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    Brake System

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    riznknk
    This document discusses different types of brake systems used in Indian locomotives. It describes air brake and vacuum brake systems, including the components and functioning of independent brake, proportionate brake, and brake pipe systems. Some key components discussed are the A9 automatic brake valve, SA9 independent brake valve, C2 relay valve, VA1B control valve, HS4 valve, and air flow indicator valve. The advantages of air brakes over vacuum brakes are also listed. The document provides information on the purpose and working of various valves that control brake applications and releases.

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    © All Rights Reserved
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    Brake System

    Uploaded by

    riznknk
    293 views33 pages
    This document discusses different types of brake systems used in Indian locomotives. It describes air brake and vacuum brake systems, including the components and functioning of independent brake, proportionate brake, and brake pipe systems. Some key components discussed are the A9 automatic brake valve, SA9 independent brake valve, C2 relay valve, VA1B control valve, HS4 valve, and air flow indicator valve. The advantages of air brakes over vacuum brakes are also listed. The document provides information on the purpose and working of various valves that control brake applications and releases.

    Original Description:

    brake system of railways

    Original Title

    58977368 Brake System

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    © © All Rights Reserved

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    This document discusses different types of brake systems used in Indian locomotives. It describes air brake and vacuum brake systems, including the components and functioning of independent brake, proportionate brake, and brake pipe systems. Some key components discussed are the A9 automatic brake valve, SA9 independent brake valve, C2 relay valve, VA1B control valve, HS4 valve, and air flow indicator valve. The advantages of air brakes over vacuum brakes are also listed. The document provides information on the purpose and working of various valves that control brake applications and releases.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    293 views33 pages

    Brake System

    Uploaded by

    riznknk
    This document discusses different types of brake systems used in Indian locomotives. It describes air brake and vacuum brake systems, including the components and functioning of independent brake, proportionate brake, and brake pipe systems. Some key components discussed are the A9 automatic brake valve, SA9 independent brake valve, C2 relay valve, VA1B control valve, HS4 valve, and air flow indicator valve. The advantages of air brakes over vacuum brakes are also listed. The document provides information on the purpose and working of various valves that control brake applications and releases.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 33

    BRAKE SYSTEM

    BY:
    G.N.Singh,
    AP/DSL/IRIMEE

    TYPES
    TYPE

    LOCO
    BRAKE

    TRAIN
    BRAKE

    DESIGNED
    BY

    FITTED IN

    28 LV1

    AIR

    VACUUM

    WABCO

    WDM2, YDM4,
    WDS5, WDS6

    28 LAV1

    AIR

    AIR & VACUUM

    WABCO

    WDM2A,
    WDM2C, WDP2,
    WDG2, WDP1

    KNORR

    AIR

    VACUUM

    M/s KNORR
    BREMSE,
    GERMANY

    WDM3, WDS4,
    ZDM3, WDS3

    IRAB

    AIR

    AIR

    RDSO

    WDM2C, WDP2,
    WDG2, WDM3C

    CCB

    AIR

    AIR

    KNOR BREMSE

    WDG4, WDP4

    ADVANTAGES OF AIR BR. OVER VAC BR.

    Easy to maintain
    Lesser weight
    Maint cost low (about I/5th of vac br. Stock)
    Pre departure delays less (about 50 to 60 secs vs 4 mins for vac. Br.)
    Possibility of longer train formation (about 2000 mtrs without pr. Drop in
    br.van) vs ( max. 600 mtrs long for vac train due to vac drop > 30% at
    br van)
    Brake power drop is negligible in every 400 kms for air brake train
    (significant in case of vac br. Stock)
    No brake fade in down grades due to inherent inexhaustibility ( in vac br
    stock it is significant and require additional loco in down grades)
    Braking distance is quite low (about 550 to 870 m at 75 kmph) vs In
    vacuum br. stock it is quite long (about 1150 to 1780 mtrs at 75 kmph)
    Percentage ineffectiveness is 10 times lesser than vacuum brake stock

    SUB SYSTEM

    Independent Brake System


    Vacuum Brake System
    Proportionate Brake System
    Brake Pipe System
    Feed Pipe System

    AIR BRAKE SYSTEM VALVES


    S.No.
    Description
    1. A9. Automatic Valve
    2. SA 9 Independent Brake Valve
    3. MU 2B
    4. F 1 Selector
    5. C2. W. or Additional C2. Valve

    Purpose
    Brake application for Loco as well as formations.
    Brake Application for Loco alone
    M.U. Operation, used as gate valve
    M.U. Operation, used as gate valve
    Feeding B. P. Pressure to the formation

    6.
    7.

