T HR RS 00500 ST - Locomotive Hauled Passenger Vehicle … · 2019. 5. 23. · 2.5 Wheel and axle assembly . Refer to ESR 0001 – 200, Section 6 (RSU 230) for common wheel and axle

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Technical Note TN 099 : 2014

Subject: Change of standard numbering from ESR 0001 – 500 to T HR RS 00500 ST

Issued date 19 December 2014 Effective date 19 December 2014

For queries regarding this document [email protected]

www.asa.transport.nsw.gov.au

This Technical Note is to advise the change to the standard numbering for ESR 0001 - 500

Minimum Operating Standards for Rolling Stock – Locomotive Hauled Passenger Vehicle

Specific Interface Standards.

This standard was previously numbered ESR 0001 – 500, it has now been updated with a

revised numbering of T HR RS 00500 ST.

The content of this standard remains unchanged.

The change to numbering is to ensure alignment with the remaining sections of the Minimum

Operating Standards for Rolling Stock.

Authorisation

Technical content prepared by

Checked and approved by

Interdisciplinary coordination checked by

Authorised for release

Signature

Name Jakub Zawada Michael Uhlig David Spiteri Graham Bradshaw

Position Principal Engineer, Rolling Stock Access Integrity

Lead Engineer, Rolling Stock

Chief Engineer Rail Principal Manager Network Standards & Services

Technical Note - T HR RS 00500 ST.doc Asset Standards Authority © State of NSW through Transport for NSW Page 1 of 1

mailto:[email protected]

http://www.asa.transport.nsw.gov.au/

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RSU 500 - MINIMUM OPERATING STANDARDS FOR ROLLING STOCK

- LOCOMOTIVE HAULED PASSENGER VEHICLE SPECIFIC

INTERFACE STANDARDS

ESR 0001-500

Engineering Standard Rolling Stock

Version 1.3

Issued June 2013

Owner: Chief Engineer Rolling Stock

Approved Stephen White, Authorised Michael Uhlig, by: A/Manager, by: A/Chief Engineer Rolling Stock

Rolling Stock Access Integrity

Disclaimer This document was prepared for use on the RailCorp Network only. RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by RailCorp. RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes any liability which arises in any manner by the use of this document. Copyright The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of RailCorp.

UNCONTROLLED WHEN PRINTED Page 1 of 20

RailCorp Engineering Standard — Rolling Stock RSU 500 - Minimum Operating Standards for Rolling Stock - Locomotive Hauled Passenger Vehicle Specific Interface Standards ESR 0001-500

© Rail Corporation Page 2 of 20 Issued June 2013 UNCONTROLLED WHEN PRINTED Version 1.3

Document control

Revision Date Summary of change Reformatted and renumbered ESR – 500. All locomotive

1.0 June 2010 hauled passenger vehicle specific RSUs (RSU 500 to RSU 542) have been combined into one document.

1.1 Draft A November 2010 Reference & total ride index formula corrected 1.1 Draft B February 2011 Coupling hose receptacles added, type corrected 1.1 February 2011 Issued 1.1 Draft B February 2011 Coupling hose receptacles added, type corrected 1.1 February 2011 Issued 1.2 November 2011 Issued 1.3 June 2013 Issued

Summary of changes from previous version

Summary of change Section 1.1 Draft A Reference corrected 4.7 Formula for Total Ride Index corrected 7.4 1.1 Draft B Coupling hose receptacles added 3.7 Type “locomotive hauled passenger vehicles” was “locomotives” 5.2 Draft 1.2 “locomotives” amended to read “cars” 3.7 Requirement for collision protection added 4.2.3 Reference to AS 7531 replaced with ESR 0001 – I (RSU Appendix I) 4.6.2 New section on fire resistance added 4.9 Requirement for tail lights added 4.10 Draft 1.3 Minor reformatting ITSR amended to read ONRSR 1.2 The relationship with the Australian Standards for Rolling Stock further defined 1.5 Requirements for the maintenance of tail lights added 4.11

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Contents

1 Introduction RSU 500........................................................................................................................5 1.1 Introduction ...............................................................................................................................5 1.2 Scope ........................................................................................................................................5 1.3 Purpose.....................................................................................................................................5 1.4 Application.................................................................................................................................5 1.5 Referenced Documents ............................................................................................................6 1.6 Australian Standards for Railway Rolling Stock........................................................................6 1.7 Authorisation of vehicles ...........................................................................................................6

