nos. of master valve as per relevant drawings outlined in Index Drg. No. RSD-6315-051 (latest alteration) complete with spindle and operating hand wheel.

2 Nos. of lubricated taper plug valve for bottom discharge generally to RDSO Particular Specification with latest revision and amendment as mentioned in relevant drawings outlined in Index Drg. No. RSD-6315-051 latest alteration. The valves should be procured only from RDSO approved suppliers.

8.6.13 Tolerances on dimensions of the tank barrel shall be as under:

1 Length of barrel measured over the centers of two dished ends.

+ 10 mm - 3 mm

2 Circumferential length The external circumference of the completed barrel shall not depart from the calculated circumference based upon nominal inside diameter and the actual thickness by ± 0.25% of the outside diameter for barrels having over 600 mm outside dia.

3 Ovality or “out of roundness” The difference between max. and minimum diameter at any cross section of the barrel shall be within 1% of the nominal internal diameter with a maximum limit of- (Inside diameter+ 1250)/200

4 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 be increased by 25% if the length of irregularity does not exceed one quarter of the length of the barrel ring, with a maximum of 1000 mm.

5 Inside diameter of manhole ± 2.0 mm

6 Height of dome ± 2.5 mm



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8.6.14 Each dished end of the barrel shall be made in two pieces welded together as shown in relevant drawings outlined in Index Drg. No. RSD-6315-051 latest alteration. Joining of the two pieces by welding should be done before dishing. After dishing, 100% radiographic examination of the welding joint should be done to ensure that no defect has crept in during the process of dishing.

8.6.15 Each dome of the barrel shall be provided with a rubber sealing ring as shown in

relevant drawings outlined in Index Drg. No. RSD-6315-051 latest alteration. The ring shall be fitted in accordance to relevant drawings outlined in Index Drg. No. RSD-6315-051 latest alteration. .

8.7 Underframe and Cradles 8.7.1 The under frame is of all welded construction and shall be in accordance to

relevant drawings outlined in Index Drg. No. RSD-6315-051 (latest alteration) and cradle shall be in accordance to relevant drawings outlined in Index Drg. No. RSD-6315-051 (latest alteration).

8.7.2 The procedure and sequence of welding and assembly should have the prior approval of the ‘Engineers’.

8.8 Platform and Ladder

Platform & ladder shall be in accordance to relevant drawings outlined in Index Drg. No. RSD-6315-051 (latest alteration).

8.9 Welding (other than Barrel) 8.9.1 General requirements and comprehensive guidance with regard to fit up for

welding, welding procedure and inspection of welded joints shall be in accordance with instructions contained in Tech. Pamphlet No.G-72 (latest revision with amendments) issued by RDSO. These shall be strictly followed.

8.9.2 Wherever welding is specified or adopted in the manufacture of the wagons or in

the fabrication of the sub-assemblies and components, the Contractor shall submit his proposed welding procedure and sequence to the ‘Engineers’ as well as to the ‘Inspection Officer’ for their prior approval. This, however, will not, in any way, reduce the Contractor’s responsibility for satisfactory execution of the contract in all respects.

8.9.3 Three copies of welding procedure and sequence of assembly of the wagon finally

approved by the ‘Inspecting officer’ shall be furnished to the ‘Engineers’ by the Contractor before commencement of regular production.

9. TESTING OF TANK BARREL, VALVES AND WAGON 9.1 Hydraulic Test of Barrel



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The barrel complete with internal fittings including master valve and bottom discharge valve after being mounted on the under frame shall be tested hydrostatically to pressure of 2.8 kg/cm2 against leakage of longitudinal and circumferential weld seams of the barrel. The joints should not show any sign of leakage when the pressure is maintained for 30 minutes. Caulking to prevent/close the leakage is prohibited. Openings of domes and safety valve shall be closed by dummy flanges during hydraulic test. Water for the test shall preferably be free of dissolved chlorine.

9.2 Pneumatic Test of Barrel Mountings

The barrel shall be mounted on and anchored to the under frame and all barrel fittings shall be mounted on the barrel before the pneumatic test. The pressure inside the barrel shall gradually be increased to 1.2 kg/cm2 and the same pressure will be maintained for sufficient length of time to enable a thorough examination to be made against leakage at all the flange joints of the valves and accessories. The pneumatic test can be carried out by filling the entire barrel with air and the pressure raised to the required value. Alternatively, after the hydraulic test, the fittings can be mounted on the barrel and the barrel drained partially leaving 10% empty space and pneumatic pressure built up to the required value in the empty space.

