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Government of India-Ministry of RailwaysResearch Designs & Standards Organisation

Lucknow - 226 011

No. SD. MISe. Eng. (Fire) Dated 30.09.2011.

CMPE/Diesel-All Zonal Railways.CWE-AII Zonal Railways.CME/DMW/PTA.CME/DLW.

Sub: Fire in Diesel Locomotives.Ref: Rly Bd's Letter No: 2004/M (L)/466/7101 dated 03.08.2011.

Vide letter under reference above, detailed feedback regarding prevention of fire(accident) measures taken by the Railways on Diesel Locomotives have been collected. Onthe basis of such feedback, an Instruction Bul/etin (IB) No: MP.IB.EN.01.03.11 dated26.09.11 has been prepared and herewith circulated to the Railways for implementationwith immediate effects.

The said IB has also been uploaded on the website: http://irdieselpower.in for easyavailability to the Railways, which may be accessed to as:

http://irdieselpower.in -7 Publications -7 ROSa Publications -7 Instruction Bulletins.(It is also mentioned that related references may also be accessed to through appropriatecategory of above-mentioned 'RDSa Publications').

DA: As above

Copy to:DMErrr/Rly Bd.

Government of IndiaMinistry of Railways

Research Designs and Standards OrganisationManak Napr, Lucknow - 226 011.

INSTRUCTION BUUEnN NO: MP.IB.EN.Ol.03.ll, dated 26.09.11.

1. TITLEImplementation of fire (accident) prevention measures on Diesel Locomotives of IR.

2. BACKGROUNDThe Diesel locomotives of IR have been broadly provided with mechanical and electricalequipment systems. Some cases of locomotive catching fire have been experienced whereinprimarily there has been generation and spreading of the unwanted fire in the locomotivecausing disruption and/or physical damage to the locomotive operation. Some of the causesbehind such cases are: leakages in fuel and lube pipeline, leakages in compressor and expressordelivery pipelines, absence of thermal insulation around exhaust manifold,unsecured/uncovered electrical wires/cables, poor cleanliness of the underframe etc. In order toavoid such cases of locomotive catching fire, preventive steps have, at times, been taken by theRailways depending upon the experience. Some examples of such preventive steps for Alcolocomotives are: Use of fire retardant Aeroquip hoses in fuel oil system, Use of flame retardantfluoroelastomer insulated main lead & brush gear connector cables in traction motors, thermalinsulation (lagging) of delivery pipings of expressor/compressor, Use of E-Beam irradiatedpolyolefin cables etc. In addition, Railways have put into action local TSOs, summer drives,special drives etc for prevention of the fire in Diesel Locomotives.

3. OBJECTIVEThe objective of this Instruction Bulletin (IB) is to standardize the fire prevention measures sothat the same may be implemented by the Railways in Diesel Locomotives in a uniform manner.

4. DETAILSOF STUDY DONEFeedback had been invited from the Railways on the fire prevention measures implemented.Such feedbacks received have been analyzed and suitably incorporated in framing this lB.

5. SCOPE OF APPUCAOON TO THE LOCOMOTIVESIn regard to the fire prevention measures from the viewpoint of the maintenance/repairs to betaken in the Diesel Locomotives, contained herein, it is mentioned that:

i. The equipments/parts/components/systems/subsystems etc may vary with theclass/type of the Diesel locomotives, and accordingly, the Railways may take necessaryaction regarding implementation of the fire prevention measures contained herein inorder to cover all the Diesel locomotives in service in IR.

li, The nature of maintenance/repair and the quantum of work involved may vary with themaintenance unit viz Satellite/Trip Shed, Diesel loco Shed, Repair Workshop, ProductionUnit etc in context of the Diesel locomotives of IR. Accordingly, the Railways maystreamline the fire prevention measures for application to the Diesel Locomotives.

iii. The fire prevention measures contained herein are applicable to the Diesel Locomotivesfrom the viewpoint of maintenance/repairs and are intended to supplement those whichare implemented by the Railways from the viewpoint of loco/train operation,

disaster/accident management etc in order to make the fire prevention measures moreeffective.

iv.. The fire prevention measures contained herein are based on the presumptions that: (a)The equipments/parts/components/systems/subsystems etc used in the Diesellocomotive are of standard design and have been procured from the approved sources,and, (b) The Standard Schedules of Maintenance are well in place in terms ofimplementation, and these measures are intended to strengthen/supplement the samein order to have 'more confirmatory' approach towards the fire prevention.

v. The fire prevention measures contained herein are not exhaustive. All additional possiblesteps may be taken by the Railways in order to prevent the fire (accident) cases.

Seen in the light of abovementioned points i, ii, iii, iv and v, this Instruction Bulletin is applicableto all Diesel locomotives of IR.