2 Bogie components RSU 510 ............................................................................................................7 2.1 Introduction ...............................................................................................................................7 2.2 Wheels ......................................................................................................................................7 2.3 Wheel profiles ...........................................................................................................................7 2.4 Axles..........................................................................................................................................7 2.5 Wheel and axle assembly .........................................................................................................7 2.6 Axle bearing assemblies ...........................................................................................................7 2.7 Bogie frames and associated componentry..............................................................................7 2.8 Vehicle suspension ...................................................................................................................7

3 Brakes and pneumatic equipment RSU 520...................................................................................8 3.1 Introduction ...............................................................................................................................8 3.2 General requirements ...............................................................................................................8 3.3 Location of end equipment........................................................................................................8 3.4 Standard pressures and timings ...............................................................................................8 3.5 Brake equipment .......................................................................................................................9 3.6 Identification of cocks................................................................................................................9 3.7 Dummy couplers .....................................................................................................................10

4 Body, underframe and appointments RSU 530............................................................................11 4.1 Introduction .............................................................................................................................11 4.2 Design loads and stresses......................................................................................................11

4.2.1 Structure.....................................................................................................................11 4.2.2 Underframe ................................................................................................................11 4.2.3 Collision protection .....................................................................................................12

4.3 Couplers and draftgear ...........................................................................................................12 4.4 Jacking and lifting points .........................................................................................................12 4.5 Doors.......................................................................................................................................13 4.6 Marking and identification .......................................................................................................13

4.6.1 Code & number ..........................................................................................................13 4.6.2 Reflective delineators .................................................................................................13 4.6.3 AEI tags......................................................................................................................13

4.7 Wooden bodied vehicles.........................................................................................................13 4.8 Toilets......................................................................................................................................13 4.9 Fire resistance.........................................................................................................................14 4.10 Tail lights .................................................................................................................................14

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4.11 Maintenance............................................................................................................................14 5 Vehicle performance RSU 540 .......................................................................................................15

5.1 Introduction .............................................................................................................................15 5.2 Test requirements summary ...................................................................................................15

5.2.1 Jacking point vertical load test. ..................................................................................16 5.2.2 Static end compression test .......................................................................................16 5.2.3 P2 force determination. ..............................................................................................16

6 Braking performance RSU 541 ......................................................................................................17 6.1 Introduction .............................................................................................................................17 6.2 Net brake ratio.........................................................................................................................17 6.3 Air brake..................................................................................................................................17 6.4 Spring parking brake or handbrake.........................................................................................18 6.5 Disc brakes .............................................................................................................................18 6.6 Single car air test ....................................................................................................................18

7 Vehicle ride performance RSU 542................................................................................................19 7.1 Introduction .............................................................................................................................19 7.2 Base ride performance requirements......................................................................................19 7.3 Recommended ride performance requirements .....................................................................19 7.4 Ride index algorithm ...............................................................................................................20

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1 Introduction RSU 500

1.1 Introduction RailCorp has established interface requirements pertaining to vehicles operating on the RailCorp network.

The 500 series of standards are part of the RailCorp Minimum Operating Standards for Rolling Stock. This series should be read in conjunction with the entire standard, which is made up of the following parts:

000 series General Requirements

100 series General Interface Requirements

200 series Common Interface Requirements

RSU Appendices

1.2 Scope The 500 series of Rolling Stock Units contain specific interface requirements for locomotive hauled passenger vehicles operating on the RailCorp network.

For the purposes of interpretation of this RSU, power cars used for propulsion and which do not carry passengers shall be treated as a locomotive and meet the requirements specified in the 300 series of Rolling Stock Units. Dedicated trailer cars which operate in conjunction with the above mentioned power cars shall be treated as locomotive hauled passenger cars and meet the requirements of the 500 series of Rolling Stock Units.

1.3 Purpose The purpose of these standards is to ensure that all rolling stock operating on the RailCorp network meet the minimum standards required by RailCorp’s accreditation with the Office of National Rail Safety Regulator (ONRSR).

1.4 Application The requirements of these standards will apply to all new, substantially modified vehicles and vehicles that have not operated on the RailCorp network. Older rolling stock that is operating on the RailCorp network as at August, 1997 may not fully comply with the requirements of these Units but will be assessed considering the design and proposed use of the vehicle(s).

