guidelines for standardisation of infrastructural

CAMTECH/ 2013-14/M/INF-BTPN/1.0 1

Standardisation of Infrast4ructure Facilities for Examination of BTPN Wagons in ROH Depot & Yard

CAMTECH

GUIDELINES FOR STANDARDISATION OF

INFRASTRUCTURAL FACILITIES FOR

EXAMINATION OF BTPN WAGONS

IN ROH DEPOTS & YARDS

CAMTECH/2014-15/M/INF-BTPN/1.0

January - 2015

MAHARAJPUR, GWALIOR—474005

(Govt. of India) (Ministry of Railways)



INDEX

SN Description Page No.

01 Requirement of Infrastructural Facilities:

1.1. BTPN ROH Depot

1.2. Train Examination Line in yards

3

3

4

02 MS Gantry for BTPN ROH Depot 5

03 Layout of Proposed ROH Shed with the provision of MS Gantry 6

04 MS Gantry for BTPN Examination Line in Yards 9

05 Top view of Yard Gantry walk-way width 1.2 meters with the

provision of safety railing at both the ends.

10

06 View of Lighting arrangement for BTPN examination yard lines. 12

07 View of dome cover fittings, sealings and master valve opening

arrangement.

13

07 Service Building 14

08 Effluent Treatment Plant ( ETP) 16

09 Steam Cleaning Plant 17

10 Annexure-A Specification for CC Pathway for Yard line

18

11 Specifications of Pathway with Estimated cost per Sq. Meter 19

12 Annexure-B

Lighting arrangement & other Electrical Facilities at BTPN

Examination Yard.

21

13 Annexure-C Multi-utility vehicle specification for ROH Depot

23

14 Annexure-D Structural Drawings

24

15

Hand Tool & Gauges for BTPN Wagon maintenance 25



1.0 Infrastructural Facilities Required: The following infrastructural facilities are considered to be essential for the

maintenance schedules of BTPN wagons in ROH Depots and train examination

in Yards:

1.1 For BTPN ROH Depot: MS Gantry for dome attention in ROH depot Movable welding facilities to be kept in the depot but not in the yard. Adequate illumination facilities all along the ROH Gantry Pallets for material storage/dispensing Road between office/store and ROH shed. Walkie Talkie sets with charging arrangements 02 Nos. Mobile platforms (Battery operated) at least 04 Nos. Multi -utility vehicles for Depot (As per requirement) Non sparking tool kit. (Ring Spanners, Open ended Spanners, Pliers,

punch, Hammers & other tools recommended by CAMTECH) Sufficient Spares/ sealing rings in sub store for Vapor extractor Cock,

Filling pipe cap , Dome cover etc. Rechargeable LED head lamp Suitable recommended adhesive for sealing arrangement Construction of SSE(ROH) office/rooms with toilets Construction of Staff room for ROH depot staff Constructions of Sub-Store room for keeping BTPN wagon items Construction of computer Room Steam Cleaning plant with standby Boiler Suitable capacity Effluent Treatment Plant ( ETP) Compressor Room SWTR (Single wagon test rig) Approach Road for ROH depot Water pipe line with suitable capacity pump for testing of barrels RCC floor in ROH depot shed Drinking water facilities Staff canteen Performance parameters Boards Drainage system on both side of track for draining sludge, generated

during chemical cleaning of barrel.



1.2 For BTPN Examination Line:

Two examination lines without OHE of full rake length in dedicated

BTPN rake examination yards and atleast one examination line in

other yards with both side Cement Concrete pathways of about 1.5

meter width.

In case of OHE lines, the facilities for isolation of lines by providing

isolators is mandatory.

Adequate illumination facilities all along the examination line in Yard

Pallets for material storage/dispensing

Road between office/store and examination yard.

Walkie-Talkie sets with charging arrangements 04 sets per rake

Mobile platforms (Battery operated) at least 02 Nos.

Non sparking tools. (Ring Spanners, Open ended Spanners, Pliers,

punch and Hammers)

Spares/ sealing rings for Vapor extractor Cock, Filling pipe cap , Dome

cover etc.

Rechargeable LED head lamp

Suitable recommended adhesive for sealing arrangement in Yard

MS Gantry along the nominated track for dome fitting attention in

examination yards

Construction of SSE(Yard) Office/rooms with toilets

Construction of Staff room

Construction of toilet block for staff

Constructions of Yard Sub-Store room for keeping BTPN wagon items

Construction of CC pathway for yard lines on both sides for full length.

Illumination facilities in Yard & pathways

Rake testing Rig for each examination line

Compressor Room with Air Dryer

Hand Tool kit with bag

Drinking water facilities

Performance Parameters Boards in Yard office



2.0 MS Gantry for ROH Depot :

For maintenance of dome fittings and other top fittings in BTPN wagons during

ROH schedule, following points to be taken in to consideration for developing

Gantry in the ROH shed for carrying out ROH of wagons in the shed.

1. The gantry should be constructed as per CAMTECH drawing No.

BTPN/Infra/Facilities/CAMTECH/M/GWL/Gantry/1.0, 2.0, 3.0 & 4.0 for

atleast 03 BTPN wagon length covering two tracks for placement of

minimum two wagons for ROH schedule.

2. The length of the Gantry should be 38000 mm

3. The height of Gantry platform be kept 4000 mm as shown in the drawing.

4. The width of the gantry platform ( walk way) to be kept 3000 mm as shown

in the drawing.

5. Both end stair steps to be provided

6. Steps tread depth be kept 10” without nose

7. Steps riser height be kept 6” vertically to avoid slipping of man carrying

load.

8. Width of stair case should be 1200 mm.

9. Both side round pipe of suitable specifications support on the stair case to

be provided and not the iron angle.

10. ROH shed sheets to be of galvalium

11. Drain at centre of the track to be provided for both the tracks

12. Discharge of both drains to be brought to ETP Plant developing an open

drain between two tracks about 120 meters with adequate falling gradient.

13. Water supply hydrants to be provided at top of the gantry platform for

checking of leakage of master valve & cleaning of tank barrel ( total 06

nos. with 50 mm dia pipe line).

