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Air Brake Testing on Single Car Rig

The document outlines various tests that should be conducted for an air brake system on a single car test rig, including leakage tests of feed and brake pipes, filling and releasing times of the brake cylinder, sensitivity and insensitivity tests, emergency application tests, piston stroke measurements, leakage tests of the brake cylinder, and functional tests of the passenger emergency alarm system, guard's emergency valve, and manual release system. Key acceptance criteria are provided for pressure changes and timing in each test.

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Pesala Manoj Kumar
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219 views4 pages

Air Brake Testing on Single Car Rig

The document outlines various tests that should be conducted for an air brake system on a single car test rig, including leakage tests of feed and brake pipes, filling and releasing times of the brake cylinder, sensitivity and insensitivity tests, emergency application tests, piston stroke measurements, leakage tests of the brake cylinder, and functional tests of the passenger emergency alarm system, guard's emergency valve, and manual release system. Key acceptance criteria are provided for pressure changes and timing in each test.

Uploaded by

Pesala Manoj Kumar
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd

The different tests that should be conducted for an Air brake Rolling using

single car test rig are:


1. Leakage in Feed pipe.
2. Leakage in Brake pipe.
3. Brake cylinder filling time.
4. Brake cylinder releasing time.
5. Sensitivity test.
6. Insensitivity test.
7. Emergency application test.
8. Piston Stroke.
9. Leakage in the Brake cylinder.
10. Graduated Application test.
11. Graduated release test.
12. Working of PEAS.
13. Working of GEV.
14. Manual release Test.
1. Leakage in FP and BP:
a. Charge the system fully.
b. Observe the pressure drop in FP and BP for three minutes. The
leakage rate in the FP and BP should not be more than
0.2 Kg/cm2 in one minute in FP
0.2 Kg/cm2 in one minute in BP for coaching
stock
0.1 Kg/cm2 in one minute in BP for goods
stock

2. BC filling time.
a. Charge the system fully
b. Bring the A-9 valve to full service application position.
c. Observe the BC pressure.
d. The BC pressure should reach to 3.6 Kg/cm2 within
e. Observe the maximum pressure. It should be 3.8 Kg/cm2.
3 to 5 seconds for Coaching stock
18 to 30 seconds for Goods stock.
3. BC releasing time:
a. Bring the A-9 valve to release position.
b. Observe the BC pressure.
c. The BC should drop from 3.8 Kg/cm2 to 0.4 Kg/cm2 within
15 to 20 seconds for Coaching stock
45 to 60 seconds for Goods stock.

4. Sensitivity test:
a. Wait for 6 seconds and reduce the BP pressure by 0.6 Kg/cm2 in 6
sec
b. Observe the Brake cylinder. The brake should be in applied
condition.
5. Insensitivity test:
a. Wait for 60 seconds and reduce the BP pressure 0.3 Kg/cm2 in 60
seconds
b. Observe the Brake cylinder. The brake should not be in applied
condition.
c. Observe the BP and CR pressure. Both should be at 4.7 Kg/cm2
6. Emergency Application Test:
a. Charge the system fully.
b. Observe the Brake cylinder pressure. The maximum BC should be
3.8Kg/cm2.
7. Piston stroke:
After the emergency or full service application measure the piston
stroke. It should be within
90 ± 10 mm for coaching stock
85 ± 10 mm for goods stock –Empty
130 ± 10 mm for goods stock - load
25 to 32 mm for BMBC

8. Leakage in BC:
a. After the emergency brake application observe the leakage in the
Brake cylinder.
b. The leakage in the BC should not be more than 0.1 KG/cm2 in 5
minutes.

9. Working of PEASD:
[Link] the system fully.
[Link] the alarm chain from inside the coach.
c. Observe the BP pressure and BC.
d. BP pressure should drop and brake should apply.
e. Reset the PEASD.
f. Observe the BP pressure and BC.
g. BP pressure should reach to 5 KG/cm2 and brake also should
release.

10. Working of GEV (Guard Emergency Valve):


a. Charge the system fully.
b. Operate the GEV handle.
c. Observe the BP pressure and BC.
d. BP pressure should drop and brake should apply.
e. Bring back the GEV to normal position.
f. Observe the BP pressure and BC.
g. BP pressure should reach to 5 KG/cm2 and brake also should
release.

[Link] RELEASE TEST.


a. Disconnect the test rig from the rolling stock.
b. Pull the release valve handle.
c. Observe the CR pressure and BC.
d. The CR pressure should drop to 0 KG/cm2 and Brake should release without any
jerks.

Common questions

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In the Brake Cylinder releasing time test, the A-9 valve is brought to the release position, and the BC pressure should drop from 3.8 Kg/cm2 to 0.4 Kg/cm2 within 15 to 20 seconds for coaching stock .

In a manual release test, after disconnecting the test rig and pulling the release valve handle, the CR pressure should drop to 0 Kg/cm2 and the brake should release without any jerks .

An insensitivity test checks whether a small reduction in brake pipe pressure affects the brake application. After reducing the BP pressure by 0.3 Kg/cm2 over 60 seconds, the brake cylinder should not be in the applied condition, and both BP and CR pressures should remain at 4.7 Kg/cm2 .

To test the Guard Emergency Valve (GEV), the system is fully charged, and the GEV handle is operated to observe a drop in BP pressure and application of the brake. Once the GEV is returned to its normal position, the BP pressure should reach 5 Kg/cm2, facilitating brake release .

The graduated release test checks that brakes gradually release pressure as expected. The procedure would examine system response increments and verify correct proportional reductions in brake cylinder pressure .

In the emergency application test, the system is fully charged, and the maximum pressure in the brake cylinder should be observed to reach 3.8 Kg/cm2, indicating a proper emergency brake application .

In the sensitivity test, after waiting for 6 seconds, the brake pipe pressure is reduced by 0.6 Kg/cm2 in 6 seconds. The brake cylinder should be observed to be in the applied condition if the sensitivity is correct .

The acceptable leakage rate in the feed pipe (FP) and brake pipe (BP) for coaching stock is not more than 0.2 Kg/cm2 in one minute .

Piston stroke is measured after an emergency or full service application. The acceptable limits are 90 ± 10 mm for coaching stock, 85 ± 10 mm for goods stock when empty, 130 ± 10 mm for goods stock when loaded, and 25 to 32 mm for BMBC .

For coaching stock, the brake cylinder should fill and reach a pressure of 3.6 Kg/cm2 within 3 to 5 seconds, while for goods stock, it should reach this pressure within 18 to 30 seconds .

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