In these standards, the terms “owner” and “operator’ are used. They refer to the owner of the rolling stock and the operator using that rolling stock. These may or may not be the same organisation.

When the words “shall” or “must” are used in this document, the requirements shall be read as mandatory for vehicles operating on the RailCorp network.

When the word “should” is used in this document, the requirements shall be read as recommended.

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When the word “may” is used in this document, the requirements shall be read as advisory.

1.5 Referenced Documents ROA Manual of Engineering Standards and Practices.

Australian Standards for Railway Rolling Stock

AS 7531 Lighting and Rolling Stock Visibility

RailCorp Train Operating Conditions manual TMR 001 – OS 001 IM

1.6 Australian Standards for Railway Rolling Stock Where the requirements of these standards differ from the requirements of the Australian Standards for Railway Rolling Stock, there will be a text box detailing the difference.

AS 75xx Differences between RailCorp Minimum Operating

Standards and the Australian Standards for Rolling Stock will be indicated in a box such as this.

For any vehicle to operate on the RailCorp network, the requirements of these standards will take precedence to the Australian Standards where there are conflicts in requirements.

As the RailCorp Minimum Operating Standards for Rolling Stock only specifies interface requirements, there are additional requirements specified in the Australian Standards for Railway Rolling Stock. All rolling stock should be manufactured to meet the additional requirements contained in Australian Standards for Railway Rolling Stock.

Note: The gap analysis of the RailCorp Minimum Operating Standards for Rolling Stock and the Australian Standards for Railway Rolling Stock is ongoing. As new Australian Standards for Railway Rolling Stock are published and as the gap analysis progresses, additional text boxes will be added to these standards.

1.7 Authorisation of vehicles For the assessment of locomotive hauled passenger vehicles to operate on the RailCorp network, the vehicle information pack in ESR 0001 – A3 (RSU Appendix A3) shall be completed and submitted.

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2 Bogie components RSU 510

2.1 Introduction This section contains bogie related requirements which are specific to locomotive hauled passenger vehicles.

All requirements in ESR 0001 – 200 (RSU 200 series) which are common requirements also apply to locomotive hauled passenger vehicles.

2.2 Wheels Refer to ESR 0001 – 200, Section 2 (RSU 210) for common wheel requirements.

• ESR 0001 – 200, Section 3 (RSU 211 Wheels, design & manufacture.

• ESR 0001 – 200, Section 4 (RSU 212) Wheels, minimum operational requirements.

2.3 Wheel profiles Refer to ESR 0001 – 200, Section 3.3.4 (RSU 221) for wheel profiles

2.4 Axles Refer to ESR 0001 – 200, Section 5 (RSU 220) for common axle requirements.

2.5 Wheel and axle assembly Refer to ESR 0001 – 200, Section 6 (RSU 230) for common wheel and axle assembly requirements.

2.6 Axle bearing assemblies Refer to ESR 0001 – 200, Section 7 (RSU 240) for common axle bearing assembly requirements.

2.7 Bogie frames and associated componentry Refer to ESR 0001 – 200, Section 8 (RSU 250) for common requirements for bogie frames and associated componentry.

2.8 Vehicle suspension Refer to ESR 0001 – 200, Section 9 (RSU 260) for common vehicle suspension requirements.

• ESR 0001 – 200, Section 10 (RSU 261) Suspension springs

• ESR 0001 – 200, Section 11 (RSU 262) Suspension damping

• ESR 0001 – 200, Section 12 (RSU 263) Resilient suspension components

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3 Brakes and pneumatic equipment RSU 520

3.1 Introduction The braking systems fitted to locomotive hauled passenger vehicles must be compatible with the brake systems on locomotives to ensure that the brakes apply and release as required. Otherwise skidded or scaled wheels could occur.

3.2 General requirements Locomotive hauled passenger vehicles shall generally comply with the following requirements:

The control valve should be of the diaphragm type with timings selected to suit passenger train service. The brake system may also incorporate gradual release, electro-pneumatic control, and control of the brake cylinder pressure by means of a relay valve.

[Reference: ROA Manual of Engineering Standards and Practices, Section 12.13]]

The control equipment shall be compatible in operation with existing equipment.

