TB 10029-2009 English PDF (TB10029-2009)

In order to improve the servicing quality of railway passenger cars, ensure the safety of passenger cars, unify the technical standards for the design of passenger car rolling stock facilities, make the design of passenger car rolling stock facilities to be technologically advanced, economical and reasonable, safe and applicable, this code is hereby formulated.

TB 10029-2009
TB
INDUSTRY STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
UDC
P TB 10029-2009
J 165-2009
Code for design of railway passenger car rolling stock
facilities
ISSUED ON: JULY 01, 2009
IMPLEMENTED ON: JULY 06, 2009
Issued by: Ministry of Railway of PRC
INDUSTRY STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
Code for design of railway passenger car rolling stock
facilities
J 165-2009
Main drafting organization: China Railway Second Engineering Group Co., Ltd. Participating drafting organization: The Third Railway Survey and Design Institute Group Co., Ltd.
Effective date: July 6, 2009
2009 • Beijing
Table of Contents
Foreword ... 6
1 General ... 8
2 Terms ... 9
3 Passenger car rolling stock depot ... 11
3.1 General rules ... 11
3.2 Selection of passenger car depot site ... 12
3.3 Scale of the passenger car rolling stock depot ... 12
3.4 General layout of the passenger car depot ... 13
3.5 Repair garage ... 16
3.6 Paint warehouse... 18
3.7 Bogie room ... 18
3.8 Axle room ... 20
3.9 Wheel shed ... 21
3.10 Rolling bearing room ... 21
3.11 Accessory repairing center ... 22
3.12 Servicing workshop for passenger car's air-conditioning units ... 23 3.13 Hook buffer room ... 23
3.14 Electrical and electronic servicing workshop ... 24
3.15 Brake room ... 25
3.16 Other servicing workshops ... 25
3.17 Laboratory ... 26
3.18 Metering room ... 26
3.19 Equipment servicing room ... 27
3.20 Boiler room ... 28
3.21 Compressed air station ... 28
3.23 Material warehouse ... 29
3.24 Transportation equipment... 30
4 Passenger car technical servicing depot ... 31
4.1 General rules ... 31
4.2 Location and general layout of passenger car technical servicing depot ... 32 4.3 Line layout and main facilities on the line group ... 33
4.4 Repairing workshop... 38
4.5 Power facilities ... 43
4.6 Material warehouse and garage ... 43
4.7 Oil depot ... 44
5 Passenger car inspection department ... 45
6 Information system ... 46
6.1 General ... 46
6.2 System composition and function ... 46
6.3 Network design... 47
6.4 System software and hardware configuration ... 48
6.5 Others ... 49
Explanation of wording in this code ... 50
Code for design of railway passenger car rolling stock
facilities
1 General
1.0.1 In order to improve the servicing quality of railway passenger cars, ensure the safety of passenger cars, unify the technical standards for the design of passenger car rolling stock facilities, make the design of passenger car rolling stock facilities to be technologically advanced, economical and reasonable, safe and applicable, this code is hereby formulated.
1.0.2 This code is applicable to the engineering design of new or rebuilt railway passenger car facilities with standard gauges in the national railway network. 1.0.3 The design of railway passenger car facilities shall include facilities such as passenger car rolling stock depot (referred to as passenger car depot), passenger car technical servicing depot, railway passenger car inspection department (referred to as passenger car inspection department).
1.0.4 The design year of railway passenger car rolling stock facilities shall be divided into short-term and long-term. The short-term is the 10th year after delivery and operation; the long-term is the 20th year after delivery and operation.
The design of railway passenger car rolling stock facilities shall be a combination of short-term and long-term, focusing on the short-term, reserve development conditions based on the long-term scale.
1.0.5 The design of passenger car rolling stock facilities shall be based on factors such as the car type, number of cars attached, the workload of overhaul and operation and servicing, transportation organization, related passenger car rolling stock facilities, as well as the passenger car repair system, car technology development, road network planning.
