BRAKE SYSTEM

BY:
G.N.Singh,
AP/DSL/IRIMEE
 TYPES
TYPE LOCO TRAIN DESIGNED FITTED IN
BRAKE BRAKE BY

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,
WDM3, WDS4,
ZDM3, WDS3
GERMANY

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 Purpose
1. A9. Automatic Valve Brake application for Loco as well as formations.
2. SA 9 Independent Brake Valve Brake Application for Loco alone
3. MU – 2B M.U. Operation, used as gate valve
4. F 1 – Selector M.U. Operation, used as gate valve
5. C2. W. or Additional C2. Valve Feeding B. P. Pressure to the formation
6. 24 A. Double Check Valve This will allow only one operation at a time.
7. C3. W. Distributor Valve Proportionate Brake valve application during A9. application.
8. C2. Relay Valve For Locomotive Brake.
9. Pressure Switch Loco will be brought to idle during A9 emergency application.
10. D1. Emergency Valve For Emergency brake application.
11. D1. Pilot air valve During Dynamic brake Loco brake will be released.
12. Pressure Limiting Valve Pilot air to C2.Relay valve for synchronized brake application
is Limited to 2.5 kg / Cm2
13. M. R. Safety Valve When M. R. Pressure goes beyond 10.5 kg / Cm2 This valve
will operate and release excess pressure from MR.
14. Duplex Check Valve This valve will connect MR1 with feed valve when MR
(6 kg / Cm2 ) pressure exceeds 6 kg / Cm2
15. D 24 – Feed Valve For Feed pipe Pr: 6 kg / Cm2.
 INDEPENDENT BRAKE SYSTEM

30 MU2B
SA 9
20 2
20

DOUBLE Brake application

CHECK through A9
VALVE

2 C2 RELAY
VALVE
1 Brake Cylinder
2

MR LINE

INDEPENDENT BRAKE APPLICATION

 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 driver’s control stand for indicating brake cylinder pressure.
 INDEPENDENT BRAKE SYSTEM

MU2B
SA 9

DOUBLE Brake application

CHECK through A9
VALVE

C2 RELAY
VALVE
Brake Cylinder

MR LINE

INDEPENDENT BRAKE RELEASE

INDEPENDENT BRAKE SYSTEM LAYOUT

MR BC
BC MR GAUGE GAUGE
GAUGE GAUGE

SA 9 MU2B SA9

20 2
30
30
20
20 DCV
DCV FROM F1
A9 30 SELECTOR
14 VALVE

1 C 2 RELAY
3
VALVE
EXH
2
BC EQ. PIPE

BC . PIPE

J- MR 2
FIL
TE
R
 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 self–lapping 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

PROTECTION VALVE CONTROL AIR

A 9 AUTOMATIC AT 24 PSI
BRAKE VALVE

MR PIPE

BRAKE PIPE

VAC TRAIN PIPE

 VACUUM BRAKE APPLICATION POSITION

TO ATMOSPHERE

TO EXHAUSTER

CONTROL AIR AT
A 9 AUTOMATIC PROTECTION VALVE 24 PSI
BRAKE VALVE

MR PIPE

BRAKE PIPE

VAC TRAIN PIPE

 VACUUM BRAKE SYSTEM

HS4
BC BP MR HS4 VALVE

A9 MU2B

30
53 63 13 3
1
5
3
VA 1B
7 6
ATM VALVE
2
GD80D
8
FILTER 1
TO EXPR

2” CHECK VALVE

VAI RELEASE VALVE

COC

FROM
MR 2
GD 80 E FILTER 24 A D C VALVE
H FILTER
BRAKE PIPE FROM A1 DIFF
PILOT AIR VALVE
MR EQ. PIPE
BC EQ. PIPE
VAC BR PIPE
 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 Average

M/E 53 47 50

Passenger 50 44 47

Goods 46 38 42
 (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, Over-
reduction, 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 PROTECTION
BRAKE VALVE VALVE

28 VB
VALVE

C2 RELAY
BR. CYL

MR PIPE

BRAKE PIPE

VAC TRAIN PIPE

 PROPORTIONATE BRAKE RELEASE

VA1B
TO ATMOSPHERE CONTROL
VALVE

TO EXHAUSTER
CONTROL AIR AT
PROTECTION 24 PSI
A 9 AUTOMATIC VALVE
BRAKE VALVE

28 VB
VALVE

C2 RELAY
BR. CYL

MR PIPE

BRAKE PIPE

VAC TRAIN PIPE

 PROPORTIONATE BRAKE SYSTEM

MU2B
7
SA9
1 FOR IND. BR.APPLICATION
30
20
28 VB VALVE
N1 REDUCING
VALVE

30 VAC. RES
16 7
10 1 800 cu
COMBINED CUT OUT
inch
COCK & STRAINER
VOL. RES
90 cu
H FILTER
inch
MR 2 4

FROM SA9 16
30
DOUBLE CH
VAL 14

F1 SEL.
C2 RELAY VALVE
VALVE

TO BR.CYL
BR.PIPE
MR EQ. PIPE
BC EQ. PIPE
VAC. BR. PIPE
 BRAKE PIPE SYSTEM

AIR FLOW
AIR FLOW INDICATOR
INDICATOR
BP
HS4 VALVE
BP
A9
A9 MU2B

30 53 63 13 3
1
5

COC COC

R6
AUDIO VISUAL
VALVE
INDICATOR

AIR
1 FLOW
C 2 RELAY
VALVE IND. RESERVOIR
EXH VALVE MR2
3 110 cu
2 inch

BRAKE PIPE
 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 Driver’s 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

To port No 15 F1
selector valve
Selector valve

7 SAFETY
D 24 FEED VALVE
VALVE DOUBLE CHECK
1a VALVE

20 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: 3.5±0.1 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