भारत सरकार GOVERNMENT OF INDIA
रे ल मं ालय MINISTRY OF RAILWAYS
रे लवे बोड RAILWAY BOARD
No. 2015/M(N)/204/4. (E-3365989) New Delhi, dated: 25.02.2025
PCMEs
All Zonal Railways.
Sub: Monitoring of modification in BTAP Wagons.
Ref: (i) This office letter No. 2015/M(N)/204/4. (E-3365989) dated 25.02.2025
(ii) RDSO’s letter no. MW/CS/Balco dated 19.02.2025.
In continuation of the instructions issued vide ref (i), it may please be noted that subject
modification in BTAP wagons must be monitored at both the divisional and
headquarters levels. The details (wagon wise) should be shared with Railway Board daily,
in addition to being updated on the FMM/WISE portals.
It is, therefore, requested that CRSEs Freight be advised to share on a daily basis, the
depot/ workshop/ wagon number in which the wagons have been modified on the
previous day.
May kindly ensure the same.
HAPPY WALIA Digitally signed by HAPPY WALIA
Date: 2025.02.25 18:40:32 +05'30'
(HAPPY WALIA)
EDME/Freight
Mobile: 9717997801
Email: edmef@[Link]
Copy to:
1. PSO to MTRS for kind information of M(T&RS).
2. MD/CRIS - for necessary flagging of the modified BTAP wagons in the FMM &
WISE Portal.
भारत सरकार GOVERNMENT OF INDIA
रे ल मं ालय MINISTRY OF RAILWAYS
रे लवे बोड RAILWAY BOARD
No.2015/M(N)/204/4. (E-3365989) New Delhi, Dated: 25.02.2025
The Principal Chief Mechanical Engineers
All Zonal Railways
Sub: Provision of modified holding brackets for securing of the Discharge and Air
Fluidizing System (AFS) in BTAP wagon
Ref: RDSO’s letter no. MW/CS/Balco dated 19.02.2025 (Copy enclosed).
In a recent derailment case, two BTAP wagons derailed in the BRKA-MURI
section of Ranchi Division on 6th February 2025 due to the falling of the
fluidizing system pipeline arrangement onto the track, leading to subsequent
entanglement. Upon further analysis, it was found that the fluidizing system
holding brackets had worked out due to poor welding.
In this connection, a joint investigation was conducted on 14.02.2025 by RDSO
in association with SER, ECoR, ECR, SCR, SECR, WCR, and representatives of
wagon owners i.e. Nalco, Hindalco and Vedanta. It was observed that the
fitment of holding brackets for the AFS was improper, with poor welding
quality, improper fusion, intermittent welding bead, and inadequate welding
length on two BTAP wagons (Nos. 46440808882 & 46440809117, both
belonging to M/s Hindalco Ltd).
To prevent recurrence, the design of AFS holding brackets has been revised,
incorporating increased welding length and lock bolts for secure pipe clamping
as detailed in RDSO’s letter at ref (i). A standard holding arrangement, as per
design drawing No. WD-25010-S-01, will be used for BTAP wagons fitted with
STAG or Simotra AFS. For wagons modified with non-standard AFS and non
standard securing arrangement, original fittings should be reinstate and until
Room No. 312-C, Rail Bhawan, Raisina Road, New Delhi - 110001
then, securing arrangements should follow the modifications as prescribed
RDSO.
It is requested that modifications work in BTAP wagons as advised by RDSO be
carried out with immediate effect during Sick line attention, ROH and POH.
Additionally, these modifications should also be implemented for new BTAP
wagon manufacturing.
HAPPY WALIA Digitally signed by HAPPY WALIA
Date: 2025.02.25 12:32:19 +05'30'
DA: As above.
(Happy Walia)
EDME (Freight)
Railway Board
Email – edmef@[Link]
Copy to:
1. PED RS(S)/Railway Board for kind information and communication to all Wagon
manufacturers
2. PED (RS)/RDSO/LKO- for information and to advise all ED(QAs) and Wagon
manufacturers
3. ED(S)/Wagon/RDSO
Room No. 312-C, Rail Bhawan, Raisina Road, New Delhi - 110001
File [Link]-MW0WD(CHRB)/1/2020-O/o PED/SW/RDSO
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vuqla/kku vfHkdYi vkSj ekud laxBu
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Government of India - Ministry of Railways
QSDl@Fax : 91-0522-2452494 Research Designs & Standards Organisation
VsyhQksu@Tele: 0522- 2462638 Lucknow – 226011
MW/CS/Balco Date: 19.02.2025
EDME (Freight)
Railway Board
New Delhi.
fo"k;% Modified holding brackets for securing of the Discharge and Air Fluidizing
System in BTAP wagon.
lanHkZ% i) This office letter of even number dt.12.02.2025.
ii) Report of joint investigation of BTAP discharge/fluidizing system at ROH
depot, BNDM on 14.02.2025.
