report on doors of bcnhl wagons - … report on...wdr-001-bcnhl door-2017 6 july ˇ2010 texmaco...

WDR-001-BCNHL DOOR-2017

INDIAN RAILWAYS

Report on Doors of BCNHL Wagons

February 2017

Issued By : Wagon Directorate

Research Designs and Standards Organization Manak Nagar, Lucknow-226011.


Contents 1. BACKGROUND: .......................................................................................................................... 3

2. TYPES OF DOORS: ...................................................................................................................... 3

A. Two-flap hinge door ............................................................................................................... 3

B. Single sliding door .................................................................................................................. 3

C. Retrofit table Two -part sliding door ...................................................................................... 3

Table: 1 ......................................................................................................................................... 4

3. Problems noticed in workshops and Wagon depots. .................................................................. 7

3.1. Observation at Khanalampura Depot, Ambala Division........................................................... 7

3.2. Observations at CPC Goods Yard, Kanpur. .............................................................................. 7

3.3. Observations at Madar Depot, Ajmer Division. ....................................................................... 7

3.4. Observations at Jhansi Workshop. ......................................................................................... 8

3.5. Observations at Kota Workshop. ............................................................................................ 8

4. Repair Guideline to Door: .......................................................................................................... 8

4.1. Two Flap Hinge Doors: ........................................................................................................... 9

4.2. Single Sliding Door: ................................................................................................................ 9

4.3. Two part Sliding Door: ........................................................................................................... 9

5. Precaution in Retro fitment of two part sliding door ................................................................ 10

6. Recommendations: .................................................................................................................. 11

Annexure-A ................................................................................................................................. 12


1. BACKGROUND: Railway Board vide minutes of CME conference, held on 17 December 2016 , issued vide letter no 2016/M(N)/951/30 dated 17/01/2017 directed RDSO to review the issues pertaining to BCNHL door design. Zonal Railways observed that there are nine designs of BCNHL doors running in field and they face a lot of problems in maintaining them. In view of above, RDSO undertook this study so as to come out with comprehensive report detailing all aspects of BCNHL door design issue. RDSO personnel visited Jhansi Workshop, Kota workshop, ROH depot Khan Alampura, Wagon Depot Madar, Ajmer and CPC yard Kanpur to understand the problems being faced by field staff in maintenance of various types of BCNHL doors. This report is based on this field experience and feedback received over the time from various workshops and Wagon depots. This document will help field maintenance personnel in better understanding of various BCNHL Door designs, how to repair the various type of doors and precautions to be taken in retro fitment of twin part sliding door. This report also recommends the standardisation of only two designs of BCNHL doors to ease their maintenance in field.

2. TYPES OF DOORS:

Broadly there are three different types of BCNHL wagon doors.

A. Two-flap hinge door B. Single sliding door C. Retrofit table Two -part sliding door

A. Two-flap hinge door It consists of original door design, Mod-1 design, Mod-2 design and Besco design door. All variant of Two-part flap door (6-Link or 4-Link with hinge) differ only in locking arrangement in the same door. Their details are furnished in table no 1.

B. Single sliding door It consists of TWL design sliding door, Texmaco design Single Piece Sliding Door (SS) and RDSO design Single Piece Sliding Door (MS). Their details are furnished in table no 1. The material specification and design of whole structure of BCHNL (Design-D) and BCHNL (Design-E) are same except those drawings which are concerned with BMBS. Therefore, single sliding door arrangement can be procured from either WD-10068-S-16 or WD-11054-S-16 for both type of BCNHL wagon.

C. Retrofit table Two -part sliding door • Mild steel, 2 Part Sliding Door with top mounted rollers moving in a guide channel

and supported with bottom guide rail. This retrofit able door can be easily fitted on those wagons which are manufactured with 2-flap hinge door of BCNHL wagons. There are two provision provided to drain the rain water in two part sliding door design. A slot is provided on mating plate of one door of two part sliding door and a rain protection plate (WD-06076-S-15 it-12) is welded with top coping throughout the length above the door opening. This rain protection plate has been extended with addition of a plate beyond the side stanchion so that the rain water will flow outside of the slider channel of door.