14. Provision of ROH shed as per drawing for placement of atleast 04 BTPN

wagons on each line (total 08 wagons on both the tracks of the gantry).

15. Provision of roof mounted turbo ventilators in the shed.



Layout of Proposed ROH Shed with the provision of MS Gantry for 03 BTPN wagons on each track & suitable flooring.

View of Gantry structure, pillars, extensions for dome covers and supporting members for ROH Shed



Front view of Gantry extensions for maintenance staff

Top view of Gantry walk way width 3.00 meters with protection railing at both ends.



Top view of Gantry extension with additional safety chains and Lighting arrangements.



3.0 MS Gantry for BTPN examination Line:

For maintenance of dome fittings and other top fittings in BTPN wagons for

safety certification/Commercial certification in nominated examination yards,

following points to be taken in to consideration for developing Gantry in the

examination line.

Gantry should be constructed as per CAMTECH Layout.

BTPN/Infra/Facilities/Examination line/Gantry for full rake length i.e. 50 BTPN

wagons covering only nominated one line for placement of one rake.

1. Gantry should be proposed only for non OHE line, nominated for BTPN

examination.

2. The length of the Gantry should be for 50 wagons ( i.e. 622000 mm) along

the nominated line.

3. Only one line to be nominated for safety certification and Gantry be

proposed for this line.

4. Gantry pillars should be placed at a distance of 1.2 meters across the

track on pathway from the edge of the sleeper for easy movement of

listers and trolleys.

5. The height of Gantry platform be kept 4000 mm as shown in the drawing.

6. The width of the gantry platform ( walk way) to be kept 1500 mm as shown

in the drawing.

7. Both end stair steps to be provided for gantry

8. Steps tread depth be kept 10” without nose.

9. Steps riser height be kept 6” vertically loosed to avoid slipping of man

carrying load.

10. Width of stair case should be 800 mm.

11. Both side round pipe of suitable specifications support on the stair case to

be provided and not the iron angle.



Top view of Yard Gantry extension and floor width 1.2 meters. for train examination staff

Top view of Yard Gantry walk way width 1.2 meters. with the provision of safety railing at both the ends



Supporting structures for yard gantry, height 4000 mm

Supporting member( I- section 4”x8” )



View of Lighting arrangement for BTPN examination yard lines.



View of dome cover fittings, sealings and master valve opening arrangement.



4.0 SERVICE BUILDING: ROH depot and examination Yard:- To facilities maintenance staff of BTPN

ROH depot and examination yard, the following infrastructural facilities should

also be provided.

1. SSE/ROH room size 4500 x 5000 mm alongwith toilet size 2000 x 2385

mm.

2. SSE Yard room size 4000 x 5000 mm with attached toilet size 2000 x

2385 mm.

3. Sub-store room size 4500 x 5000 mm with proper ventilation.

4. Staff room size 7000 x 5000 mm

5. Toilet block size 1970 x 1768 mm HE toilet & 1970 x 1768 mm BHE toilet

including urinal (over all dimension 3000 x 5000 mm)

Specification for service Building:- NOTES AND REFERENCES FOR DRAWING OF SERVICE BUILDING:

ALL DIMENSIONS ARE IN MILLIMETERS UNLESS OTHERWISE MENTIONED IN THE DRAWING.

THE BUILDING SHALL BE LOAD BEARING WALL STRUCTURE.

FOUNDATION & PLINTH SHALL BE OF BRICK MASONARY IN CEMENT MORTAR 1:6 WITH R.C.C. PLINTTH BEAM AT LEVEL.

SUPERSTRUCTURE SHALL BE OF BRICK MASONARY OF SECOND SORT CEMENT MORTAR 1:4.

WALL FINISHING THE EXTERNAL & INTERNAL SURFACES SHALL BE PLASTERED WITH 20MM & 15MM THICK IN CEMENT MORTAR 1:4 RESPECTIVELY. INTERNAL SURFACE SHALL BE PROVIDED WITH TWO COATS OF OIL BOUND WASHABLE DISTEMPER OF APPROVED COLOUR & SHED AFTER ONE COAT OF PRIMER. EXTERNAL SURFACES SHALL BE PROVIDED WITH TWO COATS OF WATER PROOFING CEMENT PAINT OF APPROVED COLOUR AND SHADE.

(I) FLOORING SHALL BE FURNISHED WITH VITRIFIED TILES IN SSE, SE ROOM & STAFF ROOM.

(II) FLOORING SHALL BE FURNISHED WITH HYDRAUNIT CEMENT CONCRETE IN STORE ROOM.



(III) FLOORING SHALL BE FURNISHED WITH KOTA-STONE IN VERANDAH.

(IV) CERAMIC TILES TO BE PROVIDED IN TOILET BLOCK

(V) 40MM THICK I.P.S. FLOORING SHALL BE PROVIDED IN GARRAGE & COMPRESSOR ROOM.

(VI) ALL FLOORS TOPING SHALL BE LAID OVER 100MM THK. C.C. 1:3:6, LAID OVER 150MM THK. RUBBLE SOALING HAND PACKED OVER WELL RAMMED.

ROOFING- R.C.C. SHALL BE PROVIDED WITH WATER PROOFING COMPOUND WITH SUITABLE SLOPE.

DOORS OF SSE ROOM WILL BE SINGLE LEAF FLUSH TYPE WITH AUTOMATIC HYDRAULIC DOOR CLOSERS.

TWO PLATFORMS TO BE PROVIDED IN COMPRESSOR ROOM FOR KEEPING THE TRANSFORMER.

HOOKS FOR FANS SHALL BE PROVIDED IN ADVANCE WHILE CASTING SLAB.

DEPTH OF FOUNDATION TO BE DECIDED BY ENGINEER IN-CHARGE AT SITE AS REAL SITE CONDITION.

DIMENSION OF FOUNDATION SHOWN IN THE DRAWING ARE TENTATIVE & SHALL BE DECIDED BY ENGINEER IN-CHARGE TO SUIT THE SITE CONDITIONS / SAFE BEARING CAPACITY OF SOIL AT FOUNDATION LEVEL.