6. INSTRUcnON CONTENTThe following are the fire prevention measures to be implemented by the Railways in the Diesellocomotives:

6.1 Mechanical6.1.1 Engine System:

1. Ensuring no leakage of oils including fuel oil, lube oil etc.2. Connecting fuel leak off to drain gallery in all FIPsupports as applicable.3. Proper making of fuel jumper joints as applicable.4. Checking the traces of oil leakage over the engine and equipment room parts and

necessary corrective action thereupon.5. Use of fire retardant Aeroquip hoses in fuel oil system as per the instructions. (Reference:

item 11 (a) gWen herein)6. Ensuring proper condition of the hose pipes by means of regular checking/replacement

or otherwise.7. Ensuring proper maintenance of the crankcase vacuum.8. Jacketing of the fuel crossover hose pipe and proper securing of fuel/lube oil hose pipes

to avoid rubbing etc.9. Use of autofrettaged HPtubes as per instructions. (Reference: item 11 (b) gWen herein)10. Ensuring no leakage of exhaust gases from the manifold joints, cylinder head joints etc.11. Provision of thermal insulation (loco guard) over the exhaust manifold as per the

instructions. (Reference: item 11 (c) gWen herein)12. Ensuring timely checking of the filters including fuel filters, lube oil filters, carbody filters,

air intake filters etc and replacement of the same as per requirement.13. Ensuring proper cleaning of the heat exchangers including Turbo Aftercooler, lube oil

cooler etc.14. Fitment of water tank pressurization caps and ensuring proper working thereof.

(Reference: item 11 (d) gWen herein)15. Proper cleaning of water level gauge glass and regular checking of water level against

falling below alarming level.16. Ensuring fast cooling down time.17. Ensuring safe fuel transfer between the locomotives or even from locomotive to a

container.18. Proper cleaning and use of the indications of tell-tale devices meant to indicate the

condition of filters etc and corrective action thereupon.

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19. Proper cleaning of the complete floorings covering the engine and equipment room etcand cleaning of drain holes/pipes H' any.

6.L2 Expressor/Compressor Compartment:1. Ensuring proper loading/unloading time.2. Ensuring no leakage of oil in the compartment and no leakage of air in the pipelines.3. Use of thermal insulation/lagging on the delivery pipelines.4. Avoiding stagnation of oil/water and ensuring blockage free drains in the pit.5. Ensuring proper cleaning of the intercooler etc and confirming the working of the safety

valves.6. Proper fitment and regular cleaning of lube oil level indication glass and ensuring filling of

lubricant oil in proper quantity.6.1.3 Radiator Room: .

1. Ensuring no leakage of oil etc.2. Ensuring proper cleaning of the Radiators.3. Proper sealing of the Radiator room and fixing of the protective grill.4. Checking of RlTM bearings for abnormal sound/overheating! high temperature etc.5. Proper cleaning of the complete floorings and cleaning of drain holes/pipes.

6.1.4 Generator Compartment:1. Ensuring proper sealing of the partition between the Generator Room and Engine

Compartment.2. Ensuring dry and spillage free compartment.3. Ensuring proper quantity of oil filling and oil filling cap in place.4. Checking the condition of the filters for proper working.5. Ensuring timely checking of the carbody filters etc and replacement of the same as per

requirement.

6.2 Electrical1. Ensuring timely checking, proper cleaning and proper securing of the electrical

components including switches, circuit breakers, fuses, relays, grids, resistors, contactors,cards, wires, cables etc.

2. Ensuring that the circuit breakers are not bypassed.3. Timely checking of the electrical parameters including voltage, current, insulation

resistance (IR) etc wherever applicable and corrective action thereupon H' any.4. Checking the condition of carbon brushes, contact leads, terminal lugs etc and

replacement of the same if required.5. Regular checking of all the sensors including temperature sensors, pressure sensors,

speed sensors, voltage sensors, current sensors etc for proper working.6. Ensuring proper protection of the electrical machines including blowers, traction motors,

generator/alternator etc against ingress of foreign objects.7. Proper cleaning and sealing of the junction boxes, control cubicles etc against any ingress

of oils, water etc.8. Ensuring proper connections/contacts of the electrical circuit including proper conditions

of crimpings, lugs, thimbles, contacts etc.9. Checking the condition of flash guards and corrective action thereupon.10. Checking the condition of electrical wires, cables, leads etc with respect to: condition of

insulation, physical damage, signs of flashover, jacketing and securing, terminal contactsetc and corrective action thereupon.

11. Checking the condition of the bearings of rotating electrical machines with respect toabnormal sound, over heating etc and subsequent corrective action.