Some older vehicles may not fully comply with these requirements but will be assessed considering the brake equipment fitted and the proposed use of the vehicle.

Alternate brake systems, such as electronically controlled pneumatic (ECP) brake will be considered. Alternative brake systems must be failsafe.

3.3 Location of end equipment Terminal locomotive hauled passenger vehicles in fixed train consists and vehicles not in fixed train consists shall have coupling cocks located on the terminal ends as follows:-

• Brake pipe

The brake pipe coupling cocks shall be located as shown in ESR 0001 – G, Diagram G7 (RSU Appendix G) of this manual.

• Main reservoir pipe and independent brake control pipe (optional)

Main reservoir and independent brake control hoses and cocks shall be located such that they can couple to a locomotive or adjacent vehicle without causing damage or kinking hoses.

Vehicles not fitted with standard automatic couplers, shall have emergency couplers provided, with standard coupling hoses, which will couple with standard vehicles.

3.4 Standard pressures and timings Standard pressures shall comply with the following requirements:

The following data apply for a single vehicle:

• Brake pipe: 32 mm N.B. throughout the vehicle inclusive of end coupling cocks, hoses, coupling connections and bifurcations.

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• Brake pipe pressure: 500 kPa nominal.

• Brake cylinder diameter: 254 mm, 305 mm or according to bogie design.

• Brake cylinder pressure: nominal 350 kPa (loaded condition), design 380 kPa maximum,

• Braking ratio: As specified In Section 6 (RSU 541) of this standard.

• Brake cylinder piston travel requirements are as follows for underframe mounted brake cylinders.

Nominal operating: 100 mm

Design for reservoir volumes: 200 mm.

• Brake cylinder filling time from 0-275 kPa: 10-13 seconds.

• Charging time of auxiliary reservoir:

Initial filI: 0-400 kPa in 60 seconds,

Recharge: 250-450 kPa in 20-25 seconds.

• Accelerated release reservoir charging time:-

0-420 kPa in 180 seconds nominal.

• Supplementary reservoir charging time:

Initial fill: 100-110 seconds

• Propagation rate in a train:

Brake application: 250 m/s - minimum.

Brake release: 80 m/s - minimum,

• Inshot capability:

70 to 84 kPa brake cylinder pressure shall be obtained in 1.5 to 2 seconds after control valve operation.

[Reference: ROA Manual of Engineering Standards and Practices, Section 7.4.]

Performance requirements:

• Control valve performance shall comply with the requirements specified in the latest revision of the AAR. Manual of Standards, Section E, wherever applicable, except as specified above.

[Reference: ROA Manual of Engineering Standards and Practices, Section 7.4.]

3.5 Brake equipment Refer to ESR 0001 – 200, Section 15 (RSU 271) for common brake equipment.

3.6 Identification of cocks All cut-out or isolation cocks, operating handles and embossed letters of the air brake equipment shall be painted white. An inverted “U” or the word release shall be painted on the vehicle underframe on each side of the attachment of the release cable.

[Reference: ROA Manual of Engineering Standards and Practices, Section 7.5.10.]

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3.7 Dummy couplers All new cars shall be fitted with dummy couplings or coupling hose receptacles for all coupling hoses.

It is recommended that all existing cars be fitted with dummy couplings or coupling hose receptacles.

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4 Body, underframe and appointments RSU 530

4.1 Introduction Vehicle owners/operators shall have controlled rail industry accepted standards which govern the operation of a vehicle with a damaged body or structure.

Some earlier designs of passenger vehicles may not fully comply with these requirements but will be assessed considering the equipment fitted and the proposed use of the vehicle.

4.2 Design loads and stresses

4.2.1 Structure The structure of passenger vehicles shall be capable of sustaining repetitive longitudinal coupler forces of five (5) times the vehicle mass i.e. 5g, without fatigue damage occurring to the vehicle or the coupler. When loaded to its nominal capacity the structure of the vehicle shall be capable of withstanding the following forces applied through the centre-line of the coupler without exceeding the maximum stresses for the material as specified hereunder:

Force-kN Max. Stress Force type

3500 Ultimate High impact

2000 Yield Impact

+1000 Larger of 1/2 yield Steady force -1000 or 1/3 ultimate

Table 1- Design stresses

The steady force used in the above stress calculations shall not be less than the maximum combined tractive effort of the number of power units expected to be used for hauling the vehicle(s).