ALL 03 SIDES OF VERANDAH SHALL BE PROVIDED WITH IRON GRILL AND 3M WIDE SINGLE GATE.

STORE ROOM SHALL BE PROVIDED WITH SLAB OF RCC IN THE WALL FOR MATERIAL STACKING. R.C.C. SLAB SHALL BE 800 MM WIDE AND SPACING 1M 800 mm, 800mm.



5.0 ETP Plant (Effluent Treatment Plant):- [ Supply, Errection & commissioning of compact skid mounted type

effluent treatment plant cum oil water separator ]

Construction of ETP plant is also recommended for collection of wasted chemical

oil from wagons in the ROH depot. Approx 6000 Lts. Capacity ETP plant should

be constructed in BTPN ROH depot as per Central Pollution Control Board

guidelines.

Constructional Details:- 1. Control Room

2. Sledge Drying bed

3. Plate from for ETP

4. Skimmer Unit

5. Oil free raw water storage

Reinforcement Details:- 1. Base slab-U/G collection tank: 8 TOR @ 300 CC both ways & both sides

2. Outer Walls ( all around) : Vertical 10TOR @ 250 CC both sides

: Horizontal 08 TOR @ 250CC both sides

3. Inner walls: (Dividers) : Vertical 10 TOR @ 120 CC

: Horizontal 08 TOR 150CC

4. Top Slab – U/G collection tank : 10 TOR @ 120 CC both ways

5. Columns (150 X 150) : Vertical 12 TOR X4 Nos.

: Binder 08 TOR @ 150 C/C

6. Lintel Beam : Horizontal: 10 TOR X4 Rows

: Binder 08 TOR @ 150C/C

7. Chhajja (D+W) : 08 TOR @ 90 C/C both ways

8. Roof slab – Control Room : 10 TOR @ 120C/C both ways

Other Details:- 1. Under ground collection tank : size 490MX250MX3.00M

: Capacity: 30,000 Lts.

2. Under ground oil collection tank : Size 160MX130MX3.00M

: Capacity: 6000 Ltrs.



3. Foundation of ETP : Size 6.00MX250M

: Area 15.00M2

4. Sludge Drying Bed : Size: 2.04MX1.58MX1.07M

: Compartments: 02 Nos.

5. Control Room : Size: 3.80MX250MX3.00M

Carpet area : 09.50 M2

Steel Door : 01 No. size 2.10MX1.00M

Glazed window : 01 No., size 1.50MX1.20M

Floor : Ceramic tiles

6. Side preparation for circular path & boundary wall with PCC surrounding

ETP : PCC: 1:2:4 (29.00MX1.00MX0.20M)

6.0 Steam Cleaning Plant:

Steam cleaning plant is also required in ROH depot of BTPN wagon for cleaning

of BTPN wagon barrels during ROH schedule as mentioned in G-90. General Specification for boiler: Make : Energy pack

Type : Oil fired

Capacity : 4.0 ton

Barrel Length : 8000 mm

Barrel Dia : 2090 mm

Pressure : 10.2 Kg/Cm2

Room size : 10 M Width X 12 M Length X 8 M Height



Annexure-A

Specification for CC Pathway for Yard line

CROSS SECTION OF PATH WAY

150 mm 40 mm Stone Soling

Cement Concrete 1:2:4 (M-15)

150 mm Stone Soling 150 mm

100 mm

1675 mm

Compact Excavated Earth

(Not to scale)

Ground Level

40 mm Stone Soling

Concrete Sleeper

Finished Concrete Surface with required slope (Slope 1in 40 away from Track )



SPECIFICATIONS OF PATHWAY WITH ESTIMATED COST PER SQ.M.

1. Earth work in excavation Earthwork in excavation in Railway premises including near Railway lines up to

desired depth as per the direction of the Engineer-in-charge as per approved

drawing in congested area with disposal of surplus excavated earth up to any

lead beyond railway premises with compaction of final excavated layer so as to

achieve 98% of density in field. The rates quoted by the tenderer for disposal of

surplus excavated earth and compaction with all tools and plants are inclusive

under this item and nothing shall be paid extra on this account.

Rate : Rs. 150/- per cu.m. 2. Stone soling

Providing and laying stone soling on compacted earth up to a depth of 150 mm

with maximum size of stone/gravel of 150 mm with compaction either by

manually or mechanically with contractor's own tools and plants.

Rate : Rs. 1000/- per cu.m.

3 Cement Concrete (M-15, 1:2:4)

Providing and laying 150 mm thick Cement Concrete (M-15) to required slope

and camber in panels as required using surface vibrator and other equipment

including the cost of cement, fine aggregate and coarse aggregate (size up to 20

mm) for specified floor slab including provision of construction joint at 6 m c/c

cutting thickness of concrete slab with mechanised screw and filling the same

with semi-rigid epoxy for giving adequate finishing surface and expansion of joint

to the satisfaction to the Engineer-in-charge.

Rate : Rs. 3000/- per cu. m.



Schedule of quantity & cost

Sr. No. (1)

Description of item (2)

L (m) (3)

W (m) (4)

D (m) (5)

Qty. (m3)

(6) = (3) x (4) x (5)

Unit

(7)

Rate (Rs.) (8)

Amount (Rs.)

(9) = (6) x (8)

1 Earth work in excavation

1.0 1.0 0.15 0.15 M3 150/- 22.50

2 Stone soling 1.0 1.0 0.15 0.15 M3 1000/- 150.00

3 Cement Concrete (1:2:4)

1.0 1.0 0.15 0.15 M3 3000/- 450.00

Total amount in Rs.

Says Rs.

622.50

623.00

Rate per Sq.m. = Rs. 623.00 Note:

1. The rate of various above items as per market survey. 2. The above rates may vary as per site condition / geographical

proximity.



Annexure-B

LIGHTING ARRANGEMENT & OTHER ELECTRICAL FACILITIES AT BTPN EXAMINATION YARD

1. 230V/ 415V INDUSTRIAL SOCKET

230V/ 415V AC 3 phase socket Fitted in MS box size Ht.60 x W 45 x D 15 cm Having suitable ISI approved 500V, 63 Amp. socket switch unit

combined set including bus bar chamber 200 Amp. capacity complete with cable bushing for incoming and out going cable.