When determining the design plan of the passenger car rolling stock facilities, a technical and economic comparison shall be made to select the best plan. 1.0.6 During the renovation and expansion of railway passenger car rolling stock facilities, existing equipment may be used to minimize demolition and abandonment work, reduce the impact and interference of construction on production.
rolling stock facilities (including passenger car rolling stock depots, passenger car technical servicing depots, passenger car inspection department, etc.). 2.0.2 Passenger car rolling stock depot
The production premises that undertake the servicing of railway passenger car depots and the management tasks of the operation and servicing of passenger car rolling stock facilities within its jurisdiction.
2.0.3 Passenger car technical servicing depot
The passenger car operation and servicing place which is responsible for the technical inspection of passenger cars of the departure and the final arrival, as well as the regular servicing of the passenger cars and the electric equipment. 2.0.4 Passenger car inspection department
The operation and servicing space for passenger cars that undertakes technical inspections of passenger cars, brake tests, repairs without taking off the trains. 2.0.5 Passenger car stabling sidings
In the passenger car technical service depot, the line which is used for parking under the passenger car.
2.0.6 Coefficient of non-serviceable rolling stock
The ratio of the sum of the number of spare cars and the number of overhauled cars to the number of cars in use.
2.0.7 Utility factor of car repairing positions
The ratio of the number of cars in the daily servicing of car equipment to the number of servicing depots in the repair garage (shed).
2.0.8 Coefficient of passenger car servicing tracks
The ratio of the number of passenger car servicing tracks configured to the number of servicing passenger train sets that needs to enter the servicing position.
2.0.9 Length of each car repairing position
The length of each car repair position occupying the repairing track.
2.0.10 Calculation length of car
The length of the car as specified for calculating the length of the track occupied by the parked car.
loading and unloading lines and roads; there shall be sufficient space near the warehouse. The storage rooms for flammable, explosive, toxic, hazardous and other dangerous goods shall be set up separately, which shall comply with relevant requirements for safety and environmental protection.
3.4.3 The workshop that generates noise and shock vibration shall be far away from the laboratory, metering room, bearing room, brake room, etc. Workshops that produce high temperature, dust, and toxic and harmful gases shall be arranged on the upwind side of the annual minimum frequency wind direction, whilst the metering room shall be arranged on the downwind side of the annual minimum frequency wind direction.
3.4.4 Power facilities such as compressed air stations and substations shall be close to the load center.
The compressed air station shall be arranged on the leeward side of the annual minimum frequency wind direction of the workshop that emits dust and harmful gases; meanwhile it shall avoid the impact of noise and vibration on the surrounding environment.
3.4.5 The storage site for scrap iron and steel in the depot shall be located in a place that is convenient for loading and relatively hidden. The location of sewage treatment facilities in the depot shall be determined according to factors such as the location of the discharge outlet, wind direction, servicing management, transportation.
When coal-fired boilers are used, coal yards, slag yards, fences shall be set near the boiler room. When oil-fired boilers are used, corresponding oil storage tanks shall be installed and safety protection measures shall be taken. 3.4.6 Circular transportation roads shall be designed in the depot; there shall be no less than two entrance and exit connected with roads (or transportation roads) outside the depot.
The road should adopt a concrete pavement; the width of the pavement is 6.0 m for main arterial road (two-way lane), 3.5 m for non-main arterial road (single- lane), not less than 2.0 m for sidewalk.
3.4.7 The width of the passage between the buildings in the depot shall comply with the requirements for fire protection, safety and health; meanwhile it shall meet the requirements for building roads, laying various underground and overhead pipelines, greening. The width of the main channel shall not be less than 18.0 m; the width of the general channel shall not be less than 12.0 m. 3.4.8 The determination of the fire separation distance between adjacent buildings and the fire hazard rating of the buildings in the depot shall comply with the current national "Code of design on building fire protection and 3.4.13 The passenger car depot shall have a parking lane; its effective length shall be determined by 1.5 ~ 2.5 times the number of car repair positions multiplied by the calculated car length of 26.5 m. There should be no less than two parking lanes; a pedestrian hardened passage with a width of 1.0 m shall be set between the tracks.
The parking lane should be flat slope; the gradient of the longitudinal cross- section shall not be greater than 1.0‰ when there is difficulty. The space between the parking lanes and the outside of the lane group (the range of 3.0 m from the center line of the lane) should be filled with fine ballast to the bottom of the rail.