    24 A. Double Check Valve


    C3. W. Distributor Valve

    This will allow only one operation at a time.


    Proportionate Brake valve application during A9. application.

    8.

    C2. Relay Valve

    9.
    10.
    11.
    12.

    Pressure Switch
    D1. Emergency Valve
    D1. Pilot air valve
    Pressure Limiting Valve

    13. M. R. Safety Valve


    14. Duplex Check Valve
    (6 kg / Cm2 )
    15. D 24 Feed Valve

    For Locomotive Brake.


    Loco will be brought to idle during A9 emergency application.
    For Emergency brake application.
    During Dynamic brake Loco brake will be released.
    Pilot air to C2.Relay valve for synchronized brake application
    is Limited to 2.5 kg / Cm2
    When M. R. Pressure goes beyond 10.5 kg / Cm2 This valve
    will operate and release excess pressure from MR.
    This valve will connect MR1 with feed valve when MR
    pressure exceeds 6 kg / Cm2
    For Feed pipe Pr: 6 kg / Cm2.

    INDEPENDENT BRAKE SYSTEM

    SA 9

    MU2B

    30

    20

    20

    2
    DOUBLE
    CHECK
    VALVE

    Brake
    application
    through A9
    2 C2 RELAY
    VALVE
    1
    2

    MR LINE

    INDEPENDENT BRAKE APPLICATION

    Brake Cylinder

    INDEPENDENT BRAKE SYSTEM


    Independent Brake/loco Brake handle (SA9) has 3 position
    Application, Release , Quick release.
    When (SA9) handle is brought in application position,SA9 port 30
    connects port 20 and starts supplying pilot air to C2-Relay air valve.
    The pilot air passes through MU2B Valve port no. 2 & 20 and
    inters to C2-Relay at port no.2.
    The pilot air pressure depends upon the handle position; in full
    application it is 3.5kg/cm2. The C2-relay air valve actuates after
    getting pilot air and connects MR pressure to brake cylinders of
    locomotive through port no.1 & 3.
    The brake cylinder pressure depends upon pilot air pressure,
    supplied into C2-Relay chamber through port no.2.
    The locomotive brake can be graduated on and off with either the
    automatic (A9) or the independent brake valves (SA9). It is always
    possible to release the locomotive brakes with the SA9 valve. Gauge
    line connection is taken from BC pipe near front truck of locomotive
    to the drivers control stand for indicating brake cylinder pressure.

    INDEPENDENT BRAKE SYSTEM

    MU2B
    SA 9

    Brake
    application
    through A9

    DOUBLE
    CHECK
    VALVE
    C2 RELAY
    VALVE

    Brake Cylinder

    MR LINE

    INDEPENDENT BRAKE RELEASE

    INDEPENDENT BRAKE SYSTEM LAYOUT

    BC
    GAUGE

    MR
    GAUGE

    MR
    GAUGE

    BC
    GAUGE

    SA9

    MU2B

    SA 9

    20

    30

    30
    DCV

    20

    DCV
    FROM
    A9
    30
    14

    3
    EXH

    20
    F1
    SELECTOR
    VALVE

    C 2 RELAY
    VALVE

    2
    BC EQ. PIPE

    BC . PIPE
    JFIL
    TE
    R

    MR 2

    SA 9 INDEPENDENT BRAKE VALVE


    The SA9 Independent Brake Valve
    maintains 3.5kg/cm2-air pressure in the
    independent brake system against
    normal leakage through C2-Relay valve.
    It is suppose to maintain graduated
    application and release according to its
    handle position.
    The SA9 Independent Brake
    Valve consists of a selflapping
    regulating portion, which supplies or
    exhausts air pressure for piloting the
    graduated application or release of brake
    cylinder pressure on the locomotive.
    This brake valve also includes a quick
    release valve.

    C2 RELAY VALVE
    The C-2 Relay Valve is a
    diaphragm operated, self-lapping
    valve which functions to supply
    and exhaust brake cylinder air
    pressure during brake applications
    and release.
    The C2-Relay valve maintains
    3.5kg/cm2-air pressure in
    locomotive brake system against
    normal leakage.