The box should be fitted with necessary clamps and supporting channel for installation 63 Amp. TPN MCCB.

This also includes 5 pin 15 Amp. 230V AC socket flush type fitted inside the MS box.

Approximate rate : Rs. 9709/- each.

(As per estimate prepared by Dy.CEE (Co)/ Jhansi/ NCR Tender No. JHS/Dy.CEE/C/T/04/2007

Location : 25 m between two sockets

2. GENERAL AREA LIGHTING Illumination required : 50-100-150 lux Mounting : Street lights fitted on poles

SPECIFICATION FOR 70W METAL HALIDE STREET LIGHT FITTING:

Specification for 70W street light fitting luminaire may be as given below:

Voltage : 230V AC 1, 50Hz Lamp : 70 watts Metal Halide Lamp Lamp type : Single ended clear elliptical/ tubular Metal Halide lamp Lamp base : E - 27. Lumen output

: 5000 – 5600 lumens Luminaire type

: Deep drawn aluminium street light luminaire Lamp holder base : ES-27, skirted porcelain.

Reflector : Super high purity symmetrical aluminium reflector. Control gear

: Heavy duty copper wound ballast, ignitor, and power factor correction capacitor suitable for 70 watt metal halide lamp. The control gear tray shall be removable for easy maintenance.

Earthing terminal : Suitable for 14 SWG earthing wire. Mains connector : 2 way 10 amps G.F.P. mains connector suitable for 4 sq.

mm incoming cable. Installation : Suitable for mounting on MS pole with outer dia. less



than 50 mm (alongwith adjustable U clamps) Wiring : All accessories of luminaire shall be prewired up to

terminal block. Tightness level : For control gear & lamp compartment IP 43. IS : Luminaire shall confirm IS: 10322. Make : Philips, Bajaj, Crompton Greaves, Asian, Wipro

LIGHT FITTING CONFIGURATION

Street light fitting should be fitted on poles. Two fittings on each pole

along the track in opposite directions.

Distance between the two poles in a row along the pathway/track shall

be 25 metres.

The light fitting shall be mounted at a height of 5 metres from the rail

level.

The cablings shall be done underground.

The directions of fittings shall be parallel to the track and angle of

fitment shall be adjusted accordingly.

Poles and metal body of each fitting should be connected to the earth

properly.

Each row of lighting poles shall be controlled by a separate MCCB of

suitable rating and shall be supplied by separate phase.

Approximate rate : Rs. 18000/- each pole fitted with two fittings. ABSTRACT ELECTRICAL ESTIMATE

For two examination line S.No. Item Description Qty. Rate

(Rs.) Cost (in

Rs.) 1. 230V/ 415V industrial socket 24 nos. 9709 2,33,016 2. 70 W metal halide double

fitting with pole including installation and commissioning at a distance of 30 m each

72 nos. 18000 12,96,000

3. Cabling 3,00000 Total 18,29,016



Annexure-C

Multi-utility vehicle specification for ROH Depot:

The TATA ACE BS-II (TA) vehicle retrofitted with following accessories duly making necessary changes in body and chassis:

Sl. No.

Description Qty per MU

vehicle 1 1.1 The necessary changes in chassis and body as shown in drawing :

1.2 M&P’s/T&P’s on MUV a) Portable welding plant -01 nos

b) Portable grinder -01 nos

c) Tool kit - As per requirement

d) Focus lamp with 50 W tungsten halogen bulb on the top of drivers cab.

e) Copper cable 15 meter long for electrode holder

f) Copper cable 10 meter long for earthing purpose

g) Four racks to keep spare parts

1 set

2 CR sheets of 1.2 mm thickness to fabricate following: a) Shelter b) Tools and material rack as per the sketch

3 Commissioning of Focus light as per the following: a) Focus lamp with 50 W tungsten halogen bulb on the top of drivers cab.

b) The lamp shall draw power from auxiliary battery. Necessary

arrangements shall be made for it.

c) The lamp shall be fixed in an all weather enclosure and arrangement to

swivel it 360 deg and with arrangement to turn it up or down.

1 set

4 Necessary stickering with retro-reflective 3M stickers/painted with

yellow/black stripes shall be made as desired by the zonal railways.



ANNEXURE-“D”

Structural Drawings Following lay out drawings have been prepared for ROH shed, ROH Gantry, Yard Gantry & CC Pathways, service building & ETP. The parameters given in the drawings are tentative and same may be altered as per field requirements. The suggestions on the drawings from zonal railways will be incorporated at appropriate locations in the drawings in final report. A-For ROH Gantry:

1. Foundation plan and details of gantry

2. Sectional elevation of main column, Plan of footing, detail of RCC & holding bolts

3. Stair case, inspection bridge and plan of footing

4. Plan of walk way

B-For Yard Gantry:

1. Lay out plan

C-For Service building:

1. Plan elevation section of service building for BTPN wagon ROH Depot

D-For ETP Plant:

1. General arrangement and lay out plan for ETP Plant



Hand Tools and Gauges for BTPN Wagon Maintenance

Following Hand Tools and Gauges are recommended for maintenance of BTPN wagons.

1.1 List of hand tools for wagon maintenance (Fitter-Repair/ Examination Gang at Examination Yard)

1. Bar with flat nose (local made)

2. Chiesel : Octagonal chiesel 150x16 mm

3. Chiesel : Flat chiesel 300x25 mm

4. Hammer: Ball pein hammer 600 grams

5. Hot axle detector

6. Pipe wrench : 450 mm

7. Punch : Centre punch 12” long


9. Punch : Cotter punch 8” long

10. Spanner 12x13 mm






16. Spanner adjustable 305x35 mm

17. Screw driver 250x8 mm

18. Scale/tape : Measuring tape 3 m

19. Scale/tape : Steel rule 6”

20. Tongue (local made)

Gauges

1. Gauge for ‘A’ dimension of SAB

2. Gauge for CBC projection

3. Shank wear gauge

3. Tyre defect (profile) gauge

Others

1. Hand gloves

2. Helmat 3. Rechargeable examination lamp

4. Tool bag 5. Walkie -talkie



1.2 List of hand tools for wagon maintenance {Fitter-(Brake testing) at wagon Examination Yard)}

1. Allen key (full set)


3. Hammer : Ball pein hammer 600 grams



6. Punch : Cotter punch 8” long

7. Pipe wrench : 350x48 mm

8. Spanner 10x11 mm

9. Spanner 13x17 mm



12. Scale/tape : Measuring tape - 3 meter



Gauges

1. Air pressure gauge (0.1 kg/cm2 least count)

2. Dummy palm


4. Piston stroke gauge

Others

1. Helmet

2. Hand gloves

3. Rechargeable examination lamp

4. Tool bag

5. Teflon tape

6. Walkie talkie

Note :

1. Quantities of the hand tools/gauges to be carried by fitter are to be decided locally depending

on the gang strength.