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12. Proper cleaning of the ducts meant for canying blower discharges for cooling of theTraction Motors.

13. Checking the condition of bellows meant for the cooling of Traction Motors and theinspection windows; and corrective action thereupon.

14. Checking the condition of fire alert system for proper working if fitted. (Reference: iteml1(e) given herein}

15. Checking the condition of batteries and ventilation holes of the battery boxes against anyabnormality.

16. Ensuring timely checking of the filters including carbody filters, dynacell filters etc andreplacement of the same as per requirement.

17. Use of approved fire resistant cables in control and power circuit as per the extantinstructions. (Reference: item l1(f) given herein)

18. Ensuring proper securing and protection of MUcouplers.

6.3 Driver Cabin1. Provision of vinyf flooring and maintenance of FRPControl Stand if fitted.2. Use of fire resistant cushion for driver seat.3. Ensure proper condition of sight glasses, window glasses, windows, doors etc.4. Ensuring proper cleaning of the cabin including the floorings and fitment of proper

rubber beading for sealing of the windows, doors etc.5. Maintaining proper condition of the markings for operation, indications, stencilings,

instructions etc at proper and prominent locations.6. Checking the condition of horn buttons, alerts, buzzers, ringing bells etc provided in the

cabin for proper working.7. Ensuring the steps viz training of crew regarding the use of fire extinguishers,

maintenance and provision of the fire extinguishers, updating of the instructions etc asimplemented by the Railways from the viewpoint of loco/train operation,disaster/accident management etc.

6.4 General1. Ensuring proper cleaning of the complete flooring (underframe) of the locomotive right

from one end to the other and cleaning of all the drain holes/pipes provided.2. Ensuring proper protection to the electrical equipments during washing of the

locomotive.3. Ensuring proper provision of the fillingcaps and securing thereof wherever required.4. Checking the condition of clearance between the brake blocks and wheel tread against

any rubbing in brake released position and corrective action thereupon.5. Ensuring proper working of the components of brake system including brake panel,

various valves, air dryers, safety valve, air flow indicator, drain valve, brake cylinderpiston travel etc.

6. Maintaining· proper condition of the markings for operation, indications, letterings,stencilings, instructions etc at proper and prominent locations of the locomotive.

7. Checking the condition of locomotive at the time of turn-out for the presence of anyunwanted materials particularly the combustible one and removal thereof.

8. Checking the condition of locomotive· at the time of turn-out for anyloose/hanging/sparking wire/cable etc and corrective action thereupon.

9. Ensuring proper working of the doors including engine flap doors, radiator room door,driver cabin door etc and also ensuring 'closed position' thereof during locomotive run.

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10. Checking the condition of locomotive at the time of tum-out for anydribbling/draining/leaking oils etc and corrective action thereupon.

11. Checking the undergear equipments induding gearcase etc for any leakage at the time oftum-out and corrective action thereupon.

12. Ensuring that the underframe drain-offs do not spread over the undergear equipments.

It is reiterated that the fire prevention measures contained herein are not exhaustive. Alladditional possible steps may be taken by the Railways depending upon the type of locomotive,local conditions etc in order to prevent the fire (accident) cases.

7. MATERIALS REQUIRED AND SOURCES OF SlIPPLYThe sources mentioned in RDSOVendor Directory No: VENDOR LIST - QMO/OOOl (latest)may be made use of as applicable.

8. ADDITIONAL INFORMATION (SPECIAL BENEFITS, FINANCIAL IMPUCATIONS etc.)Proper implementation of the fire prevention measures contained herein by the Railways isexpected to reduce the fire (accident) cases in Diesel locomotives of fR.

9. AGENCY AND SCHEDULE OF IMPLEMENTATIONAll Diesel Sheds, Repair Workshops and PUsof Indian Railways.

10. DISTRIBunoN AS PER THE ENClOSED USTCMPE (Diesel) of all Zonal Railways, CWEof all Zonal Railways, CME/DMW/PTA, CME/DlW.

11. IMPORTANT REFERENCES(a) Instruction Bulletin No.MP.lB.ES.OS.31.09 dated 12.05.2009.(b) Modification Sheet No. MP.MOD.ES.Ol.12.09, May, 2009.(c) Specification No. MP.0.2600.24 Rev-1, September, 2009.(d) Investigation Report No.MP-INV-34, June 2004.(e) Specification No. MP.0.2400.26 Rev-O.06,March, 2010(f) i. Specification No. MP.0.52.00.08 (Rev - 03) March 2008,

ii. MP.lB.EM.07.14.08 dated 25.04.2008iii. MP.lB.EM.02.03.08 dated 24.01.2008iv. MP.lB.EM.03.04.08 dated 24.01.2008

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