    VACUUM BRAKE RELEASE POSITION


    TO ATMOSPHERE
    VA1B
    CONTROL
    VALVE
    TO EXHAUSTER

    A 9 AUTOMATIC
    BRAKE VALVE

    PROTECTION VALVE

    MR PIPE
    BRAKE PIPE
    VAC TRAIN PIPE

    CONTROL AIR
    AT 24 PSI

    VACUUM BRAKE APPLICATION POSITION


    TO ATMOSPHERE

    TO EXHAUSTER

    A 9 AUTOMATIC
    BRAKE VALVE

    PROTECTION VALVE

    MR PIPE
    BRAKE PIPE
    VAC TRAIN PIPE

    CONTROL AIR AT
    24 PSI

    VACUUM BRAKE SYSTEM

    HS4
    BC

    BP

    MR

    HS4 VALVE
    MU2B

    A9
    30
    1
    5

    53

    63

    13

    ATM
    GD80D
    FILTER

    VA 1B
    VALVE

    3
    6
    2
    1

    TO EXPR

    2 CHECK VALVE
    VAI RELEASE VALVE

    COC

    FROM
    MR 2

    GD 80 E FILTER

    H FILTER
    BRAKE PIPE
    MR EQ. PIPE
    BC EQ. PIPE
    VAC BR PIPE

    24 A D C VALVE
    FROM A1 DIFF
    PILOT AIR VALVE

    Test of VAC Brake Train

    1. BLOCKAGE TEST:
    Remove one end of the vacuum hose pipe and raise it upwards.
    If
    more than 8cm vacuum is created, there is a blockage in the
    system.
    2. EFFICIENCY TEST:
    Against an 8 mm leak disc, the loco should create 53 cm
    vacuum.
    3. LEAKAGE TEST:
    Vacuum on dummy and on leak disc should not vary more than 3
    cm.
    The Board has therefore standardized the vacuum level in engine and brake van for all Railways in
    both the traction.
    Type of service

    Engine

    Brake van

    M/E

    53

    47

    Passenger

    50

    44

    47

    Goods

    46

    38

    42

    Average
    50

    (A9) AUTOMATIC BRAKE VALVE


    The A-9 Automatic Brake Valve is a
    compact, self-lapping, pressure
    maintaining brake valve, which is
    capable of graduating the application or
    release of locomotive and train brakes.
    The A-9 Automatic Brake Valve has
    five positions: Release, Minimum
    Reduction, Full Service, Overreduction, and Emergency.
    The A9 maintains 5kg/cm2-air
    pressure in B.P System against normal
    leakage at its release position.
    It also maintains air pressure drop in
    the system according to its handle
    position.

    VA1B CONTROLVALVE
    VA1B control valve is deployed in vacuum
    brake system to apply and release the train brake.
    The VA1B Control valve is a very sensitive
    valve, which works on two deferent pressure
    5kg/cm2 & 1.7 kg/cm2 and controls the vacuum
    of train pipe.
    It connects the train pipe to atmosphere or
    exhauster as per variation in BP pressure.
    It helps to operate the train vacuum brakes.
    This valve also acts as a pilot to operate the
    locomotive air brake through proportionate brake
    valve.
    It has six pipe connections
    3 Brake Pipe pressure
    6 Vacuum train pipe
    2 --Vacuum train pipe
    1 Vacuum Control pipe
    7 Vacuum Reservoir Pipe to exhauster
    8 Atmosphere through GD-80 filter

    HS 4 VALVE
    The HS4 control air valve delivers a
    constant, uniform, predetermined air
    pressure.
    It serves to regulate the operation of
    another device in the system.
    In addition, the air delivered through
    the valve may be used to operate
    auxiliary devices.
    HS4 valve is provided to supply
    constant air pressure to bottom
    chamber of VA1B control valve. It is
    adjusted at 1.7kg/cm2.