9.3 Master Valve of Barrel 9.3.1 Master valve shall be tested in assembled position against leakage in the

following sequence of operations:

Close the master valve tightly. Fill the barrel with water upto a height of 1 metre. Operate the valve 10 times in quick succession and finally close it.

There should not be any leakage at the bottom opening of the valve.

9.4 Discharge Valve

Discharge valve shall also be tested in assembled position against leakage.

9.5 Load testing of Wagon

9.5.1 Before proceeding with the regular production of wagon, the pattern wagon shall

be fabricated and offered for inspection and load testing in accordance to relevant drawings outlined in Index Drg. No. RSD-6315-051 (latest alteration). The wagon shall be inspected and tested for load deflection under gross load and also with 25% overload. Clearances found between the various members of the under frame and the bogies shall be measured under tare, fully loaded, 25% overload



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and unloaded conditions at various locations. The report of the tests shall be submitted to the ‘Engineers’ through Inspecting Officer.

9.5.2 Any other tests to be conducted on the pattern wagons shall be decided by the

Inspecting Officer in consultation with the Engineers.

9.5.3 Any modifications that may be called for as a result of these tests and inspections, will have to be made free of cost by the Contractor during the bulk production of wagons

9.6 Calibration 9.6.1 Preparation of Calibration Chart

20% of the total no. of tank wagons ordered shall be physically calibrated and calibration chart prepared by the Contractor in their premises as per procedure outlined in ANNEXURE-II as accepted by the Chairman, Calibration Committee. The carrying capacities both in tonnes and litres alongwith corresponding dip height for the commodities given in the following table shall also be incorporated in the calibration chart.

TABLE

S. No. Name of Commodity

1. Motor Sprit (Petrol)

2. Naphtha

3. Superior Kerosene

4. ATF

5. HSD

6. LDO

7. FO

The work of calibration shall be witnessed and certified by Inspecting Officer.

10. GUARANTEE

Tank barrels supplied in conformity with this specification shall be guaranteed against defects of workmanship and materials for a period of 18 months from the date of dispatch of the tank wagon or for a period of 12 months from the date of their being put into service.

11. PAINTING AND MARKINGS 11.1 Painting

The surface preparation and painting of wagons shall be as stipulated in General Standard Specification No. G-72 with latest revision and amendments if any.



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11.2 Marking 11.2.1 Markings shall be done in accordance to relevant drawings outlined in Index Drg.

No. RSD-6315-051 (latest alteration). 11.2.2 The tare weight of the wagon shall be marked in tonnes up to one decimal place

as determined by method detailed in ANNEXURE I. 11.2.3 The direction of operation of hand brake wheel shall be marked as ‘ON’ and ‘OFF’

as indicated in relevant drawings outlined in Index Drg. No. RSD-6315-051 (latest alteration).

11.2.4 Cast iron standard plates shall be screwed on to the underframe sole bars at

diagonally opposite corners as shown in relevant drawings outlined in Index Drg. No. RSD-6315-051 (latest alteration). One plate on each underframe shall be in English and the other shall be in Hindi. Mild steel drop stamped standard plate is acceptable as an alternative.

11.2.5 Railways initials to be marked will be intimated later. The mechanical code

‘BTFLN’ is to be stenciled and stamped at locations shown in relevant drawings

outlined in Index Drg. No. RSD-6315-051 (latest alteration).

12. INSPECTION

The inspection of the wagon with all its fittings is to be carried out by RDSO, Wagon Inspection Wing. The wagon manufacturer will provide all the facilities to the Inspecting Officer.

13. DISPUTE REGARDING INTERPRETATION

In case of dispute between the manufacturer and the purchaser regarding the interpretation of any clause/clauses of this specification, the decisions of the ‘Engineers’ will be final and binding on both the parties.

14. DRAWINGS

The wagons shall be manufactured strictly in accordance to relevant drawings outlined in Index Drg. No. RSD-6315-051 (latest alteration). The alteration number against each drawing are, however, subject to advancement in course of construction of these wagons and the contractor shall comply with these amendments in manufacturing of components. The detailed design drawings can be had from Director General (Wagon), Manak Nagar, RDSO, Lucknow. Copies of such amended drawings will be supplied to the Contractor free of cost. The



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drawings listed are complete in all respects and any detailing, if necessary, will be done by the Contractor.

15. ‘AS MADE’ DRAWINGS 15.1 The contractor shall supply two sets of ‘As Made’ Polyster film tracings (50 micron

thick matte) of each drawing of the complete set of drawings followed in the manufacture of the wagon to the ‘Engineers’ for their record. The diagram shall indicate the leading particulars, overall dimensions and salient features.