• This door can also be retro fitted with minor modification in body side where TWL design Single Piece Sliding Door is fitted.


Table: 1 BCNHL wagons are in operations, with the following types of doors, owing to modifications/ design changes based on field experience gained over time:

S.No. Time/ Period of

Introduction

Pictorial View Door Type Fitted in

Approx Number

of Wagons

1 May’2008

ORIGINAL: 6 Hinge Door (SS) with center locking from inside.

1000

2 June’2009

MOD-I: 6 Hinge Door (SS) with center locking inside & cotters-Long & Short provided on door sides.

3065


3 June’2010

MOD-II: 6 Hinge Door (SS) with center locking outside & inside alongwith cotters-Short provided on door sides.

3000

4 Aug’2010

BESCO Design 4-HINGE DOOR: 4 Hinge Door (SS) with center locking outside & inside alongwith cotters-Short provided on door sides.

500

5 Sept’2009

TWL Design Sliding Door: SS, Single Piece Sliding Door with Bottom mounted rollers.

58


6 July’2010

TEXMACO Design Sliding Door: SS Single Piece Sliding Door with Top mounted rollers.

300

7 July’2012

RDSO Design Sliding Door: MS (micro alloyed) Single Piece Sliding Door with Top mounted rollers alongwith securing, rolling & locking modifications.

11000

8 Jan’2013

Retrofit able 2-Part Sliding Door: MS, 2 Part Sliding Door with top mounted rollers moving in a guide channel. Retrofit able design for older BCNHL wagons.

116


3. Problems noticed in workshops and Wagon depots.

3.1. Observation at Khanalampura Depot, Ambala Division. • Railway board has sanctioned RSP for retro fitment of two part sliding door in

4000 wagons fitted with Original and Mod-1 hinge type doors. In Khan Alampura, feed had wagons fitted with all types of doors including Mod-II, Besco design etc.

• Provision was there in BCNHL drawings to prevent the bulging of side sheet at opening of door. Door way side sill pressing (WD-06076-S-13 it-18) is to be fitted with door link bracket frame (WD-06076-S-13 it-16) with continuous fillet welding. It was observed that continuous welding was not available resulting in ineffectiveness of provision and excessive bulging of side wall near door.

• Excessive gap in between door and side wall was seen after fitment of horizontal and vertical stiffeners on bulged sidewalls. Picture at item no 12 of Annexure-A.

• An additional plate was found welded with barrel bolt hold bkt(WD-11043-S-01 it-24) in level of floor plate. This would cause ingress of rain water from bottom side of door. These plates are to be removed. Picture at item no 6 of Annexure-A.

• It was observed that only half of 320 wagons had the contractual provision of providing stiffeners as per RDSO drg no.WD-06076-S-13 Alt-5.

• In general field staff did not find any issue with performance of two part sliding door.

3.2. Observations at CPC Goods Yard, Kanpur. • Incorrect dimension of angle (50X50X6mm) for guide rail. Due to excess

dimension of angle, this angle rubs with fixed structures. Picture at item no 1 of Annexure-A.

• Due to Incorrect dimension and Position of guide rail angle (50X50X6mm), this angle infringes with fixed structure. Picture at item no 2 of Annexure-A.

• One rib is provided at each horizontal flange of guide rail angle against the prescribed two nos Ribs as per drg no .WD-11043-S-01 item-23. Picture at item no 4 of Annexure-A.

• Location and dimension of Bkt. for barrel bolt are not found welded as per RDSO drg. no WD-11043-S-01. Picture at item no 5 of Annexure-A.

3.3. Observations at Madar Depot, Ajmer Division.

Single sliding door • To prevent the derailment of roller from the door top track, 04 no. of door

safety piece (8X18X50) (WD-10068-S-17 it-2(V) are provided in each door. During inspection none of the wagon has been found with these safety pieces. Picture at item no 13 of Annexure-A.

• Excessive gap has been observed between water protection cover pressing and door safety pressing angle due to missing/loose fitment of fasteners,


which leads to bulging and create excessive gap between door and door safety pressing. Picture at item no 14 of Annexure-A.