3.4.14 There shall be wheelset loading and unloading line in the passenger car depot. The length of the wheelset loading and unloading line into the wheelset shed shall be able to meet the requirements of parking a gondola and crane hook operation range and shunting operation safety.
The material transportation line shall be located near the material warehouse or boiler room. When conditions permit, a wheelset loading and unloading line and a material transportation line can be built together.
3.4.15 The passenger car depot should be equipped with shunting machines, with shunting machine parking lines and shunting hangars.
3.4.16 The passenger car depot shall be set up as a lead line as required; its effective length shall be determined according to the number of car repairing positions, the calculated length of car, the length of the shunting machine, the safe distance for shunting operations. When conditions permit, the entry and exit line can also be used as a lead line.
3.4.17 The wheel storage shed should be adjacent to the bogie room and
between the axle room; the wheel transport line shall be provided in the shed to communicate with the axle room.
3.4.18 The passenger car depot should be equipped with a passenger car
cleaning shed (warehouse). The shed (warehouse) shall be equipped with
passenger car chassis washing equipment.
3.5 Repair garage
3.5.1 The type of repair garage shall be determined based on the workload, operation methods, repair techniques of the car, combined with factors such as topography and meteorological conditions.
3.5.2 The method of repairing the car can adopt positioning operation or stage operation. The number of repairing positions for each line of the repair garage 4 When there is a bogie or wheel-set lateral conveying track at the end of the repair garage, the distance from the center of the line to the inner side of the end wall shall meet the requirements of the hanging bogie of bridge crane or the wheelset operation;
5 Compressed air, water supply, power wiring shall be laid in the repair garage; the AC 380 V and DC 600 V surface external test power supply
and electric welding secondary lines shall be installed as required. It is strictly forbidden to use the repair line's rails as electric welding secondary circuit circuits.
6 The repair garage may be provided with servicing trenches as needed.
7 Drainage and ventilation facilities shall be provided in the repair garage. 3.6 Paint warehouse
3.6.1 The passenger car depot shall set up a separate paint warehouse. When restricted by conditions, the paint warehouse can be set up at the end of the repair garage (or combined garage), meanwhile the paint stand is separated from the repair position (or adjacent workshop) by a firewall and fire door. 3.6.2 The number of booths in the paint warehouse shall match the capacity of the repair garage; it should be designed according to 1/5 ~ 1/6 of the number of positions in the repair garage.
3.6.3 The length of the paint warehouse can be designed as 36 m for each position; the warehouse length will increase by 30 m for each additional position; the headroom of the warehouse shall be determined according to the
requirements of the painting process and equipment.
3.6.4 The paint warehouse shall be equipped with painting, drying, paint mist purification equipment and ventilation facilities as required; the electrical and lighting equipment in the warehouse shall be explosion-proof.
3.7 Bogie room
3.7.1 The bogie room should be designed according to the positioning operation and servicing process; meanwhile it shall be provided with the bogie
disassembly, rust removal, servicing, testing, assembly positions.
3.7.2 The number of bogie inspection positions shall be determined according to factors such as inspection workload, inspection time, imbalance.
The number of positioning inspection stations can be calculated by the following 3.8 Axle room
3.8.1 The axle room of the passenger car rolling stock depot shall be considered by the railway bureau as a whole. It should not set up the axle room in each passenger car rolling stock depot.
3.8.2 The axle servicing process shall be determined according to the process layout between the bogie room as well as the combination form of the servicing process of wheelsets, axle boxes, bearings, etc. When the axle room and the bogie room are set at the same span, the top surface of the crane rail shall be at the same elevation.
3.8.3 Axle box disassembly, axle box overhaul, axle inspection, rust removal, flaw detection and other assembly lines, machining operation area, same temperature assembly chamber shall be set up between the axle rooms.