BRKA-MURI section of Ranchi Division on 6th Feb’ 2025.
Two BTAP wagons derailed in BRKA
This derailment was caused due to falling of fluidizing system pipe line arrangement on
the track and subsequent entanglement. On further analysis it was found that fluidizing
system holding brackets have worked out due to poor welding. Accordingly, vide ref. (i)
above, SE Rly was requested for organizing
organizing joint investigation at BNDM involving
concerned Zonal Railways and owners of BTAP wagons.
RDSO team visited ROH Depot, BNDM on 14.02.2025 and joint investigation was done
with SER, ECoR, ECR, SCR, SECR & WCR and representative of wagon owners. owner Two
BTAP wagons nos. 46440808882 & 46440809117 both of M/s Hindalco Ltd., placed at
ROH depot were examined in this joint studystudy. Both the wagons were found fitted with
STAG make air fluidizing system. The STAG make air fluidizing system has different
piping arrangements ts for the air supply than the Simotra
Simotra make fluidizing system
system. Joint
report is attached herewith.
During investigation it was observed that the fitment of holding brackets for AFS is not
proper. Poor welding quality having improper fusion, intermittent welding bead as well
as less welding length have been observed. Therefore, to avoid the working out of the
AFS holding brackets, its design has been revisited and following modifications are
recommended:
A. BTAP wagons fitted with STAG or Simotra make AFS:
i. The design drawing no. WD-25010-S-01 has been prepared and is attached
herewith. This will be followed for provision of standard holding bracket for both
make of AFS as per arrangement indicated in the drawing.
ii. Besides, increased welding length provision of lock nuts between holding
bracket and cross member has also been included for sturdier joint
joint.
iii. For improved securing of air pipe line, design of clamp has also been reviewed
and provision of lock bolt for pipe clamping has also been prescribed.
B. BTAP wagon modified locally and fitted with non-standard
non AFS:
File [Link]-MW0WD(CHRB)/1/2020-O/o PED/SW/RDSO
i. The non-standard fittings should be replaced with original equipment fitted in the
wagon at time of manufacturing.
ii. However, till replacement is done, securing arrangement of all pipelines and
associated fittings shall be done in accordance to para A above.
Above modification works can be undertaken during sick line/ROH/POH attention of the
wagon. Zonal Railways may be advised for implementation above modification for
entire fleet of BTAP wagons. Above modification (para A) has also been incorporated in
the standard drawing list for manufacturing of BTAP wagons.
DA: As above.
(Sanjay Kumar)
Director/ Wagon Design
For Executive Director Stds. (Wagon)
Copy:
1. ED/QA (Mech.), 3, Koilaghat Street, Kolkata.
2. ED/QA (Mech.), New Annexe Building, 1st floor, for kind information and necessary
W. Railway, Mumbai-400020 action please.
3. ED/QA(Mech.), Near IRCOT Building, Shivaji Bridge,
Behind Shankar Market, New Delhi
File [Link]-MW0WD(CHRB)/1/2020-O/o PED/SW/RDSO
Joint Investigation of BTAP discharge/fluidizing system at ROH
DEPOT/BNDM on 14.02.2025. (Wago No.-O 46940Bo282-Windalca
464o8091 Hindaco)
fay : Derailment of BTAP wagon at Ranchí Division of SE Railway.
HY: RDSO Letter no. MWICS/Balco, dated 12.02.2025
Adetail investigation of the discharge/fluidizing system of BTAP Wagon was carried out in
presence of representatives from zonal railways and the wagon owners.
SL. Name
No.