• Door guard is found rubbing with sole bar, which prevents easy sliding of door. Picture at item no 16 of Annexure-A.

• Safety catch holder, Retaining catch, Retaining catch rivet, shoulder rivet, cotter etc found missing from various wagon. Picture at item no 15 of Annexure-A.

Two part sliding door

• To ease the sliding of retro fittable two part sliding door arrangement, 10 no. transfer ball (WD-11043-S-01 it-22) are provided in one set door. These transfer balls not found fitted in any door which were provided in Jagadhari workshop.

• To stop the sliding of each door beyond the centre line of door opening, the stiffening plate (WD-11043-S-02 it-08 &10) are provided. These plates not provided during retro fitment of door in Jagadhari workshop.

• In some wagons door sheet found bulged and obstructing sliding of two part sliding door.

3.4. Observations at Jhansi Workshop. • Door frame straightening not found being done. • Misalignment of transfer balls with bottom guide rail. Picture at item no 3 of

Annexure-A. • Fabricated guide rail welded with sole bar in place of one piece angle guide

rail. • Additional plate found welded with sole bar for strengthening locking

bracket. It would cause water ingression. Picture at item no 6 of Annexure-A. • Stitch welding at door way side sill pressing(WD-06076-S-13 it-18) with door

link bracket frame(WD-06076-S-13 it-16) instead of continuous fillet welding. Picture at item no 11 of Annexure-A.

3.5. Observations at Kota Workshop. • Horizontal Roller found missing in roller assembly at top of door. • An additional piece of Item no.-28 of WD-11043-S-01 required to be added at

end of guide rail. • Door frame straightening not found being done. • In some wagons door sheet found bulged and obstructing sliding of two part

sliding door.

4. Repair Guideline to Door: Door failures have been reported by Zonal Railways on BCNHL wagons & various corrective actions for the same have been regularly advised. For the purpose of general guidance, the following are re-iterated, however, it is expected that detailed RDSO letters/ drgs issued to address the reported door failures along with instructions/ sanctions issued by Rly Bd shall be duly studied/ referred-to by the ZRs/ W’shops to undertake/ decide on door repairs in BCNHL wagons:


4.1. Two Flap Hinge Doors: • For BCNHL Wagons manufactured prior to June’2010 and fitted with Door

Design-Original, MOD-I, Railway board has instructed and sanctioned RSP for retro fitment of these doors by 2-part sliding doors as per RDSO Drg No. WD-06076-S-13 & WD-11043-S-01(Alt-1), WD-11043-S-02(Alt-1). Detail procedure and precautions to be ensured for retro fitment of these doors is given in para-5. It is again recommended that these door modifications be carried-out (if not already done) at the earliest .

• In case of other 2-flap hinge type door(Mod-2 and Besco design), if the under-repair BCNHL wagon is damaged to an extent that the entire door warrants a replacement, it is recommended that the door be replaced by the retrofit able two part sliding door as detailed in Drg. No. WD-06076-S-13 & WD-11043-S-01(Alt-1) and WD-11043-S-02(Alt-1). Railway Board is requested to issue necessary instructions/ RSP sanctions to facilitate these replacements.

4.2. Single Sliding Door: • Gap between water protection cover pressing and door safety pressing angle

should be as shown in relevant RDSO drawing by straightening the door safety pressing angle and providing missing/loose fasteners as shown in enlarged view “B” and “F” of drg no WD-10068-S-15. Picture at item no 14 of Annexure-A.

• To prevent the derailment of roller from the door top track, 04 no. of door safety piece (8x18x50 mm) as shown in RDSO drg no WD-10068-S-17 it-2(V) to be provided in each door. Picture at item no 13 of Annexure-A.

• Safety catch holder, Retaining catch, Retaining catch rivet, shoulder rivet, cotter etc. should be provided at proper location as shown in drawing noWD-10068-S-16, S-17,S-18. Picture at item no 15of Annexure-A.

• Proper Gap, as shown in drawing, between Door guard and sole bar to be maintained to ensure easy sliding of door. Picture at item no 16 of Annexure-A.