Vehicles shall be marshalled in trains so that the trailing load on any vehicle does not exceed the rated capacity of that vehicle's draft gear or underframe.

4.2.2 Underframe The underframe shall be designed to act in conjunction with the body structure in resisting the forces listed above.

Vertical anti-collision members shall be provided at each end of the vehicle. These members shall withstand, without permanent deformation, a longitudinal force of 540 kN applied at a point 1650 mm above rail level combined with a lateral force of 90 kN applied to diagonally opposite corners at the same height.

The longitudinal force applied to the ends of the vehicle shall be considered to be proportionately distributed to all longitudinal members according to area.

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Walls, partitions, fixtures and other interior and exterior fittings shall be designed and attached so as to withstand accelerations of 3 g laterally, 5 g longitudinally and 3 g vertically without failure of the component or fastenings.

[Reference: Section 12.2 of the ROA Manual of Engineering Standards and Practices]

4.2.3 Collision protection Anti-climbers shall be fitted to the ends of all cars other than those ends which are permanently or semi-permanently coupled in service; for those ends anti-climbers are recommended. Anti-climbers shall include horizontal bars which have the capacity to interlock and restrict relative vertical movement between adjacent cars in the event of longitudinal impacts causing the car ends to come into contact.

Operators shall specify their interlocking requirements, including bar size, protrusion, spacing and height above rail level.

Anti-climbers should consist of not less than three (3) steel shelves or bars, spaced 55-60 mm apart and where possible should extend across the full width of the car body structure. Each bar should be not less than 12 mm thick and protrude 50 mm. The height above rail shall match that of other vehicles with which the car(s) is likely to operate.

Anti-climbers shall be capable of withstanding a minimum vertical load of 200 kN (applied upwards and downwards individually) without exceeding the yield stress of the material used. The force shall be applied under the anti-climbers, centrally and uniformly between the centre sill webs.

4.3 Couplers and draftgear Automatic couplers and draftgear shall comply with the requirements specified in ESR 0001 – 100, Section 5 (RSU 140).

Coupler heights shall be within the following limits:

• New condition 890 to 900 mm.

• In service condition 875 to 915 mm.

4.4 Jacking and lifting points Suitable jacking points shall be supplied at the junction of the underframe side sill and the bolster adjacent to each bogie centre and also under the drawgear pocket.

[Reference: ROA Manual of Engineering Standards and Practices, Section 8.2.13.]

Vehicles shall have suitable lifting points or brackets to insert lifting hooks and shackles.

The lifting brackets shall consist of pairs of vertical plates preferably mounted at the ends of the body bolsters and located to align with bolster web plates. Features to be incorporated in each lifting bracket are shown in ESR 0001 – 100, Section 8 Diagram 21 (RSU 170)

[Reference: ROA Manual of Engineering Standards and Practices, Section 8.2.14]

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4.5 Doors Passenger entry doors shall be fitted with a positive latching system to prevent doors being opened accidentally whilst train is in motion.

Hinged doors must not open outward.

4.6 Marking and identification

4.6.1 Code & number Each locomotive hauled passenger vehicle shall have a unique identification code/number clearly marked on each side of the vehicle.

The vehicle code and number shall be readable from trackside, on station platforms and from signal boxes.

4.6.2 Reflective delineators To enhance visibility of passenger vehicles from the side at level crossings, all passenger vehicles shall be fitted with reflective delineators (reflectors) in accordance with ESR 0001 – I (RSU Appendix I).

4.6.3 AEI tags All locomotive hauled passenger vehicles shall be fitted with standard AEI tags as specified in ESR 0001 – H (RSU Appendix H).

Reuse of used AEI tags is not permitted

4.7 Wooden bodied vehicles Wooden bodied vehicles shall be fitted with approved steel collision posts at each end of the underframe to provide protection against vehicle over riding and/or telescoping in the event of a collision. Refer to clause 4.2.2.

Where possible it is recommended that double shelf couplers be provided as added protection against vehicle over riding and/or telescoping in the event of a collision

Any wooden bodied terminal vehicle carrying passengers but not fitted with the above collision protection will only be permitted to move on the RailCorp network under complete block working in accordance with Network Rule NSY 512 Manual Block Working. If the wooden bodied terminal vehicle is not carrying passengers then the train is not restricted to manual block working.