15.2 The contractor shall incorporate in the above set of tracings of ‘As Made’ drawings

any deviations, modifications and relaxations granted in the course of manufacture of wagons.

15.3 ‘As Made’ drawings detailed above shall contain full details of each component/

sub-assembly/assembly inclusive of material specification, actual average weight and reference drawings. The general order of the drawings title block etc. shall be strictly as indicated in RDSO’s Drg. No. SK.67521 with space for Drg. Number. The size of the sheet shall be A-1 (841 mm x 594 mm) and the Code of Practice for Drawing shall conform to IS Specification No. 696.

16. PHOTOGRAPHS AND MODELS 16.1 The Contractor shall furnish free of cost the following negatives and photos of the

assembled wagon to the Purchaser/Engineer: 16.1.1 Two copies of the coloured negatives. 16.1.2 Two copies of the black and white negatives. 16.1.3 Three enlarged photographs – prints in colour (size 60 cm x 45 cm). 16.1.4 Three enlarged photographs in black & white (size 25.4 cm x 30.5 cm). 16.1.5 Any other photographs of the wagon as desired by the Purchaser/Engineer. 16.2 One 1/16-scale model made out of sheet steel or as indicated by the

Purchaser/Engineer. ***************************



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ANNEXURE-I

METHOD OF DETERMINING THE TARE WEIGHT OF WAGONS All contractors will arrange to weight each wagon. Tare weight of the wagon shall also be intimated to ‘Engineers’ duly certified by the Inspecting officer.

Payload of the wagon would be fixed as given on its ‘Diagram/ Drawing’.



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ANNEXURE-II

Procedure of Calibration Start filling the tank wagon with water from a tank with a static head through a reliable calibrated bulk-meter. The quantity of water shall gradually be increased in the following steps till it is filled up to brim and corresponding dip-height in nearest millimeters against different volumes of water in litres shall be recorded in a register to be maintained by the Contractor.

DIP READINGS TO BE TAKEN FROM BOTH DIP-HOLES

Quantity Steps Steps of No. of Steps

250 to 500 Litres 250 Litres* 2

500 to 1000 ,, 500 ,, 1

1000 to 5000 ,, 1000 ,, 4

5000 to 10000 ,, 5000 ,, 1

10000 to 50000 ,, 10000 ,, 4

50000 to 60000 ,, 5000 ,, 2

60000 to 61000 ,, 1000 ,, 1

61000 to 61500 ,, 500 ,, 1

61500 to up to Brim ,, 250 ,, As per actuals

*First two steps dips to e taken from dip hole and also from fill pipe. The volume of water contained in the tank when filling up to brim shall also be noted. Calibration Chart

The chart shall be drawn up using the readings recorded in the register mentioned above. The maximum carrying capacity in litres shall be worked out by deducting minimum prescribed air space of the full volume capacity of the barrel. This maximum carrying capacity divided by conversion factor of the particular commodity will give the carrying capacity in tonnes provided the figure so obtained does not exceed the max. carrying capacity/max. payload in tonnes of the wagon. Maximum pay load in tonnes shall be obtained by deducting the average tare weight from the max. permissible gross load. However, if it exceeds the max. payload, the max. payload itself is to be taken as carrying capacity in tonnes and the corresponding carrying capacity in litres shall be worked back by multiplying this value by the conversion factors in litres/tonne of the commodity.

The dip heights corresponding to the carrying capacity in mm for the various commodities listed in the clause 9.6.1 shall be arrived at from the table of dip height against various volumes in litres (Interpolation of reading may be resorted to if necessary). The calibration chart shall thus be prepared as per sample chart attached herewith.



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SAMPLE CALIBRATION CHART Dip (mm) Volume (lit.) Dip (mm) Volume (lit.) Dip (mm) Volume (lit.)