.



1.3 List of hand tools for wagon maintenance

{SE/JE (incharge) in BTPN wagon Examination Yard}



3. Circlip plier (internal & external 19-60 mm)

4. Chiesel : Octagonal chiesel (full set)

5. Chiesel : Flat chiesel (full set)

6. Chiesel : Chiesel 8” with wire handle

7. Hacksaw with blade 12”

8. Hammer :Ball pein hammer 600 & 800 grams

9. Hammer :Cross pein hammer 600 & 800 grams

10. Hammer : Sledge hammer 7 kg (local made)

11. Pipe wrench (300,350 & 450mm)

12. Punch : Centre punch 8” and 12” long

13. Punch : Cotter punch 8” and 12” long

14. Punch : Punch 8” with wire handle

15. Power drill

16. Power grinder

17. Spanner: Ring 12 pcs.set (6-32 mm)

18. Spanner: Double open end spanner 13 pcs set(6-36 mm)

19. Spanner: Double open end spanner 04 pcs set(3/8 to 7/8 inches)

20. Spanner:Spanner adjustable 305x35 & 255x30 mm

21. Screw driver 8x250mm

22. Scale/tape : Measuring tape 3 meter



25. Set of non sparking tools (for yard handling tank wagon

26. Socket 12.5mm (22 sockets) and accessories


Gauges

1. Air pressure gauge

2. Buffer height gauge


4. Gauge for shank wear



5. Gauge for CBC

6. Gauge for brake block condemnation

7. Knuckle nose wear gauge


9. Tyre defect gauge

10. 7.5 mm test palm and 8 mm and 12 mm test plate

11. Wheel gauge

Others

1. Jacks 30t,20t,15t,5t

2. Wooden packing for jacks

3. Wooden wedges

4. Danger board (glow sign)/lamp

5. Line block skid

6. Walkie talkie

7. Tool bag

8. Helmet

9. Hand gloves

10. Rechargeable examination lamp

11. Ladder with platform 10 ft. height

Note :

1. Quantities of the hand tools/gauges to be carried by fitter are to be decided locally

depending on the gang strength.

2. List should be displayed in SE/JE(C&W) office for the knowledge of working fitters.



1.4 List of hand tools for wagon maintenance (Fitter- repair in ROH/Sick line wagon depot)


2. Chiesel : Octagonal chiesel 150x16 mm, 125x9 mm

3. Chiesel : Flat chiesel 200x25 mm

4. Hammer: Ball pein hammer 800 & 1200 grams


6. Punch : Drift punch 8” and 12” long


8. Spanner 12x13 mm

9. Spanner 13x17 mm



12. Spanner adjustable 305x35 mm




Gauges

1. Gauge for A dimension of SAB

2. Gauge for CBC projection



Others

1. Helmet

2. Hand gloves

3. Tool bag (local made)

Note :





1.5 List of hand tools for wagon maintenance {Fitter - Air brake (testing) in ROH/sickline wagon depot}



3. Hammer : Ball pein hammer 600 grams




7. Screw driver 8x250mm

8. Spanner 13x17 mm

9. Spanner 17x19 mm




13. Tongue

Gauges

1. Air pressure gauge


Others

1. Hand gloves

2. Helmet

3. Tool bag

Note :





1.6 List of hand tools for wagon maintenance (Welder- in ROH/sickline wagon depot)

1. Cutting blow pipe/Gas cutter

2. Gas torch for welding

3. Hammer : Chipping hammer 300 grams

4. Nozzles of different sizes (as per requirement)

5. Punch : Pin punch 8” long

6. Screw driver

7. Spanner cum cylinder key

8. Welding electrode holder

Others

1. Apron

2. Bucket

3. Gas lighter

4. Goggles

5. Hand gloves

6. Hand shield

7. Leg pad (leather)

8. Mask

9. Pin (to clean nozzle)

10. Safety shoes

11. Wire brush


(Rivetter- in ROH/sickline wagon depot)

1. Chiesel : Chiesel with wire handle

2. Hammer : Rivetting hammer 4 kg

2. Hammer : Ball peen 800 gm.

3. Punch : Punch with wire handle

4. Pneumatic buster/ rivet cutter

5. Pneumatic riveter / chipping hammer

7. Snap ( as per requirement)

8. Tongue



Others

1. Apron

2. Ear buds

3. Goggles

4. Hand gloves

5. Helmet

6. Safety shoes


(Tool Room- In ROH/sickline wagon depot)