4.8 Toilets Toilet facilities on passenger vehicles shall have holding tanks and decanting facilities.

Refer to ESR 0001 – 100, Section 6.6 (RSU 150).

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4.9 Fire resistance Consideration shall be given to limit the fire resistance, flammability & toxicity properties for materials used in the construction of rolling stock.

Note: This requirement is to limit the spread of fire/smoke/fumes initiating on a train/vehicle to the infrastructure (stations, buildings or other rolling stock) or personnel in the vicinity of the railway line.

4.10 Tail lights Each locomotive hauled passenger car shall be fitted with tail lights as detailed below:

• A red tail light fitted at any trailing end.

• A red tail light shall be fitted as high and wide as practical, at both sides of each end.

• Each tail light shall have a luminous intensity of at least 0.75 candela.

4.11 Maintenance The operation of tail lights is critical to the safe operation of trains.

Accordingly, all globes and lenses shall be inspected and maintained to ensure their operation as specified above.

AS 7531 AS 7531 specifies normal interior lighting, emergency interior lighting,

access lighting and coupler lighting. Because ESR 0001 is an interface standard for access onto the RailCorp

network, these types of lights are not specified in this document.

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5 Vehicle performance RSU 540

5.1 Introduction The performance specified in this Unit relates to the operation of the locomotive hauled passenger vehicle on the RailCorp network

5.2 Test requirements summary The following table summarises the test requirements for locomotive hauled passenger vehicles.

The following table summarises the test requirements for locomotive hauled passenger vehicles

Compatibility test References standards

in other Referencesthis standard

in

Static rolling stock outline test ESR 0001 – 200, Section 19 (RSU 281)

Static vehicle weigh test ESR 0001 – 200, Section 20 (RSU 282)

Static vehicle twist test ESR 0001 – 200, Section 21 (RSU 283)

Vehicle/bogie swing test ESR 0001 – 200, Section 22 (RSU 284)

Vehicle/vehicle swing test ESR 0001 – 200, Section 23 (RSU 285)

Static brake test ESR 0001 – 200, Section 24 (RSU 286)

Section 6 (RSU 541)

Ride performance test ESR 0001 – 200, Section 26 (RSU 288)

Section 7 (RSU 542)

Kinematic rolling stock outline test ESR 0001 – 200, Section 27 (RSU 289)

see note below

Pitch & bounce test ESR 0001 – 200, Section 28 (RSU 290)

Environmental tests ESR 0001 – 200, Section 29 (RSU 292)

Electrical safety inspection ESR 0001 – 200, Section 31 (RSU 294)

Fitment of AEI tags ESR 0001 – 200, Section 31 (& Appendix H)

Section 4.6 (RSU 530)

Fitment of reflective delineators Section 4.6 (RSU 530)

Table 2 - Test requirements

Refer to ESR 0001 – 200, Section 18 (RSU 280) for sequencing of tests, and requirements for the movement of vehicles and for conducting dynamic tests.

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5.2.1 Jacking point vertical load test. It is recommended that the owner/operator conduct jacking point vertical load tests to ensure that the vehicle is capable of withstanding loads imposed during vehicle recovery.

Refer to ESR 0001 – 200, Section 34 (RSU 297) Vehicle structural tests.

5.2.2 Static end compression test It is recommended that the owner/operator conduct a static end compression test to ensure that the vehicle is capable of withstanding the loads imposed during operation. Loads shall be commensurate with the proposed maximum duty of the vehicle.

Refer to ESR 0001 – 200, Section 34 (RSU 297) Vehicle structural tests.

5.2.3 P2 force determination. The P2 force shall not exceed the limits specified in ESR 0001 – 100, Section 3 (RSU 120).

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6 Braking performance RSU 541

6.1 Introduction Braking performance is specified to ensure that locomotive hauled passenger trains are able to stop within the current signalling system spacings.

Refer to ESR 001 – 100 Section 7 (RSU 160)

6.2 Net brake ratio The net brake ratio is the ratio of the sum of the actual measured brake block forces in kilograms divided by the total vehicle mass at rail, in kilograms. The net brake ratio is only applicable to vehicles fitted with tread brakes.

Brake block forces are measured for a brake pipe reduction of 150 kPa. When measuring the brake block forces for the air brake, the rigging pins shall be tapped with a hammer to overcome static friction of the brake rigging.