Designation Zonal Railway Signatur
1
Representatives
Sri Sanjay Kumar DIRWagon RDSO
2 Sri R.R. Rasik [Link]/CKP CKP Div/SER
Sri Siddhanta Mishra DME/F/SBP SBP Div/[Link].R
Sri Lokesh Nanda DME(F)WAT WAT Div/[Link].R
5 Sri Dillip Kumar Sethi ADME/C&W/BNDM CKP Div/SER
6 Sri U.P. Singh ADME/CPU/DHN DHN Div/ECR
7 Sri D.D. Rajesh ADMEJCOA BZA Div/SCR
8 Sri Neeraj Kumar ADMEJC&W/BNDM CKP Div/SER
Sri R.K. Tamarkar SSE/RDSO RDSO
10 Sri S.P. Mishra SSE/BSP BSP Div/SECR
11 Sri Satish Kumar
12 Sri Mukesh Meena
SSE/C&WIOBR OBR Div/ECR
13
SSE/C&WINKJ JBP DivNCR
Sri J. Satyanarayana SSE/C&W/COA BZA Div/SCR
14 Sri K.E.V. Appa Rao
15
SSE/C&WICOA BZA Div/SCR
Sri Prempal Singh Consultant/NKJ JBP DivWCR
16 Sri Ranjeet Kumar Tech-/C&WICOA BZA Div/SCR
17 Sri Jagat Singh Meena Tech-/C&VWINKJ JBP DivWCR
SL. No. Name Designation
1
Wagon Owners Signature
Sri Anuj Jha DGM M/s Hindalco
2 Sri Tapas Panda Asst. Manager M/s Hindalco
3 Sri Suraj Lugun Manager(Mech) M/s Nalco
4 Sri Sudhansu Asst. Manager M/s Vedanta, JSG
Sekhar Sahu
Sri Kamal Patnaik Asst. Manager M/s Vedanta, JSG
6 Sri Sunil Kumar GM Logistic M/s Hindalco
Verma
7 Sri Kenneth Dvaz GM Logistic M/s Hindalco
Observations:
1. The BTAP wagon placed at ROH Depot were inspected. The wagons are fitted with
Stag make discharge/fluidizing system. The system has been localy modified by the
wagon owner and most of the pipe line arrangements for supply of the pressurised
air have been removed.
Page 1 of 2
File [Link]-MW0WD(CHRB)/1/2020-O/o PED/SW/RDSO
2. With the above arrangement discharge from one hopper at a time can only be taken.
But by the standard system the discharge from both the hoppers can be taken
simultaneously as the supplied air can be fed to both the hoppers simultaneously.
3. Due to discharge from a single hopper at a time the unloading time per wagon shall
be more.
4. The local modifications in the fluidizing system has been done by the
without the information of the concerned railways maintaining the rake. wagon owner
5. In the discussion, the present wagon owners consented for the standard design of
the fluidizing system.
5. All the wagon owners and the zonal railways are advised to get the census of such
wagons which have been modified locally. The detail census shall be shared by the
Zonal railways to RDSO.
7. Due to the local modifications most of the air pipe
arrangement has become
abandoned whereby no adequate attention for their maintenance are given either by
the railways or the wagon owners. Putting the standard system back is a difficult task
due to unavailability of the spare parts. The spare parts from the same
manufacturers
i.e. M/s Stag shall be required. Therefore, till the system is put back to standard
system the redundant air pipe lines and allied parts shall be removed Considering
safety aspects. The zonal railways shall take decision on it in consultation with the
the
wagon owners.
8. The wagon owner has been compelled for doing the local
of the NRV and safety valves of AFS. Instead of making the modifications due to theft
local
wagon owner shall make good the theft part for making the systenmmodifications
the
without any local modifications. functional again
9. RDSO mandates for maintaining the standard
system. The BTAP wagon has been
design with Simotra type air fluidizing system for which standard design
brackets for air pipingarrangement have been prescribed in BTAP wagons of holding
[Link] BTAP wagons owned by M/s Hindalco has air fluidizing system of Stag drawings.
and has different piping arrangement compared to the Simotra make
make fluidizing
system. The different holding brackets fitted for holding the air piping and other
equipment's are also different.
[Link] brackets welding were not found adequate and satisfactory. Welding
such as improper fusion, intermittent welding bead etc have been observed. defects
12. RDSO will study and advise welding and / or huck bolting for proper
brackets for the Stag Make AFL. securing of the
[Link] present the AFL system and the barrels are being maintained by the wagon owner
and the under gear systems are being maintained by the Railways. Therefore during
the under gear examination no adequate attention is paid to the AFL and the allied
system. The deficiencies found in the system is either not communicated to them or
the communicated deficiencies have been attended or not is not known to other party.
Therefore asuitable mechanism/policy shall be in place to address the above issue.
The Zonal Railways in consultation with the wagon owners may devise a suitable
mechanismpolicy.
(Suhaa)
Page 2 of 2
File [Link]-MW0WD(CHRB)/1/2020-O/o PED/SW/RDSO