10 24 440 6931 870 18542

20 68 450 7163 880 18843

30 125 460 7398 890 19145

40 193 470 7634 900 19448

50 269 480 7873 910 19752

60 354 490 8114 920 20058

70 447 500 8357 930 20364

80 546 510 8602 940 20671

90 652 520 8849 950 20979

100 763 530 9098 960 21288

110 881 540 9349 970 21598

120 1004 550 9602 980 21909

130 1132 560 9857 990 22220

140 1264 570 10114 1000 22533

150 1402 580 10373 1010 22846

160 1544 590 10633 1020 23160

170 1691 600 10895 1030 23475

180 1842 610 11159 1040 23791

190 1996 620 11424 1050 24108

200 2155 630 11692 1060 24425

210 2318 640 11960 1070 24743

220 2484 650 12231 1080 25061

230 2655 660 12503 1090 25380

240 2828 670 12777 1100 25700

250 3005 680 13052 1110 26021

260 3186 690 13329 1120 26342

270 3369 700 13607 1130 26664

280 3556 710 13886 1140 26986

290 3746 720 14168 1150 27309

300 3939 730 14450 1160 27633

310 4135 740 14734 1170 27957

320 4334 750 15019 1180 28281

330 4536 760 15306 1190 28606

340 4741 770 15594 1200 28932

350 4949 780 15883 1210 29258

360 5159 790 16174 1220 29584

370 5371 800 16466 1230 29911

380 5587 810 16759 1240 30239

390 5805 820 17053 1250 30566

400 6025 830 17348 1260 30894

410 6248 840 17645 1270 31223

420 6473 850 17943 1280 31552

430 6701 860 18242 1290 31881



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Dip (mm) Volume (lit.) Dip (mm) Volume (lit.) Dip (mm) Volume (lit.)

1300 32210 1750 47082 2200 60995

1310 32540 1760 47408 2210 61280

1320 32870 1770 47733 2220 61564

1330 33200 1780 48057 2230 61847

1340 33530 1790 48381 2240 62128

1350 33861 1800 48705 2250 62407

1360 34192 1810 49028 2260 62686

1370 34523 1820 49350 2270 62962

1380 34854 1830 49672 2280 63238

1390 35186 1840 49993 2290 63511

1400 35517 1850 50314 2300 63783

1410 35849 1860 50634 2310 64054

1420 36181 1870 50953 2320 64323

1430 36513 1880 51272 2330 64590

1440 36845 1890 51590 2340 64855

1450 37177 1900 51907 2350 65119

1460 37509 1910 52223 2360 65381

1470 37841 1920 52539 2370 65642

1480 38173 1930 52854 2380 65900

1490 38505 1940 53168 2390 66157

1500 38837 1950 53481 2400 66412

1510 39169 1960 53794 2410 66665

1520 39501 1970 54105 2420 66916

1530 39833 1980 54416 2430 67165

1540 40165 1990 54726 2440 67412

1550 40497 2000 55035 2450 67657

1560 40828 2010 55343 2460 67900

1570 41160 2020 55650 2470 68141

1580 41491 2030 55957 2480 68380

1590 41822 2040 56262 2490 68617

1600 42153 2050 56566 2500 68851

1610 42484 2060 56869 2510 69083

1620 42814 2070 57171 2520 69313

1630 43145 2080 57472 2530 69541

1640 43475 2090 57772 2540 69766

1650 43804 2100 58071 2550 69989

1660 44134 2110 58369 2560 70210

1670 44463 2120 58666 2570 70427

1680 44791 2130 58961 2580 70643

1690 45120 2140 59255 2590 70856

1700 45448 2150 59549 2600 71066

1710 45776 2160 59840 2610 71273

1720 46103 2170 60131 2620 71478

1730 46430 2180 60420 2630 71680

1740 46756 2190 60708 2640 71879



Page 19 of 20

Dip (mm) Volume (lit.)

2650 72075

2660 72268

2670 72458

2680 72645

2690 72829

2700 73009

2710 73186

2720 73360

2730 73530

2740 73696

2750 73859

2760 74018

2770 74173

2780 74323

2790 74470

2800 74612

2810 74750

2820 74883

2830 75011

2840 75133

2850 75251

2860 75363

2870 75468

2880 75567

2890 75600

2900 75745

2910 75822

2920 75889

2930 75946

2940 75990

2950 76014



Page 20 of 20

ANNEXURE-III

NYLON HAND BRAKE GEAR BUSHES IN THE HAND BRAKE GEAR ARRANGEMENT OF THE WAGON

1. Hand brake bushes of Nylon 66 shall be procured as per RDSO Specification with latest revision and amendments.

2. Nominal dimensions of Nylon 66 bushes to be used will be same as of steel bushes, inclusive of step sizes, outside diameter. However, the tolerances and the chamfering should be as per STR.

3. Undersized holes should be drilled initially in the fork type support brackets or fork

end of pull/push rods. These holes should be drilled together to the required size only after the assembly but before the Nylon bushes are fitted therein. This will ensure that the two holes are concentric and therefore, the pins passing through the bushes fitted therein will not tilt.

4. Steel pins used with Nylon 66 bushes shall be with fine finish machined on all

contact surfaces with the bush.

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Documents

INDIAN · PDF fileWD-02-BTFLN-2017 (Superseded WD-01-BTFLN-2006) Particular Specification for Bogie POL Tank Wagon Type BTFLN Page 1 of 20 INDIAN