    PROPORTIONATE BRAKE APPLICATION

    TO ATMOSPHERE
    VA1B
    CONTROL
    VALVE

    TO
    EXHAUSTER
    A 9 AUTOMATIC
    BRAKE VALVE

    PROTECTION
    VALVE
    28 VB
    VALVE

    C2 RELAY

    MR PIPE
    BRAKE PIPE
    VAC TRAIN PIPE

    BR. CYL

    PROPORTIONATE BRAKE RELEASE

    TO ATMOSPHERE

    VA1B
    CONTROL
    VALVE

    TO EXHAUSTER
    A 9 AUTOMATIC
    BRAKE VALVE

    CONTROL AIR AT
    24 PSI

    PROTECTION
    VALVE
    28 VB
    VALVE

    C2 RELAY

    MR PIPE
    BRAKE PIPE
    VAC TRAIN PIPE

    BR. CYL

    PROPORTIONATE BRAKE SYSTEM

    MU2B

    SA9

    1
    30

    FOR IND. BR.APPLICATION

    20

    28 VB VALVE
    N1 REDUCING
    VALVE

    30
    10

    COMBINED CUT OUT


    COCK & STRAINER

    16

    H FILTER
    4

    MR 2
    16

    FROM SA9
    DOUBLE CH
    VAL

    30
    14

    C2
    VALVE

    TO BR.CYL
    BR.PIPE
    MR EQ. PIPE
    BC EQ. PIPE

    VAC. RES
    800 cu
    inch
    VOL. RES
    90 cu
    inch

    RELAY

    F1 SEL.
    VALVE

    BRAKE PIPE SYSTEM


    AIR FLOW
    INDICATOR

    AIR FLOW
    INDICATOR

    BP

    HS4 VALVE
    A9

    BP
    MU2B

    A9
    30
    1
    5

    53

    63

    COC

    13

    COC

    R6
    VALVE

    C 2 RELAY
    VALVE

    1
    EXH
    3
    2

    AIR
    FLOW
    IND.
    VALVE

    BRAKE PIPE

    AUDIO VISUAL
    INDICATOR

    RESERVOIR
    MR2

    110 cu
    inch

    AIR FLOW INDICATOR VALVE


    The air flow measuring valve is
    suitable for use on locomotives that are
    equipped to operate trains fitted with
    28LAV1 brake system and is designed for
    fitting in the main air supply pipe.
    This valve indicates the leakage
    of BP pipe through an indicator in term of
    wagon.
    Indicator is provided on driving
    control stand so that Driver can watch easily.

    R6 VALVE
    R-6 Relay valve is a simple
    relay valve which provides air
    pressure in 1:1 ratio and is mounted
    just near the AFM valve. It is required
    because of long piping from the AFM
    valve to the indicator.
    This is a simple relay
    valve, which provides air pressure in
    1:1 ratio and mounted in between the
    indicator and the AFM valve. It is
    required because of long

    AIR FLOW INDICATOR


    It is a device through which BP (Air brake train ) leakage can be seen in the Drivers cabin.
    This gauge has two pointers Red & White. Red pointer is called reference pointer, which is
    attached to a knurled knob and protrudes through the dial glass, so that it can be set manually
    in any desired position,
    where as the other pointer moves on the scale depending up on the air flow.
    The indicator is connected to the measuring valve through R-6 relay valve.
    The scale on the gauge is calibrated not in the units of airflow but in numbers which
    normally indicates the number of wagons.
    The 60 marks correspond to the maximum rate of airflow that can be accepted to overcome
    leakage on a 60 wagon train.

    FEED PIPE SYSTEM


    FP
    GAUGE

    FP
    GAUGE

    COC

    7
    1a

    D 24 FEED
    VALVE

    DOUBLE CHECK
    VALVE

    20

    To port No 15
    F1 selector
    valve Selector
    valve
    SAFETY
    VALVE

    MR EQ
    PIPE

    FEED PIPE
    CHECK
    VALVE
    MR2

    MR1

    FEED VALVE

    The D24B Feed valve supplies and regulates air pressure to feed pipe system. It is
    connected from MR-1.
    In single pipe operation D24B Feed valve is isolated through a cut out cock.

    Testing of Brake system


    System Pressure:
    MR Pressure: 10.1 kg/kg/cm2
    Aux Pressure: 6 ..1 kg/cm2
    Limiting valve pressure(BC): 2.5 kg/cm2
    BP pressure: 5 kg/cm2
    FP pressure: 6 kg/cm2

    System Efficiency
    Initial charging from 0- 10 kg/cm2 at idle: 6 min (6 CD 4 UC)/
    3 min with 6 CD 3 UC

    Charging from 8 to10 kg/cm2 at idle: 60 secs (6 CD 4 UC)/


    35 secs (6 CD 3 UC)

    BP leakage:

    0.7 kg/cm2

    /5 min

    MR leakage (with A9 in emergency): 0.5 kg/cm2 /3 min


    MR leakage (with Ind Br on):

    0.6 kg/cm2

    /3 min

    Auto Br valve (A9)Test


    Full service application/ release:
    BP Pressure on FS application: 3.50.1 kg/cm2
    Time for BP to drop: 3 to 5 secs
    Time for BC to attain 2.5 kg/cm2:G/25 -30 secs, P/ 7- 10 secs
    Time for BP to charge (Loco): 2 to 4 secs
    Time for BP to charge (train with 59 wagons): 3 min
    Time for BC to drop from max to 0.4 kg/ cm2:

    G/40 -50 secs, P/ 15-20 secs

    Emergency application / Release:


    Time for BP to drop to 0: 1 to 2 secs
    BP charging time on release: 4 to 7 secs

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