3. Circlip plier (internal and external 19-60 mm capacity)

4. Chiesel : Octagonal chiesel (full set)

5. Chiesel : Flat chiesel (full set)

6. Combination plier 150,200 mm length

7. File : Flat, round and half round 12”

8. Hacksaw with blade 12”

9. Hammer: Ball peen hammer 600,800,1000,1500 grams

10. Hammer :Cross peen hammer 600 & 800 grams

11. Hammer : Nylon hammer with handle 2 lbs

12. Pipe wrench (300,350,450mm)



15. Power drill

16. Power grinder

17. Pneumatic buster/rivet cutter

18. Pneumatic riveter/chipping hammer

19. Pneumatic weld flux chipper

20. Set of non sparking tools (for depot handling tank wagon

21. Sockets 12.5 mm (22 sockets) and accessories

22. Spanner: Ring 12 pcs. set (6-32 mm)

23. Spanner: Double open end spanner 13 pcs set(6-36 mm)

24. Spanner: Double open end spanner 04 pcs set(3/8 to 7/8 inches)

25. Spanner : Spanner adjustable 305x35 & 380x43 mm



26. Spanner : Single end spanner AF-27,32,50,63,65 mm

27. Screw driver 8x250mm, 8x300 mm




31. Tongue

32. Torque wrench 7-35 kg.m, 7-50 kg.m

Gauges

1. Air pressure gauge (0.1 kg/cm2 least count)

2. Buffer height gauge

3. Caliper of wheel diameter

4. CBC height gauge

5. Filler gauge


7. Gauge for CBC


9. Shank wear gauge


11. Ultrasonic leak detector(for tank wagon depot)

12. Wheel gauge

Others

1. Jacks 30t,20t,15t,5t

2. Wooden packing for jacks ( 2’, 1.5’ and 1 feet long)

3. Wooden wedges

4. Danger board(glow sign)/lamps

5. Line block skid with locking arrangement

6. Walkie talkie

7. Tool bag

8. Helmet

9. Hand gloves

10. Rechargeable examination lamp (dry cell)

11. Ladder with platform 10 ft. height

12. Wire brush



Note :



2. List should be displayed in SE/JE (C&W) office for the knowledge of working fitters.



DESCRIPTION AND DETAIL OF THE HAND TOOLS 2.1 ALLEN KEY Description :Chrome Vanadium Steel, Burnished finish Generally conforming to IS 3082-1988

Range of set No. of pieces Price/Set Approx

1.5-10 mm (1.5mm,2mm,2.5mm,3mm,4mm,5mm,6mm,8mm,10mm)

09 164.00

2.2 CHISELS Description : Octagonal Chisel made from high grade steel, forged and ground. Differential heat treatment for cutting edge and striking end to ensure long life. As per IS 402/ 1990

Length In mm Cutting Edge in mm Price Each Rs. Approx.

150 16 57.00

200 25 108.00

250 30 143.00

300 32 176.00



Flat Chisel

Length In mm Cutting Edge in mm Price Each Rs. Approx 150 16 101.00 200 25 117.00 250 25 124.00

2.3 CIRCLIP PLIERS Description:

Internal and external circlip pliers Insulated With Thick C.A. Sleeve

Generally Conforming to- IS 7989-1976 High grade steel

Description Capacity mm Length in mm

Price Each Rs Approx.

Internal Straight 19-60 195 190.00

External straight 19-60 180 190.00

Internal bent 19-60 195 190.00

External bent 19-60 180 190.00



2.4 FILE Description : Engineer’s file with plastic handle

Generally Conforming to IS 1931-1962

Description Finish Size (mm) Price each(Rs.) Approx

Flat file Bastard 200 96.00

Flat file Bastard 300 156.00

Flat file Smooth 200 148.00

Flat file Smooth 300 239.00

Half round file Bastard 200 217.00

Half round file Bastard 300 379.00

Half round file Smooth 200 257.00

Half round file Smooth 300 432.00

Round file Bastard 200 127.00

Round file Bastard 250 200.00

Round file Smooth 150 139.00

Round file Smooth 250 198.00



2.5 HACKSAW

Description : Generally Conforming to IS: 2594

Dimensions for type C Straight Adjustable Flat Hacksaw

Nominal size L Rs. Each Approx.

250, 300 105.00

Tubular 300 mm 106.00



2.6 HAMMER WITH HANDLE Description: Head drop forged from high grade steel and heat treated with good quality

knotless seasoned wooden handles or bamboo handles. (Ball Peen, Cross peen)

Head as per IS 841-1983

Ball peen and Cross peen

Weight in gms. Price Each Rs. Approx 200 108.00 500 157.00 600 186.00 800 218.00

2.7 Pipe Wrenches

Description: Conforming to IS 4003-1978 (Part-I), Heavy duty housing with integral I-

beam handle made of SG Iron for maximum strength. Suitably proportioned handle for comfortable grip (powder coated).

Size mm

Capacity mm Price each Rs. Approx

250 35 175.00 300 44 247.00 350 48 299.00 450 60 455.00 600 76 838.00



2.8 PUNCHES

Description : Generally Conforming to IS 7177-1974 Made out of high grade chrome steel accurately machined and heat treated. Deep knurling on the body to ensures firm grip.

Description Length in mm Price each Rs. Approx. Centre Punch 100 29.00

Centre Punch 125 38.00

Drift Punch 100 31.50

2.9 SPANNERS 2.9 A Adjustable Spanners

Description : Standard pattern Chrome Vanadium steel Generally Conforming to IS 6149-1984 Grade II

Length

mm Capacity (mm) Black Phosphate Finish

Price Each Rs Nickel Chrome Plated Price Each Rs Approx.

150 19 90.00 126.00

200 26 110.00 166.00

250 30 145.00 217.00

300 35 195.00 277.00

380 43 358.00 505.00



2.9 B Double Open End Spanners

Description : Drop forged Chrome Vanadium Steel, Chrome Plated, Generally Conforming IS 2028-1998

Size in mm Price Each Rs. Size in Inch Price Each Rs

6 x 7 17.00 3/8 x 7/16 43.00 8 x 9 18.00 9/16 x 5/8 100.00

10 x 11 23.00 5/8 x 3/4 124.00 12 x 13 29.00 3/4 x 7/8 229.00 14 x 15 32.00 16 x 17 42.00 18 x 19 50.00 20 x 22 61.00 21 x 23 68.00 24 x 26 87.00 25 x 27 97.00 30 x 32 125.00 30 x 36 142.00



2.9 C RING SPANNERS

Bi-hexagonal

Deep Off Set

Chrome vanadium steel, Chrome plated polish Generally Conforming to IS-2029-1998

Range of set No. of pieces Approx. Price/Set Approx 6-22 mm 08 476.00 6-32 mm 12 1149.00

No. of Pieces

Contents Price in Rs.