• Care needs to be taken to ensure that the correct/ recommended material of construction of door/ its components is used in repair of the door/ its assemblies.

• In case Texmaco design single sliding door (SS) warrants complete replacement owing to damages then RDSO design single sliding door (MS) to be used as replacement.

4.3. Two part Sliding Door: • If doors are found jammed, the fitment of transfer balls at bottom of doors to

be checked for proper fitment. The doors should be fitted with 05 nos transfer balls on each part.

• Replacement of rollers can be done only after cutting of one nearest side stanchion of one side of door.

• Any missing latching and locking component to be provided as per RDSO drawing.


5. Precaution in Retro fitment of two part sliding door • Remove the old hinge type door. • Check the side wall near door portion for straightness. If found bulged, the side walls

should be straitened by use of turn buckle or any other suitable method. Now the side wall to be strengthened by providing horizontal and vertical stiffeners as per RDSO drawing no. WD-06076-S-13 Alt-5 to prevent the bulging of side wall and to avoid water ingress due to gap in between side wall and door. Ensure maintenance of clearance in between door and side wall in range of 17 mm.

• Slider channel to be welded with top coping as shown in enlarged view at-‘Y’ of Drawing no-WD-11043-S-01.

• The guide rail to be fitted with sole bar ensuring the alignment of door. • Slider Channel and door assembly to be fabricated as per drawing no WD-11043-S-01

& S-02. Alignment of the slider channel with the door frame and guide rail to be done such that the both end of door fully overlap top to bottom after closing. (Section-PP overlap on section-OO in full height of door as shown in Drg. no WD-11043-S-02)

• 12 mm wide slot must be ensured throughout the length on the inside portion of lapped door (As shown Section-OO of Drg WD-11043-S-02). Picture at item no-9 of Annexure-A.

• The size of transfer ball must be ensured as shown in item no-22 of Drg WD-11043-S-01. The transfer ball should be procured from the approved manufacturer of RDSO as shown in drawing.

• The transfer ball is to be fitted on the inside bottom plate of door (As shown section-NN of WD-11043-S-02) for ease of sliding of door with guide rail. The fitment of guide rail must be such that the transfer balls are in proper contact with guide rail. The correct fitment of transfer ball is shown as enlarged view at-‘Z’ in Drg.No.-WD-11043-S-01. Picture at item no-3, 7 of Annexure-A.

• The guide rail fabrication with angle must be ensured as shown in section-CC of WD-11043-S-02. Picture at item no-1 of Annexure-A.

• The angle for guide rail (WD-11043-S-02 it-14) should be in one piece and 85 mm wide slot to be cut only on top flange at six locations on equal distance.

• Supporting plate for guide rail angle (WD-11043-S-01 it-28) to be carefully welded with sole bar so that this plate could provide the strength to guide rail angle.

• Stiffener plate (WD-11043-S-02, item no.-8 & 10) to be welded at proper location so that the door movement can be ensured up to required distance and door can be closed with proper alignment and tight overlapping.

• The barrel bolt hold bracket (WD-11043-S-01, it-24) to be welded from both side (outside and inside) with sole-bar at right location so that the door can be locked at right location maintaining the alignment and tight overlapping of door. This would also ensure proper strength of bracket.


6. Recommendations: • RDSO recommends standardising all available 8 variants of doors into two types of

doors i.e. RDSO design single sliding door (MS) and two part sliding door. • All types of 2 flap hinge doors (Original, Mod-1, Mod-2, TWL design single sliding

and Besco design) can be converted into two part sliding door. Railway board has already sanctioned RSP for retro fitment of two part sliding door in 4000 wagons fitted with Original and Mod-1 hinge type doors. Suitable instructions/RSP sanctions from Railway Board is to be issued for door conversion of 3558 wagons fitted with Mod-2 type hinge door , Besco design hinge door and TWL design single sliding door into two part sliding door.

• Texmaco design single sliding door (SS) can be converted into RDSO design single sliding door (MS). They will have to be done on conditional basis whenever complete door warrants replacement.

• All new BCNHL wagons, to be manufactured from now onwards, to be fitted with two part sliding door.

