Post on 13-Mar-2018
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INDIAN RAILWAYS
MAINTENANCE INSTRUCTION FOR
REPAIR OF DOORS OF BCNHL WAGON
S. No.
Month/Year of issue
Revision/
Amendment
Page No.
Reason for Amendement
01 October 2017 Nil First Issue
Issued By :
Wagon Directorate
Research Designs and Standards Organization
Manak Nagar, Lucknow-226011.
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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. Repair Guideline to Door: ............................................................................................................... 7
3.1 Two Flap Hinge Doors: ................................................................................................................ 7
3.2 Single Sliding Door: ..................................................................................................................... 7
3.3 Two part Sliding Door: ................................................................................................................ 8
4. Precaution in Retro fitment of two part sliding door ..................................................................... 8
5. Recommendations: ......................................................................................................................... 9
Annexure-A ....................................................................................................................................... 10
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1. BACKGROUND:
Railway Board in reference of minutes of CME conference, held on 17 December 2016 ,
issued 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 various
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. RDSO has prepared a
report(WDR-001-BCNHL-DOOR-2017), based on field experience and feedback received
over the time from various workshops and Wagon depots. The report has been
examined and approved by Railway Board vide letter No. 2005/M(N)/204/1 Vol. IV
dated:18.09.2017.This wagon maintenance instruction will help field maintenance
personnel in better understanding of various BCNHL Door designs, repair of various type
of doors and precautions to be taken in retro fitment of two part sliding door. This
instruction also standardizes 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
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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 may 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
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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
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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
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3. 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:
3.1 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(with latest alteration) & WD-11043-S-01(with latest alteration),
WD-11043-S-02(with latest alteration). Detail procedure and precautions to
be ensured for retro fitment of these doors is given in para-4. It is again
instructed 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 instructed 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(with latest alteration) and WD-11043-S-02(with latest
alteration).
3.2 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.
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3.3 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.
4. 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(with latest alteration).
• 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(with latest alteration). 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) (with latest alteration)
• 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(with latest alteration).
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(with latest alteration). 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(with latest alteration) 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(with latest alteration). 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(with latest alteration). Picture at item no-1 of Annexure-A.
• The angle for guide rail (WD-11043-S-02(with latest alteration), item no-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(with latest alteration), item no-
28) to be carefully welded with sole bar so that this plate could provide the strength
to guide rail angle.
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• Stiffener plate (WD-11043-S-02(with latest alteration) 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(with latest alteration), item no-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.
5. Recommendations:
• RDSO has standardized all available 8 variants of doors into two types of doors i.e.
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) may be replaced by two part sliding door. They will have to be
done on condition basis whenever complete door warrants replacement.
• Texmaco design single sliding door (SS) may be converted into RDSO design single
sliding door (MS). They will have to be done on condition basis whenever complete
door warrants replacement.
• All new BCNHL wagons, to be manufactured from now onwards, to be fitted with
two part sliding door.
• The correct fitment of two part sliding door and single sliding door may be ensured
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 4.
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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.
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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
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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.
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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
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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
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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.