6 6

Size M 6x7, 8x9, 10x11, 12x13,14x15, 16x17 16x17,18x19,20x22, 24x26, 25x28,30x32

285.00 540.00

6

1/8x3/16,3/16x1/4, 1/4x5/16,5/16x3/8,3/8x7/16,7/16x1/2

420.00



2.10 SCREW DRIVERS

Description : Generally conforming to IS 844

Blade made from high-grade chrome vanadium steel, chrome plated fully hardened to give long life, Handles from high impact cellulose acetate.

Blade size (mm) Tip size (mm) Price Each Rs. Approx.

3x50 3 x 0.5 27.00 3x80 3 x 0.5 30.00 8x250 8x1.2 85.00 8x300 8x1.2 95.00



2.11 SOCKETS- 12.7 mm (1/2” ), SQUARE DRIVE

AND ACCESSORIES Description : High Grade Chrome Vanadium Steel. As per IS 6131-1980 & 7381-1986 Bi-hexagonal & Hexagonal One Set

Product Item Sockets (mm)

Price Per Set Rs. Approx.

22 Sockets 10,11,12,13,14,15,16,17,18,19,21,22,23,24,26,27,28,29,30,32,33,34

3575.00 5 Accessories

Extension bar 125mm,255mm, Universal joint T Handle , Ratchet Handle



2.11 A. Sockets Accessories As per IS:7991 & IS:7975-1991

Item Length in mm Price each Rs. Approx. Extension Bar 125 146.00 Extension Bar 250 176.00 Universal Joint 75 230.00 “T” Handle 300 170.00 Ratchet Handle 250 440.00 Offset handle 189 100.00

Product No. Contents Price each (Rs.) Approx

11 sockets + 4 accessories

10,11, 13,14,17, 19,22, 24, 27, 30, 32 Extension bar 125mm,250mm,ratchet reversible 265 mm, sliding handle

2535.00

14 sockets + 4 accessories

8, 9,10,11, 12,13,14,15,16,17, 18,19, 21, 22 Extension bar 125mm,250mm, T Handle, Offset handle

2206.00

6 sockets + 1 accessory

11, 14,17, 19,22, 24 Accessory (Offset handle)

570.00



2.12 SAFETY HELMET

IS No. : 2925, To use during maintenance

SIZE Price Approx.

540 mm to 590 mm Labour Helmet – Rs. 72/- Supervisor Helmet-Rs. 85/-

Note : It is preferable to use Fibre Reinforced Plastic Fluorescent Helmet.



2.13 TORQUE WRENCHES

Description : The Torque wrench is a calibrated tool recommended for use in controlled tightening of nuts and bolts to avoid over/under stressing. To set simply turn an adjusting lever and set the reading on the scale. To operate, just pull the handle and when set torque is reached, the wrench will signal with an audible “click”. Release the wrench, it is set for the next operation.

Torque capacity Square drive mm Price /piece Approx

1-7 kg.m 7-50 Lb.Ft.

12.5 3475.00

7-35 kg.m 50-250 Lb.Ft.

12.5 3650.00

14-56 kg.m 100-400 Lb.Ft.

12.5 6926.00

2.14 WELDING TOOLS/EQUIPMENT 2.14 A Electrode Holders : Conforming to IS : 2641-1989



2.14 B Cutting nozzles Conforming to IS: 7653-1975

2.14 C CUTTING TORCH Description : Conforming to IS : 7653-1975

Body and head are of forged brass to eliminate casting porosity. Standard model is 450 mm in length with right-angled head.



2.15 HIGH TORQUE DRILL Description :

Dia. In steel : 10 mm Power input : 420 W No-load speed : 2200 rpm Weight : 1.4 kg Make/Model No. : BOSCH Approx. Price : Rs. 5050/-

2.16 ANGLE GRINDER Description :

Grinding disc dia. : 180 mm Spindle thread : M 14 Power input : 2000 W No-load speed : 8500 rpm Weight : 4.2 kg Make/Model No. : BOSCH Approx. Price : Rs. 15330/-



2.17 LONG NECK STRAIGHT GRINDER Description : Grinding points max. dia. : 25 mm

Power input : 500 W No-load speed : 27000 rpm Weight : 1.6 kg Make/Model No. : BOSCH Approx. Price : Rs. 19740/-

2.18 WELD FLUX CHIPPER (Pneumatic)

Description : Blows per minute : 4200

Approx. Weight : 2 Kg Overall Length : 257 mm Air Inlet : Rc ½” Type of handle : Straight Make/model no. : CP-455 L Chicago Pneumatic Approximate price : 8567/-



2.19 PNEUMATIC BUSTERS/RIVET CUTTERS Description : Used for cutting rivets and bolts Rivet cut dia. : 25.4 mm Bore & stroke : 30.2x279 Blows/min : 720 Approx. weight : 15 kg Type of handle : Pistol grip Make/model no. : CP-4181 Chicago Pneumatic Approximate price : 42263/-



2.20 CHIPPING HAMMER (RIVETER) Description: Riveting capacity in steel (hot) : 24 Blows per minute : 1320 Approximate weight : 8.6 kg Overall length : 327 mm Air inlet : Rc ½” Type of handle : Pistol grip Standard equipment : Snap clip retainer Approximate price : 19968/-



LIST OF NON SPARKING TOOLS

Description :Generally Conforming to IS:4595-1969, Material : Aluminium bronze, Finish : Natural

Sl. no

Description Size (mm)

Length (mm)

Wt. gms

Budgetary Cost per pc. Approx.Rs.