Handbrake forces are measured at the brake block with a 560 Newton tangential force applied to the rim of the handbrake wheel, or the handbrake arm. When measuring the brake block forces for the handbrake or spring parking brake, the rigging pins must not be tapped.

6.3 Air brake The following net brake ratios are mandatory in order to provide effective braking without skidding the wheels.

Brake block type Vehicle condition Net brake ratio

Low friction composite Tare or empty 55 % maximum

Fully loaded 28 % minimum

Medium friction composite Tare or empty 55 % maximum


High friction composite Tare or empty 35 % maximum


Cast iron Tare or empty 55 % maximum


Table 3 - Brake percentages for air brake

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6.4 Spring parking brake or handbrake The spring parking or handbrakes shall be able to hold the loaded vehicle on a 1 in 30 grade indefinitely.

The following net brake ratios are recommended in order to provide an effective parking brake

Brake block type Vehicle condition Net brake ratio

Low friction composite Fully loaded 28 % minimum

Medium friction composite Fully loaded 20 % minimum

High friction composite Fully loaded 13 % minimum

Cast Iron Fully loaded 13 % minimum

Table 4 - Brake percentages for parking brake

6.5 Disc brakes For vehicles fitted with disc brakes, the vehicle shall be tested in a train consist for stopping distance. Refer to ESR 0001 – 100, Section 7.4 (RSU 160)

6.6 Single car air test Each locomotive hauled vehicle shall have a single car air test carried out prior to entering service. Refer to ESR 0001 – 200, Section 24.4 (RSU 286).

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7 Vehicle ride performance RSU 542

7.1 Introduction The following bogie related performance parameters are the minimum requirement for the operation of locomotive hauled passenger cars on the RailCorp network.

7.2 Base ride performance requirements The base ride performance requirements are as specified for all vehicles in ESR 0001 – 200, Section 26 (RSU 288).

For bogies equipped with air springs, the base ride performance also applies for vehicles with deflated air springs. A reduction in maximum permissible operating speed may be required to achieve this for operation with deflated air springs.

7.3 Recommended ride performance requirements In the interests of passenger/crew comfort and safety, the ride quality specified below is recommended.

Speed (km/h) Vertical Ride Index Lateral Ride Index

Maximum design speed 2.8 2.8

Table 5 - Ride indices [Reference: ROA Manual of Engineering Standards and Practices Section 12.10]

These ride index values are recommended for wheel profiles up to the fully worn condition.

Sustained hunting shall not be permitted. Hunting shall be defined as sinusoidal lateral oscillations of the wheelset resulting in greater than 0.5 Hz sinusoidal lateral body accelerations measured at the bogie centre of greater than 0.15 g sustained for 10 seconds or longer.

The recommended ride performance requirements are in addition to the base ride performance requirements.

For bogies equipped with air springs, the above ride performance also applies for vehicles with deflated air springs. A reduction in maximum permissible operating speed may be required to achieve this for operation with deflated air springs.

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7.4 Ride index algorithm The ride index algorithm is implemented as follows: Acceleration data is weighted by the function:

Ri = 7.07 (Vi)0.1

where the i-th value refers to the peak amplitude of a frequency component derived from an FFT analyser.

The function Vi is defined as follows:

Frequency Range Vi Vi (Hz) (Vertical) (Lateral)

0 – 6 0.32 fa3 4.32 a3

6 – 20 400 a3 / f3 650 a3 / f3 20+ a3 / f a3 / f

Table 6 where f = frequency, (Hz), a = amplitude, g peak (1 g = 9.81 m/s2)

The total ride index is calculated from the i values by:

RItotal = [∑ (RIi)10]0.1i=ni=1

Notes:

1. Frequency analysis will utilise FFT analysis of at least 400 lines with 0.25 Hz resolution. Data shall be averaged over 32 averages to minimise statistical error. 16 averages is acceptable for comparative evaluations only.

2. Analysis shall be restricted to the 0.5 to 50 Hz band. 3. Weighting filters implementing the above weightings are acceptable provided:

– integration is performed over 10-15 second periods.

– the Integrated values are recorded over at least 3 km of track and reported as a mean and sample variance.

4. Data for analysis shall come from samples at substantially constant speed (variance ± 5 km/h).

[Reference: ROA Manual of Engineering Standards and Practices, Section 13.4.2]

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