3.8.4 The axle room shall be provided with 3t electric single-girder bridge crane, wheelset bearing fault diagnosis equipment, axle box bearing disassembly equipment, wheelset rust removal and washing machine, wheelset flaw
detection equipment, wheel rim flaw detectors, wheelset servicing equipment, induction heaters, control panels, wheel lathes, etc. According to needs, the axle room may also be provided with wheelset dynamic balance test benches and wheelset weight removal equipment, brake disc wheelset rust removal equipment, gearbox cleaning and rust removal equipment, etc.
The axle box servicing work area shall be equipped with axle box washing machine, inner hole de-rusting machine, parts cleaning machine, sealing ring pressing machine, dryer, necessary axle box conveying device and lifting equipment. The same temperature assembly chamber shall be equipped with a 3t electric single-beam bridge (or suspension) crane, journal cleaning machine, bearing spray machine, wheelset bearing axle box assembly
equipment, axle box transmission device, electric heating constant temperature drying box, oil injection machine, the axle running-in test bench, etc. 3.8.5 The span between the axle rooms shall be determined according to the wheelset servicing process and the layout of adjacent workshops. The height from the top surface of the crane rail to the top surface of the indoor line rail shall not be less than 5.1 m.
3.8.6 The axle room shall be laid with a storage line for the to-be-repaired wheelsets and a repaired wheelset; which shall be connected to the storage shed and the bogie room; the same temperature assembly chamber shall also be equipped with a storage line for the wheelsets.
3.8.7 Except for the flaw detection work area and the same temperature
more than 80 mg/m2. The amount of 24 h natural dust falling of bearing testing compartment should not exceed 60 mg/m2. The relative humidity of bearing storage compartment should not be greater than 40%.
3.11 Accessory repairing center
3.11.1 The accessory repairing center shall be designed to undertake the work of de-rusting, flaw detection, welding repair, machining of the bogie parts, basic brake parts, hook buffer parts, the center disc.
3.11.2 The accessory repairing center should be set up near the bogie room or separately; its span shall be determined according to the process layout. The accessory repairing center should be equipped with a 2t electric single-beam crane; the height from the top of the traveling rail of the crane to the indoor floor shall not be less than 5.1 m.
3.11.3 The accessory repairing center shall set up the brake beam inspection work area, the air spring inspection work area, the unit brake cylinder inspection work area, the spring testing work area, the inserting work area, the accessories de-rusting work area, the accessory flaw detection work area, the accessory welding repair work area, machining work area according to the types of accessory to be repaired. The accessory welding repair work area shall be equipped with light barriers or partition walls and smoke and dust removal devices. 3.11.4 The accessories repairing center shall be equipped with accessories handling equipment, accessories removal equipment, saddle lathes, bullhead planers, cylindrical vertical driller, single-column correction presses, electric welding machines, brake beam end shaft processing machines, brake shoe
supporting arc surface processing machine, accessories flaw detection
equipment, tensile testing machines and other equipment. Metal spraying equipment, plastic spraying equipment, etc. can be equipped according to needs.
3.11.5 The spring testing area shall be equipped with spring test press, spring paint spraying (dipping) equipment, drying equipment, spring disassembly and assembly equipment, etc.
3.11.6 The air spring servicing work area shall be equipped with an air spring disassembly and assembly machine and an air spring test bench.
3.11.7 The unit brake cylinder inspection work area shall be equipped with equipment such as disassembly, inspection, assembly, painting workbench and cleaning equipment, unit brake cylinder test bench and other equipment. 3.13.3 The equipment of the hook buffer room should be arranged according to the servicing process division; the hook buffer room with a large workload can be designed according to the servicing process line of the coupler, buffer, hook tongue, hook frame.
The hook buffer room should be equipped with a storage area for the complete set of hook buffer devices to be repaired and completed, as well as a storage area for accessories. The area can be determined according to the amount of servicing tasks.
The hook buffer room is equipped with a heat treatment work area as required; meanwhile it is equipped with a heat treatment furnace.
3.13.4 The hook buffer room shall be equipped with a 2t electric single-beam crane, a complete set disassembly and assembly machine of hook buffer, a four-column hydraulic press, shot blasting de-rusting equipment, a sleeve inserting machine, a buffer accessory cleaning machine, a hook three-state action test bench, a hook buffer forklifts and other equipment; it may also be equipped wi...