Place of use

1 Hexagonal Socket (NS-72) 30 mm 46 mm 251 6935 R/B axle boxes 2 Hexagonal Socket (NS-72) 32 mm 48 mm 279 7220 R/B axle boxes 3 Spanner open jaw D end 16x17 mm 205 mm 134 3790 Release valve 4 Spanner open jaw D end 17x19 mm 220 mm 179 3790 Vac.cylinder 5 Spanner open jaw D end 19x22 mm 235 mm 229 3790 Bottom flange 6 Spanner open jaw D end 24x26 mm 265 mm 369 4550 Bottom flange 7 Spanner open jaw D end 30x32 mm 300 mm 564 6773 Buffer 8 Spanner Single end open

jaw 32 mm 273 mm 358 4232 Buffer &

manhole 9 Spanner Single end open

jaw 36 mm 297 mm 504 6500 Manhole

10 Spanner open jaw D end 32x36 mm 303.5mm 542 6773

Buffer

11 Combination ring & open End wrenches

17 mm 188 mm 121 3360 D.V. repair


19 mm 215 mm 173 4849 D.V. repair


24 mm 275 mm 313 5642 D.V. repair


32 mm 352 mm 642 10166 Top joint

15 Combination Plier 150 mm 150 mm 140 3640 General purpose 16 Pipe Wrenches Stillson

Type 115-18 mm 450 mm 1798 19600 General purpose

17 Hammer Ball Pein 500 gms 300 mm 650 4875 General purpose 18 Hammer Ball Pein 800 gms 370 mm 1000 7364 General purpose

Source of supply : M/s Hindustan Everest Tools Ltd.

54


Safety Rules For Hand Tools 1. Always use the right size and type of tool for the job being done. Keep tools in proper working

condition. Never alter a tool from its original condition. 2. Always wear safety goggles when using punches, chiesels, hammers and cutting tools. 3. Never use a tool as a hammer unless manufactured for that purpose. 4. Never use a pipe extension to increase the leverage of any wrench. 5. Adjustable wrenches should be tightly adjusted to the nut and pulled so that the force is on the

side of the fixed jaw. 6. Never use a pipe wrench to bend, raise or lift a pipe. 7. Ratchet mechanisms should be cleaned and lubricated periodically with light grade oil. 8. Keep hammer heads tight on the handle. Never use a hammer with a loose or damaged handle. 9. Metal cutting chiesels are intended for cutting, shaping and removing metal softer than the

cutting edge itself. 10. Always strike the struck base of a Chiesel or punch. The striking face of the hammer should have

a dia. approximately 10 mm larger than the struck face of the punch or Chiesel. 11. Never use screw drivers with rounded tips. 12. Never use a screwdriver as a Chiesel, punch, scraper or pry bar. Use screw driver for screw

driving only.

55


Source of supply : 1. M/s Hindustan Everest Tools Ltd. Dohil Chambers, 46 Nehru Place New Delhi-110019 Web-site : http://www.eversttools.com 2. M/s Taparia Tools Ltd. 423/424, A-2, Shah & Nahar Lower Parel (West), Mumbai-400013 Web-site : http://www.tapariatools.com 3. M/s Mekaster Tools Ltd.

10168, East Park Road (K.C.P.) Karol Bagh, New Delhi-110005

4. M/s Jhalani Tools (India) Ltd. Gedore House 51-52, Nehru Place New Delhi-110019 3. M/s BOSCH

Motor Industries Co.Ltd., Power tool division, Hosur Road, Adugodi Banglore-560030

6. Shree Ganesh Fibre Glass Co. ( for safety helmet ) New Delhi-34

7. Chicago Pneumatic Sales (for pneumatic tools) Chemtex house, Hiranandani Gardens Powai, Mumbai-400076 Website: www.cp.com 8. Ador Welding Limited C-116, Naraina Industrial Area, Phase-I New Delhi-110028 Website: www.adorwelding.com

http://www.eversttools.com/

http://www.tapariatools.com/

http://www.cp.com/

http://www.adorwelding.com/

(ANNEXURE2 TO RDSOLetter No. EL/EM/0303/1 Dated 24.05.2013)

ILLUMINATIONNORMS FOR FREIGHT EXAMINATIONDEPOTS

Availability of appropriate illumination level is essential for safety examination andrunning repairs of freight stock. At the same time, provision of very high outdoor ambientlux during night hours is wasteful of electric energy in keeping with the goal of energyconservation, illumination level is to be co-ordinated with actual requirement in reference

to space as well as time. Accordingly, the lighting arrangement shall comprise of: 0) aneconomical level of ambient lux; and (ii) portable lighting (to be switched ON only whenrequired) for achieving the high lux required to intensive examination and repairs. In themeantime, feedback received from railways on RDSO's letter dated 22.01.2013 for freightexamination depots illumination norms has also been taken into account. The illuminationnorms for freight examination depots shall be as follows:

I

l

[

l

l

t[l

5. Unless otherwise stated, lux levels shall be measured at 1m above the floor level for allambient lighting to respect of directed lighting, lux levels shall be achieved on the task.

6. The illumination is to be achieved on the task by means of directed portable lighting.The light should be switched ON only when actually required. THE portable lightingsolution would encompass handheld lighting devices as well as luminaries mounted onlight weight portable trolleys.

2. Choice of lighting technology will have to be made on the basis of energy efficiency aswell as cost considerations. Since both energy efficiency and cost of luminaries areundergoing significant changes., it is difficult to make prescriptions which will hold goodfor a long time. Nevertheless, some directives are necessary with respect to adoption ofLEDluminaries. At this time, provision of LEDlighting throughout the freight examinationdepots across the country will not be economical, railways can however carry out small

Sl.No. Locationwithin freight examinationdepot MinimumLuxlevel$

1 Rakeexaminationyard n Pathway lighting 10-20 Lux

ii) Intensive Examination of (50-100)#under gear( examinationonlv

iii) Intensive undergear 150#Luxexamination as well asrepair work

2. Marshalin{!vard n Flat Marshaling yard 10-15 Luxii) Stabling Area 50 Lux

iii) Coupling-un2oupling 50 Lux iarea

3. Stabling Yard 5 Lux

4. Departure yard 10 Lux

scale pilot projects and study the outcome, However, for portable lighting, LEDtechnologyshould be the preferred option.

3. Railways should try to achieve the illumination norms with minimal investment.Keeping in, this view, in as far as it is possible and efficient, efforts should be made toaugment and/or rationalize the existing arrangements. On the railways, diverse lightingarrangements exist i.e. high masts, pole mounted luminaries, etc. As such, the nature oflighting augmentation and/or rationalization will need to be tailored to suit the individualsites, giving due consideration to the situation of pilferage/theft.

guidelines for standardisation of infrastructural

Documents