• RDSO to issue advisory to zonal railways about common errors in fitment of two part sliding door and single sliding door as detailed in Annexure A.

• Zonal Railways to ensure correct retro fitment of two part sliding door by preparing check sheets based on precautions mentioned in para 5.


Annexure-A

Common fitment errors noticed during field observations in retro fitment of two-part sliding door and Single sliding Door.

A. Two part sliding door S.No. Error Noticed Correct Fitment as per drawing 1

Incorrect dimension of angle (50X50X6mm) for guide rail. Due to excess dimension of angle, this angle rubs with fixed structures

Guide rail fabrication with angle of size (50X30X6mm) must be ensured as shown in section-CC of WD-11043-S-02

2

Due to Incorrect dimension and Position of guide rail angle (50X50X6mm), this angle infringes with fixed structure.


3

Wrong fitting of transfer ball, it should be in proper contact with guide rail

4

One rib(WD-11043-S-01 item-23) is fitted with each horizontal flange of guide rail angle

Two rib(WD-11043-S-01 item-23) to be weld with each horizontal flange of guide rail angle

5

The location and dimension of Bkt. for barrel bolt are not found welded as per RDSO drg. no WD-11043-S-01

Guide Bkt. for barrel bolt to be fitted according to drg. no WD-11043-S-01


S.No. Error Noticed Correct Fitment as per drawing 6

An additional plate was found welded with barrel bolt hold bkt(WD-11043-S-01 it-24) in level of floor plate. This would cause ingress of rain water from bottom side of door.

The additional plate is not provided in RDSO drawing. However, it can be welded at bottom face of barrel bolt hold bkt(WD-11043-S-01 it-24)to provide the strength of barrel bolt hold bkt(WD-11043-S-01 it-24).

7

Transfer ball are fitted in blind hole. Due to such error of fitment, the projection of ball are more.

The transfer ball to be fitted on the inside bottom plate of door(As shown section-NN of WD-11043-S-02) for ease of sliding of door with guide rail.

8

The welding area of Hasp locking pin Bkt(WD-11043-S-01 item-14) is less and due to poor welding quality, this bkt. found missing

Hasp locking pin Bkt(WD-11043-S-01 item-14) to be welding according to this photograph.


S.N

Error Noticed Correct Fitment as per drawing

9

Slots are not provided. The slot will prevent the rain water to flow inside the wagon.

12 mm wide slot must be ensured in throughout length on the inside lapped door (shown Section-OO of WD-11043-S-02).

10

The doors are misaligned and door part are not properly mate on each other. Due to such defect, water will ingress into the wagon.

The barrel bolt hold bracket (WD-11043-S-01, it-24) to be welded from both side (outside and inside) with sole-bar at right location .

11

Stitch welding of door way side sill pressing(WD-06076-S-13 it-18) with door link bracket frame(WD-06076-S-13 it-16) instead of continuous fillet welding

Door way side sill pressing(WD-06076-S-13 it-18) with door link bracket frame(WD-06076-S-13 it-16) to be done continuous welding as per Section-GG


12

Excessice Gap between door and side wall

Normal Gap between Door and Side wall

B. Single sliding door S.No. Error Noticed Correct Fitment as per drawing 13

Door safety piece are missing.

v

WD-10068-S-17 Item no-2(V) To prevent the derailment of door the Door safety piece are provided, it must be weld as per drawing


S.No. Error Noticed Correct Fitment as per drawing

14

Excess gap found between door top pressing(WD-10068-S-17, item-02) and Door safety angle pressing(WD-10068-S-15,item-16).

This gap shall be filled by fitment of suitable thickness of plate.

15

Missing Safety catch holder, Retaining catch, Retaining catch rivet, shoulder rivet, cotter etc

Safety catch holder, Retaining catch, Retaining catch rivet, shoulder rivet,cotter etc. to be provided at proper location as per drg noWD-10068-S-16, S-17,S-18.

16

Door Guard is rubbing with sole bar.

Door Guard(WD-10068-S-17 item-6) to be welded as per drawing.

report on doors of bcnhl wagons - … report on...wdr-001-bcnhl door-2017 6 july ˇ2010 texmaco...

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